ZAES expands its range of accessories for industrial pressure gauges used in critical processes

Greater protection, stability and reliability in pressure measurement for steam, gas, chemical, petrochemical, energy and industrial hydraulics applications.

Measuring pressure seems straightforward until the process ceases to be so.

High temperatures, steam, continuous pulsations, pressure surges, corrosive fluids, vibrations or intensive operating cycles can affect both the reading and the service life of a pressure gauge.

In these circumstances, choosing the right instrument is important. But so is something that is sometimes given less attention: the fittings installed between the process and the pressure gauge.

For this reason, ZAES is expanding its range of accessories for industrial pressure gauges, developing a range of products designed to protect instrumentation, facilitate maintenance and ensure more stable pressure measurement in demanding industrial applications.

The range includes siphon tubes for pressure gauges, pulsation dampers, pressure gauge valves, instrumentation fittings and adaptors, extension tubes and overpressure protection systems, amongst other solutions.

The aim is simple: to ensure that every pressure gauge can operate under better conditions and for longer.

Why are pressure gauge accessories important?

A pressure gauge fitted directly onto a process line may be subjected to conditions that differ significantly from those under which the measuring mechanism normally operates.

For example:

• steam and high-temperature fluids;
• pulsations caused by pumps or compressors;
• water hammer;
• pressure spikes;
• vibrations;
• corrosive fluids;
• high-pressure hydraulic systems;
• continuous cycles of starting and stopping.

The problem is that many of these conditions do more than just cause the pressure gauge needle to fluctuate.

They can also accelerate wear and tear on their internal components, reduce reading stability and lead to premature breakdowns.

That is why, in industrial instrumentation, There is no single accessory that works for all problems.

Every element has a function.

A siphon provides protection against temperature changes.

A shock absorber helps to control vibrations.

A valve allows the instrument to be isolated.

An overpressure protector helps to prevent certain pressure spikes from reaching the pressure gauge directly.

And a connector or adapter enables the instrument to be fitted correctly into the system.

The appropriate selection must be made taking into account, amongst other factors, fluid, pressure, temperature, pulsation, connections and actual operating conditions.

ZAES siphon tubes: protection for pressure gauges in steam and high-temperature applications

One area where protection is particularly important is the pressure measurement in steam lines.

When high-temperature steam comes into direct contact with the instrument, it can affect the pressure gauge’s internal mechanism.

This is where the siphon tube for a pressure gauge, also known internationally as pressure gauge siphon, steam siphon o pigtail siphon depending on its design.

Its operating principle is simple but effective.

The siphon allows a column of condensate to form between the process and the instrument. This barrier helps to reduce the temperature reaching the pressure gauge directly and protects its mechanism.

ZAES offers a range of configurations for siphons for pressure gauges, including U-shaped geometries and helical configurations, or pigtail, with different materials and connections depending on the application.

They are particularly interesting in:

• boilers;
• steam collectors;
• heating systems;
• saturated steam lines;
• superheated steam;
• industrial processes involving hot fluids;
• certain applications involving thermal oil.

A small component can make a big difference to the protection of the instrument.

Pressure gauge dampers: when pulsations are the problem

In reciprocating pumps, compressors, presses and certain hydraulic circuits, the pressure is not always stable.

It can change rapidly several times per second.

The result is easy to spot: the pressure gauge needle vibrates constantly, making it difficult to obtain a stable reading.

These vibrations can also accelerate wear and tear on the internal mechanism.

The shock absorbers for ZAES pressure gauges, known internationally as pressure snubbers o gauge snubbers, are specifically designed to minimise the effect of these rapid pressure fluctuations on the instrument.

Depending on the application, they may use restriction systems or sintered components that reduce the speed at which the pulses reach the pressure gauge.

The result is a more stable reading and better protection for the instrument.

These accessories are commonly used in:

• piston pumps;
• compressors;
• hydraulic systems;
• printing presses;
• industrial machinery;
• systems subject to pressure surges;
• circuits subjected to rapid cycling.

It’s not just a matter of getting the needle to “move less”.

The aim is to protect a measuring instrument that may be in operation for thousands of hours.

Valves for pressure gauges: isolation, maintenance and safety

Another key component in a pressurised system is the pressure gauge valve.

Its main purpose is to isolate the instrument from the process.

This facilitates inspection, maintenance, replacement or calibration without the pressure gauge being constantly exposed to the conditions in the line.

ZAES solutions can be configured with various industrial connections, including BSP and NPT, and different construction materials depending on the operating conditions.

They can also be used in instrumentation systems needle valves, particularly when smooth opening or closing and precise control are required.

The valve fitted upstream of the pressure gauge thus goes from being a simple shut-off device to becoming a key component of the system’s maintenance strategy.

Overpressure protectors: to protect the instrument against pressure spikes

Not all processes maintain a completely uniform pressure.

In certain installations, transient overpressures or pressure spikes may occur which temporarily exceed the pressure gauge’s operating range.

The following can be used for these applications overpressure protectors for pressure gauges, also known internationally as overpressure protectors o gauge savers.

