How to Select a Suitable Test Pressure Gauge

Requirements for the Selection of Test Pressure Gauge

Some important considerations for selecting a suitable Test Pressure Gauge are mentioned below:


The most suitable range of this instrument is around double the highest value of operating pressure. In case this range is very low, this can result in:

  • Excessive operating stress can cause low fatigue life of the equipment.
  • Extreme pressure fluctuations are much higher than the normal operating pressure.

Test Pressure Gauge


When using a dry or a liquid-filled Test Pressure Gauge, selecting the most suitable temperature is essential.


It is crucial to select suitable material for the process sensing element, which goes perfectly with the process media. You can use a diaphragm seal along with your Test Pressure Gauge in case of a pressure media which:

  • It consists of heavy particles
  • Possesses corrosive property
  • It has a dense and thick nature or may become hard even at room temperature

Oxidizing Media                                                                    

It is important to clean it when used directly on the oxidizing media.

Vibration or Pulsation

You can dampen the pressure pulsation by several procedures.

It is hard to detect the high-frequency pulsation,

which may be indicated by an upscale zero shift produced do the movement wear.

High pressure test pressure gauge


Choosing a suitable fill for filling is an important factor to consider. In most cases, glycerin is this fluid, with a temperature range of 20/180°F.

How can you Verify your Test Pressure Gauge?

For accurate verification testing of your Test Pressure Gauge, perform the given procedure:

  • Detach it from the industrial system or remove it from the valves.
  • If there is any fluid in the system, then ensure that you take out all the air or gas; this may be done after priming the system.
  • Establish a secure connection between the working and reference Test Pressure Gauge.
  • After this, run the machinery and note down the readings.
  • Make a comparison between the readings.
  • If these readings are similar, the Test Pressure Gauge is verified.
  • If these readings are very different, it is essential to perform the error calculation to continue the calibration procedure.
  • To test the efficiency, you can use the primary device or the calibrator, which acts as a standard for the calibration process.
  • To decrease the fluctuation in the measurements before measuring the pressure readings on the calibrator.

How to Calibrate a Test Pressure Gauge?

To calibrate Test Pressure Gauge, perform the following procedure:

  • Detach the ring, window, and back closure assembly.
  • Pressurize it to the maximum limit and then to zero.
  • Set the micrometre pointer at the zero position. Detach the pointer and dual for the open front Test Pressure Gauge, followed by pressing the pointer at the pinion at a 9 o’clock angle.
  • After applying full-scale pressure, measure the magnitude of the span error.
  • Now, apply the midscale pressure and measure the error. Even if the Test Pressure Gauge is correct at zero and full-scale position, it may not be true at the midpoint, termed the linearity error.

Ensure that you note the friction error during recalibration, which should not be more than the basic accuracy value. If this friction error exceeds, mostly due to the wrong setting of the hairspring, replace the movement.

stainless steel dry test pressure gauge

How to Functionally Test your Test Pressure Gauge?

To check the consistency of your Test Pressure Gauge, you can perform the functional test to test its operational capability, explained in the following steps:

  • Double-check the measuring range to make it according to the range listed in the manufacturer’s booklet.
  • Ensure that your Test Pressure Gauge and reference one are attached to the same pressurized industrial space.
  • Fix 5 different pressure point ranges including 0%, 25%, 50%, 75%, and 100% for the equipment.
  • Note the values on each point from both, then compare them.
  • After reversing the whole procedure, decrease the pressure to 0%, and note down the readings.
  • Compare these readings with the standard readings.

What are the Safety Recommendations Related to a Test Pressure Gauge?

The safety recommendations related to a Test Pressure Gauge are:

  • Ensure proper construction and range for safe operation.
  • Treat problems like shock pressure, over-pressure, and fatigue.
  • Install a solid wall between the glass dial cover and the Bourdon tube.
  • For venting ruptured tube’s pressure, install a blowout disc in the back of the case
  • Do not exceed the recommended temperature limits.
  • Calibrate and recalibrate your Test Pressure Gauge timely.
  • Choose the appropriate installation site for safe working.
  • Ensure that the accuracy does not exceed the recommended range for your specific application type.

What are the Installation Tips for your Test Pressure Gauge?

For the proper installation of your Test Pressure Gauge, follow these instructions:


The installation site should be chosen to minimize extreme moisture, vibration, and temperature parameters. Always prefer dry locations that are far from high-temperature sources. In case of high mechanical vibration, locate it remotely on a wall and use a flexible tubing connected to a power source.


Installation of a new Test Pressure Gauge is recommended for new applications whenever possible to avoid previous media’s reaction.


