{"id":10415,"date":"2018-12-04T10:23:14","date_gmt":"2018-12-04T15:23:14","guid":{"rendered":"https:\/\/blog.wika.com\/us\/\/?p=10415"},"modified":"2025-06-17T13:21:09","modified_gmt":"2025-06-17T18:21:09","slug":"pressure-sensor-withstands-chlorinated-gas-environment","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/products\/pressure-products\/pressure-sensor-withstands-chlorinated-gas-environment\/","title":{"rendered":"Case Study: Custom Pressure Sensor Withstands Aggressive Chlorinated Gas Environment"},"content":{"rendered":"

For a leader in industrial flow equipment and services, one specific application was causing significant difficulties for their end user. The harsh environment \u2013 high-temperature chlorinated gas for fiber optic production \u2013 was causing half of their pressure transmitters to fail. By working with WIKA\u2019s experts in quality instrumentation on a custom pressure sensor solution, the customer overcame their systematic field problem with great success.<\/strong><\/p>\n

The fiber optic cable market could reach almost $6 billion by 2025, driven mostly by the world\u2019s increasing internet use. As global demand grows for faster data transfers and more bandwidth, the demand for fiber optic cables grows as well.<\/p>\n

However, this industry faces challenges as well as healthy growth. For one, the manufacturing of fiber optic cables requires using high temperatures and harsh chemicals \u2013 elements that can damage standard measuring instrumentation.<\/p>\n

Challenge: Standard Pressure Sensor Not Robust Enough<\/h2>\n

<\/span>A long-time WIKA customer, a global distributor of flow components and services for ultrahigh purity (UHP)<\/a> and industrial markets, had a challenge. One of the distributor\u2019s end user, a process equipment manufacturer, has an integrated vapor flow control system for fiber-optic production that requires high-temperature, chlorinated gases. The problem? The standard pressure sensors used to measure the chlorinated gas pressure were unable to withstand the environment\u2019s high temperatures and harsh chemicals. The end user\u2019s pressure sensors in the field began failing at an unacceptable rate of 50%.<\/p>\n

Due to WIKA USA\u2019s proven track record and reputation for quality instrumentation, the distributor reached out to us for advice and solutions. The need: A pressure transmitter that could withstand these two challenging environments \u2013 accurately and reliably \u2013 for this critical application.<\/p>\n

Solution: A Customized Pressure Sensor<\/h2>\n

<\/span>WIKA USA\u2019s project management (PM) team spent considerable time with the distributor to better understand the need and outline the end user\u2019s application requirements. This team then worked closely with WIKA\u2019s engineering and production teams to define the product specifications.<\/p>\n

One thing quickly became clear: The situation required more than an off-the-shelf product from WIKA\u2019s semiconductor line. From there, those teams worked on a custom solution. The customer service team aligned samples for prototypes and First Article Inspection (FAI) with the distributor\u2019s test schedules.<\/p>\n

After several evolutions, much feedback, and many hours of retooling the S-20 pressure sensor<\/a>, WIKA hit upon the perfect solution for the end user\u2019s high-temperature, chlorinated gas environment.<\/p>\n\n

\"WIKA

For a customer’s end user, WIKA developed a custom pressure sensor that can withstand high temperatures and a chlorinated gas environment.<\/p><\/div>\n \n

Results: Faster Uptimes and Zero Field Failures<\/h2>\n

After switching to the customized S-20 pressure sensor, the end user reported a 200% increase in system uptime. What\u2019s more, there have been zero field failures for the more than 1,000 pressure transmitters. Based on this successful initial result, the distributor\u2019s end user expects to add around 500 WIKA pressure sensors each year to its growing install base.<\/p>\n

In the end, it was WIKA\u2019s partnership and innovation that resulted in an instrumentation solution rugged enough to not only survive, but thrive, in a high-temperature, chlorinated gas environment where other sensors had failed.<\/p>\n

\u201cThe WIKA product is a \u2018slam dunk\u2019 solution,\u201d said an executive from the global distributor. \u201cIt works great, is easy to use, and doesn\u2019t fail.\u201d<\/p>\n

The WIKA USA Advantage<\/h2>\n

WIKA has a global reputation for high-quality, cost-effective measurement instrumentation. But more than that, what separates us from the competition is our dedication to value innovation<\/a>. We listen to our customers, question the status quo, and seek to come up with effective solutions that previously couldn\u2019t be found in the marketplace.<\/p>\n

WIKA uses a SMART approach to value innovation:<\/p>\n