Pressure gauges for 40,000 psi and above are critical for numerous applications where monitoring extremely high system pressures is a required safety precaution. Such gauges must be manufactured so they can withstand the rugged conditions they will be exposed to at these extremely high pressures.
Ultra-high-pressure applications are typically found on pumping systems used to generate flow at extremely high pressures. Your pressure gauge must be able to withstand extreme pulsation and vibration. If it is not manufactured to tolerate such conditions, it can fail and cause damage to your equipment or possibly your operators.
How do you know if your pressure gauge is well-suited for ultra-high pressure?
This article will explain the requirements for a gauge to handle high stresses successfully and what you should consider when selecting a gauge for your process.
Considerations When Selecting Ultra-High-Pressure Gauges
Pressure gauges manufactured for such conditions must be assembled to exacting standards. Only gauges manufactured per ASME B40.100 or EN 837-1 should be considered. Gauges manufactured to these standards must pass fatigue and vibration testing to confirm they are suitable for use.
In addition, the long-term life cycling of the gauge can be enhanced by incorporating a throttling device within the gauge to reduce the hydraulic pressure spikes created by the pump. The design and type of throttling device should be reviewed based on the type of media and whether abrasives may be present, which can clog a throttling device.
The design and manufacture of the bourdon tube system is also an important factor. The design of the tube must be such that it can withstand very high pressures and potential overpressure of the system.
With ultra-high pressures, safety is of the utmost concern. Any pressure gauge used for these ultra-high pressures should always have a solid-front case style.
A solid-front case is designed with a solid internal wall, which has the bourdon tube 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 (see Figure 1 below).
Figure 1: Solid Front Pressure Gauge Operation
The process connection is also an important safety consideration. With NPT unable to contain higher pressures, you will need a stronger, better-sealing fitting that's designed specifically for high pressure.
Depending on the level of pressure in your application, there are several types of connections to choose from. In instrumentation, the most common is the 9/16 -18 in. UNF-2B female port for ¼ in. O.D. high-pressure tubing (often designated by the brand reference “Autoclave F-250-C”).
The inlet itself is a simple female straight-thread port, distinguishable by its interior flat bottom with a counter-sunk pressure passage hole in the center (see Figures 2 and 3 below).
Common Ultra-High-Pressure Applications
There are a number of applications that require specialized instruments that are designed to handle ultra-high-pressure environments.
Water Blaster
Water blaster applications use pressurized water to clean. These pressures range from 10,000 to 40,000 psi. Typical applications are:
Heat exchanger cleaning
Pipe cleaning
Tank and pressure vessel cleaning
Tank trucks
Process line and reactor cleaning
Surface preparation and profiling
Refractory and rubber lining removal
Scales, coatings and epoxy removal
Vapor, polymer and resin lines cleaning
Paint booth cleaning
Water Jet
These applications present a unique set of challenges in measuring pressure. With high pressures of 35,000 psi and above, coupled with the presence of vibration and pulsation, these applications demand rugged pressure instrumentation.
In these applications, high-pressure water, often mixed with an abrasive, is used to cut a variety of materials such as:
Metal
Concrete
Stone
Asphalt
Glass
Plastic
Ashcroft offers quality options for ultra-high-pressure gauges. These gauges are specially made to withstand high-stress applications.
1379 Pressure Gauge
The 1379 pressure gauge is manufactured per ASME B40.1 specifications. The gauge has a solid-front, 6-inch dial size and aluminum case. Key features include:
Pressure ranges available up to 100,000 psi
Micrometer adjustable pointer
PLUS!™ Performance option dampens vibration, shock and pulsation effects
T6500 Pressure Gauge
The T6500 pressure gauge is manufactured per EN 837 specifications. The gauge has a solid-front, 100 mm dial size and is available in 304 Stainless steel (standard) or 316 Stainless steel (YW option). Key features include:
High pressure up to 100,000 psi (7,000 bar)
Solid-front, all-welded, Stainless-steel case
Weatherproof protection IP66
ATEX approval Ex II 2 GD c
Dry, liquid filled or PLUS!™ Performance option
We don’t like to pressure you, but we have more information.
Now that you know what factors to consider when finding a quality ultra-high-pressure gauge, you can research the solution that’s right for you to help keep your process running and your operators safe.
For more information on pressure gauges, check out some other articles we’ve written:
Feel free to contact us today to talk with one of our experts and get all your measuring instrument questions answered.