Never apply torque on the case; instead, use a wrench (adjustable or open-end) to fit it into the pipe or fitting. You can also use a thread sealant like Teflon tape to prevent leakage and ensure secure tightening.

Process Isolation

Install a shut-off valve between the process in order and the Test Pressure Gauge for isolating it for replacement or inspection without process shut-down.

Surface Mounting

Keep it free from piping strain and opt for a case mounting feet to clear the mounting surface and pressure-relieving back.

Flush Mounting

Choose the most suitable panel mounting cutout dimensions.

How to Replace your Test Pressure Gauge?

For replacing your Test Pressure Gauge, follow these steps:

  • Remove the battery by turning off the control unit and unlocking the screws using the Allen key.
  • Access the Test Pressure Gauge by separating the control unit and the panel.
  • Remove the tubing and open the screws using a flat screwdriver, removing the metal ring and removing the elbow fitting.
  • On the new Test Pressure Gauge, around the thread, wrap the tape and tighten the elbow fittings.
  • Install the new metal ring, properly orient the new gauge, and tighten the screws.
  • Refit the panel in the control unit and reinstall the batteries.

dry test pressure gauge

How to Operate your Test Pressure Gauge?

For operating your Test Pressure Gauge, follow these instructions:

Inspection Frequency

It is dependent on the pressure accuracy and the severity of the service. For critical applications, monthly inspections are preferable, whereas, for non-critical applications, annual inspections are acceptable.

In-Service Inspection

Look for random or erratic pointer motion and remove the improperly working Test Pressure Gauge to prevent pressure boundary failure.

Accuracy Check

Always check the accuracy of the pointer to show any suspicious behavior.


If the accuracy is only 0.5% beyond the specification of a 3-2-3% Test Pressure Gauge, you should consider recalibration. If the accuracy is only 0.1%, then recalibration is a must.

Other Considerations

Other considerations include checking the window and ensuring that it is not broken. Checking for leakage, discolouration, and extreme pressure pulsation.

What are the Maintenance Guidelines for your Test Pressure Gauge?

To maintain your Test Pressure Gauge, you must prepare a maintenance program that includes checking the following things:

  • Pressure indication
  • Condensate presence
  • Gasket tightness
  • Cleaning of the components

It is also recommended to schedule the replacement as per the maintenance program for heavy work instruments used in extreme conditions. These include sediments or corrosive fluids, vibrations, combustible fluids or fuel, and pulsating pressures.

If your Test Pressure Gauge is not working properly, you must take unplanned and emergency checking measures. Keep it indoors and in its original packaging to protect it from humidity.

Maintain the stocking temperature within a range of -25 to +65°C. Move it carefully, even inside the packaging, to safeguard the metrological features.

Also, install an interception valve after installing the Test Pressure Gauge on the pressure generator to verify the sensing element condition. Look for any leakage problems.

Repeat the recalibration if there is a difference between the previous calibration and the nominal values. Ask your supplier for necessary help in severe technical or mechanical problems.

stainless steel test pressure gauge

How to Customize your Test Pressure Gauge?

For the customization of your Test Pressure Gauge, consider the following options:

Peak Load Indicator

For customizing dual scales and special measuring units.

Slotted Link

To protect from sudden pressure damage and movement.

Hand Carry Case

For easy and safe transportation and storage.

Thermal Compensation

For correcting ambient temperature’s effects and maintenance of accuracy.

What are Some Major Problems Related to a Test Pressure Gauge?

Some major problems related to a Test Pressure Gauge are:

Fatigue Rupture

Oscillations of indication can highlight continuous pressure variation, overall decreasing the service life. For this, allowing the indicator to rest is recommended to prevent continuous pressure variation.

Overpressure Rupture

In the case of compressed gases, the damage is even higher due to the opening of the safety device. There could also be an explosion due to breakage in the case of high-pressure operations. To avoid breakage from overpressure, opt for a solid front blowout back.

Corrosion Rupture

It occurs when the process medium is incompatible with the Test Pressure Gauge. To prevent this, ensure the compatibility of the component material and the medium.

Explosion Rupture

Some chemical reactions release high thermal energy, like adiabatic oxygen compression when hydrocarbons are involved. For such applications, use a specifically recommended Test Pressure Gauge.


The Test Pressure Gauge uses atmospheric pressure as the zero point and has different units, including bar and psi. Always look for the construction quality, reliability, suitability, and function when choosing one for your application.

To get your customized or standard Test Pressure Gauge or other sensing equipment at a very affordable price, email us at Our highly motivated customer care team is ready to solve your queries.

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