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2026.10.04

Implementing Compressed Air Dew Point Monitoring in Thai Factories: Selection, RFP and Acceptance

Implementing Compressed Air Dew Point Monitoring in Thai Factories: Selection, RFP and Acceptance

You want to implement compressed air dew point monitoring, but where should the instruments go, and what should count as acceptance? Equipment teams at Thai factories often face these questions. Start by putting the air quality required by each product or process, the conditions for measuring pressure dew point, the different purposes of monitoring at the dryer outlet and point of use, and the actions to take after an alarm into one requirements document. This article connects procurement, testing and daily operation.

What to Decide First When Implementing Compressed Air Dew Point Monitoring

Dew point is the temperature at which water vapor in air begins to saturate. In a compressed air line, the concern is not simply that the air seems humid. Moisture may become liquid under the specified operating conditions and affect pipes, valves, pneumatic equipment, painting, measurement and product contact areas. A room thermometer and relative humidity meter cannot stand in for a measurement of dryness inside the pipe. Dew point also depends on pressure: measuring the same sample under line pressure and after reducing it toward atmospheric pressure produces values with different meanings.

The first deliverable should be a one-page requirements table, rather than a purchase request for a dew point meter. List the compressed air system diagram, critical points of use, quality limits, measurement locations, measurement pressure, actions after an alarm and users of the records. If these are blank, even a functioning instrument may fail to provide the control the process needs. The U.S. Department of Energy’s compressed air guidance also recommends a systems approach covering both supply, including compressors, dryers and filters, and demand, including piping and end-use equipment. Dew point monitoring is one way to verify air quality within that system; the instrument alone does not guarantee energy savings.

How This Differs from Ambient Humidity and Power Monitoring

Factory temperature and humidity monitoring observes the surrounding air. Compressed air dew point monitoring observes water vapor remaining after compression, drying and distribution. Both readings can appear on the same screen, but they must not share a sensor, measurement conditions or acceptance criterion. Energy monitoring of compressor power and airflow can help improve leak management and operating control. Dew point data, in turn, shows whether a dryer maintained outlet quality and whether sufficiently dry air reached the end of the line. Design dew point for quality and flow and power for energy as separate indicators; compare them on the same timeline when useful.

Using ISO 8573-1 and ISO 7183 for Different Purposes

ISO 8573-1:2010 addresses contaminants and purity classes in compressed air, classifying solid particles, water and oil. An order can be specified more clearly by stating the water class needed for the process and where it applies than by asking only for “dry air.” The classes do not replace an assessment of risks specific to the product. There is no basis for applying one dew point requirement indiscriminately to food, electronic components, painting and general assembly. Establish limits from customer requirements, product standards, process conditions and records of past defects.

ISO 7183:2007 covers compressed air dryer specifications and testing, including methods for measuring pressure dew point, flow, pressure drop, air loss and power consumption. It helps compare dryer performance during procurement, but a performance figure at the dryer outlet does not by itself guarantee air quality at the point of use. The site assessment must also cover piping, receivers, bypasses, maintenance work and moisture entering downstream.

Implementing Compressed Air Dew Point Monitoring in Thai Factories: Selection, RFP and Acceptance - figure 1

Do Not Confuse Pressure Dew Point with Atmospheric Dew Point

“What is the dew point?” is an incomplete question without the measurement pressure. Pressure dew point describes compressed air at the relevant pressure; atmospheric dew point describes it under conditions after pressure reduction. If pressure changes while the amount of water vapor remains the same, the partial pressure of water vapor changes, so the indicated dew point of that air stream is not the same. To manage condensation risk at line pressure, define the conditions under which pressure dew point is recorded.

For a sampling cell, show the takeoff point, pressure-reduction point, valves, flow restriction and exhaust destination on the drawing. A configuration that keeps the sensor at line pressure and one that reduces pressure before measurement require different interpretations of the displayed value. Vaisala’s sampling cell documentation shows that cell types differ in where pressure is maintained and how flow is controlled. Ask the vendor to answer in writing: “At what pressure is the displayed dew point defined?” and “How is a change in actual pressure compensated?” A proposal that says only “dew point sensor included” cannot be compared properly.

Before comparing sensing principles and ranges alone, define the required dew point range, allowable error, response time, operating pressure, inlet temperature and possible oil or particle contamination. Refrigerated and adsorption dryers have different expected dryness ranges and operating behavior. Adsorption dryers also regenerate and switch desiccant beds, so the design must distinguish normal cyclic changes from faults. Atlas Copco’s technical explanation describes how desiccant retains water vapor and how the regeneration method changes system configuration. Do not choose a dryer type from this article alone; compare quotations against the required air quality, load and maintenance conditions.

Eight Parts of a Pressure Dew Point Sensor Selection Specification

1. Measurement conditions. State normal, minimum and maximum pressure; air temperature; flow; expected dew point range; starts and stops; dryer changeover; and recovery after a power outage. Ask for the required accuracy and response within the stated range, not merely a catalog claim that the reading falls “within measuring range.” A process that never needs very low dew points need not buy excessive specifications. Conversely, a displayed value outside the sensor’s guaranteed range cannot support acceptance.

2. Definition of the displayed dew point. Specify whether it is pressure or atmospheric dew point, the unit, source of the pressure-correction input, rounding in the display and communications, and treatment of timestamps. A PLC tag named only “dew point” can mix values from different systems or change meaning when a device is later replaced. Keep the system, location and pressure reference in the tag name or metadata.

3. Sampling method. Decide between direct insertion and a bypass cell, and specify takeoff pipe material and length, inlet and outlet valves, filters, leak checks, purge procedure and exhaust destination. A stagnant sample cannot follow actual changes, while moisture entering through pipes or fittings can create an apparently high dew point. As Vaisala’s documentation shows, a sampling cell is part of the pressure- and flow-controlled measurement system, not merely a mounting bracket.

4. Contamination resistance and protection. Check whether oil, liquid water, dust or condensate can reach the sensor, and specify necessary pretreatment and maintainable filters. Repeated liquid water upstream of the sensor should be addressed in the dryer, drains, filters or bypass rather than treated as an instrumentation problem alone.

5. Signals and power. Specify whether the system will use 4–20 mA, digital communications, contacts or a gateway. Require status signals that distinguish power loss, communication loss, broken wires and invalid readings from a real dew point exceedance. When a dashboard value stops updating, it must not continue to present the last good reading as “good.” Preserve timestamps and data quality flags.

6. Calibration and replacement. Check calibration certificates, calibration points, traceability, conditions for removal on site, spare instruments and configuration after replacement. Separate checks that can be done on site from work requiring return to the manufacturer or a calibration laboratory. Set the calibration interval from product risk, operating environment, historical drift and customer requirements, rather than one universal number.

7. Cost of ownership. In addition to purchase price, include sample piping, valves, filters, panel modifications, wiring, network work, PLC and SCADA configuration, calibration, consumables, shutdown work and training in the quotation. No procurement country, model or installation scope has been specified here, so this article does not invent a uniform price. Ask vendors to cost the same scope when comparing bids.

8. Support. Confirm a contact in Thailand, first response to failures, supply of replacements, notification of specification changes, software update methods and maintenance documents in Thai and English. The ability to maintain data continuity during calibration and failures matters more to long-term operation than the first days after installation.

Implementing Compressed Air Dew Point Monitoring in Thai Factories: Selection, RFP and Acceptance - figure 2

The Air Dryer Outlet and Point of Use Answer Different Questions

Measuring at the dryer outlet asks whether the dryer and nearby treatment system deliver the required value. A high dew point there calls for investigation of overload, cooling conditions, refrigerant or desiccant, drains, bypasses and inlet temperature. If the outlet reading is good but liquid water appears at the end of the pipe, inspect for moisture entering or remaining downstream. It is risky to treat the dryer outlet as representative of the whole factory without verification.

Measuring at the point of use asks whether the air actually reaching the process meets the requirement. A position near a critical process is more likely to capture the effects of long piping, dead legs, local receivers, bypass operation and moisture introduced during maintenance. An end-point reading alone, however, may not reveal where a problem began. Consider a combination of the dryer outlet and critical points of use when both equipment fault diagnosis and process quality assurance are needed. This does not mean installing the same number of instruments at every outlet. Select representative monitoring locations based on product risk and pipe layout.

Draw “compressor → aftercooler → water separation → receiver → pretreatment → dryer → downstream filter → main piping → point of use” on the system diagram, then correct the order to match the actual plant. Add bypasses, standby dryers, pipe low points, drains and existing sampling ports. Write one question for each measurement point. For example, at the outlet: “Can we detect deterioration in outlet pressure dew point during a dryer shutdown or changeover?” At a point of use: “Is the line within the quality limit before it contacts the product?” Different questions may need different alarm priorities.

Commonly Missed Details in Sampling Cell Design

Bypass measurement can make sensor maintenance easier. But a closed valve, blocked filter, reverse flow or insufficient exhaust can leave the display showing a stagnant sample rather than the air currently in the pipe. Design a way to confirm sample flow or circulation, and consider showing maintenance isolation on the monitoring screen. Pipe and fitting leaks, and the entry of ambient air, also matter in low dew point measurement. Check the integrity of the sampling path before attributing every abnormal value to dryer failure.

Avoid ports where liquid water directly strikes the sensor, oil collects at a low point, or maintenance access is impractical at height. Check actual pressure, temperature, flow direction and safe installation procedures against the manufacturer’s operating conditions. Every configuration needs physical space for an operator to isolate and depressurize it safely and exchange it for a calibrated spare. An initial drawing can prevent a layout that later requires an extended production shutdown simply to disconnect a pipe.

Design Alarms Around Both Values and Site Actions

Do not copy a representative alarm value from a catalog. Start with the product or process limit, then account for measurement error, response delay, pipe transit time and transient behavior at startup when defining warning, response and process-stop conditions. Set numeric thresholds through a risk assessment and tests for the specific factory. Hysteresis, persistence time and reset conditions can reduce repeated alarms during brief changeover fluctuations. Excessive delay, however, can hide a quality problem; measure the actual air transit time and the time before the process is affected.

At the warning stage, maintenance checks sample flow, dryer condition, drains, filters and load. At the response stage, notify quality and production, and record the affected lots and time period. If a stop condition is reached, define who decides to isolate the process or quarantine the product. Recovery should require more than a normal dew point reading: define the sequence for eliminating the cause, replacing air in the pipe, checking the point of use and deciding the disposition of affected lots.

An abnormal-condition notification should include the measurement point ID, pressure conditions, current value, preceding trend, start time, duration, sensor diagnostics, sample status, dryer operating state and affected process. In Thai factories, shift operators may read these messages, so prepare short operating instructions in English or Thai. A number sent to a phone will not speed up action if nobody knows which valve to check.

Implementing Compressed Air Dew Point Monitoring in Thai Factories: Selection, RFP and Acceptance - figure 3

Turn Trends from Displays into Decisions

Alongside dew point, the time-series view should be able to show line pressure, air temperature, dryer operation and changeover status, approximate flow, and alarm and maintenance histories at the same time. A change in line pressure can change how the dew point reading is interpreted. Look for the operating conditions under which the trend worsens, such as immediately after regeneration, at shift startup or during peak demand. Investigate sensor contamination and insufficient sample flow as possible causes. Do not assume every deterioration calls for replacing the dryer.

Using alarm count alone as an operations KPI is weak because changing alarm settings can reduce the count. Review time outside the required dew point, affected processes, time to identify the cause, evidence of corrective action and recurrence together. Show periods without data as missing, not “good.” Where a quality audit requires it, define calibration history, approval of threshold changes, time synchronization and raw-data retention.

If the measurement is connected for remote monitoring, document the boundary of responsibility between the dew point instrument and the PLC or data collection platform. Decide whether a local alarm is required when communications fail or whether cloud analysis is enough. For an example of remotely detecting abnormal conditions in steam equipment, see wireless steam trap monitoring in Thai factories. For consistent equipment data meaning and communications status, see MQTT Sparkplug B implementation design. These related articles concern maintenance data integration and operations design; they are not substitutes for dew point measurement.

What to Include in a Dew Point Monitor RFP

A request for quotation cannot be compared on sensor unit price alone. Begin with the purpose, the compressed air system, critical points of use and effect on product quality. State the basis of the required moisture limit and the conditions under which pressure dew point must be displayed. Say whether the scope covers the dryer outlet, points of use or both, and whether the same instrument type is required at both. The buyer can specify measurement requirements and operating conditions even before selecting a model.

RFP itemEvidence to request from the vendorCommon omission
Measurement definitionPressure reference, range, accuracy, response“Dew point display” only
InstallationPiping drawing, mounting position, sampling path, exhaustSensor body drawing only
SignalsTags, communication specification, handling of broken wires and missing dataDemo showing normal readings only
AlarmsThreshold settings, delays, reset conditions, notification recipientsAlarm lamp only
CalibrationCertificate, inspection procedure, replacement procedureVerbal explanation of interval
TestingFAT/SAT cases, acceptance criteria, record format“Complete site adjustment”
CostsBreakdown for instruments, installation, controls, maintenance and sparesSensor price only

Ask for model numbers, versions, drawing numbers, test cases and the party responsible for installation, not a simple “can comply” response. If a sampling cell is required, define the supply scope to include valves and exhaust piping. Specify interface definitions and acceptance tests separately for existing SCADA connections and quality-system records. Keeping the measurement point tag separate from the dew point conditions preserves the meaning of records when a sensor is replaced later.

Compare Costs on the Same Total Scope

In the bid comparison, examine whether each vendor covers the same scope, not simply which equipment price is lowest. Check port machining, shutdown work, sample pipes, filters, PLC I/O, communication gateways, screens, alarm logic, calibration and replacement, maintenance training and on-site SAT line by line. Assign a connection owner even when outsourced work is contracted separately. Prices vary by location, instrument count, installed equipment and calibration scope, so compare quotations against the same requirements table instead of relying on an unsupported market price here.

Use FAT and SAT to Accept More Than a Displayed Number

FAT verifies tags, outputs, communications, alarm logic, simulated faults and data storage at the vendor’s facility. SAT checks whether the same requirements are met with the site’s actual pressure and piping, existing PLC, real operation and shift work. Give every test case a requirement ID, input conditions, expected result, evidence and assessor. A number appearing on a screen is not evidence that measurement pressure and sample flow are correct.

FAT examples include high and low simulated dew point values, broken wires, lost communications, power cycling, clock offsets, permission to change thresholds and missing data. SAT examples include leak tests of site piping, confirmation of sample flow, records during dryer shutdown and changeover, comparison with a point of use, notification recipients, comparison with a calibrated reference instrument and sensor replacement under the work procedure. Deliberately introducing wet air that may endanger the process should be replaced with simulated input or an isolated test after assessing product risk.

Do not automatically require the dryer outlet and point-of-use readings to match exactly at SAT. Pipe length, pressure, sample conditions and sensor response differ. First align the measurement definitions and expected behavior at each point, then define the investigation sequence for any difference. Time-synchronized trends, line pressure and dryer status submitted together can help diagnose differences between points. After testing, obtain signed confirmation of settings and notification recipients so the system is not handed over with alarms disabled.

Roles and Change Control After Implementation

Roll Out in Small Stages

Before distributing instruments across several factories, establish the measurement definition on one system with a clear quality risk. First review process requirements, dryer specifications, pipe drawings, existing problems and the route by which moisture could affect the product. Then inspect candidate points at the outlet and critical uses on site, considering shutdown feasibility and safe sample takeoff. Once measurement pressure and data logging have been defined, use a short preliminary measurement period to understand normal load changes, shift startup and dryer changeover. Set alarm thresholds and delays based on those measurements, then verify them through FAT and SAT. This sequence can avoid the cost of rolling out a poorly placed measurement point across the whole factory.

Do not call only the driest instant in the preliminary measurement a performance result. Record the production plan, demand, ambient conditions, operating pressure and dryer state together, and examine what happens under adverse conditions. Even if hot and humid seasons in Thailand are a concern, relate conclusions to measured line conditions rather than estimating compressed air dew point from outdoor humidity. If the project cannot wait to test across seasons, state its scope and unverified conditions in the acceptance record and plan a later follow-up test.

Connect Product Quality and Equipment Maintenance Data

Dew point data is more useful when it reaches beyond maintenance. Relating lot start and end times, the air line used and manufacturing times to affected processes can narrow the product range requiring review after a dew point excursion. A dew point reading alone, however, does not prove a product defect. Painting conditions, raw materials, process temperature and other air contaminants may also affect quality. Use dew point as condition information that triggers an investigation; make the final decision under product and process inspection criteria.

Put failed drain discharge, filter replacement, desiccant maintenance, bypass operation, power outages, restarts and sensor calibration on the same maintenance timeline. If someone operated a bypass immediately before an abnormal reading, inspect the piping state before replacing the dryer. In recurrence reviews, check whether the cause was removed and equipment or procedures changed, rather than merely whether someone cleared the alarm. Even when remote monitoring is outsourced, the factory retains authority to operate valves and isolate products. Include the chain from notification to first response in the contract.

Define the Record of Truth and Handle Missing Data

When the same reading is passed to a PLC, SCADA, historian and quality system, define the authoritative raw record and its timestamp. With communication delay or buffered transmission, receipt time differs from measurement time. Keep time synchronization and time zone rules, units, pressure reference, rounding and any correction in the metadata. For analog output, test which current values and quality codes indicate out-of-range readings, broken wires and maintenance. Interpolating missing values may sometimes make an operations screen easier to read, but audit source records must identify the gaps.

Record the dates of sensor replacement, measurement location changes and pressure-correction changes so trends can be compared later. For example, if dew point improves after point-of-use piping is modified, but the sampling cell and measurement pressure also change, the measured improvement cannot be assigned directly to the piping work. Distinguishing measurement-system changes from process changes is necessary for both quality control and assessment of cost effectiveness.

Operators receive alarms and perform the specified first checks and product isolation. Maintenance inspects the dryer, drains, piping, sampling system and sensor diagnostics. Quality manages affected lots and the decision to resume. IT/OT maintains data connections, accounts, time synchronization and backups. The equipment vendor supports calibration, fault analysis and software updates. Where responsibilities overlap, state who makes the final decision.

Treat configuration changes as formal process changes. When thresholds, delays, pressure correction, measurement points, PLC tags, dashboard units or notification recipients change, record the reason, approver, before-and-after settings, affected data period and retest results. After a sensor is exchanged for calibration, do not resume operation without checking pressure reference, analog scaling and alarm settings merely because its model and measurement range are the same.

In site handover instructions, describe “high dew point,” “lost communications,” “no sample flow” and “calibration overdue” as separate events, alongside normal readings. Whether to isolate product or stop equipment after a high dew point differs by process. Translate illustrated procedures into the working language on site and rehearse them across shifts. Judge the benefit of implementation by the ability to detect a problem, limit its effect on products, and document its cause and prevention of recurrence, rather than completion of a dashboard.

Handover to Daily Operations and Expansion

Carry Site Acceptance Checks into Daily Operation

Some factories discard the test sheet prepared for acceptance after handover. Yet sample flow, pressure conditions, alarm notifications and the display of missing data, all verified during acceptance, should also be checked routinely. A screen that operators check every day should clearly show whether each measurement point is operating, whether its current value is valid and within the required range, and whether any alarm has been left pending, rather than crowding the screen with too many figures. Detailed trends and calibration certificates can be on separate screens. The essential point is to prevent missing quality-related data or maintenance status from blending into a green “normal” display.

Write four distinct parts into the operating procedure: checks at the start of a shift, handover between shifts, first response to an abnormal condition and approval to resume. At startup, check the system, dryer operation, communication with measurement points and the position of sample valves. At shift change, pass on alarms from the previous shift, equipment under maintenance and quarantined products. During an abnormal condition, state who checks the dryer and sampling system and who decides whether the affected process may continue. For recovery, require the cause, product disposition, a fresh check at the point of use and an approval record, as well as a restored reading. Preparing these instructions in the local working language helps keep the response consistent when the night shift changes personnel.

Checking an alarm email or screen notification once during acceptance is insufficient if staff or notification recipients later change. Review contacts and duty rosters regularly to make sure alerts reach the people who will actually respond. For maintenance that temporarily suppresses an alarm, record who started the suppression, why, its scheduled end time and the alternative monitoring method. Reinstate the alarm automatically or with approval after the work. A system with alarms suppressed indefinitely cannot be considered an effective monitoring implementation.

Set a Diagnostic Sequence to Avoid Unnecessary Replacements

When dew point rises, assuming immediately that the dryer has failed risks replacing a functioning machine while leaving the cause in place. First verify that the reading is valid: check sensor diagnostics, calibration status, sample valves, flow, exhaust, line pressure and the reading’s timestamp. Next inspect conditions at the dryer inlet and outlet, drains, filters, bypasses and the changeover state of standby equipment. Then compare the condition at the end of the piping and at points of use with any moisture found in the process. The investigation scope differs depending on whether both upstream and downstream readings worsened or only a point of use did.

