Fundamentals of

Moisture Measurement in
Industrial Applications
Presented by: Robert T. Bailey, Product Manager
Kahn Instruments, Inc.
Wethersfield, CT

Topics of Discussion
Moisture/moisture measurement terminology
Why measure moisture?
Moisture measurement technologies
Capacitive (ceramic) sensor technology
Optical (chilled mirror) sensor technology

Hygrometer Products
Industries and applications
Benefits of moisture measurement

Basic Definitions and Terminology

Humidity
The presence of water vapor in the air or
industrial gases
Relative humidity
0% to 100%

Absolute humidity
Dewpoint in F or C; PPM

Hygrometry
The subject of humidity measurement
Hygrometer measures humidity
Multiple device names

Basic Definitions (continued)

Dewpoint
The temperature in F or C at which condensation
(dew) occurs if a gas is cooled at constant pressure
Absolute humidity
Relates directly to water vapor pressure
High dewpoint = more humidity (water vapor)
Low dewpoint = less humidity (water vapor)

Hygrometers are specified/calibrated in a

dewpoint measurement range
Example: -100C to +20C (-148F to +68F)

Why Measure Moisture?

Moisture is a serious contaminant
Exists in all industrial gases
Is capable of penetrating most
materials, including plastics, copper,
bronze and carbon steel

To determine precise point where

condensation will form

Why Measure Moisture?

(Continued)

Moisture as a Contaminant
Penetrate virtually any surface
Cause poor product quality
Cause corrosion in pipes, tubing and
instruments
Enable ice formation at low temperatures
Invalidate test results
Cause equipment failure and premature wear
React with other chemicals and gases
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Moisture Measurement
Technologies
Two primary technologies for industrial
moisture measurement
Capacitive (ceramic or aluminum oxide)
sensor technology
Optical (chilled mirror) sensor technology

Capacitive Technology
Sensing element produces a capacitance
value thats related to the amount of water
vapor it measures
Increases/decreases in water vapor pressure
cause changes in capacitive device output
Respond rapidly to changes in applied moisture

Feature a broad calibrated range

Widely used in many industrial moisture
measurement applications

Challenges: Long term drift

Temperature effects

Capacitive Technology
Typical dewpoint measurement range
-100 to +20C (-148 to +68F)

Porous Conductive
Layer

Hygroscopic
Active Layer

Conductive Layer

Ceramic Substrate

Optical (Chilled Mirror) Technology

Optical hygrometers cool a sample of the
gas to the point where condensation forms
on a metallic mirror and a temperature
sensor measures the temperature at which
this occurs - the dewpoint.
A fundamental measurement method

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Chilled Mirror Optical Hygrometer

Operating Principle

Peltier thermoelectric cooler cools

mirror to form dew or frost

Optical-electronics system detects

dew or frost on mirror surface

Feedback loop holds mirror temp

precisely at point where dew or
frost has just formed

PRT in mirror measures temp at

which dew or frost has formed

Measurement is provided as visual

display or output signal

Optical (Chilled Mirror) Technology

Optical sensors vs. capacitive sensors
Fundamental measurement method
More precise
Dewpoint accuracy to 0.1C vs. 1.0 to 2.0C for
capacitive

Measure higher dewpoints

Up to +90Cdp vs. +20Cdp

Operate in higher temperatures

Up to +130C vs. +60C

Drift-free
Longer term calibration stability
Challenges:

Higher cost per measurement

Larger footprint

Measurement Techniques
Direct Insertion

Simple
Low cost
Exposes sensor to contaminants
Requires process shutdown for
maintenance
Sample Bypass
Temperature, pressure, flow rate too
A filter minimizes contamination
high
A valve facilitates maintenance
Sample Block
Higher initial cost
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Hygrometer Products

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Kahn Hygrometers Capacitive

For fixed on-line measurements in
non-hazardous areas
Cermet II Hygrometer
Easidew Transmitter
Pura Pure Gas Transmitter
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Cermet II Hygrometer

Ceramic dewpoint sensor

Digital display
6-ft long sensor cable
Power cord for 120 VAC
-148 to +68Fdp range
-100 to +20Cdp range
0 to 10,000 PPM
4-20 mA or 0-10 VDC
analog output
Programmable alarm relays
Optional NEMA 4 enclosure
for display
Cermet II Display in NEMA 4 enclosure

