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  • Writer's pictureDavid Oyston

What are Common Errors When Calibrating Pressure Gauges?

Updated: May 29

Pressure gauge calibration is an important procedure in various industries to guarantee the accuracy and reliability of pressure gauge readings. In Australia, sectors like mining, manufacturing and oil and gas rely heavily on pressure measurements for safety, efficiency and adherence to regulations. Despite its importance errors during pressure gauge calibration are common. This can impact the accuracy of the readings. These mistakes often arise from issues such as setup, environmental factors, mechanical problems with the gauge and human oversight. Recognising these errors and taking steps to address them are key to upholding the integrity of pressure measurement systems.



worker holding a pressure gauge

Errors with Setup are Common Errors When Calibrating Pressure Gauges


One prevalent error encountered during pressure gauge calibration is setup. This can be put down to factors including using unsuitable equipment, incorrectly connecting the gauge or failing to zero the device before calibration. In Australian industries like mining, challenging conditions must ensure accurate setup or safety issues can occur.


For instance using faulty hoses or fittings with the pressure gauge may result in leaks or pressure discrepancies that affect calibration accuracy. Also, if the gauge isn't correctly zeroed beforehand subsequent measurements will be skewed by this error. To prevent errors it's crucial to secure all connections, utilise the calibration tools correctly and adhere to the manufacturers setup instructions.


Environmental Factors can Affect Pressure Gauge Calibration


The accuracy of pressure gauge calibration can be heavily influenced by the conditions they operate in. In places like Australia, where extreme temperatures, humidity levels and atmospheric pressures vary widely these factors must be carefully monitored. Changes in temperature can cause the materials within the pressure gauge to expand or contract resulting in irregular readings. For example, a gauge that is calibrated in a controlled environment might not provide correct measurements when used in the high temperature conditions of a mining site in Western Australia.


Humidity also plays a role in affecting calibration processes. Moisture penetration can lead to corrosion and mpact the mechanical parts of the gauge thereby altering its precision. Moreover, fluctuations in pressure—especially common in mining operations at high altitudes—can influence gauge readings if not taken into consideration during calibration.


How do you Overcome Environmental Impacts on Pressure Guage Calibration



pressure gauge that has been affected by rust

To counteract these impacts it is vital to calibrate pressure gauges under conditions that mirror their actual operating environments closely. Maintaining controlled temperatures and ensuring sealing against moisture infiltration can help uphold calibration precision. Additionally, accounting for adjustments due to pressure during calibration can ensure that the gauge delivers accurate readings within its designated operational context.


Problems Arising from Gauge Mechanics can Cause Calibration Issues


One reason for calibration errors is the mechanical problems within the pressure gauge itself. Over time the internal components of the gauge can be impacted by wear and tear causing inaccuracies. In industries like oil and gas where gauges face pressures and harsh environments, mechanical deterioration can happen more rapidly.


Typical mechanical problems include worn out diaphragms, damaged bourdon tubes and blocked orifices. These parts are crucial for the functioning of pressure gauges and any damage or wear can result in significant measurement errors. For instance a damaged bourdon tube may not respond accurately to pressure variations leading to readings.


Regular upkeep and examination of pressure gauges are vital to spot and fix issues before they disrupt calibration. Replacing worn out parts and ensuring that the gauge is in good condition can preserve the accuracy of pressure readings. In Australias envirnment where remote areas and tough conditions are prevalent, implementing a maintenance routine is key for dependable gauge performance.


Mistakes During Pressure Gauge Calibration Due to Human Error


Human error is an aspect that can impact the precision of pressure gauge calibration. With inappropriate tools and conditions errors made by technicians can result in inaccurate calibrations.


Common mistakes can vary from errors like misreading a scale or recording data incorrectly to more intricate ones such as using the incorrect calibration method or misunderstanding calibration standards.


In Australia, industries heavily depend on technicians for calibration tasks highlighting the importance of ensuring these professionals are well trained and competent. Training programs covering the calibration techniques, standards and best practices can help decrease human error. Also, incorporating operating procedures (SOPs) and checklists can assist technicians in navigating the calibration process effectively promoting consistency and accuracy.


Automated Systems can Work but Proficient Technicians is Essential


The use of automated calibration systems can reduce human involvement and related errors. These systems offer precise results by following specific procedures and removing the variability introduced by human operators. Nonetheless it remains crucial to have proficient technicians oversee and validate the calibration process to promptly address any irregularities.


How do you Avoid Typical Calibration Errors


Efforts to tackle calibration mistakes require a holistic approach that includes proper training, utilisation of suitable equipment and adherence to best practices. In Australia, industries stand to gain from establishing calibration protocols tailored to address local environmental conditions challenges and operational requirements.


To begin with, investing in high quality calibration equipment and regularly maintaining it can help prevent errors related to setup and mechanical issues. Calibration facilities need to be designed in a way that controls factors like temperature and humidity creating conditions that replicate operational settings as closely as possible.


Moreover implementing a training program for technicians can significantly reduce the chances of human error. These programs should emphasise calibration skills, understanding calibration standards and using modern calibration tools and software. Offering refresher courses and certifications can ensure technicians stay informed about the latest industry advancements and best practices.


Finally, incorporating automated calibration systems where applicable can improve accuracy and consistency. These systems are capable of handling calibration tasks with precision decreasing the risk of human error. However, experienced technicians oversight remains crucial to address any issues and validate the outcomes.


Calibrating pressure gauges is a procedure that guarantees the precision and dependability of pressure measurements across various industries. In Australias context, where challenging environmental conditions and rigorous operational demands are prevalent recognising and mitigating calibration errors is vital. Incorrect setup procedures, environmental impacts, gauge related mechanical problems and human errors all contribute to compromises in calibration accuracy.


By training employees employing the right tools for the calibration task and following industry guidelines, companies can uphold the accuracy of their pressure measurement systems. Precise pressure gauge calibration not only improves efficiency and safety but also guarantees adherence to regulations bolstering the effectiveness and dependability of industrial activities in Australia and throughout the world.


For you Pressure Gauge Calibration needs, contact Torctight-QLD.




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