How to Calibrate and Maintain Pressure Sensors

Pressure sensors are vital to a range of operations and industries, providing a means of accurately responding to pressure fluctuation while creating electrical signals for readings. This basic function is paramount for applications ranging from aerospace and automotive vehicle operations to medical and industrial equipment functionality. For pressure sensors to maintain their accuracy and reliability across these settings, it is necessary to carry out regular calibration and maintenance. Without these essential practices, users may face a host of measurement errors and issues, leading to inefficiencies, safety risks, and even the chance of system failure. In this blog, we will provide an overview of the importance of calibrating and maintaining pressure sensors, detailing best practices to uphold their performance and longevity.

Why Do You Need to Calibrate Pressure Sensors?

Over time, even the best sensors can face performance drift as a result of environmental factors, mechanical stress, or aging components. Calibration is a practice that helps correct these deviations by comparing the sensor’s readings against a known reference standard and making necessary adjustments. In industries like aerospace, pharmaceuticals, and manufacturing, calibration is a necessary element of operations that goes beyond performance objectives, as it ensures compliance with industry standards and safety regulations.

What Pressure Sensors Require Calibration?

Virtually all pressure sensors benefit from periodic calibration, but the frequency and necessity will vary based on the application in question, the exact type of pressure sensor used, and other various factors. High-precision sensors used in critical environments like aviation or healthcare tend to require more frequent calibration than others, a result of the stringent accuracy requirements they are built to meet. Meanwhile, industrial sensors exposed to extreme temperatures, pressure fluctuations, or corrosive materials may also necessitate more frequent checks. While these examples feature intensive environments and conditions, even sensors in less demanding applications should be calibrated periodically to maintain operational reliability and prevent gradual performance degradation.

How to Calibrate Pressure Sensors

The calibration process for a sensor typically involves several steps to ensure accuracy and consistency. The following are common methods used in pressure sensor calibration, where users should review specific manufacturer documentation for exact practices:

• Preparation: To begin, ensure that the sensor and all calibration equipment are clean, organized, and in good working order. It is also beneficial to keep everything in an ambient temperature zone that is stable, ensuring a lower chance of errors.
• Zeroing: From there, a known zero pressure, such as atmospheric pressure, should be applied to the sensor. At this time, the sensor output should be set to zero to create a new baseline.
• Applying Known Pressures:After zeroing, the sensor can then have a series of known pressures applied across its measurement range. Be sure to record the output at each pressure point for documentation.
• Comparison and Adjustment: Comparing the output values to known pressure values or references will indicate further discrepancies. To fix these issues, the sensor’s calibration settings can be adjusted, with span and offset being two notable attributes that may cause errors.
• Verification: the general pressure application and comparison process should be repeated until the output matches known values, indicating that it is accurate. At this time, all procedures and results should be documented for record-keeping purposes.

Best General Maintenance Practices for Pressure Sensors

Routine maintenance can extend the lifespan of pressure sensors and ensure consistent performance. There are a range of general practices that are common for pressure sensors of all types, including:

• Regular Inspections: Check for physical damage, corrosion, or debris accumulation on a regular basis, as these issues may affect sensor readings.
• Cleaning: Always use appropriate cleaning tools, chemicals, and methods to remove dust, oil, or contaminants from sensors without damaging sensitive components.
• Electrical Connections: Regularly check that wiring and connectors remain secure and free of corrosion or damage, repairing or mending any issues found right away.
• Environmental Protection: If the sensor operates in harsh environments, it is highly advantageous to secure enclosures or filters that increase protection.

When to Replace Pressure Sensors

Even with optimal maintenance practices and regular inspections, pressure sensors have a finite lifespan and will eventually require replacement. To stay on top of this, generally look out for the following signs that may indicate it is time to replace your pressure sensor:

• Frequent Calibration Drift: If a sensor consistently requires frequent recalibration that goes beyond typical expectations, it may no longer be reliable.
• Erratic or Inconsistent Readings: Unexpected fluctuations or unstable measurements from a sensor may signal internal component wear or damage that should be attended to as soon as possible.
• Physical Damage: Cracks, corrosion, or other structural damage can compromise accuracy and performance and may not be treatable through typical repair jobs, necessitating a full replacement.
• Inability to Meet Specifications: If a sensor fails to meet industry or manufacturer specifications despite calibration and maintenance, replacement is often the best course of action.

Partnering with a Reliable Distributor for Pressure Sensors

Selecting a high-quality pressure sensor is just as crucial as maintaining and calibrating it, with trusted distributors ensuring access to top-tier products that meet or exceed industry standards. ASAP Semiconductor is a well-established distributor of pressure sensors and related components, offering customers access to an extensive inventory that is sourced from leading manufacturers and suppliers worldwide. By providing quality-assured parts with competitive pricing and reliable service, customers can secure the components needed to maintain optimal system performance with peace of mind. See if ASAP Semiconductor is the right option for your needs by connecting with industry representatives by phone or email at your convenience.