Calibrating pressure gauges is crucial for maintaining the sustainability of industrial operations. Yet, it is often perceived as an unnecessary expense. In reality, this routine process is a long-term investment that enhances industrial systems’ efficiency, reliability, and sustainability.
Neglecting calibration can lead to potential hazards and costly losses, putting companies and manufacturers at risk and jeopardizing environmental sustainability.
Businesses may face financial penalties, production halts, or even the shutdown of facilities for failing to meet national and international calibration standards.
Understanding the critical role calibration plays in the industry, the Bawalaksana team aims to illuminate several overlooked benefits of pressure gauge calibration.
Preventing Costly Issues and Losses
The primary benefit of calibrating pressure gauges is preventing potential issues and significant financial losses. In a previous article, “4 Reasons Why You Should Calibrate Pressure Gauges,” we discussed how inaccurate pressure measurements can lead to several problems, such as:
- Production process disruptions
- Waste of raw materials
- Damage to expensive equipment
Pressure measurement errors can cause severe manufacturing defects in critical industries like petrochemicals, pharmaceuticals, food and beverage, electronics, and automotive. These mistakes often result in unusable products, which waste raw materials, time, and labor.
Moreover, production downtime may increase as manufacturers work to correct errors caused by faulty pressure readings.
In some cases, machinery or other equipment damage can occur, further driving up operational costs.
By regularly calibrating pressure gauges, businesses can avoid these costly disruptions, ensure smoother production processes, and reduce waste.
Ensuring the Safety of Industrial Environments and Operators
Pressure gauges play a crucial role in industrial settings beyond their primary function of measuring fluid pressure. One of their most critical functions is to serve as an early warning system for operators, alerting them to significant pressure changes that could pose a potential danger.
By providing this warning, pressure gauges allow operators to anticipate potential hazards and take preventive actions, ultimately helping to avert explosions or catastrophic damage that could endanger lives and the surrounding environment.
If a pressure gauge provides accurate measurements, operators may be aware of potential hazards in the industrial process.
Therefore, accurate pressure measurement ensures smooth and efficient production processes and enhances industrial operators’ safety and well-being.
Even if a gauge is designed to be robust, there remains a potential for damage if the pressure exceeds 14,000 psi. For example, the rupture of a Bourdon tube could result in operators nearby being struck by gauge fragments or exposed to sprays of toxic fluid.
The negative impact worsens when the released fluid is aggressive and explosive.
To mitigate these risks, selecting pressure gauges with solid construction and design and a high accuracy class is imperative.
An example of such an instrument is the Safety Pattern Test Pressure Gauge, specifically designed to meet the requirements of Safety Patterns S1, S2, and S3, with an Accuracy Class of 0.6 following the EN837 standard.
This instrument offers a higher level of safety compared to standard pressure gauges, featuring Safety Pattern attributes such as:
- Full blow-out devices
- Solid casing made of stainless steel 304
- Strong multilayer window glass
- Superior accuracy class.
What are the Advantages of the Safety Pattern Test Pressure Gauge?
The Safety Pattern Test Pressure Gauge offers several key advantages, including a solid casing, high accuracy, and enhanced resistance to breakage. Even in the event of failure, the gauge is designed to prevent fragments or fluid sprays from being directed toward nearby operators.
For instance, under extreme conditions that cause the Bourdon tube to rupture, the entire back section of the gauge detaches, safely channeling any pressure release. The front glass remains intact, preventing shattering and the scattering of dangerous fragments.
This thoughtful design effectively shields operators from potential hazards by ensuring that no particles or fluid sprays are projected forward, reducing risks in the industrial environment.
However, it is essential to highlight that such critical safety features are absent in low-cost or substandard pressure gauges, particularly counterfeit products that need proper calibration.
It underscores the importance of selecting pressure gauges with reliable accuracy and robust construction for industrial applications, where safety is paramount. Ensuring the protection of both the industrial environment and operators is essential, as they deserve the highest safety standards.
Enhancing Process Efficiency
Accurate pressure measurement tools play a crucial role in assisting production operators to make informed decisions while operating systems. This capability is instrumental in ensuring the production process’s smooth, consistent, and sustainable running.
Process efficiency, operational stability, and the effective anticipation of pressure changes that surpass established limits are encompassed. It ensures the uninterrupted continuation of the production process, even when potential system disruptions may occur.
