Pressure gauges are among the most widely used instruments in industrial, commercial and sanitary applications. From monitoring boiler pressure to validating sterile conditions in pharmaceutical processes, gauges provide operators with the real-time data they need to keep systems safe, efficient and compliant.
But what happens when a gauge stops working? While it may seem practical to repair the instrument instead of replacing it, this is not always the best option. Ashcroft, a leading authority on pressure gauges since 1852, has been addressing this question with customers for more than a century.
Read this article to understand why replacing a damaged gauge can be a better option than trying to repair it on your own.
Why pressure gauge repair is not recommended
When a pressure gauge fails, the temptation is to “fix” it by tightening a loose pointer, resealing a cracked case or recalibrating it. Unfortunately, these attempts often create bigger risks, including:
- Loss of Accuracy. Pressure gauges depend on precision components such as Bourdon tubes, diaphragms and sensors. Even minor wear or tampering can compromise calibration, making the readings unreliable. For critical processes, a small error could lead to equipment failure and operational disruptions.
- Safety Risks. A compromised gauge may not withstand process pressure. Leaks, case rupture or glass breakage can occur and expose workers to hazardous conditions.
- Cost Inefficiency– By the time you factor in labor, parts, recalibration, and downtime, repairing a gauge is often more expensive than replacing it.
Ultimately, attempting to repair a gauge can introduce unnecessary risks to performance, safety and compliance, and may increase costs over time.
What are the cost factors for pressure gauge replacement vs. repair?
A key reason why replacement is favored over repair is cost. When evaluating how to handle a malfunctioning gauge, it’s important to look beyond the initial purchase amount. The total cost of ownership includes not only the instrument itself, but also the time, labor and risks involved in keeping it in service.
Replacement offers a predictable, low-cost path back to reliable operation, while repair often introduces hidden expenses that add up quickly. Here are three examples:
- Affordable Replacement Costs. Commercial gauges are relatively inexpensive. In most cases, the price of a new gauge is lower than sourcing parts and the labor cost of attempting a repair.
- Warranty and Certification. New gauges often come with factory warranties, certifications and calibration traceability. A repaired unit cannot provide the same assurance.
- Minimized Downtime. A replacement can most often be installed more quickly, whereas repairs often require shipping, waiting for parts and retesting for accuracy before use.
For operations that depend on continuous monitoring, avoiding lengthy delays is often worth more than the potential for small upfront savings of attempting a repair. Every hour of downtime adds up. Quick replacement ensures operators can restore process visibility immediately.
What are the repair vs. replace considerations by gauge type?
Each type of pressure gauge is engineered for specific process conditions. Because the design and construction vary so widely, some may assume certain types of gauges are more “repairable” than others. In practice, however, the unique features that make these instruments suitable for their applications are reasons repairing your gauge introduces more risk than replacing it.
| Gauge Type | Repair vs. replace? |
| Commercial Pressure Gauges | Used in HVAC, water treatment, and general equipment monitoring, commercial gauges are widely available and inexpensive. Replacement is always the most economical path. |
| Industrial Pressure Gauges | Industrial gauges are built for higher durability and pressure ranges. However, if damaged, their complex internal parts (Bourdon tubes, movement mechanisms) are difficult to restore to factory calibration. Replacing ensures long-term reliability. |
| Digital Pressure Gauges | Digital gauges include electronic sensors, microprocessors, and displays. Repairing the electronics is impractical and may introduce errors in performance. |
| Differential Pressure Gauges | These instruments measure pressure differences across filters, pumps, and systems. Their diaphragms and springs must remain perfectly balanced. Attempted repairs can disrupt accuracy and compromise the system’s efficiency. |
| Test Gauges | Designed for precision calibration and validation, test gauges demand the highest accuracy. A repaired test gauge may no longer meet the stringent accuracy class required, making it unsuitable for critical calibration work. |
| High Purity and Sanitary Gauges | In pharmaceutical, food, and biotech applications, regulatory compliance is critical. Any tampering or repair compromises the gauge’s sanitary certification. In these industries, only validated, factory-sealed replacements are acceptable. |
If repairing a gauge is not the answer, what should operators do?
The best approach to addressing a damaged pressure gauge is to extend instrument life through proactive maintenance and protection, then replace when necessary. Here's how:
- Conduct regular calibration and inspections. Schedule calibrations to detect drift early and maintain accuracy.
- Use proper instrument selection. Be sure gauges are matched to process requirements, including pressure range, media compatibility and environmental conditions.
- Use protective accessories. Use diaphragm seals, snubbers, and isolation rings to shield gauges from pulsation, corrosion, and clogging.
- Partner with trusted suppliers. Working with a reputable manufacturer, such as Ashcroft, ensures you receive instruments backed by warranty, certification, and technical support.
By taking preventative steps, you can extend the instrument's lifespan, minimize downtime and ensure that when a replacement is needed, it’s quick and easy. So, the next time a gauge shows signs of failure, consider a replacement—it’s the best practice for accuracy, safety, long-term performance and cost.
Ready to learn more?
For a more in-depth look at pressure gauges, we have several relevant articles that may interest you.
- How Do I Select the Right Pressure Gauge Range?
- Choosing the Right Pressure Gauge Dial Size
- How Often Should I Check the Calibration of My Pressure Gauge?
- How Does Temperature Affect Pressure Gauge Performance?
- Why Did My Pressure Equipment Fail? 6 Instrument Killers
- How Much Do Mechanical Pressure Gauges Cost?
Contact us to speak to an Ashcroft product expert and get all your pressure gauge questions answered. In the meantime, check out our pressure gauge selection tool to help you find the best instrument for your needs.
