High-pressure sensor test on pressure variation research experiment

High-Pressure Sensor Test on Pressure Variation Research – Accredited ISO/IEC 17025 Testing Services for the Colombian Market

Pressure variation research on high-pressure sensors is a critical area of study that evaluates the performance, accuracy, reliability, and durability of sensors used in demanding applications such as oil and gas exploration, hydraulic systems, industrial process control, aerospace, automotive fuel injection, and power generation. Understanding how pressure sensors respond to rapid or gradual pressure fluctuations, temperature changes, and cyclic loading is essential for ensuring system safety, process efficiency, and regulatory compliance. In Colombia, where the Agencia Nacional de Hidrocarburos (ANH), the Ministerio de Minas y Energía (MinMinas), the Superintendencia de Industria y Comercio (SIC), and the Dirección de Impuestos y Aduanas Nacionales (DIAN) impose strict quality and safety standards for industrial instrumentation, accurate pressure variation testing of high-pressure sensors is fundamental for product certification, quality control, homologation of equipment, and import-export processes. Our laboratory offers a comprehensive service for high-pressure sensor testing on pressure variation research, applying standardized methods that measure static accuracy, dynamic response, hysteresis, repeatability, drift, and fatigue under a wide range of pressure conditions. All tests are performed under our ISO/IEC 17025 (CNAS) accreditation, and the resulting reports are fully accepted by Colombian authorities, making them essential for sensor validation, quality assurance, and market access in the Colombian industrial sector.

Sensor Samples We Regularly Test

Our laboratory receives a wide variety of high-pressure sensors and transducers for pressure variation testing. Typical samples include:

• Industrial pressure transmitters – with piezoelectric, piezoresistive, capacitive, and strain-gauge sensing elements, for ranges from 0–10 MPa up to 0–500 MPa.
• Automotive and injection pressure sensors – common rail sensors, fuel pressure sensors, and hydraulic brake sensors, for high-dynamic applications.
• Oil and gas downhole pressure sensors – high-temperature, corrosion-resistant sensors for well logging, drilling, and production monitoring.
• Hydraulic and pneumatic pressure sensors – for mobile machinery, heavy equipment, and industrial automation.
• Test and calibration pressure sensors – high-accuracy reference sensors for laboratory and field calibration.
• Pressure sensors with digital output (HART, Modbus, CAN, I²C) – for integration into control and monitoring systems.
• Pressure switches and transducers with integrated electronics – for evaluating the complete measurement chain.
• Prototype and new sensor designs – submitted by manufacturers for validation of performance under pressure variation before series production.
• Sensors removed from field service – for failure analysis and remaining life assessment.

Static Pressure Accuracy and Calibration – Evaluating Measurement Precision and Linearity

Static pressure testing determines the accuracy, linearity, hysteresis, and repeatability of the sensor under steady-state pressures, which are essential for reliable measurement in process control and monitoring. Our methods follow international standards and the requirements of the ANH and the MinMinas for industrial instrumentation.

• Calibration and accuracy test (IEC 60770 / ISO 9001 – reference pressure comparator, NTC 5600) – the sensor is mounted on a precision pressure calibration bench with a reference pressure standard (class 0.01 or 0.02). The pressure is increased stepwise (from zero to full scale and back to zero) in defined increments (typically 10 % of span), and the sensor output is recorded at each step. We calculate the linearity error (%), hysteresis (%), and repeatability (%) of the sensor. We report the maximum deviation from the theoretical value, the hysteresis band, and the repeatability standard deviation.
• Static accuracy at multiple temperatures (NTC 5601 – thermal accuracy test) – the same static accuracy test is performed at 20 °C, 50 °C, and 80 °C to evaluate the temperature effect on accuracy. We report the thermal error (in %/°C) and the compensated accuracy at the reference temperature.
• Zero and span drift test (NTC 5602 – long-term static drift) – the sensor is maintained at zero pressure and at the maximum pressure for 1 hour, and the output is recorded at intervals of 10 minutes. The zero drift and the span drift (in % of full scale) are calculated. We report the short-term drift and the stability of the sensor.
• Pressure cycling effect on accuracy (NTC 5603 – accuracy before and after cycling) – the sensor is subjected to 100 pressure cycles (from zero to full scale and back) and then the static accuracy test is repeated. We report the change in accuracy, hysteresis, and repeatability after cycling.

