At Automation Products Group, Inc. (APG), we specialize in level and pressure sensors designed to withstand even the harshest conditions. For this post, we’ll define harsh conditions as an environment, man-made or otherwise, that makes level and pressure measurement difficult compared to other application variables. Plenty of difficult circumstances are solved by the proper sensor application.
Here are six harsh conditions that can challenge a sensor:
Dirt and dust can render a sensor useless if they creep their way into circuit boards or build up on electrical connections. It’s important to seek out sensors with adequate dust protection, indicated by their IP (Ingress Protection) rating. IP ratings are codes representing the level of ingress protection a product has to dust and water.
IP ratings have 2 numbers. The first number indicates the protection against solid objects. There are a total of 7 possible numbers (0-6), with 0 equaling no protection while 6 equals total protection against dust.
Our PG7 and PG10 digital pressure gauge models have IP ratings that start with a 6, meaning they’re totally protected against dust.
Keeping sensitive electronics safe from water is essential in many applications. As with dirt and dust, IP ratings determine how a sensor handles moisture. The second number indicates the protection against liquids. There are a total of 9 possible numbers (0-8), with 0 being no protection and 8 being the highest level of protection against liquids.
For example, APG’s PG10 has an IP rating of IP65. This means it’s totally protected against dust and protected against low pressure jets of water from all directions. The PG7, with an IP67 rating, can even withstand submersion in up to 1 meter of water without performance loss. For applications that require deeper submersion, our IP68-rated submersible pressure transducers operate effectively at depths up to 575 feet.
When working with caustic chemicals, compatibility between the sensor and the media is critical. Chemical interactions can degrade certain materials. Use our online chemical compatibility database on APG's website to identify which materials to avoid. Be sure to know the material your sensor is made from and which parts of the sensor may come into contact with the chemical.
APG’s pressure transducers are made from 316L stainless steel, a material known for high chemical resistance. Additionally, several of our sensors have PVDF housings, another material known for compatibility with many chemicals.
Extreme temperatures can impact sensor performance, potentially causing adhesives to degrade at high temperatures or making materials brittle in the cold. APG provides temperature ratings for each sensor in our data sheets to help you choose a solution suitable for your application.
There are three types of temperature ranges to consider:
Whether it’s from pumps or other equipment, vibration from machinery can quickly destroy a sensor not designed for these stresses. In the oilfield, vibration and collisions are expected. APG's heavy-duty pressure transducers are built with rugged housings, fully potted circuit boards, and laser welded assemblies to withstand harsh, high-vibration environments.
In applications where a display is desired, we recommend tethering the sensor to the display with a cable. This setup allows the display to be mounted away from sources of vibration.
When flammable gases are present, ensure your sensor is certified to operate in hazardous locations to mitigate risks in these applications. Make sure you understand the hazards present at your application to determine which type of class or division/zone approvals you’ll need for the measurement device.
Sensors approved for use in environments with flammable vapors must have Class 1 approval. How often you expect the hazardous gas to be present determines what the division or zone needs to be.
Please reach out to us if you would like assistance with picking the right sensor to work in harsh conditions. We’re always happy to help you find the best solution for your application.
