How can you tell if a pressure gauge is damaged or could fail?

Gauges seem unimportant, but they are a critical part of systems in all industries. The visual indication of system pressure they provide lets you know if everything is operating within the desired range or if there is an impending problem. An inaccurate pressure gauge can lead to a lower production quality of your system, due to the loss of valid data and the resulting effects of excessive or insufficient pressure in the system. A failing gauge can also release fluid from the system to the environment and lead to possible injury to employees, damage to the system requiring downtime and money to repair, and loss of system production and profits.

 

Recognizing gauge failure indicators and their cause will help you quickly recognize that pressure readings are no longer accurate, helping you avoid undesirable results.

 

If you suspect you don't have the best gauge for your application, read on for the warning signs of failure.

 

What are the Gauge Failure Signs?

 

The top five causes of gauge failure, the signs you will see, and the steps you can take to resolve the problem are:

 

Excess Pressure Gauge

 

A pressure gauge with the pointer fixed at the top indicates that you are working near or beyond its maximum pressure. This means that the installed gauge has the wrong pressure range for the application and is unable to reflect the system pressure. As a result, the Bourdon tube can rupture and cause complete failure of the pressure gauge.

 

The Bourdon tube is a curved, hollow tube, usually made of metal, that is inside the pressure gauge. This tube responds to system pressure and moves the attached pointer to display a pressure reading on the Pressure Gauge dial.

 

Select a gauge rated at twice the expected operating pressure of the system to provide a larger measurable pressure range, or include overpressure protection (for example, a relief valve) in the system preceding the gauge . In extreme system conditions, use a gauge with an orifice restrictor (0.3mm) to limit flow, or consider the option of a diaphragm shutoff instead of a Bourdon tube design for a more efficient solution. robust.

 

 Pressure peaks

 

If the pointer is bent, broken or nicked, the pressure gauge has likely been subjected to a sudden increase in system pressure, caused by a pump on / off cycle or by the opening / closing of an upstream valve . The force of striking the pointer against the end of its travel can damage it. These sudden pressure changes can cause the Bourdon tube to rupture and the pressure gauge to fail. 

 

Evaluate your system design to eliminate pressure spikes and resulting stress on system components, including the pressure gauge. Another option is to select a gauge with a higher pressure range to accommodate anticipated pressure peaks.

 

Mechanical vibration

 

A misaligned pump, piston compressor, or improperly mounted indicator can cause the pointer, lens, lens ring, or back plate to pop out. There may also be traces of black powder on the dial, or scratches on the dial from the loose pointer. The movement of the pressure gauge is connected to the Bourdon tube, and the vibration can break the component that transmits the movement, which means that the sphere no longer reflects the pressure of the system. Using a liquid fill will dampen movement and eliminate or reduce unnecessary vibration in the system. In extreme system conditions, use a damper or a pressure gauge with a diaphragm closure.

 

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 Pulsation Pressure

Frequent and rapid cycles of fluid through the system create wear on the moving components of the gauge. This can affect the ability of the gauge to measure pressure and will be evident because the pointer will move randomly. This situation can cause the Bourdon tube to rupture and the complete failure of the pressure gauge. Redesign the system and relocate the gauge to reduce cycle times by the gauge and maintain the necessary measurement integrity. In case you cannot redesign the system, using a liquid-filled pressure gauge, orifice limiter, or damper will help reduce the effects of pulsation.

Read also: 7 Tips for Building Safer Industrial Fluid Systems