You can also download our eBook to learn how to avoid pressure equipment failure:
Pressure tests are a non-destructive way to guarantee the integrity of equipment such as pressure vessels, pipelines, plumbing lines, gas cylinders, boilers and fuel tanks. It is required by the piping codes to confirm that a piping system is able to bear its rated pressure and it has no leaks. Pressure testing, also called hydrostatic testing, is carried out after the cooling or heating installation of any pipeline and before it is put into use.
By performing a pressure test we find a reliable method for testing all types of pipework, including the ones in district cooling or district heating systems. This type of analysis, besides guaranteeing the right functioning, will also allow us to detect if there are leaks in a specific pipe so that reparations can be made.
The most widely used code for pressure and leak test is the ASME B31 Pressure Piping Code. Among its several sections, the requirements and procedures listed in the codes below are followed by Araner:
Pressure tests may be done either with liquid, usually water (hydrostatic), or with gas, usually dry nitrogen (pneumatic).
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Isolation of equipment and piping not subjected to pressure test: Equipment that is not to be subjected to the pressure test shall be either disconnected from the system or isolated by a blank or similar means.
Figure 1: Isolation of piping
The hydrostatic test pressure at any point in the piping system shall not be less than 1.5 times the design pressure, but shall not exceed the maximum allowable test pressure of any non-isolated component, nor shall it exceed the limits of calculated stresses due to occasional loads.
The test pressure shall be not less than 1.5 times the design pressure. When the design temperature is greater than the test temperature, the minimum pressure shall be calculated by eq. P T = 1,5P S T/S , where =allowable stress at test temperature, S=allowable stress at component design temperature, P=design gage pressure. The test pressure may be reduced to the maximum pressure that will not exceed the lower of the yield strength or 1.5 times the component ratings at test temperature. The pressure shall be continuously maintained for a minimum time of 10 minutes and may then be reduced to the design pressure and held for such time as may be necessary to conduct the examinations for leakage. Examinations for leakage shall be made of all joints and connections.
The pneumatic test pressure shall not be less than 1.2 nor more than 1.5 times the design pressure of the piping system. It shall not exceed the maximum allowable test pressure of any non-isolated component. The pressure in the system shall gradually be increased to not more than 1/2 of the test pressure, after which the pressure shall be increased in steps of approximately 1/10 of the test pressure until the required test pressure is reached. The pressure shall be continuously maintained for a minimum time of 10 min. It shall then be reduced to the lower of design pressure or 100 psig [700 kPa (gage)] and held for such time as may be necessary to conduct the examination for leakage. Examination for leakage by soap bubble or equivalent method shall be made of all joints and connections.
The test pressure shall not be less than 1.1 times the design pressure and shall not exceed the lower of 1.33 times the design pressure or the pressure that would produce a nominal pressure stress or longitudinal stress in excess of 90 % of the yield stress of any component at the test temperature. The pressure shall be increased until a gage pressure, which is the lower of 0.5 times the test pressure or 170 kPa (25 psi), at which time a preliminary check shall be made. Thereafter, the pressure shall be gradually increased in steps until the pressure is reached, holding the pressure at each step until the piping strains are equalized. The pressure shall then be reduced to the design pressure before examining for leakage. During the test, a pressure relief device shall be provided, having a set pressure not higher than the test pressure plus the lower of 345 kPa (50 psi) or 10% of the test pressure.
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The test pressure shall be at least 1.1 and shall not exceed 1.3 times the design pressure of any component in the system. The pressure in the system shall be gradually increased to 0.5 times the test pressure, after which the pressure shall be increased in steps of approximately 1/10 of the test pressure until the required test pressure is reached. The test pressure shall be maintained for at least 10 minutes. It may then be reduced to the design pressure and conduct the examination for leakage. During the test, a pressure relief device shall be provided, having a set pressure above the test pressure, but low enough to prevent permanent deformation of any of the system components.
Working with a company that specializes in heating and cooling services, maintenance and testing is often more beneficial than integrating dedicated personnel inhouse, reducing cost, time, and resources.
Other benefits of outsourcing a pressure test include:
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Pressure tests carried out according to the asme procedure allow us to guarantee the correct performance of the system and to detect that there are no leaks and that the installation is robust.
That is why it is important to consider specialised district energy contractors such as Araner. It is essential to work with top-notch, quality-oriented professionals to ensure the safety of the plant.
We are experts in designing, manufacturing and installing tailor-made industrial cooling solutions with a positive economic impact. We have worked worldwide in the development of Turbine Inlet Air Cooling, District Cooling and Thermal Energy Storage. Get in touch with our experts if you are interested in any of our solutions or if you need technical advice. We will be glad to help!
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