The Importance of Installing Analog Pressure Gauges with Pressure Transmitters

This article was originally published on June 27, 2022, and was updated on March 20, 2024.

Critical process applications demand implementing critical safety measures. The safety of your operators and your customers depends on using high-quality pressure measuring instruments that can help you avoid disaster.

The one thing I've learned in over 25 years of industry experience is that you can never be too careful. Unfortunately, when I visit process plants and other facilities, I often find that proper instrumentation is not installed on many applications. Understanding which instruments to use can be the difference between a successful operation and a dangerous one. 

In this article, you will learn why installing both an analog pressure gauge and a pressure transmitter to monitor air, gas or liquid pressure in challenging industrial applications is a good safety strategy. They each have a specific job to do.

When you are finished reading, you can decide if having both types of instruments working for you is the right decision. You will also get links to additional information that you may find useful. 

Why use a pressure transmitter?

Pressure transmitters are used to monitor and control air, gas or liquid pressure in demanding, large-scale industrial applications. The benefit of using a pressure transmitter is its ability to convert pressure measurements into an electrical signal (typically 4-20 mA)  and transfer that data over a long distance to communicate any issues with a control room. 

Why use an analog pressure gauge?

Analog pressure gauges are an efficient and reliable way to measure pressure in your process. But, with so many digital sensor options on the market today, why wouldn’t you only want the latest technology with all the bells and whistles that come with it? The answer is: in many cases, you should install both.

A pressure gauge is still necessary as a local indicator to get local readings to keep operators who are working in the unit safe. These tried-and-true instruments have been around since the 1800s, and because they’re analog, there are no wires, and no electricity is needed to operate them. Analog gauges are powered by the process.

This means if there is a loss of power, the gauge will continue providing local measurements, which helps ensure a safe working environment for the operators. With a gauge, you will always have a point of reference and a reliable instrument that doesn’t depend on a power source.

Here are a couple of other analog pressure gauge benefits: 

• Price. These gauges are reasonably priced and require a minimal amount of time to install.
• Readability. Their larger scale is easier to see, leading to less possibility of error in getting an accurate reading.
• Local indicators. This enables technicians to verify if their processes are running safely and efficiently while they are in the field.

An example of mounting an analog pressure gauge in tandem with a transmitting sensor would be installing an Ashcroft® 1279S Series pressure gauge in close proximity to an Ashcroft® E2 Series Pressure Transducer/Transmitter in a process line.

Figure 1: Ashcroft 1279 and E2 Pressure Assembly.

Ashcroft offers many other instrument combination options when considering a gauge/transducer installation.

Pressure gauge maintenance improves safety and reliability

If your instrumentation isn’t performing properly, you’re not maintaining a safe working environment for your operators. Pressure gauges are often overlooked when it comes to regular maintenance.

A gauge without a diaphragm seal in a corrosive application could corrode or leak. The solution to this problem isn’t just removing the gauge, it’s getting the right accessories for your applications.

Training is also important to ensure that operators, engineers, and instrument designers understand the importance of pressure gauges, why they should be utilized as local indicators, and how to make sure they’re properly maintained over time. Ashcroft offers training that addresses these topics as well as proper instrument protection against the process when necessary and product selection.

Maximize the benefits of pressure instrumentation with proper maintenance, range selection, and recalibration. Read How Often Should I Check the Calibration of my Pressure Gauge to learn more. 

How can Ashcroft help you with your process?

Proper selection of instrumentation will help alleviate any issues you may have with pressure measurement indicators. Ashcroft offers Critical Application Solution Experts® (CASE®) who will visit your work site, review your process conditions and try to help you find a solution to problems you might be facing.

Ashcroft also offers detailed site surveys, including instrument audits which involve reviewing and analyzing existing temperature and pressure instruments. Once all instrumentation is reviewed and analyzed, full documentation is provided detailing each instrument’s current performance, potential problems, and appropriate solutions for optimal productivity and safety.

Although our experts look into your process to make sure the correct instruments are in place, as well as check material compatibility, connections and accessories (siphons, diaphragm seals, etc.), you still have to maintain your pressure gauges and recalibrate them over time.

Ready to learn more?

Now that you better understand the difference between pressure gauges and pressure transmitters and why they are both still critical to your process, you can research the solution that’s right for you to help keep your operators safe.    

Take a look at some of our other articles about pressure gauges that you may find helpful:

• 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?
  

Feel free to contact us today to talk to one of our industry experts and get all your measuring instrument questions answered.

You can also download our guide to learn 5 mistakes to avoid when choosing pressure gauges: