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Imagine driving your car on the highway. You look down at the speedometer, and it says you are doing 100 km/h. But in reality, due to a mechanical fault, you are doing 120 km/h. You feel safe, but you are actually in the danger zone, risking a fine or an accident.
This same scenario plays out every day in industrial plants, but the stakes are much higher.
A pressure transmitter is the speedometer of your process. If it lies to you, your control system makes decisions based on bad data. This is why Pressure Sensor Calibration is not just a “nice-to-have” maintenance task—it is a non-negotiable requirement for operational safety.
ADYAA looks at the results of neglected instruments all too often. In this guide, we break down exactly why keeping your pressure instruments accurate is the backbone of a safe facility.
Many facility managers assume that once a sensor is installed, it stays accurate forever. Unfortunately, this is not true.
All sensors suffer from “drift”—a gradual degradation of accuracy over time. This happens due to:
Regular Pressure Sensor Calibration is the only way to detect this drift and reset the instrument to the “truth.”
The most immediate risk of an uncalibrated sensor is safety.
If your pressure transmitter reads 10% lower than the actual pressure, your pumps might keep pushing fluid into a tank that is already full, or a pipe that is already at its limit.
As we discussed in our guide on Industrial Sealing, gaskets and O-rings have specific pressure ratings. If the system pressure exceeds these limits because a sensor failed to trigger a shut-off valve, you risk a blowout. Pressure Sensor Calibration ensures that your system pressure never unknowingly exceeds the design limits of your RTJ Gaskets or flanges, preventing leaks, fires, and explosions.
In industries like Food & Beverage or Chemical Processing, pressure dictates quality.
By prioritizing Pressure Sensor Calibration, you ensure that your “recipe” is followed exactly, every single time. This reduces scrap and guarantees that the product leaving your factory meets customer specifications.
For most Australian industries, calibration is a legal or contractual obligation.
During an audit, a missing calibration sticker or an expired certificate is a major non-conformance. Routine Pressure Sensor Calibration provides the traceable paper trail you need to pass audits with flying colours.
An uncalibrated sensor can quietly steal money from your energy budget.
Consider a compressed air system. If the pressure switch reads lower than the actual pressure, the compressor will work harder and run longer than necessary to reach the “set point.” You end up paying for electricity to generate pressure you do not actually need. Accurate sensors ensure your automation systems run efficiently, aligning with the principles outlined in our Industrial Automation Sensors efficiency guide.
There is no “one size fits all” answer, but here are the general rules of thumb:
However, if a sensor experiences a shock, vibration, or extreme temperature event, it should be checked immediately.
ADYAA does not just put a sticker on the gauge. Whether performed in our NATA-traceable lab or at your site, our Pressure Sensor Calibration service involves a full health check of the unit. We adjust, clean, and verify the instrument across its full range to ensure linearity and hysteresis are within tolerance.
Don’t let a $500 sensor put your million-dollar plant at risk.
Is your calibration schedule up to date?
Book Your Pressure Sensor Calibration Service.
Contact us for a free audit of your instrument needs.