Its function is to protect the instrument when the pressure exceeds certain thresholds set for the protection system.

The suitability of installing this type of accessory should always be assessed on the basis of the characteristics of the process and the instrument used.

The aim is once again the same: to prevent abnormal process conditions from causing premature damage to the instrumentation.

Fittings, adaptors and extension tubes for instrumentation

In an industrial plant, it is common to find equipment from different manufacturers and with different connection standards.

BSP, NPT, different sizes, orientations or configurations may make it necessary to use adaptors.

For this reason, the ZAES range also includes fittings and adaptors for industrial instrumentation, designed to facilitate the integration of the pressure gauge into the system.

Depending on the configuration, they can be used for:

• adapt BSP and NPT connections;
• change connection sizes;
• to facilitate substitutions;
• install instrumentation in confined spaces;
• to improve accessibility;
• move the instrument away from certain areas of the process.

The instrument extension tubes They can also be useful when it is necessary to physically separate the pressure gauge from a hard-to-reach point or an area with particularly harsh environmental conditions.

A comprehensive solution centred on the pressure gauge

One of ZAES’s approaches is not to analyse these products as entirely separate components.

In many applications, the right solution is precisely to combine various accessories.

For example, on a steam line it may be necessary to install:

Process → siphon → pressure gauge valve → pressure gauge

Whilst, in a system subject to strong pulsations, it may be advisable to consider a configuration such as:

Process → valve → shock absorber → pressure gauge

Other applications may also require protection against overpressure, adaptors or various instrumentation components.

The correct combination will always depend on the actual operating conditions.

This approach allows us to consider instrumentation as a whole, rather than simply as the selection of a single pressure gauge.

AISI 316 stainless steel and materials for demanding industrial processes

The material of the fitting must be selected taking into account the fluid, temperature, pressure and environmental conditions.

ZAES offers solutions in a range of materials, with a particular focus on AISI 316 and AISI 316L stainless steel for applications where mechanical strength and corrosion resistance are particularly important.

Other materials may also be used, depending on the model and the requirements of the installation.

The right choice should not be based solely on price.

In critical industrial processes, it is important to analyse the whole picture:

fluid + pressure + temperature + connection + material + function of the fitting.

This is where making the right technical choice can prevent problems later on.

Applications in the steam, chemical, petrochemical, gas, energy and hydraulic sectors

ZAES pressure gauge accessories can be used in a wide range of industrial sectors.

Industrial steam

Boilers, manifolds, heat exchangers and steam distribution networks where it is necessary to protect the pressure gauge from high temperatures.

Chemical and petrochemical industry

Processes in which chemical compatibility, materials, pressure and temperature must be taken into account.

Oil & Gas

Facilities where the reliability of instrumentation and connections is particularly important.

Industrial hydraulics

Presses, pumps, machinery and equipment subject to pulsations or rapid changes in pressure.

Energy

Thermal power stations, auxiliary systems and power generation processes where pressure is a critical operating variable.

Food and pharmaceutical industry

Auxiliary steam applications and processes where it is necessary to carefully control materials and operating conditions.

Water treatment

Pumps, booster stations, treatment and distribution systems where pulsations and water hammer may occur.

ZAES compared with the major international instrument manufacturers

The international instrumentation market includes widely recognised manufacturers such as WIKA, Ashcroft, Winters, Badotherm, Parker or Swagelokamong others.

ZAES approaches this market from a different angle: industrial specialisation, manufacturing and technical expertise in valves and instrumentation, close commercial ties and the ability to supply a range of products relating to pressure measurement.

For many distributors, engineering firms, maintenance contractors and machinery manufacturers, having a supplier capable of providing valves, fittings and instrumentation components from a single source can considerably simplify an installation.

The aim is not merely to provide a reference.

It helps to determine which solution is best suited to each process.

A siphon, shock absorber, valve or overpressure protector?

A simple way to tell them apart is as follows:

If the problem is the temperature: siphon tube.

If the problem is the heart rate: shock absorber for a pressure gauge.

If you need to insulate the instrument: pressure gauge valve or needle valve.

If there are pressure spikes that could damage the pressure gauge: overpressure protector.

If the connections do not match: coupling or adapter.

And if several problems arise at the same time, it will probably be necessary to combine different accessories.

This is precisely why it is essential to have a clear understanding of the operating conditions before selecting any instrumentation.

ZAES is expanding its range of industrial pressure measurement solutions

With this expansion of the range, ZAES is expanding its range of accessories for pressure gauges and industrial instrumentation and continues to develop solutions designed to protect pressure instruments in demanding operating conditions.

Siphon tubes, shock absorbers, pressure gauge valves, needle valves, adaptors, fittings and protection systems enable the configuration of bespoke solutions for the steam, gas, chemical, petrochemical, hydraulic, energy and other process industries.

Because in an industrial setting, ensuring a pressure gauge is properly protected may seem like a minor detail.

Until that small detail prevents a stoppage, a breakdown or an incorrect reading.

ZAES — Valves and industrial instrumentation for demanding processes.