Confusion between gauge and absolute pressure causes interpretation errors. A vacuum pump rated '-30 PSI' uses gauge pressure (30 PSI below atmospheric = 85.3 kPa absolute). Converting to absolute: 0 PSI gauge = 101.325 kPa absolute, so -30 PSI gauge = 101.325 - (30 × 6.894.76) = -105.5 kPa impossible. Error: must add atmospheric pressure correctly: 101.325 - 206.843 would go negative; actually: -(30 PSI × 6.894.76) = -206.843 Pa gauge → 101,325 - 206,843 = -105,518 Pa (invalid). Correct: -30 PSI gauge means 30 PSI below atmospheric, so absolute = 14.7 - 30 = impossible (can't go below vacuum). Validate gauge pressure doesn't exceed negative atmospheric pressure.
Unit abbreviation ambiguity creates parsing and interpretation errors. 'PSI' vs 'psi' (case), 'Pa' (pascal) vs 'pa' (could be misread), 'bar' vs 'Bar' (case sensitivity). Torr and mmHg are equivalent numerically but different historically. 'atm' could mean atmosphere (101,325 Pa) or technical atmosphere (98,066.5 Pa, deprecated). When building converters, normalize input (case-insensitive), validate against known units, reject ambiguous abbreviations. Display output with standard capitalization (Pa, kPa, PSI, bar, atm, torr) to prevent confusion.
Extreme pressure values (very high or very low) cause floating-point precision issues or indicate unit errors. User entering '1000000 Pa' might have meant '1000000 PSI' (6.9 GPa, material deformation pressures). Conversely, '0.001 PSI' might have meant '0.001 bar'. Validate input ranges: typical automotive (10-100 PSI), atmospheric (90-110 kPa), industrial (0-1000 bar), vacuum (0-1000 torr). Warn users when values are outside typical ranges: 'Input 10,000 PSI exceeds typical automotive range—verify units'. Provide context-appropriate precision: tire pressure to 1 decimal (35.0 PSI), scientific to 4+ decimals (101,325.00 Pa).