It is imperative to highlight that a pressure gauge that cannot accurately measure pressure in line with the actual pressure values deprives operators of a “danger” signal. This can lead to severe damage to various industrial devices, resulting in leaks and even fires that disrupt process efficiency in the industry.
Notably, the accuracy of pressure gauge measurements can only be guaranteed if regular calibration is performed. Because a pressure gauge, when used or even stored for a certain period, will not maintain its calibration indefinitely.
Consequently, over time and with use, the measurement results from a pressure gauge can experience deviation (error), even though proper calibration of the pressure gauge had been performed previously. This deviation can be attributed to factors such as mechanical wear and extreme operating conditions, including high temperatures, vibrations, or pressure pulsations.
The combination of mechanical wear and environmental factors can expedite the deterioration of mechanical components within the gauge or decrease accuracy. As a precautionary measure, it is recommended to establish a calibration cycle tailored to the industry’s specific needs.
For instance, a calibrated backup pressure gauge can be prepared and stored in a dedicated area. This approach ensures the swift replacement of the pressure gauge that has been in use for a certain period with a backup unit during scheduled maintenance (Preventive Maintenance).
Product Integrity and Customer Satisfaction
Product integrity is closely tied to customer satisfaction. Defective products can lead to customer complaints and, ultimately, damage a manufacturer’s reputation.
One common cause of defects is poor production quality due to inaccurate pressure measurements.
In industries like pharmaceuticals, controlling pressure during chemical reactions is critical. An inaccurate pressure gauge can disrupt these reactions, producing unsafe or low-quality products.
Similarly, in the food and beverage (F&B) sector, pressure gauges are vital for monitoring pressure during processing to ensure the final products are safe for consumption and meet quality standards.
Beyond process control, pressure gauges also play a crucial role in maintaining cleanliness and preventing contamination. In sectors like pharmaceuticals, they help maintain system pressure within safe limits, ensuring compliance with industry standards and safeguarding product purity.
So, what happens if pressure gauges in industries such as pharmaceuticals, drugs, or F&B are inaccurate?
The result could be erratic chemical reactions, lower product quality, or contamination that compromises product sterility.
Regular calibration is the best way to ensure consistent, accurate pressure measurements. It is especially crucial for industries like petrochemicals, pharmaceuticals, automotive manufacturing, and food and beverage, where precision and safety are paramount.
High-quality, consistent products are a powerful customer lead magnet and help build a company’s reputation. On the other hand, inconsistency in the production process can damage a business’s image, leading to perceptions of poor integrity.
Products that fail to meet standards due to inaccurate pressure measurements may face high rejection rates from both customers and regulators.
To avoid these issues, prioritizing the calibration of pressure measurement instruments is essential. By doing so, your company can benefit in several ways, including:
- Consistently producing high-quality products
- Minimizing raw material waste and failed production batches
- Reducing the risk of costly rework
- Building customer trust by consistently meeting product specifications
- Preventing economic losses from production failures that result in waste
In recognizing the importance of maintaining production integrity, it’s also vital to exercise caution when selecting pressure measurement instruments. Don’t be tempted by low prices, even from well-known vendors.
The market has seen a rise in counterfeit or substandard pressure gauges that, while cheap, are of deficient quality.
As previously discussed, high-quality pressure gauges are characterized by solid construction and high accuracy, meeting industry standards.
In contrast, counterfeit pressure gauges often lack essential features such as a solid casing or blow-out protection and do not meet the accuracy requirements of EN837.
Using such low-grade instruments can lead to significant issues and costly losses.
Complying with Industry Standards and Avoiding Penalties
One key benefit of calibrating pressure gauges is ensuring traceability that aligns with national and international standards through an uninterrupted calibration chain. It is consistent with the guidelines set by Indonesia’s National Standardization Agency (BSN) for pressure measurement instruments.
In Indonesia, the National Standard (SNI) ISO/IEC 17025:2017 outlines general requirements for testing and calibration laboratories. To meet these requirements, BSN has developed nine calibration guidelines that serve as a reference for calibration laboratories.
These guidelines are based on international standards, national regulations, and publications recognized by the global metrology community.
