Humidity Matters

Reduce Compressed Air Electricity Usage with Dewpoint Demand Switching

In Episode 20 of Humidity Matters, we discuss how you can see significant energy savings in compressed air plants using a process called dew point demand switching for heatless desiccant dryers. We'll discuss the significance of compressed air in industrial settings, often referred to as the "fourth utility" due to its widespread use and energy-intensive nature. Compressing air is a highly energy-intensive process, requiring up to 7-8 times more electricity than an electric motor to achieve the same amount of horsepower.The core of the discussion revolves around the heatless desiccant dryers and the potential energy savings achievable through dew point demand switching. Unlike refrigerated dryers that condense water vapor by cooling the air, heatless desiccant dryers use chemicals like silica gel or activated alumina to adsorb water vapor. These dryers operate with two towers: while one dries the air, the other regenerates using a portion of the dried compressed air. Typically, these dryers function on a timed cycle, which can be inefficient during periods of low demand. Dew point demand switching, however, allows these cycles to be controlled based on the actual dewpoint in the air as it exits the drying chamber, leading to significant energy savings. For instance, in a hypothetical scenario, implementing dew point demand switching in a two-shift plant operating seven days a week could save up to 20% in energy costs.Key points:- Compressed air is an essential yet energy-intensive utility in manufacturing.- Heatless desiccant dryers offer the potential for significant energy savings.- Dew point demand switching optimizes dryer operation by measuring real-time dewpoint temperature.- The technology is particularly effective during periods of low demand, preventing unnecessary energy use.- Implementing dew point demand switching can lead to substantial energy cost savings, up to 20% in some cases.Download the news article and read more about reducing energy usage with dewpoint demand switching.A podcast by Bruce McDuffee and Steven Santoro of Vaisala

Measuring Dewpoint in Compressed Air Systems

In episode 19 of "Humidity Matters," Steve and Bruce discuss measuring and managing dewpoint in compressed air systems.  We discuss five common questions:What is dewpoint?How does pressure affect dewpoint measurement?What do pressure and atmospheric dewpoint mean, and why are those terms important?How does dewpoint measurement indicate compressed air quality?What are some important aspects of choosing a dewpoint instrument for a compressed air system?Key points covered include:Dew point temperature is crucial for indicating moisture levels in the air and is significantly affected by pressure variations.In a compressed air system, as pressure increases, the dew point temperature also rises, potentially leading to water presence in the system.Different applications require varying air quality levels, and the podcast explores the importance of choosing the right dew point measurement instrument based on specific process requirements.A podcast by Bruce McDuffee and Steven Santoro of Vaisala

Calibration Part 3 - Accredited or Non-Accredited Calibration; That is the Question

In Episode 18 of the "Humidity Matters" podcast, the third part of the calibration series, Bruce and Steve discuss the differences between accredited and non-accredited calibrations in humidity instruments. The episode delves into the definitions, standards, and processes of accredited calibrations, including independent third-party audits and adherence to specific global and national standards. We also addresses when accredited calibrations are necessary and the value they add, alongside providing insights into various calibration practices, uncertainty, accuracy, and traceability in measurements. The episode concludes by summarizing key takeaways from the entire calibration series.A podcast by Bruce McDuffee and Steven Santoro of Vaisala

Calibration Part 2 - Practical Calibration Tips for Humidity Instruments

Episode 17, part 2 of a 3-part series, delves into the practical aspects of calibrating humidity instruments. We begin by outlining three primary approaches to calibration:Calibrate at your own In-house labSend instruments to an external lab Field calibration at your facility out in the process or on the factory floorEach method is analyzed for its pros and cons. In-house labs offer control and a consistent environment but are expensive and require significant investment in equipment and expertise. External labs provide specialized equipment and expertise without the need for capital and operating investment, but they pose risks related to shipping and turnaround times. Field calibration, while offering convenience and minimal downtime, may compromise the quality of standards and expertise available.The discussion then shifts to specific calibration practices. Emphasis is placed on understanding the frequency of calibration, which depends on the specific conditions and processes each instrument undergoes. While yearly calibration is a common default frequency, the actual calibration frequency may vary based on the instrument's performance and drift in particular environments. Other topics discussed include the importance of equilibration, ensuring instruments reach temperature equilibrium for accurate calibration and the necessity of following the manufacturer's instructions.Key takeaways from the podcast include:Three main methods for calibrating humidity instruments: in-house labs, external labs, and field calibration, each with specific advantages and disadvantages.Calibration frequency should be determined based on the specific conditions and drift of each instrument rather than a fixed schedule.Auditing third-party services for calibration, understanding calibration versus adjustment, and conducting spot checks as part of best practices in calibration management.A podcast by Bruce McDuffee and Steven Santoro of Vaisala

Calibration Part 1 - Calibration Basics for Humidity Instruments

In the 16th episode, we discuss the importance and intricacies of calibration in the context of humidity measurement instrumentation. Even the most stable and high-quality sensors require regular calibration to maintain their accuracy and reliability. Calibration is not just about ensuring that instruments meet their original specifications but is also a critical part of broader maintenance strategies.  We also discuss the concept of traceability in calibration, explaining how it forms an unbroken chain from the instrument being calibrated up to international standards and the SI units.The episode covers these key points:Calibration vs. Maintenance: Calibration is a crucial component of a broader maintenance plan, which may also include physical checks, cleaning, and parts replacement. It is essential to keep instruments functioning within their specified accuracy.Key Definitions: We clarify the definitions of accuracy, precision, error, and uncertainty. Accuracy refers to how close a measurement is to the true value, while precision is about the repeatability of measurements. Error is the deviation from the true value, and uncertainty quantifies the confidence in the measurement.Traceability in Calibration: Traceability ensures that each calibration is linked back to a known standard, forming a hierarchy that ultimately ties back to internationally recognized standards. This chain provides confidence and validity to the calibration process.A podcast by Bruce McDuffee and Steven Santoro of Vaisala