The Ultimate Guide to Choosing high accuracy pressure sensor

Your pressure sensor is a vital component of your equipment or system. When properly specified your system will operate safely and to expected performance levels over the design life of the system or equipment, but only if you have the right sensor that’s appropriate for your application.

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The wrong pressure sensor can result in equipment damage, worker injury or out-of-specification measurements. So, how can you ensure you choose the right one?

There are many factors to consider when selecting the right pressure sensor. This article will discuss five important considerations that should help you make the best choice for your application.

5 Factors to Consider when Choosing a Pressure Sensor

Keep these factors in mind while making your selection:

1. Materials

The sensor wetted material you choose must be compatible with your process media. If you are using the wrong materials, you may encounter instrument damage, failure or out-of-specification readings over time.

For example, pressure sensors that are suitable for ultra-low-differential-pressure-based airflow measurements are very different than those for high-pressure hydrogen applications.

Ashcroft has a material selector tool available on our website that can help you find what will work best for your process.

2. Shock and Hydraulic Effects

Shock is typically associated with mechanical shock on a piece of equipment or the pressure sensor itself and typically addressed on pressure sensor data sheets. In this case, we refer to hydraulic shock or water hammer, which can occur within fluid-based systems due to a fluid's incompressible nature.

Hydraulic shock or water hammer is the pressure surge caused by a sudden change in the fluid velocity. This effect can be many times the system operating pressure and occur faster than the output can indicate, yet permanently damage the sensing diaphragm /element. Understanding whether this is possible in the system and, if necessary, address in the system or sensor design to ensure long-term reliable pressure sensor operation.

Besides options in the sensor design, technology and calibration itself there are several accessories and other instruments that can help counteract these negative process effects, such as pressure snubbers, pulsation dampeners and capillary lines.

If not properly addressed, this can result in what is seen as a pressure sensor overpressure failure (out of accuracy condition due to an offset of the zero pressure output reading or worse, diaphragm failure).

3. Pressure Reference

The pressure reference (gauge/vacuum, absolute or differential) is the first step in determining which transducer technologies can be used in a design. What pressure do you want to measure? Is the pressure reference to current atmospheric conditions (Gauge reference) or absolute zero pressure (Absolute reference)?

This is particularly important when trying to measure below atmospheric pressure conditions while determining the amount of vacuum. It is critical to know whether the measurement is relative to the atmospheric condition or absolute zero pressure.

4. Accuracy

How a pressure sensor manufacturer publishes accuracy and performance specifications is often referred to as “Specmanship.” Without agreed-upon industry standards in many regions of the world, accuracy can be defined as BFSL, RSS, Terminal or End Point, Total Error Band, or Typical.

With each of the above terms, a stated accuracy of 0.25% can translate differently in many ways. In critical applications, it may be important that Zero and Span output offsets be included in accuracy as the two can add up to an additional ±2% of inaccuracy in some products. Or, if the application is exposed to a wide operating temperature range, does the accuracy statement include the effects of temperature over that range?

In some cases, if an accuracy statement is stated as typical, the question becomes: is it important that a specific accuracy be met or is typical good enough? Also consider field interchangeability, which I will discuss next.

5. Pressure Sensor Interchangeability

Maintain your system’s performance as specified by the equipment manufacturer when replacing a pressure sensor in the field. This specifically relates to whether zero and span offset errors are either included in the manufacturer’s accuracy statements or are corrected during the initial equipment manufacturing process.

Ashcroft includes zero and span errors in our accuracy statement, but many other companies don’t. This can become an issue because the original system performance may not be maintained when replacing a sensor in the field, which has zero and span offset errors that are not corrected at the time of installation.

We don’t like to pressure you, but we have more information.

Now that you know the factors to consider when choosing pressure sensors, you can research the solution that’s best for your application. Keeping these factors in mind can help ensure that you avoid problems and keep your process running with reliable and accurate pressure measurements.

If you want to learn more about pressure sensors, read some of our other blogs:

• How Does Media Temperature Affect Pressure Transducer Performance?
• How Accurate Are Your HVAC System’s Pressure Instruments?
• How Are Pressure Transducers Affected by Hydrogen Permeation?
• How to Protect and Optimize Pressure Transducers on Mobile Hydraulics
• How Much Do Pressure Transducers Cost? (6 Factors Impacting Price)

Feel free to contact us today to talk to one of our industry experts and get your questions answered.

And if you’d like to learn more about the accuracy of your pressure instruments, download our eBook:

Yuhan are exported all over the world and different industries with quality first. Our belief is to provide our customers with more and better high value-added products. Let's create a better future together.

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Pressure sensors are ubiquitous in modern technology, playing a crucial role in a wide range of applications, from industrial process control to medical devices and consumer electronics. These sensors convert pressure into an electrical signal, allowing for precise measurement and monitoring of pressure changes. In this comprehensive guide, we will explore the world of pressure sensors, including their types, applications, and key considerations for selection.

Pressure Sensor Selection Criteria

Choosing the right pressure sensor for your specific needs can be a daunting task, given the numerous options available in the market. To make an informed decision, it's essential to consider several key factors.

Accuracy and Precision Considerations

Accuracy and precision are critical parameters when selecting a pressure sensor. Accuracy refers to how close the measured pressure is to the true pressure, while precision refers to the consistency of repeated measurements. The required accuracy and precision depend on the specific application.

For instance, in medical devices such as ventilators and infusion pumps, high accuracy and precision are vital to ensure patient safety. In contrast, industrial process control applications may tolerate slightly lower accuracy and precision.

