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Common Calibration Errors in Pressure Sensors – Avoid Costly Downtime with Sensors and Gauges
Why Calibration Accuracy Matters
In industrial environments, even minor calibration deviations in pressure sensors can lead to critical measurement errors that impact production quality and safety. Regular and precise calibration ensures that your sensors maintain traceability to international standards such as ISO/IEC 17025.
Calibration errors can occur due to environmental conditions, poor handling, or incorrect reference instruments. Knowing what to look for is the first step toward maintaining your sensors’ reliability.
Top 7 Common Calibration Errors in Pressure Sensors
1. Zero Offset Errors
A zero offset occurs when a pressure sensor shows a reading above or below zero even when no pressure is applied. Common Causes:
Residual pressure in the system
Temperature fluctuations
Mechanical stress or deformation Solution: Always perform a zero balance check before starting calibration, ensuring the sensor is at ambient conditions.
2. Linearity Errors
A linearity error happens when the sensor’s output does not follow a straight line relative to applied pressure. Common Causes:
Inaccurate reference standards
Internal mechanical defects
Ageing of strain gauges Solution: Use a multi-point calibration method (e.g., 0%, 25%, 50%, 75%, and 100% pressure) to detect and correct non-linear behavior.
3. Hysteresis Errors
Hysteresis refers to the difference in readings between increasing and decreasing pressure cycles. Common Causes:
Elastic deformation of sensing elements
Mechanical fatigue
Improper calibration procedure Solution: Always perform both up and down pressure cycles during calibration to detect hysteresis and correct offset trends.
4. Temperature-Induced Errors
Temperature changes can significantly affect sensor output, especially in high-precision applications. Common Causes:
Thermal drift of strain gauges
Expansion of diaphragm materials Solution: Conduct calibration at controlled room temperature (±1°C), or apply temperature compensation factors provided by the manufacturer.
5. Incorrect Reference Instrumentation
Using a reference instrument that is not properly calibrated introduces compounding errors. Common Causes:
Expired calibration certificates
Mismatched measurement ranges
Inadequate resolution of the reference gauge Solution: Verify that your reference calibrator is NATA- or ISO-certified and within a 12-month calibration window.
6. Improper Mounting or Orientation
Pressure sensors installed at incorrect angles or under stress can distort readings. Common Causes:
Misalignment of pressure ports
Vibration or mechanical strain Solution: Ensure the sensor is mounted per manufacturer guidelines, with proper torque and support to minimize external stress.
7. Drift Due to Age or Overpressure
Over time, sensors can drift due to ageing materials, cyclic stress, or accidental overpressure. Common Causes:
Prolonged exposure to harsh environments
Corrosion or contamination of sensor diaphragm Solution: Implement a routine calibration schedule (every 6–12 months) and avoid exceeding rated pressure limits.
How Sensors and Gauges Prevent Calibration Errors
At Sensors and Gauges, we combine advanced technology with industry expertise to deliver accurate, NATA-traceable calibration for all types of pressure sensors and gauges.
Our Calibration Services Include:
Pressure range verification (vacuum to 10,000 psi)
With a dedicated lab in Smithfield, NSW, and mobile calibration teams available nationwide, we ensure your instrumentation remains accurate and compliant.
Industry Applications
Our calibration expertise supports sectors such as:
Oil & Gas – Pressure transducer calibration for safety systems
Manufacturing – Process control instrumentation accuracy
Pharmaceuticals – Cleanroom pressure monitoring
Automotive – Sensor testing and torque verification
Mining – Heavy-duty sensor calibration and diagnostics
Avoid Calibration Mistakes with Professional Help
Attempting to calibrate sensitive pressure sensors without the right tools or experience can lead to compounded inaccuracies. By working with Sensors and Gauges, you ensure:
📩 Request a Quote for professional pressure sensor calibration. Ensure compliance, accuracy, and long-term reliability with Sensors and Gauges.
Location:
Sensors and Gauges Unit 27/191, McCredie Road, Smithfield, NSW 2164
Customer Support:
Need to correct calibration errors in your sensors? 📧 sales@sandsindustries.com.au 📞 0477 123 699 💬 WhatsApp us — we’ll respond promptly to schedule your calibration service.