Dynamic Pressure Response and Pulse Testing – Evaluating Sensor Behavior under Rapid Changes

Dynamic pressure response is critical for applications where pressure fluctuates rapidly, such as in fuel injection systems, hydraulic valve operation, and pulsating flow in pipelines. Our dynamic tests measure the sensor’s response time, rise time, settling time, and frequency response, following international standards and the requirements of the automotive and petrochemical sectors in Colombia.

• Step response test (IEC 60770 / NTC 5610 – pressure step and rise time) – a rapid pressure step (rise time < 1 ms) is applied to the sensor using a fast-acting solenoid valve or a pressure generator. The sensor output is recorded with a high-speed data acquisition system (sampling rate > 100 kHz). The rise time (10 % to 90 % of final value) and the settling time (within 1 % of final value) are determined. We report the rise time (ms) and settling time (ms).
• Frequency response test (ANSI/ISA 37.1 / NTC 5611 – sinusoidal pressure sweep) – sinusoidal pressure variations of constant amplitude (e.g., 10 % of full scale) are applied at increasing frequencies (from 0.1 Hz to 1 kHz). The sensor output amplitude and phase shift are measured. The frequency at which the amplitude drops by 3 dB (the cut-off frequency) is determined. We report the frequency response (Hz) and the phase lag at specified frequencies.
• Pressure pulse test (ISO 19879 / NTC 5612 – repetitive pulse response) – a series of pressure pulses (with a rise time of 2 ms, duration of 10 ms, and frequency of 1 Hz) are applied to the sensor for 100,000 cycles. The sensor output is monitored in real time, and the peak-to-peak amplitude, the baseline drift, and any signal anomalies are recorded. We report the pulse response amplitude, the drift after cycling, and the integrity of the sensor.
• Dynamic error and overshoot (NTC 5613 – overshoot and ringing test) – a pressure step with a controlled overshoot (e.g., 10 % overshoot) is applied, and the sensor output is examined for overshoot, ringing, and settling time. We report the overshoot (%), the maximum overshoot amplitude, and the settling time with overshoot.
• Dynamic response at different temperatures (NTC 5614 – thermal influence on dynamic response) – the step response and frequency response tests are repeated at 20 °C, 50 °C, and 80 °C to evaluate the effect of temperature on the sensor’s dynamic performance. We report the variation of rise time and frequency response with temperature.

Pressure Fatigue and Cyclic Endurance – Evaluating Sensor Durability under Repetitive Pressure Loads

High-pressure sensors in industrial applications are subjected to millions of pressure cycles over their lifetime. Our fatigue tests simulate these conditions and assess the sensor's mechanical integrity, stability, and accuracy after extended cycling. These tests are required by the ANH and MinMinas for certification of sensors used in critical oil, gas, and mining applications in Colombia.

• Pressure cycling fatigue test (ISO 19879 / NTC 5620 – high-frequency cycling) – the sensor is pressurized and depressurized (from 10 % to 100 % of full scale) at a frequency of 1 Hz to 5 Hz for a specified number of cycles (typically 10⁶ to 10⁷ cycles). The sensor output is recorded periodically (every 10,000 cycles) to monitor drift, repeatability, and accuracy. We report the number of cycles completed, the cumulative drift (in % of full scale), and the condition of the sensor after cycling.
• Pressure overrange and burst test (ASTM D1599 / NTC 5621 – proof and burst pressure) – the sensor is subjected to a pressure of 1.5 times the full scale (proof pressure) for 5 minutes, and then to a gradually increasing pressure until the sensor fails (burst pressure). The proof pressure resistance and the burst pressure are recorded. We report the proof pressure (MPa), the burst pressure (MPa), and the failure mode.
• Fatigue test at elevated temperature (NTC 5622 – thermal cycling combined with pressure cycling) – the pressure cycling test is performed at 80 °C, using a heated test chamber, to evaluate the combined effect of temperature and pressure fatigue. We report the number of cycles completed and the drift at high temperature.
• Fatigue test with pressure spikes (NTC 5623 – spike endurance) – the sensor is subjected to repetitive pressure spikes (peak pressure 150 % of full scale, duration 10 ms) at a frequency of 0.5 Hz for 10,000 cycles. We report the sensor condition and the change in accuracy after spike exposure.
• Fatigue test with variable pressure profiles (NTC 5624 – random pressure cycling) – the sensor is subjected to a random pressure profile that simulates real-world operating conditions (e.g., from a hydraulic pump or a compressor), with varying amplitudes and frequencies, for 500 hours. We report the drift and the sensor’s ability to maintain accuracy.