When evaluating accuracy, consider the following:

• Total Error Band (TEB): The maximum deviation of the sensor's output from the true pressure over a specified temperature range.
• Non-Linearity: The maximum deviation of the sensor's output from a straight line over the measurement range.
• Hysteresis: The difference in output between increasing and decreasing pressure.

Range and Sensitivity Requirements

The measurement range and sensitivity of a pressure sensor are also crucial considerations. The sensor should be able to measure pressure within the required range, with sufficient sensitivity to detect changes.

• Measurement Range: The range of pressures that the sensor can measure, typically specified in units such as psi, bar, or Pa.
• Sensitivity: The change in output signal per unit change in pressure, often expressed in units such as mV/psi or V/bar.

Compatibility with Different Environments and Media

Pressure sensors can be exposed to various environments and media, including corrosive substances, high temperatures, and high pressures. Ensure that the selected sensor is compatible with the intended application.

• Material Compatibility: The sensor's wetted materials should be resistant to corrosion and compatible with the process media.
• Temperature Range: The sensor should be able to operate within the required temperature range, with minimal effects on accuracy and precision.
• IP Rating: The sensor's ingress protection (IP) rating should be suitable for the environmental conditions, such as dust and water exposure.

Advanced Pressure Sensor Technologies

Recent advancements in technology have led to the development of innovative pressure sensor solutions, offering improved performance, miniaturization, and wireless connectivity.

MEMS-Based Pressure Sensors

Micro-Electro-Mechanical Systems (MEMS) technology has enabled the creation of miniaturized pressure sensors with high accuracy and low power consumption. MEMS-based pressure sensors are widely used in consumer electronics, automotive, and medical applications.

graph LR;
    A["MEMS Pressure Sensor"] --> B["Miniaturized Size"];
    A --> C["High Accuracy"];
    A --> D["Low Power Consumption"];
    B --> E["Consumer Electronics"];
    B --> F["Automotive"];
    C --> G["Medical Devices"];

Nanotechnology-Based Pressure Sensors

Nanotechnology has opened up new possibilities for pressure sensor development, enabling the creation of ultra-sensitive and miniaturized sensors. Nanotechnology-based pressure sensors are being explored for applications such as wearable devices and implantable sensors.

The use of nanomaterials, such as graphene and nanotubes, allows for the creation of pressure sensors with high sensitivity and fast response times. For example, a graphene-based pressure sensor can achieve a sensitivity of up to \[\frac{1}{\text{Pa}}\].

Wireless Pressure Sensors

Wireless pressure sensors offer increased flexibility and convenience, eliminating the need for wired connections. These sensors are particularly useful in applications where mobility is required or where wiring is impractical.

Wireless pressure sensors typically use protocols such as Bluetooth, Wi-Fi, or Zigbee for communication. For instance, a Bluetooth Low Energy (BLE) enabled pressure sensor can transmit data to a smartphone or tablet, allowing for remote monitoring.

Best Practices for Pressure Sensor Installation and Maintenance

Proper installation and maintenance are crucial to ensure optimal performance and longevity of pressure sensors.

Installation Guidelines for Optimal Performance

To ensure accurate and reliable measurements, follow these installation guidelines:

• Mounting Orientation: Install the sensor in the recommended orientation to minimize effects of gravity and vibration.
• Cable Routing: Route cables carefully to avoid damage, noise, and interference.
• Electrical Connections: Ensure secure and reliable electrical connections to prevent signal degradation.

Calibration and Maintenance Tips

Regular calibration and maintenance are essential to maintain the accuracy and reliability of pressure sensors.

• Calibration: Calibrate the sensor according to the manufacturer's instructions, using a certified calibration standard.
• Cleaning: Clean the sensor regularly to prevent contamination and ensure accurate measurements.
• Inspection: Inspect the sensor regularly for signs of wear, damage, or corrosion.

Troubleshooting Common Issues with Pressure Sensors

Common issues with pressure sensors include:

• Drift or Offset: Check for changes in the sensor's zero-point or span, and recalibrate as necessary.
• Noise or Interference: Investigate sources of electrical noise or interference, and take corrective action.
• Damage or Corrosion: Inspect the sensor for signs of physical damage or corrosion, and replace if necessary.

Conclusion

Pressure sensors play a vital role in a wide range of applications, from industrial process control to medical devices and consumer electronics. By understanding the key considerations for selection, advanced technologies, and best practices for installation and maintenance, you can choose the right pressure sensor for your needs and ensure optimal performance.

References

1. Pressure Sensor Market by Type, Application, and Geography - Global Forecast to
2. MEMS Pressure Sensors: A Review
3. Nanotechnology-Based Pressure Sensors
4. Wireless Pressure Sensors for Industrial Applications

FAQ

Q: What is the difference between absolute and gauge pressure sensors?

A: Absolute pressure sensors measure pressure relative to a vacuum, while gauge pressure sensors measure pressure relative to atmospheric pressure.

Q: How do I choose the right pressure sensor for my application?

A: Consider factors such as accuracy, range, sensitivity, compatibility with the environment and media, and the required output signal.

Q: What is the typical lifespan of a pressure sensor?

A: The lifespan of a pressure sensor depends on various factors, including the type, quality, and operating conditions. Typical lifespans range from several years to over a decade.

Q: Can pressure sensors be used in harsh environments?

A: Yes, many pressure sensors are designed for use in harsh environments, such as high temperatures, high pressures, and corrosive media. Choose a sensor that is compatible with your specific application.

Contact us to discuss your requirements of high accuracy pressure sensor. Our experienced sales team can help you identify the options that best suit your needs.