Easidew Transmitter
4-20 mA output
-148F to +68F
-100C to +20C

Accuracy of 3.6F
(2.0C)
12 to 28 VDC operation
Pressures to 6500 PSIG
Small footprint; easy to install
Low cost

Easidew Transmitter

Pura High Purity Gas

Transmitter
Trace moisture in high purity gases
Dewpoints from -184F (<1ppbv) to 40F
VCR gas connection ports
Internal 0.25 Ra m electro-polished
finish
Double bagged and sealed in UHP inert
gas or single bagged
4-20 mA or RS485 output
12 to 28 VDC operation
Pressures from 10-9 Torr to 3500 PSIG
Local display available

Pura

Kahn Hygrometers Capacitive

For spot-check measurements in
non-hazardous areas
HygroPort Portable Hygrometer
Easidew Plus Portable Hygrometer

HygroPort Portable Hygrometer

Dewpoints from -148F to +68F
Extremely fast measurements
F or C dewpoint, PPMv, PPMw

Backlit display; easy reading in bright light

Data logging up to 320,000 points
Bluetooth wireless interface
Operates up to 5000 PSIG pressure
Durable NEMA 4 industrial design
Easy to handle and operate

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Easidew Plus Portable Hygrometer

Dewpoints from -58F to
+68F
Accuracy of 3.6F
Built-in sampling system
Pressures to 4300 PSIG
Exceptionally fast response

F or C display
NEMA 6 enclosure
Simple to operate

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Kahn Hygrometers Capacitive

For fixed on-line measurements in

flammable gases or hazardous areas
Easidew IS Transmitter
Easidew PRO IS Transmitter
Easidew PRO XP Transmitter
Easidew PRO IS Hygrometer
Pura IS High Purity Gas Transmitter

Easidew I.S. (Intrinsically Safe)

Dewpoint Transmitter
FM and CSA certified
Intrinsically safe
Class I, Div 1, Gr A, B, C, D
Use with safety barrier

Linear 4-20 mA signal

-100 to +20C dewpoint
-148 to +68F dewpoint
0 to 3000 PPMv moisture content

12 to 28 VDC operation
Pressures to 6500 PSIG

NEMA 4 stainless steel housing

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Easidew PRO I.S. (Intrinsically

Safe) Dewpoint Transmitter
Heavy duty process-type
stainless steel housing

Fitting for conduit entry

Stainless steel sensor guard

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Easidew PRO XP (Explosion Proof)

Moisture Transmitter
Explosion proof / flameproof

Heavy duty process-type aluminum,

epoxy and polyurethane powder
coated housing
Dual conduit entry fittings
Stainless steel sensor guard
Integral display module available
Use without a safety barrier
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Easidew PRO I.S. (Intrinsically Safe)

Hygrometer
Intrinsically safe dewpoint sensor, local
display, sensor cable, galvanic isolation
safety barrier, power cord for 120 VAC
FM, CSA-Certified sensor
Class 1, Div 1, Gr A, B, C, D hazardous
areas

-148 to +68F (-100 to +20C)

dewpoint range
0-10,000 PPMv moisture content

0 to 1000 Lb/MMSCF moisture content

Current, voltage, digital outputs & relays
Pressures to 6500 PSIG
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Pura I.S. (Intrinsically Safe)

High Purity Gas Transmitter
Same basic features and specs as
standard Pura
Classified for use in hazardous areas
Use with galvanic isolation barrier

Available in various models

Pura IS

Kahn Hygrometers Capacitive

For spot-check measurements in

flammable gases or hazardous areas
HygroPort IS Portable Hygrometer

HygroPort I.S. (Intrinsically

Safe) Portable Hygrometer
FM, CSA, ATEX certified intrinsically safe
Class I, Division 1, Groups A, B, C, D
-148 to +68Fdp (-100 to +20Cdp)
range
Fdp or Cdp; Pressure compensated
PPM and Lb/MMSCF moisture content

Data log 320,000 points; BlueTooth upload

Backlit display; easy reading in bright light
Durable NEMA 4 industrial design
Extremely fast measurements
Easy to handle and operate

Kahn Hygrometers
Chilled Mirror Technology

For fixed on-line measurement

Optidew Hygrometer product family

Optisure Hygrometer product family

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Optidew Dewpoint and RH Hygrometer

Chilled mirror optical sensor
Dewpoint, temperature, RH
Range: -40F to +194F,
0.36F
0.5% to 100% relative humidity
Optional integrated display
Dual 4-20mA outputs; Alarm relay
Stainless steel NEMA 4 industrial or
general purpose enclosures
Wall mount, bench top, remote
sensor models
Dynamic Contamination Correction
Drift-free dewpoint measurement
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Optisure Hygrometer
Product Family

Optisure Remote

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Optisure Hygrometer
Product Family
Dewpoint from -130F to +194F
0.18F ( 0.1C) accuracy

Intuitive, high-resolution touch screen display

Internal and remote sensor configurations
Dynamic Contamination Correction (DCC)
4-20mA, 0-20mA, and 0-1 VDC outputs
USB, MODBUS RTU digital outputs

Fundamental, drift-free dewpoint measurement

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HYGROMETER APPLICATIONS

Industrial Environments 34

HYGROMETER APPLICATIONS
Industrial Plants

HYGROMETER APPLICATIONS
Industrial Plants

Environment

General manufacturing plants, refineries,

paper mills, etc. where dry compressed air:
Powers pneumatic tools and equipment
Controls valves
Drives conveying systems
Activates painting systems

Applications

Measure dewpoint at outlet of the air dryer

Measure dewpoint downstream of the dryer
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HYGROMETER APPLICATIONS
Industrial Plants
B
Instrument quality
Compressed air
-40 deg. F dewpoint
at 100 PSIG pressure

COMPRESSOR
COALESCING FILTER
70 deg. F operating temp.
Atmospheric air
+45 deg. F
dewpoint

DESICCANT
DRYER

RECEIVER
100 PSIG

Compressed Air System

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HYGROMETER APPLICATIONS
Industrial Plants

Solutions
Hygrometers installed
permanently on or downstream
of desiccant air dryers
Cermet II Hygrometer
Easidew Transmitter

Easidew Transmitter

Spot-check measurements to
verify dryer performance or check
the accuracy of the permanently
installed hygrometer
HygroPort Portable Hygrometer
Easidew Plus Portable Hygrometer

Easidew Plus Portable

HYGROMETER APPLICATIONS
Electric Power-Generation Plants

HYGROMETER APPLICATIONS
Electric Power-Generation Plants

Environment
Coal, natural gas, oil, nuclear electric powergeneration plants

Applications
Dry compressed air is used for pneumatic
control and instrumentation
Hydrogen is used to cool electric generators

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HYGROMETER APPLICATIONS
Electric Power-Generation Plants

Solutions
Measure dewpoint of compressed air
Cermet II Hygrometer
Easidew Transmitter
Easidew Plus or HygroPort Portable

Easidew Transmitter

Measure dewpoint of Hydrogen

Easidew IS Transmitter
Easidew PRO IS Transmitter
Easidew PRO XP Moisture Transmitter
Easidew PRO IS Hygrometer

Easidew IS Transmitter

Easidew PRO XP Transmitter

Easidew PRO IS Hygrometer

Easidew PRO IS Transmitter

HYGROMETER APPLICATIONS
Electric Power Distribution

SF6 Gas Insulated Circuit Breaker

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HYGROMETER APPLICATIONS
Electric Power Distribution

Environment

High-voltage substation circuit breakers

Operate from 100,000 to 400,000 volts
Breaker is filled with SF6 gas for insulating & arc extinguishing

Application

Measure PPM moisture content of SF6

Insure low moisture levels to prevent condensation
Prevent corrosive acidic damage to circuit breaker

Solutions
HygroPort Portable Hygrometer
Easidew Dewpoint Transmitter
Cermet II Hygrometer

Easidew Transmitter

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HYGROMETER APPLICATIONS
Furnaces and Metal Heat-Treating

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HYGROMETER APPLICATIONS
Furnaces and Metal Heat-Treating

Environment
Vacuum, annealing, conveying, brazing and other furnaces
Operate at temperatures of 1000 to 2000F
Dirty atmospheres - particulates and combustion byproducts

Application
Measure dewpoint of furnace atmosphere
Measure dewpoint or moisture content of purge gas: N2, H2, Ar

Solution

Extract a sample through a coiling coil

Install a filter in the sample line
Install vacuum pump for gas flow if furnace is not pressurized
Cermet II Hygrometer or Easidew Transmitter and sample block
Sampling system with sample block, filter, valves, gauges, pump