Temperature Compensation and Thermal Drift Evaluation – Assessing Sensor Stability across the Operating Temperature Range

Pressure sensors are often used in environments with wide temperature variations, which can cause thermal errors and drift. Our tests evaluate the effectiveness of the sensor’s temperature compensation and its stability across the operating temperature range, following international standards and the requirements of the Colombian industrial and automotive sectors.

• Thermal error test (IEC 60770 / NTC 5630 – temperature cycling and pressure measurement) – the sensor is placed in a temperature chamber and subjected to a temperature cycle from -20 °C to +80 °C, at a rate of 2 °C/min, while maintaining a constant pressure (50 % of full scale). The sensor output is recorded continuously, and the thermal error (in % of full scale per °C) is calculated. We report the thermal error, the maximum deviation over the temperature range, and the compensation efficiency.
• Zero thermal drift (NTC 5631 – zero output over temperature) – the sensor output at zero pressure is measured at -20 °C, 0 °C, 20 °C, 50 °C, and 80 °C. The zero thermal drift (in % of full scale per °C) is calculated. We report the zero thermal drift and the compensation accuracy.
• Span thermal drift (NTC 5632 – span output over temperature) – the sensor output at full scale pressure is measured at the same temperatures, and the span thermal drift (in % of full scale per °C) is calculated. We report the span thermal drift and the overall temperature error.
• Long-term thermal stability (NTC 5633 – thermal aging and drift) – the sensor is maintained at 70 °C for 100 hours, and the zero and span outputs are measured before and after the thermal aging. We report the long-term thermal drift (in % of full scale).
• Transient thermal response (NTC 5634 – thermal shock effect) – the sensor is subjected to a rapid temperature change (from 20 °C to 80 °C in 10 seconds) while at constant pressure, and the output is recorded to determine the thermal shock error and the recovery time. We report the thermal shock error (in % of full scale) and the recovery time (in seconds).

Long-Term Stability and Drift Testing – Evaluating Performance over Extended Operation

For sensors used in continuous monitoring applications, long-term stability and drift are critical parameters. Our tests evaluate the sensor's ability to maintain its accuracy and repeatability over extended periods (weeks to months) under controlled conditions, which is required by the SIC and the ANH for certification of instrumentation used in oil and gas production.

• Long-term drift test (IEC 60770 / NTC 5640 – 30‑day drift) – the sensor is maintained at a constant pressure (50 % of full scale) at 23 °C for 30 days. The output is recorded daily, and the drift (in % of full scale) is calculated. We report the daily drift, the maximum drift, and the total drift over 30 days.
• Drift under cyclic pressure and temperature (NTC 5641 – accelerated life test) – the sensor is exposed to daily cycles of pressure (0 to 100 % of full scale) and temperature (20 °C to 60 °C) for 90 days. The accuracy and hysteresis are measured weekly. We report the degradation of accuracy and hysteresis over time.
• Zero and span drift after shock and vibration (NTC 5642 – combined mechanical stress) – the sensor is subjected to mechanical shock (50 g, 10 ms) and random vibration (5‑200 Hz, 2 g) for 2 hours, and then the static accuracy is re-measured. We report the change in zero and span after the mechanical stress.
• Stability against power supply variations (NTC 5643 – voltage and current variation) – the sensor is tested at different supply voltages (±10 % of nominal) and currents (4‑20 mA loop) while measuring a constant pressure, and the output variation is recorded. We report the stability against supply variations (in % of full scale).
• Drift due to electromagnetic interference (EMI) – NTC 5644 – EMI immunity test – the sensor is exposed to radio-frequency interference (10 V/m, 80‑1000 MHz) and its output at constant pressure is measured. We report the EMI-induced error (in % of full scale).

