Repair and Refurbishment Services for Diaphragm Seals and Pressure Gauges

Pressure gauges and diaphragm seals are often used with toxic and corrosive media. By using appropriate materials during manufacture you can limit the damage that fluids and gases can cause to diaphragms and pressure gauges. Overtime, even by using the most appropriate material with the toxic media, there will come a point at which the instrument may fail.

The environment that an instrument operates in can also play a part in causing a pressure failure. Instruments that operate in high temperature or corrosive environments have to be routinely checked and calibrated.

Before replacing a pressure gauge or diaphragm seal you may want to consider a repair or refurbishment of the instrument. Depending on the cost of the pressure gauge or diaphragm seal it may prove more cost effective to repair rather than buy new.

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How Does the Refurbishment Process Work?

A company such as Budenberg Gauge maintains a comprehensive customer service department, employing time-served apprentices, which give special attention to the repair and service of pressure and temperature gauges, valves and Dead Weight Testers.

Budenberg does not have fixed charges for repairs, as the cost can vary widely according to the specification of the instrument, the number of parts required and the amount of time required to complete the repair. Budenbergs charges are fixed as low as possible and are calculated after an initial investigation has been completed.

If it is found on examination that an instrument cannot be economically or satisfactorily repaired, Budenberg can offer to supply a new replacement instrument.

Repairing of Diaphragm Seals

Diaphragm seals are typically manufactured as either welded or clamped seals which can be either a screwed or flanged connection.

Budenberg manufactures a number of connection options that are well-known for the quality of their seal assemblies. Chemical seals manufactured by Budenberg are 'Field Serviceable', providing the option for the replacement of diaphragms. The removal and cleaning of wetted parts is also available which in the long term will dramatically reduce operating costs. By replacing a diaphragm rather than the whole assembly, whether connected to a gauge, transmitter or switch, is far more cost-effective.

The easiest to repair or replace are the clamped diaphragm seals, as they can simply be unbolted and removed.

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Typical Types of Damage to Diaphragm Seals

Blown Up Diaphragm
When the rings on the surface of a diaphragm seal appear buckled and disjointed, it has more than likely “blown up”. This is usually caused by the fill fluid leaking and is now on a vacuum.

Ruptured Diaphragm
This occurs when the seal is broken, allowing the process media to transfer past the diaphragm membrane and into the instrument's measuring element. As the process media flows past the membrane it will contaminate the fill fluid. This will cause corrosion and damage internally to the instrument and diaphragm.

Dents to the Diaphragm
Due to the thinness of the diaphragm, typically 0.05mm or 0.075mm, dents can easily occur if not handled or fitted with care. If a diaphragm is dented it may no longer give an accurate reading.

Bulged Diaphragm
If a diaphragm is bulging outward, this typically indicates that the process media is too hot for the fill fluid. The fill fluid expands due to the excessive heat and forces the diaphragm outwards.

Repairing of Pressure Gauges

Pressure gauges play a vital role in the safety and efficiency within industrial facilities. If a failure of a pressure gauge occurs within a process line, it can lead to downtime which can be extremely costly.

Budenberg Gauge provides a repair, recalibration and certification service. Budenberg are ISO 9001:2015 accredited and are able to offer UKAS calibration through their third-party partner laboratory.

Gauges that can be repaired include:

Causes of Pressure and Temperature Gauge Failure

Temperature
Accuracy of a gauge can be compromised by either extreme environmental or process temperatures.

Overpressure / Sudden Depressurisation
Media surges within a process stream can cause the pointer to hit the stop pin, causing the needle to bend. Overpressure of the bourdon tube or sensing element can also lead to a rupture and failure of the gauge.

Mechanical Vibration
It has been proven that vibration is a major factor in instrument failure. The effects of vibration may include nudging the pointer off the zero mark.

Corrosion
External and internal corrosion can lead to instrument failure. If the life cycle of a gauge is a lot shorter than anticipated, a review should be carried out on whether the materials used within the gauge are compatible with the media coming into contact with it.

Misuse
The mishandling and misapplication of gauges can cause damage in a number of ways. Accidental damage may occur while inspecting a gauge.

Pulsation
Pressure spikes, also known as pulsations, can cause significant damage over time. A fluttering or loose pointer often indicates a sign of pulsation damage.

Clogging
If a gauge becomes clogged it will render the pressure gauge inoperable. Media can also congeal or crystallise within the gauge also creating a potentially dangerous situation.

Steam
High pressure steam is commonly used with pressure gauges for industrial processes. One of the major reasons for gauge failure with steam is when it seeps inside the gauge, causing potential failure.

Maintaining and overseeing the operations of a facilities process plant requires constant assessment of its efficiency and safety. Any defective gauges should be either quickly replaced or repaired.

Budenberg Gauge recognises the urgency of repairing or replacing instruments promptly. They will provide a quick review and quotation for any gauges or diaphragms seals that require either a refurbishment or replacement.

Help reduce downtime, promote safety, and ultimately boost profits. Taking the time to ensure that your pressure gauges are operating at their optimum level is one of the best business investments you can make.

If you have any questions regarding the servicing of diaphragm seals or gauges within your process system, please contact the Budenberg technical support team.