Furnaces and Metal Heat Treating

Non-pressurized system
Sampling System with Vacuum Pump
Easidew Transmitter

Cable to customers display

Sample Pump Assembly

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HYGROMETER APPLICATIONS
Pipeline Construction and Maintenance

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HYGROMETER APPLICATIONS
Pipeline Construction and Maintenance

Environment
Pressurized water is used to leak test pipelines during
construction and post-construction maintenance
Hot air is blown through pipeline to dry it out

Application
Verify that the pipeline is dry before putting it into operation

Solution
Fixed on-line measurement
Two Cermet II Hygrometers, one installed to measure dewpoint of hot
air at the inlet and one installed at the outlet side of pipeline
When difference in dewpoint is <5C, pipe is considered dry

Spot-check measurement
Easidew Plus Portable Hygrometer
HygroPort Portable Hygrometer

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HYGROMETER APPLICATIONS
Natural Gas Production and Transportation

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HYGROMETER APPLICATIONS
Natural Gas Production and Transportation

Environment
Wet extracted natural gas is processed and dried using
glycol dehydration and molecular sieve

Application
Measure the moisture content of dried natural gas

Solution
Fixed on-line measurement
Easidew PRO IS Hygrometer
Easidew PRO XP Moisture Transmitter

Spot-check measurement
HygroPort IS Portable Hygrometer

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HYGROMETER APPLICATIONS
Semiconductor Manufacturing

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HYGROMETER APPLICATIONS
Semiconductor Manufacturing

Environment
Clean rooms where wafers are produced and stored
Ultra-high purity gases used in manufacturing

Applications
Measure humidity in air in clean room production areas
Measure moisture content of ultra-high purity gases

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HYGROMETER APPLICATIONS
Semiconductor Manufacturing

Solutions

Optidew-W

Clean rooms
Optidew Wall Mount
Hygrometer

Ultra-high purity gases

Pura High-Purity Gas
Dewpoint Transmitter

Pura

HYGROMETER APPLICATIONS
Air Separation and Industrial Gas Suppliers

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HYGROMETER APPLICATIONS
Air Separation and Industrial Gas Suppliers

Environment
Separating atmospheric air into
nitrogen, argon, oxygen, hydrogen,
carbon dioxide and helium

Application
Determine moisture content of the
separated gases

Easidew Transmitter

Solution
Permanent installation
Cermet II Hygrometer
Easidew Dewpoint Transmitter

Spot-check measurement
HygroPort Portable Hygrometer

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HYGROMETER APPLICATIONS
Ozone for Purification and Sanitation

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HYGROMETER APPLICATIONS
Ozone for Purification and Sanitation

Environments
Ozone generators used in purification and sanitation
processes for beverages, industrial wastewater, produce
cleaning, pulp bleaching

Application
Measure the dewpoint of air or oxygen feeding the ozone
generator

Solution
Permanent installation
Cermet II Hygrometer
Easidew Transmitter

Spot-check measurement

Easidew Transmitter

HygroPort Portable Hygrometer

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HYGROMETER APPLICATIONS
Calibration Laboratories

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HYGROMETER APPLICATIONS
Calibration Laboratories

Environment
Clean, temperature controlled indoor setting
requiring extreme accuracy and stability and a
wide dewpoint measurement range.

Applications
Reference hygrometer
Calibrate dewpoint sensors
Calibrate relative humidity sensors
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HYGROMETER APPLICATIONS
Calibration Laboratories

Solutions
Optisure Hygrometers as a
calibration reference
-90 to +90Cdp; 0.1Cdp
Internal or remote sensor
Drift-free measurement

DCS Dewpoint Calibration

Systems
Fully integrated
DP range -100 to +20C
NIST traceable calibrations

Opti-Cal Humidity Calibrator

10% to 90% RH
10 to 50C; Temp. controlled
NIST traceable reference

The Benefits of Moisture

Measurement
By understanding moisture in industrial
applications:

Improve product quality

Minimize equipment damage
Save energy
Reduce Costs
Meet contractual obligations

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Kahn Instruments, Inc.

Hygrometers and Moisture Measurement
885 Wells Road
Wethersfield, CT 06109 USA
Phone: (860) 529-8643
Fax: (860) 529-1895
Email: hygros@kahn.com
www.kahn.com
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