Record the time of the event, instruments checked, conditions observed on site, actions taken, time of recovery and product impact in the diagnostic result. Even if the cause cannot be identified, do not close the case as “temporary.” Decide what additional measurement to take if the same change recurs. For example, if an abnormality was observed only at the point of use and no dryer outlet record exists, plan a temporary measurement at the outlet next time. The monitoring installation is not complete once the first drawing is issued; records of abnormalities and responses should inform improvements to instrument placement and alarms.

Standardize the Right Items When Expanding

Once operation on one compressed air system is stable, do more than standardize the instrument model when expanding to another line or factory. Common definitions for measurement pressure, tag names, units, timestamps, data quality, alarm categories, calibration records and test forms make comparisons across sites meaningful. Quality limits may differ by process, however, so do not apply one alarm value unconditionally to every site. Review each factory’s piping diagram and product risks, and approve the shared and site-specific requirements separately. When an equipment upgrade changes the dryer type or piping, reassess whether existing dew point monitoring still represents the system adequately.

Common Failures and How to Correct Them

First, treating the dryer outlet reading as a guarantee for the whole factory. If a critical point of use has its own requirement, measure there or establish a verification plan that demonstrates compliance. Second, applying a pressure dew point limit directly to a dew point measured after pressure reduction. Record measurement pressure and, if converting a value, verify the assumptions and method. Third, mistaking the slow response of a contaminated sampling system for dryer lag. Include maintenance valves and flow in tests.

Fourth, leaving responsibility undefined after an alarm. Define decision boundaries and contact order for quality, maintenance and production. Fifth, treating calibration or replacement only as “maintenance” and forgetting data continuity and reacceptance. Record readings before and after replacement, pressure conditions and certificate numbers. Sixth, claiming energy savings solely because dew point improved. To assess energy effects, separately measure power, flow, pressure drop and dryer operating state, and compare conditions that meet the quality constraint.

Conclusion: Procure a Quality Decision Process, Not Just a Dew Point Meter

For compressed air dew point monitoring implementation, derive the required air quality from the process, standardize conditions for measuring pressure dew point, and give the dryer outlet and critical points of use distinct roles. Sensor selection must include the sampling cell, pressure, flow, signals, calibration and replacement. Align drawings, signals, alarms and cost scope in the RFP, and retain evidence of measurement, faults and operation through FAT and SAT. Use trends to diagnose causes and support quality decisions, then turn abnormal-condition responses into site procedures.

If you are selecting measurement points or preparing a dew point monitor RFP for a Thai factory, TOMAS TECH can discuss system diagrams, site surveys, monitoring and integration specifications, and FAT/SAT test cases. If you have documents describing the target process and installed dryer, send them through our contact page.

FAQ: Compressed Air Dew Point Monitoring

Is a Pressure Dew Point Sensor at the Dryer Outlet Enough?

The outlet is important when assessing dryer performance. If you must assure the quality of air delivered to a product or process, also evaluate critical points of use. Select representative points based on piping, risk and operating state.

Can an Ambient Temperature and Humidity Meter Be Used to Control Air Dryer Dew Point?

An ambient temperature and humidity meter does not measure compressed air inside a pipe. Choose a dew point instrument whose range, pressure conditions and sampling system suit the application. Converting relative humidity to dew point also requires temperature and pressure conditions.

Must We Actually Cause a Dryer Failure During Compressed Air FAT/SAT?

Usually not. Alarm logic can be verified with simulated input or an isolated test. Check the sampling path, pressure, pipe leaks, operating state and notification recipients that require the actual installation during SAT. Approve a test plan that does not endanger the product in advance.

What Should a Dew Point Monitor RFP Compare Besides Price?

Compare the definition of pressure dew point, accuracy in the required range, sampling cell, maintenance access, treatment of broken wires and missing data, calibration, local support, PLC/SCADA connectivity and FAT/SAT evidence in one table. Align quotation scopes to include installation and operating costs.

How Many Months Should Pass Between Calibrations?

There is no universal interval. Base it on product risk, the sensor’s contamination environment, manufacturer recommendations, historical drift and customer requirements, and record changes. Also specify how quality monitoring will continue during calibration.

References