XSEL® Industrial Process Gauge for Harsh Environments

Process industries rely on pressure instruments for safe and efficient operations. WIKA USA’s XSEL^® process gauges offer exceptional performance, reliability, and safety, even in the harshest conditions.

The process industry converts raw materials – crude oil, minerals, plant matter, etc. – into plastics, rubber, paper, textiles, consumables and other everyday products. In this industry are sectors ranging from oil & gas and mining to pharmaceuticals and food & beverage. In wastewater treatment, the raw material is effluent, which must be treated before the water is reused or released back to the environment. To ensure accuracy and to meet industry standards for safety, use the correct pressure instruments for particular applications.

An Industrial Process Gauge for Every Application

The wetted parts, the areas of the pressure gauge that come in contact with the process medium, are typically made of brass, 316L stainless steel, or Monel^®. Customers need to pick the right material for the application based on compatibility with the process media, as well as the operating and environmental conditions. The housing, or case, is typically made of engineered plastic or stainless steel.

WIKA XSEL^® process gauges come dry but is prepared for a case fill. They have an ingress protection rating of IP65 (with membrane) and are hermetically sealed. Another standard feature on the XSEL^® is a socket restrictor to reduce the internal orifice of the pressure channel. The reduced orifice is especially helpful for handling high pulsations, rapid pressure cycles, and pressure spikes. If users suspect that the media contains particles that could potentially clog the restrictor, this part can be easily removed with a small flathead screwdriver.

Case Filling for Extreme Conditions

In operating conditions where the process gauge is exposed to external vibrations or shock, we definitely recommend a case filling if the application allows for that. A case filling lubricates the gauge internals and reduces or eliminates pointer flutter. In most instances, liquid filling will extend the life of a pressure gauge. When a gauge is exposed to extreme environmental conditions, case filling also protects the instrument. For example, it prevents the lens from fogging up and building up ice in very low temperatures.

While glycerin is the standard case filling and works in most applications, users should choose silicone oil for extremely cold ambient temperatures or halocarbon oil in applications that involve oxidizing agents such as oxygen or chlorine.

XSEL^® process gauges are especially designed for the most challenging pressure applications in a variety of industries. This line is precision engineered to help prevent the premature failures than can interrupt operations, cause shutdowns, and even endanger personnel safety. These robust instruments deliver many years of accurate, reliable service while withstanding extreme environments.

A Perfect Pairing: Industrial Process Gauge + Diaphragm Seal

We offer several solutions for difficult processing applications, and one of most effective accessories to complement a process gauge is a diaphragm seal. By acting as a buffer, this extra layer protects the pressure sensor from hot, viscous, contaminated, and/or corrosive media. With just a simple modification, a diaphragm seal or diaphragm seal system (gauge + diaphragm seal) can make a big difference in safety and reliability.

DMS34 diaphragm monitoring system

With WIKA’s Diaphragm Monitoring System (DMS), users enjoy the extra peace of mind that the gauge’s fill fluid won’t leak into sanitary processes. This patented system has a double-diaphragm design: If the outer (wetted) one is breached, an alarm sounds while the inner seal continues to provide protection. We also offer two models of the DMS for chemical/petrochemical industries.

All-Welded System (AWS)

An excellent solutions for ensuring safety and preventing leaks in extreme applications is WIKA’s All-Welded System (AWS), comprising an XSEL^® gauge and a diaphragm seal. This assembly can be retrofitted to an existing process pressure gauge installation, thus adding a dependable, reliable, and safe system for pressure measurement. By removing all threaded connections between the pressure gauge and the diaphragm seal, the AWS is a tamper-resistant assembly that does not allow any access to the system fill, which helps eliminate potential leak paths.

All-Welded Systems have the option of an XSEL^® gauge made of Monel^®, Hastelloy^®, or 316L stainless steel.

Advantages of Stainless Steel Pressure Gauges

The choice of materials for a pressure gauge depends on cost considerations and the application itself. For companies in the process industry, especially those in chemical/petrochemical or wastewater treatment, the best option is often a stainless steel pressure gauge. These extremely durable instruments hold up beautifully in corrosive environments, and provide a long service life in applications with extreme temperatures and heavy vibration/pulsation.

WIKA has been manufacturing industrial process gauges for more than seven decades. In that time, our pressure specialists have witnessed many applications that push a gauge well beyond normal operating conditions. That is why we continue to engineer and manufacture high-quality instruments and accessories to ensure safety, avoid downtime, and lower the overall cost of ownership.

For more information about the XSEL^® line of industrial process gauges or other pressure measurement solutions, please contact the pressure specialists at WIKA USA.

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