Inaccurate pressure sensor data can lead to safety hazards, operational inefficiencies and increased maintenance costs. In high-risk environments, false sensor readings can cause catastrophic plant failures and potential loss of containment, which can cause significant damage to connected infrastructure, local ecosystems and neighbouring communities.
A "harsh environment" in an industrial context refers to conditions that challenge the reliability and functionality of electronic components. These environments can degrade sensor performance over time and include conditions such as extreme temperatures, high pressure, corrosive mediums and electromagnetic interference.
In this blog, we’ll discuss different harsh environments and how challenging operating conditions can impact pressure measurement accuracy. We’ll also look at how certain design features and maintenance tips can help improve your pressure sensor’s reliability and lifespan. Finally, we'll provide some examples of pressure sensors that can work well in these environments.
Different Harsh Environments
Pressure sensors are exposed to many harsh environments in industrial applications. Without the right design and maintenance, pressure sensors can suffer from reduced performance and longevity. Boiswood's products are designed to withstand various demanding environments such as:
- Extreme Temperatures – Pressure sensors may be exposed to both high and low temperature extremes, depending on the application. Special materials and designs are used to ensure sensors can operate effectively in these conditions.
- Vibration and Shock – Excessive vibration and sudden shocks can cause mechanical stress on pressure sensors, leading to fatigue and potential failure. Sensors are designed with robust housing and advanced dampening mechanisms to mitigate the effects of vibration and shock.
- High Levels of Humidity – Moisture can infiltrate sensor components, leading to corrosion short circuits and inaccurate readings. Pressure sensors are often designed with protective coatings, sealed housings and moisture-resistant materials to prevent moisture ingress-related issues.
- Corrosive Environments – Exposure to corrosive chemicals, such as acids, bases and solvents, can degrade pressure sensor components and compromise their performance. Using corrosion-resistant materials and protective housings help pressure sensors withstand exposure to these substances.
Challenges of Inaccurate Readings
Inaccurate pressure readings can affect safety, disrupt operations, increase costs and impact environmental compliance. Here are some examples of how unreliable data can lead to significant challenges in different industries:
Safety Hazards in Chemical Processing
Inaccurate pressure sensor data can lead to incorrect pressure levels in reactors or storage tanks, potentially resulting in leaks or uncontrolled reactions. For instance, if a pressure control system fails to detect an overpressure situation, it could cause a release of toxic gases or chemicals. This can lead to environmental contamination, costly regulatory non-compliance penalties and potential harm to nearby communities.
Operational Inefficiences in the Oil and Gas Industry
If a pressure sensor provides inaccurate readings in a pipeline, it can lead to inefficient gas compression and transportation. For example, if a sensor fails to detect pressure fluctuations accurately, it could increase energy consumption and cause unnecessary shutdowns, leading to production delays and higher operating costs.
Increased Maintenance Costs in Power Generation
Inaccurate pressure measurements can cause turbines and boilers to operate inefficiently. This can lead to increased wear and tear that requires more frequent and costly maintenance.
Design Features and Maintenace Tips for Impving Reliability and Lifespan
If you are operating in harsh environments, you need to consider specific design features and perform regulator maintenance to ensure the reliability and longevity of your pressure sensors. Here are some key areas to consider:
Robust Materials
The material of construction is one of the most important features to get right for sensor durability. For high-temperature applications, materials like stainless steel, Inconel or ceramic offer excellent resistance. These materials can withstand extreme temperatures while maintaining sensor accuracy. You can find out more about the materials used for high-temperature pressure sensors in our blog here.
Sealing and Protective Coatings
Effective sealing is essential to protect sensors from harsh environmental factors. Some examples include:
- Using robust O-rings made from materials like Viton or Teflon (PTFE)
- Applying protective coatings such as PTFE or gold plating to sensor diaphragms
- Implementing hermetic sealing techniques to prevent moisture ingress
These features protect sensitive components from corrosive substances and other extreme conditions.
Shock and Vibration Resistance
Some sensors are engineered to resist shock and vibration – useful in applications that involve heavy machinery or transportation. The designs can include:
- Housing designs with reinforced mounting points
- Damping mechanisms to absorb vibrations
Calibration Methods
Calibration should be performed using precise instruments following the manufacturer's guidelines. This helps maintain the sensor's performance over time.
Maintenance Tips
Effective maintenance practices include regular cleaning, inspection and recalibration of sensors. Consistent upkeep helps prevent sensor degradation and can reduce unexpected downtime.
Boiswood provides official manufacturer in-house servicing, testing and assembly for core products. Our experienced technicians can perform thorough maintenance checks, repairs and calibrations to ensure your pressure sensors operate at peak performance.
Testing and Verification
A robust testing and verification program can help identify potential issues before they become critical problems. For example, performing regular functional tests can help verify sensor response and identify potential drift issues.
Recommended Pressure Sensors for Harsh Environments
We offer a range of high-quality, durable and reliable pressure sensors designed for harsh environments. We carry an ever-growing stock portfolio with competitive pricing and provide quick delivery and international shipping services.
Our portfolio covers many sensors suitable for challenging conditions. Here, we have picked out three pressure sensors that excel in some of these environments:
Ultra High Purity (UHP) Pressure Sensors
Our UHP pressure sensors are designed for applications requiring extremely clean environments, such as semiconductor manufacturing, flat panel display and photovoltaic industries. These sensors feature various UHP connection types, including FaceSeal™ (VCR®), welding ends and surface mount options. Some models also have ATEX/IECEx approvals, making them versatile for different applications. These sensors ensure high accuracy and reliability, whilst maintaining the purity and integrity of processes in ultra-clean environments.
ATEX Rated Pressure Sensors
We provide a range of ATEX-rated pressure sensors specifically designed for use in explosive atmospheres. These sensors are available in Exd (ATEX Flameproof Design) and Exia (ATEX Intrinsically Safe Design) configurations, making them suitable for industries such as chemical processing and oil and gas.
Ultra High Pressure Sensors
For applications involving extremely high pressures, we offer ultra high pressure sensors are suitable for up to 15000 bar. Their robust construction ensures durability, making them some of the few pressure-measuring instruments in the world that can reliably measure pressures of this magnitude.
Conclusion
Selecting the right pressure sensor ensures safety, operational efficiency and environmental compliance. We understand that every operating environment is different, which is why we offer personalised consultations and customised solutions to accommodate unique and harsh conditions in various applications.
Our comprehensive range of high-quality, durable and reliable pressure sensors, combined with our commitment to customer service, means that you can expect a solution that delivers accurate and reliable performance time and time again. Reach out to our friendly team for a consultation or explore our extensive pressure sensors catalogue today.
