Common Causes of Pressure Gauge Failure

Understanding Pressure Gauge Failure

Pressure gauges are critical components in industrial and commercial applications, ensuring safety and efficiency. However, improper use or harsh operating conditions can lead to premature failure. Understanding these common causes can help businesses prevent costly downtime and equipment damage.

1. Vibration: The Silent Gauge Killer

Excessive vibration causes needle fluctuations, mechanical fatigue, and internal damage, leading to inaccurate readings or complete failure.

Prevention Tips:

  • Use liquid-filled pressure gauges to dampen vibrations.

  • Install remote-mounted gauges with flexible tubing to reduce direct exposure.

  • Secure gauges firmly to minimize mechanical movement.

2. Overpressure: When Limits Are Exceeded

Applying pressure beyond the gauge’s rated range can distort the Bourdon tube or diaphragm, resulting in permanent damage and loss of accuracy.

Prevention Tips:

  • Select a gauge with an appropriate pressure range, ideally 25-50% above normal operating pressure.

  • Use pressure limiters, such as relief valves or snubbers, to absorb sudden spikes.

3. Pulsation: Rapid Pressure Fluctuations

Continuous pressure surges or rapid fluctuations can strain internal components and cause premature wear.

Prevention Tips:

  • Install snubbers or pulsation dampeners to absorb fluctuations.

  • Use liquid-filled gauges to stabilize readings and extend lifespan.

4. Corrosion: The Hidden Threat

Gauges exposed to aggressive chemicals or incompatible media can experience corrosion, weakening internal components and causing failure.

Prevention Tips:

  • Choose corrosion-resistant materials such as stainless steel or Teflon-coated internals.

  • Use diaphragm seals to protect sensitive parts from harsh media.

5. Extreme Temperatures: Heat and Cold Damage

High temperatures can degrade internal mechanisms, while freezing conditions can cause expansion damage, leading to failure.

Prevention Tips:

  • Select temperature-compensated gauges designed for extreme environments.

  • Use thermal insulation or heat tracing in cold conditions.

  • Ensure proper ventilation in high-heat areas.

6. Blockage or Clogging: Flow Restrictions

Debris, sludge, or crystallization in the process fluid can clog the gauge’s pressure port, leading to false readings or failure.

Prevention Tips:

  • Install diaphragm seals to prevent direct exposure to contaminants.

  • Regularly inspect and clean gauges to ensure unrestricted flow.

  • Use filters to remove debris from process fluids.

7. Mechanical Shock: Impact Damage

Dropping, improper handling, or sudden pressure surges can cause impact-related failures.

Prevention Tips:

  • Handle gauges with care during installation and maintenance.

  • Use protective covers to shield gauges from physical damage.

  • Install surge protectors in systems prone to sudden pressure changes.

8. Process Compatibility: Material and Media Mismatch

Using a gauge with incompatible materials for the process media can lead to material degradation and failure.

Prevention Tips:

  • Verify material compatibility with process fluids before installation.

  • Consult experts when selecting gauges for chemically aggressive environments.

Ensure Long-Term Performance with Blanes Pressure Solutions

At Blanes Pressure Solutions, we offer high-quality pressure gauges designed to withstand demanding environments. Our expert team can help you choose the right gauge for your application and provide solutions to prevent premature failures.

Contact Us Today

Prevent costly downtime and ensure reliable pressure measurement with our expert solutions. Contact Blanes Pressure Solutions for premium pressure gauges and professional advice.

We also offer SANAS traceable calibrations complete with a certificate, valid for 1 year on our premises.

Blanes Pressure Solutions supplies a comprehensive range of pressure measurement instruments.

Blanes Pressure Solutions was founded in 2002 to take over the pressure business of Blanes Instruments CC, and can trace its pedigree back to 1893, when Robert Blane left Scotland to make his fortune on the Witwatersrand.

For more information on placing orders, after care and maintenance services you can contact our Sales Manager Ronel Olivier on ronel@pressuresolutions.co.za or 011 422 1749.