Moisture & Condensation Failures
Moisture is the number one killer of industrial analyzers. Liquid water entering the analyzer causes unstable readings, sensor damage, corrosion, and frequent shutdowns.
Field reality:
In most cases, moisture is present long before the analyzer trips —
it is simply ignored.
Typical Symptoms
- Erratic or drifting readings
- Sudden analyzer shutdowns
- Repeated sensor failures
- Blocked filters or flooded sample lines
Common Root Causes
- Inadequate sample cooling or heating
- Blocked or missing drains
- Incorrect sample line slope
- Cold ambient conditions causing condensation
- Failure to monitor dew point
Correct Troubleshooting Order
1) Inspect drains, knock-out pots, traps
2) Check sample line slope and insulation
3) Verify cooler/heater operation
4) Confirm dew point margin
5) Only then inspect analyzer internals
Prevention Best Practices
- Design for worst-case moisture conditions
- Use reliable moisture / dew point analyzers
- Maintain drains as critical equipment
- Never assume “gas is dry”