For industries or companies to meet the SNI ISO/IEC 17025:2017 standards, it is crucial to adopt the BSN calibration guidelines fully. Adhering to these standards ensures the accuracy of pressure measurements in industrial processes, helping to maintain product quality and operational safety.
In contrast, neglecting calibration poses significant risks. Inaccurate pressure measurements can lead to severe operational problems, compromising both safety and product quality. If an accident occurs due to an inaccurate pressure gauge, the consequences extend far beyond production losses.
If they fail to meet calibration standards, companies may face hefty fines, penalties, suspension of operational permits, or even factory closures. Such incidents not only tarnish a company’s reputation but also risk the loss of a market share that took years to build.
Early Detection of Instrument Issues
Many believe that calibrating pressure gauges is only about ensuring measurement accuracy. In reality, the benefits extend far beyond accuracy, including the early detection of deviations and potential component failures.
Why is this so crucial?
By identifying deviations or failures early, you can minimize the risk of errors, damage, or costly mistakes spreading throughout the production process.
Additionally, early detection helps reduce the expenses associated with equipment damage or expensive repairs.
As mentioned earlier, all pressure measurement instruments will experience deviations (or drift) over time. Regular calibration allows you to monitor these deviations and, if needed, make precise adjustments using tools like a Dead Weight Tester to restore the instrument’s accuracy and reliability.
Do new pressure gauges need calibration even if they’ve never been used?
Yes, calibration is necessary even for new instruments before installation. It is vital for gauges that have been modified or stored for long periods. At a minimum, pressure gauge calibration once a year is a must to ensure accuracy and compliance with international standards, such as BS-EN 837-1.
Regular calibration not only maintains measurement precision but also extends the instrument’s lifespan by ensuring internal components function correctly.
Moreover, it helps prevent total instrument failure and reduces costly production downtime caused by inaccurate readings.
Sustainable Environmental Conservation
Last but not least, the most important yet often overlooked benefit of calibration is its role in supporting sustainable environmental preservation.
Industrial processes frequently involve measuring aggressive fluids or chemicals under high pressure.
When pressure readings deviate from expected values, operating pressures can exceed safe limits without the operator’s awareness, leading to equipment failures and potentially dangerous accidents.
Such incidents not only result in financial losses but also pose significant risks to the environment and nearby communities. Equipment failures can cause damage beyond the facility, threatening public safety and environmental health.
Accidents involving leaks or explosions in industrial areas can lead to property destruction, increased waste, and environmental pollution.
For instance, spills of hazardous chemicals can release toxic substances into the environment, endangering both ecosystems and the health of nearby populations.
At a minimum, precise measurement accuracy can contribute to a zero-accident environment by reducing exhaust emissions and minimizing factory waste, both of which help prevent environmental pollution.
When your company’s engineering team prioritizes pressure gauge calibration, it demonstrates a strong commitment to sustainability and environmental stewardship.
The value of calibration goes beyond enhancing profits or gaining international recognition—it lies in the long-term protection of the environment.
In the end, the true benefit of pressure gauge calibration is not just in boosting business performance but in contributing to the sustainable preservation of the world we live in.
This vital calibration aspect is often underestimated but critical to fostering a responsible and sustainable industry.
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PT. Bawalaksana Central Industrial, as a leading supplier in the industrial and manufacturing sectors, emphasizes the critical importance of regular calibration for pressure measurement instruments.
Consistent calibration allows your company to optimize production processes, increase profitability, and contribute to environmental sustainability.
To help you achieve these goals, we offer expert recommendations for pressure gauge calibration instruments that meet international standards with an accuracy of up to 0.02%.
Our top choices include the Dead Weight Tester and Pressure Comparator from Instruments To Industry (ITI), a trusted manufacturer based in the United Kingdom.
These high-quality calibration tools deliver outstanding performance, enabling precise verification and adjustment of pressure gauges. By using these instruments, you can ensure long-term reliability and accuracy in your pressure measurement systems.
Join the ranks of industries committed to producing top-tier products while fostering sustainable environmental practices by investing in premium calibration tools.
For more details about the Dead Weight Tester and Pressure Comparator, feel free to reach out to our engineering team by clicking the consultation button below.
Romanta Pinrih Linuwih
Pneumatic Automation Systems Expert
This article was written in collaboration with Romanta Pinrih Linuwih, an expert in Pneumatic Automation Systems, to ensure accuracy and high quality.
