Liquid-filled gauges are essential components in many industrial systems and processes. Have you ever wondered why these gauges are filled with liquid, and what unique benefits make them so popular in industrial applications? Although you probably already have a good understanding of gauges, it never hurts to review everything you need to know about liquid-filled gauges and remind yourself of why they are such useful tools for your particular operations. A refresher on how to choose the right liquid-filled gauge can also be useful amid all the daily details of running a manufacturing or industrial facility.
What Is a Liquid-Filled Gauge?
A liquid-filled gauge, also known as an oil-filled gauge or dampened gauge, is a type of pressure measuring instrument that uses a liquid inside the case to dampen vibration and pulsation and lubricate its moving parts. This helps to prolong the life of the gauge by reducing wear and tear on its mechanical parts.
When and Where Should You Use a Liquid-Filled Gauge?
Liquid-filled gauges are useful in a myriad of industries, each presenting unique challenges that these tools are adept at tackling. For instance, in the petrochemical industry, these gauges are essential for maintaining the high-pressure conditions required in the refining and chemical processes.
Oil-filled gauges also play a critical role in the water and wastewater industry, where they are used to monitor the pressure in pipelines and storage tanks. Meanwhile, in the automotive manufacturing sector, these gauges are used to measure oil pressure in engines and fuel pressure in fuel systems.
The food and beverage industry uses liquid-filled gauges to ensure that cooking, packaging, and sterilization machines maintain the appropriate pressure. And in the pharmaceutical sector, liquid-filled gauges are vital in pressure monitoring during drug manufacturing and packaging processes.
What Are the Types of Liquids Used in Liquid-Filled Gauges?
Oil-filled gauges are typically filled with glycerin, silicone, or a mixture of both, depending on the application needs. Glycerin-filled gauges are popular due to their excellent damping properties and are widely used in environments with a lot of vibration, such as in the automotive and manufacturing sectors. Plus, glycerin-filled gauges are less expensive, and less prone to price fluctuations than other types of oil-filled gauges.
Silicone-filled gauges, on the other hand, are ideal for applications that require a wider operating temperature range, due to silicone’s stable viscosity at both high and low temperatures. For instance, they are commonly found in HVAC applications, outdoor installations, and in regions with extreme temperature variations. However, silicone-filled gauges can be expensive, and the price can fluctuate dramatically.
Lastly, a mixture of glycerin and silicone is sometimes used to leverage the benefits of both types of fluids, offering excellent vibration damping along with a wide operating temperature range. The choice of liquid depends primarily on the specific requirements of the application, taking into account factors like temperature range, vibration, and compatibility with the system’s working fluid.
Don’t be concerned if you notice an air bubble in your oil-filled gauge—this is intentional. The bubble is there to help dampen internal pressure and ensure accurate readings.
A cautionary note: liquid-filled gauges are sealed, and can explode on their users. However, some have a safety plugs in their casings. For example, DuraChoice brand has a specially designed safety pin that can not only minimize damage from the explosion, but can also regularly release internal pressure buildup to ensure the accuracy of the gauge.
How Do Temperature and Pressure Affect Liquid-Filled Gauges?
One of the primary reasons liquid-filled gauges are preferred in various industries is their ability to withstand extreme temperatures and pressure. The liquid inside the gauge acts as a buffer, absorbing any sudden changes in temperature or pressure, ensuring accurate readings and preventing damage to the internal components. Glycerin filled gauges can operate in temperature ranges of -30 degrees to 130 degrees Fahrenheit, while silicone gauges can operate in temperature ranges of -40 degree to 145 degrees Fahrenheit.
What Environments Require Liquid-Filled Gauges?
Liquid-filled gauges are extremely versatile and can be used in various environments. However, they are particularly beneficial in areas with high levels of vibration, pulsation, or shock. By dampening these external factors, liquid-filled gauges ensure accurate readings and long-term reliability. They are also suitable for use in outdoor installations where temperature fluctuations may affect the accuracy of traditional dry gauges.
Liquid-filled gauges are particularly useful for:
- High temperature environments: The liquid filling helps reduce the effects of thermal expansion on the gauge’s internal components, allowing them to perform accurately in high temperature environments.
- High pressure environments: The liquid filling acts as a cushion, protecting the gauge from sudden spikes or fluctuations in pressure.
- Vibration-prone environments: With their excellent damping properties, liquid-filled gauges are ideal for use in areas with high levels of vibration, such as on heavy machinery and equipment.
- Corrosive environments: In industries where the working fluid may be corrosive, the liquid filling acts as a barrier, protecting the gauge’s internal components from damage.
- Humid environments: Humidity can cause condensation to form inside traditional dry gauges, affecting their accuracy. Liquid-filled gauges are sealed and do not have this issue, making them ideal for use in humid environments.
- Freezing conditions: In regions with extremely low temperatures, the liquid filling prevents freezing and expansion of the gauge’s internal parts, ensuring accurate readings.
- Pressure spikes: In processes where pressure spikes may occur, liquid-filled gauges provide reliable and accurate readings, as they are not affected by sudden changes in pressure.
What Are the Other Benefits of Using Liquid-Filled Gauges?
There are numerous additional benefits to using liquid-filled gauges, making them a popular choice in various industries. These advantages include:
- Increased durability and longevity: The liquid filling acts as a shock absorber, reducing wear and tear on the internal components of the gauge, resulting in longer life.
- Better readability: The liquid inside the gauge reduces glare and increases contrast, making it easier to read the pressure measurement accurately.
- Reduced maintenance needs: Thanks to their durable and robust design, liquid-filled gauges require minimal maintenance, resulting in cost savings over time.
There is a lot to review when it comes to everything you need to know about liquid-filled gauges. Importantly, these devices are durable, accurate, and capable of withstanding extreme conditions, making these instruments an easy choice for many industrial environments and applications.
Consider factors such as operating pressure range, temperature range, and compatibility with the working fluid to confidently select the right type of gauge for your facility’s specific needs. Whether you’re monitoring pressure in a high-temperature process or a vibration-prone environment, choosing a liquid-filled gauge ensures consistently accurate and reliable results.
If you need additional information on the types of gauges available for various processes, contact the experts at DirectMaterial.com for consultation. We can help you find the right gauges at the right prices to keep your operations running smoothly, with minimal interruptions for gauge maintenance or replacement.
