This article was originally published on May 16, 2022, and updated on April 16, 2025.
In high-pressure applications, managing pressures of 40,000 psi and above is critical for safety and efficiency. These environments pose significant challenges, such as extreme pulsation and vibration, which can lead to equipment failure and safety hazards. That's why ensuring your gauge is designed to withstand these conditions is so important.
Since 1852, Ashcroft has been a trusted authority in pressure measurement, providing reliable solutions for demanding applications. Read this article to learn about common uses for ultra-high-pressure gauges, the standards they must follow for system and operator safety and considerations for selecting a pressure gauge for your needs.
You will also be directed to additional resources to help you deepen your knowledge of relevant pressure gauge topics.
Common ultra-high-pressure applications
Ultra-high-pressure applications are commonly found in pumping systems that generate flow at very high pressures for industrial cleaning, including:
Water blasting uses highly pressurized water between 10,000 psi and 40,000 psi for general cleaning, surface preparation and the removal of contaminants in various systems and equipment.
Water jetting uses a combination of high-pressure water starting at 35,000 psi and above mixed with an abrasive to cut and remove debris from harder materials.
Figure 1: Examples of water blasting and water jetting applications
Each of these applications requires pressure gauges that meet specific standards for design and safety compliance, ensuring they can handle the extreme conditions involving pulsation and vibration.
Considerations for selecting ultra-high-pressure gauges
Pressure gauges designed for ultra-high-pressure applications must adhere to stringent standards to ensure safety and reliability. Only gauges manufactured following ASME B40.100 or EN 837-1 should be considered. These standards for pressure gauges include specific requirements such as:
- Fatigue testing to ensure durability under repeated pressure cycles
- Vibration testing to confirm the gauge's ability to withstand operational vibrations without compromising accuracy
- A Bourdon tube system capable of handling high pressures and potential overpressure situations
- A solid-front case to protect operators in the event of a rupture
If a pressure gauge meets these requirements, it is considered a suitable option for use in ultra-high-pressure applications.
Why a solid-front design is important in ultra-high-pressure environments
With ultra-high pressures, operator safety is of the utmost concern. Using a gauge with a solid-front design and a rear blow-out plug, like the Ashcroft® T6500 Pressure Gauge gives you protection from a solid internal wall. The bourdon tube is located toward the rear of the case. In the event of a catastrophic event, the tube will rupture towards the rear and not the front of the case where an operator may be located.
Figure 2: Solid-front pressure gauge
Process connections for ultra-high-pressure applications
Since NPT fittings cannot handle higher pressures, you will need a fitting that is stronger and seals better for high-pressure conditions. Depending on the pressure level in your system, you have several connection options.
The most common is the 9/16-18 in. UNF-2B female port, used for ¼ inch outside diameter (O.D.) high-pressure tubing. These are often referred to by the brand name "Autoclave F-250-C."
The inlet is a straightforward female straight-thread port that is easily identified by its flat bottom interior and a counter-sunk hole in the center for pressure passage. (See Figures 3 and 4 below.)
Figure 3: 1/4" High-pressure tubing assembly
Figure 4: 1/4" High-pressure tubing assembly (exploded view)
Gauges, accessories and other options that can keep your ultra-high-pressure systems running safely and efficiently
Ashcroft offers several high-quality gauges designed for high performance in challenging applications, including:
- The Ashcroft® 1379 Duragauge Pressure Gauge. Manufactured to ASME B40.100 specifications, this gauge features a solid-front, 6" dial size and aluminum case, providing strong protection and minimizing the weight of your equipment.
- The Ashcroft® T6500 Pressure Gauge. Manufactured to EN 837 specifications, this instrument also features a solid-front design, comes in a 100 mm dial size and is available in all welded 304 Stainless steel (standard) or 316 Stainless steel (YW option) case. It also has IP66 weatherproof protection and ATEX approval (Ex II 2 GD c).
Both gauges are available with pressure ranges up to 100,000 psi (7,000 bar).
To improve the longevity of your pressure gauge, you can also request dampened movement technology. If you select a dry-case pressure gauge, you can dampen pulsation and vibration and improve gauge readability without the inconveniences of a liquid-filled gauge. For example, numerous Ashcroft® Pressure Gauges are available with PLUS!™ Performance technology to reduce flutter, stabilize the pointer and enhance dial readability.
Ready to learn more?
Now that you know what factors to consider for selecting a quality ultra-high-pressure gauge, you may find these additional articles helpful to deepen your knowledge even further to ensure you continue to keep your process running smoothly and your operators safe.
- Do Pressure Gauge Accessories Affect Accuracy?
- Alternatives to Liquid-Filled Pressure Gauges for Vibration Protection
- How To Identify Your Pressure Gauge and Get the Proper Replacement
- How Does Temperature Affect Pressure Gauge Performance?
- How Do I Select the Right Pressure Gauge Range?
- How Often Should I Check the Calibration of My Pressure Gauge?
You can also contact a product expert and get all your measuring instrument questions answered.
In the meantime, feel free to download our guide to learn how to avoid pressure equipment failure: