Proper selection, calibration, and installation of pressure gauges are essential to ensure they perform effectively in industrial applications. First, the choice of a pressure gauge must be based on specific usage requirements. It's important to analyze each situation carefully and select the appropriate type, model, range, and accuracy level according to technical specifications from the production process. Key factors to consider include: (1) Determining the gauge range based on the pressure being measured. For flexible gauges, it's crucial that the elastic components operate within a safe deformation range, so there should be enough room for selection. When the pressure is relatively stable, the maximum value should not exceed 3/4 of the full scale. If the pressure fluctuates significantly, the maximum should not go beyond 2/3 of the scale. To maintain measurement accuracy, the measured pressure should not be less than 1/3 of the full range. (2) Choosing the accuracy level based on the maximum allowable error in the process. Whenever possible, opt for low-cost, low-precision gauges if they meet the production needs. (3) Considering the nature of the medium being measured—such as temperature, viscosity, corrosiveness, dirt, or flammability—and environmental conditions like high temperatures, humidity, or vibration. This helps determine the suitable type and model of the pressure gauge.
Next, the calibration process involves comparing the readings of the pressure gauge with a standard one. The standard gauge should have an absolute error less than 1/3 of the tested gauge to ensure its readings can be considered accurate. If the difference between the two readings is within the allowed error range, the gauge is deemed acceptable. Finally, proper installation is critical. The pressure point should be chosen where the flow is straight, avoiding areas with vortices or dead zones. When measuring flowing media, the pressure point should be perpendicular to the flow direction, and burrs should be removed. For liquid pressure, the point should be at the bottom of the pipe to prevent gas accumulation; for gas, it should be at the top to avoid liquid buildup. The pressure guiding tube should have appropriate thickness and length, typically 6–10 mm in diameter and 3–5 meters long. If the medium tends to condense or freeze, heat tracing lines should be added. A shut-off valve must be installed close to the pressure tap. The pressure gauge itself should be placed where it is easily visible and accessible for maintenance. Avoid locations with excessive vibration or high temperatures. For steam pressure, a condensate trap should be used to protect the sensor. Corrosive media require isolation tanks filled with neutral substances. In special cases such as high temperature, low temperature, corrosion, or viscous media, additional protective measures must be taken. Sealing gaskets should be used at all connections. Asbestos paperboard or aluminum sheets are suitable for low-temperature and low-pressure environments, while annealed copper or lead gaskets are better for higher temperatures and pressures. Always consider the medium’s properties—for example, oxygen gauges should not use oil-based gaskets to prevent explosions, and acetylene gauges must avoid copper gaskets.
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