7 Causes of Pressure Gauge Failure and Solutions

A failed gauge compromises a plant’s ability to detect a problem before a safety incident occurs. Pressure gauge failure may also cause media leakage, fugitive emissions, and fire or explosion, thereby compromising safety and reliability.

Even minor accidents can cause employee injuries and cause downtime. Any accident or leakage will cause the company to arrange personnel to solve the problem, which will lead to further employee injury and loss of working time.

Many causes contribute to this dangerous situation with pressure gauges. Fortunately, they can be prevented.

Causes of Pressure Gauge Failure

Here are seven common causes of failure, so let’s take a look at them and see some of the solutions.

1. Vibration

Many devices vibrate. However, excessive vibration can cause meter failure and may indicate a problem with the component.

Solution: Install a pressure gauge that can better resist vibration, that is, a pressure gauge filled with liquid or directly driven, with only one moving part.

2. Pulsation

The rapidly circulating medium in the pressure system will cause the pointer of the pressure gauge to move irregularly and eventually cause damage to internal parts.

Solution: Install a restrictor and a liquid-filled housing to suppress the pulse on the standard pressure gauge, or replace it with a direct drive pressure gauge without gears and connecting rods.

3. Temperature

Extreme temperatures cause sweating and loosening of metal joints, and eventually lead to rupture.

Solution: Install a pressure gauge with a fully welded diaphragm seal. We can consider adding a cooling element to resist the highest temperature.

4. Overpressure and pressure peak

Frequent pegging against the stop pin can bend the gauge pointer and compromise the integrity of the Bourdon tube or sensing element, and eventually lead to rupture.

Solution: Install an overpressure protector to prevent the reading from exceeding the meter capacity.

5. Corrosion

Highly corrosive media often found in processing plants can damage the sensing materials in the pressure gauge.

Solution: Install a diaphragm seal, which is made of a material resistant to corrosion.

6. Blockage

Media containing suspended particles, viscous or crystallizing can block the pressure system and make the meter readings unreliable.

Solution: Install a diaphragm seal with an anti-clogging barrier.

7. Mishandling and abuse

Even properly installed gauges will start to malfunction if mistreated over time.

Solution: conduct regular safety and maintenance training for all employees who come into contact with or proximity to gauges.

Since the operation of managing the process industry is very complex, it is easy to understand that many people ignore smaller components (such as pressure gauges). However, using the gauge as an early warning device can improve uptime, safety, and profit. Therefore, we should pay more attention to it.