Complementary Analysis – Materials, Mechanical Integrity, and Failure Analysis

To fully understand the sensor’s behavior and failure mechanisms, we complement the functional tests with material characterization, mechanical inspection, and failure analysis. These analyses help identify the root causes of drift, hysteresis, or failure and provide recommendations for design improvement and material selection.

• Metallurgical and microstructure analysis (ASTM E3 / NTC 5650 – for metallic pressure sensor components) – we examine the microstructure of the pressure-sensitive element, diaphragm, and housing to detect corrosion, fatigue cracks, or material defects that may affect sensor performance.
• SEM and EDS analysis of failure zones (ASTM E1508 / NTC 5651) – the failed areas of the sensor (e.g., diaphragm rupture, welding points, electrical contacts) are examined using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) to identify the failure mode (ductile, brittle, fatigue, corrosion) and the chemical composition of contaminants or corrosion products.
• Leak test after pressure cycling (NTC 5652 – helium leak detection) – after the fatigue test, the sensor is subjected to a helium leak test (using a mass spectrometer) to verify the integrity of the hermetic seal. We report the leak rate (in mbar·L/s) and the sealing integrity.
• Diaphragm deflection and deformation measurement (NTC 5653 – contact profilometry) – the deflection of the pressure-sensing diaphragm is measured using a contact profilometer or a laser interferometer, before and after pressure cycling, to detect permanent deformation or creep. We report the deflection change (in μm).
• Electrical insulation and dielectric strength (ASTM D257 / NTC 5654 – insulation resistance and dielectric withstand) – the insulation resistance between the sensor terminals and the housing, and the dielectric strength (2 kV, 50 Hz for 1 minute), are measured after the pressure tests to ensure the electrical safety of the sensor. We report the insulation resistance (in MΩ) and the dielectric withstand result.

Test Report and Recognition in the Colombian Industrial Sector

All procedures described are within the scope of our ISO/IEC 17025 accreditation, with equipment calibrated periodically (pressure calibrators, temperature chambers, dynamic pressure generators, data acquisition systems, and digital multimeters) and traceability to international standards (NIST, PTB). Our test reports are issued in Spanish and include:

• Full identification of the sensor (manufacturer, model, serial number, range, output signal, supply voltage, and temperature range).
• Detailed description of the test methods applied (IEC/ISO/ANSI/ASTM/NTC standards, pressure and temperature conditions, number of cycles, and measurement uncertainty).
• Numerical results: static accuracy (%), linearity (%), hysteresis (%), repeatability (%), rise time (ms), frequency response (Hz), drift (%), thermal error (%), proof and burst pressures (MPa), and insulation resistance (MΩ).
• Graphical results: calibration curves, step response curves, frequency response plots, and drift vs. time curves.
• Comparative tables against the values specified by the client or against the limits of the NTC 5600 (Static accuracy), NTC 5610 (Dynamic response), NTC 5620 (Cyclic endurance), and the requirements of the ANH, MinMinas, and SIC for pressure instrumentation.
• Photographs and micrographs (SEM) of the sensor before and after testing, and in case of failure, images of the damaged components.
• Recommendations for improving sensor design, material selection, and manufacturing processes to enhance accuracy, durability, and temperature stability.
• Expanded uncertainty (k=2) for all key measurements, calculated according to the ISO/IEC 98-3 Guide.

These reports are fully accepted by the Superintendencia de Industria y Comercio (SIC) for product registration and quality certification, by the Agencia Nacional de Hidrocarburos (ANH) and the Ministerio de Minas y Energía (MinMinas) for homologation of sensors and instrumentation in the oil and gas sector, and by the Dirección de Impuestos y Aduanas Nacionales (DIAN) for tariff classification and quality verification in the import of pressure sensors and transmitters. Additionally, we offer consulting services for the selection of high-pressure sensors suitable for specific applications, the optimization of sensor designs for improved dynamic and thermal performance, and the implementation of preventive maintenance programs based on the results of pressure variation testing. Our services contribute to the safety, efficiency, and competitiveness of industrial operations in Colombia, from the Caribbean refining complexes to the Andean mining and energy facilities.