The analog pressure gauge is one of the simplest, mostly used instruments, and the easiest to calibrate in pressure calibration. It has a simple setup where you can easily execute the calibration. But analog pressure gauge is also one of the instruments where errors are mostly encountered.
Most errors are either “out of tolerance” or the needle is not in the “zero settings”. The following are the commonly encountered problems with the analog pressure gauge:
1. pressure gauge needle stuck;
2. pressure gauge not zeroing;
3. the pressure reading is very far or out of calibration;
4. the worst, pressure gauge not working at all
When this happens, do not immediately throw or discard the gauges. Luckily, there are still ways to adjust or repair pressure gauges.
In this post, I will share with you 5 ways on how to adjust a pressure gauge, how to identify the error and execute the adjustment. Pressure gauges have so many applications and therefore have also many construction designs.
I will present in this post the different setups for different models of gauges to be adjusted.
Below are some reasons why pressure gauges are getting out of whack (out of tolerance or not in the zero settings):
- Changes in the altitude and temperature (due to changes in environmental factors).
- Overstressed bourdon tube due to exposure to overpressure.
- Overused or overexposed to pressure cycle
- Exposure to high temperatures and excessive vibrations
- Wear in the mechanical parts.
Before we execute the gauge adjustment or repair, below are some considerations that you should determine in order to save time and effort.
- A reading near its full-scale value is shifted to more than 10%( a span shift)
- Pressure gauges that have a zero shifted to more than 25 % (a zero shift)
- Gauges with signs of leakage and corrosion of its body.
- Gauges with a needle showing an error due to excessive friction or wear on its movement (loose)
- With damage sockets and threads.
You can see more in this article from ASHCROFT
5 Techniques to Adjust or Repair a Pressure Gauge
- Opening a vent to release pressure build up
- Opening the Glass (or plastic cover) then removing the needle.
- Rotating the screw located at the face of the scale.
- Adjusting the knob at the lower side of the pressure gauge
- Adjusting the screw located at the gauge needle pointer itself.
Be reminded that the above techniques depend on the construction or design of the pressure gauges.
1. Opening a vent to release pressure build up
This is the simplest technique. Due to changes in temperature and altitude, a pressure inside the pressure gauge will be formed and affect the needle settings to zero. You can correct this by just opening the vent to release the pressure.
Do not forget to return or re-seal the vent. The oil may leak and may damage the gauge.
2. Opening the Pressure Gauge Protective Glass (or plastic cover) then removing the needle.
For a non-oil filled gauges and it is not permanently sealed (most oil-filled gauges are permanently sealed where adjustment or repair is not possible).
But in some cases where it can be opened, remove first the oil inside before removing the glass cover. You need an extra oil replacement just in case.
Remove the glass cover (some are plastic) and remove the needle pointer.
( see at the bottom of the page the tool to remove the cover and needle easily and safely).
A. To correct the Zero Shifts:
Once the cover is removed, you can now pull the needle. Once the needle is removed, position it on the zero scales then push to return. Verify the reading.
B. To correct Span Shift:
Once the needle is removed, connect the pressure gauge to a known pressure source (the Electronic Deadweight Tester or Fluke 754 with a set of pressure modules) then generate a pressure of about 50% of its Full scale. Once the pressure is set, return the needle on the same value as the supplied pressure. For example, generate a 100 psi pressure from the reference standard, then fix the needle on the 100 psi scale reading on the pressure gauge.
Most of the time, Just performing either A or B solves the problem.
3. Adjusting the knob at the lower side of the pressure gauge
Some pressure gauges have an adjustable knob in the lower side of the body. This is a diaphragm type pressure gauge that is usually used in water treatment pipings.
Just remove the lock then the knob will freely turn to adjust the needle.
4. Adjusting the screw located inside the pressure gauge mechanism
Some have an adjustable screw inside the body, at the back of the needle. This type ot gauges are used in gas lines.
Access the screw inside the gauge by removing the cover. Turn the screw and return the needle to zero position.
5. Adjusting the screw located at the gauge needle pointer itself
.Some have an adjustable screw integrated on the needle itself. Once the cover is removed, use a screwdriver and carefully turn the screw to position the needle. See the figure above or watch the video below.
Some useful tools.
- Ashcroft 3220 Hand Jack Set Gauge Needle Puller. You can use this tool to remove the needle safely and effectively:
click here to check at Amazon
In removing the needle, be careful not to pull the needle so hard to avoid damaging the pinion mechanism. Some needles are very tight where you can pull the pinion with it. In order to avoid this, you may use this tool.
2. Strap Wrench Set. Use this tool to remove the glass cover safely and easily.
Click here to check at Amazon: Craftsman 2 pc 16” Rubber Strap Wrench Set
Watch the video here at my Facebook Page: How to use the Strap Wrench
There it is, I have shared the different techniques to adjust or repair a pressure gauge. You can save a pressure gauge by following or choosing the right setup suited for a specific pressure gauge. I will add here other types just in case I see a new one.
To learn how to calibrate a pressure gauge, visit this post: pressure-gauge-calibration-using-fluke-754-process-calibrator-with-a-set-of-fluke-pressure-modules
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