Compressed air is the lifeline of its production process. The continuous monitoring system based on Vaisala humidity measurement transmitters is helping various industries improve quality, efficiency, and reliability.
Produce consumer goods and industrial packaging materials, as well as engineering materials for the construction industry. Compressed air plays a crucial role in almost every part of the five production lines in the factory, and the compressed air used must always maintain high quality. Continuous dry and clean compressed air is required for production, therefore humidity control is crucial for quality and equipment durability.
　　Lack of situational awareness in spot checks:
Previously, compressed air had relied on sampling methods, using Vaisala Indigo80 handheld display heads to check the values at different points in the compressed air production and distribution system. These inspections are carried out by Jiangsu Chenming, a trusted company specializing in modern, eco-friendly, and energy-efficient compressed air engineering.
Another challenge is that there are significant differences in dew point values measured in different measurement areas. Some of these changes may be attributed to environmental conditions, which adds additional complexity. Part of the compressed air network pipelines operate outside the factory, which means that temperature fluctuations can affect dew point readings, especially in the cold winter.
　From regular sampling to real-time continuous monitoring:
To address these challenges, Jiangsu Chenming turned to Vaisala to design and implement a continuous monitoring system for compressed air networks. This system is based on Vaisala's DMT143 micro dew point transmitter, designed specifically for use in compressed air dryers and other similar applications.
The Vaisala Dew Point Meter DMT143 has a wide measurement range and is a very sturdy and durable product with long calibration intervals. For applications, what is more important is that it has a fast response time, which is crucial in continuous monitoring systems. Due to its built-in probe heating function, it can also quickly recover from condensation state.
　　The continuous monitoring system uses DMT143 transmitters to measure dew points at two different locations in the compressed air network:
1. Immediately after the adsorption dryer at the factory compressor station
2. End point of compressed air network after production line
The system also measures compressed air pressure, flow rate, volume, temperature, and ambient temperature, all of which are integrated into one interface. The measured values are displayed on the display screen in the maintenance office and color coded to facilitate the detection of anomalies. Green indicates that the value is within the set range, while red indicates potential issues. The system can also ensure that everything is running normally, even if there are slight temporary changes in dew point measurement data. For example, SmartAir can demonstrate that small, regular peaks in numerical values can be attributed to the compressor station switching from one drying tower to another.
　　Quick response to problem situations:
The continuous monitoring system has repeatedly proven its value to various industries, especially during a dryer malfunction in the summer of 2024. The fault caused an increase in humidity levels, and the readings from the DMT143 transmitter provided an accurate description of the situation.
When the dew point in the compressed air network reaches -25 ° C, the system triggers an automatic alarm. The display in the control room visually displays the issue and automatically alerts key personnel via email. The ability to respond quickly to problems enables Walki to prevent negative impacts on the production process.
　　Reliable data ensures production quality and efficiency:
They benefit from:
1. Less uncertainty and faster decision-making, as reliable dew point data can be obtained 24/7.
2. Higher production stability and quality, due to fewer shutdowns, more reliable equipment performance, and better product quality.
3. Better maintenance of execution and investment planning, as it has accurate long-term data that is easy to share with relevant personnel.
4. Potential cost savings can be achieved by optimizing the operation of the dryer.