FYI you should turn over each of your fire extinguishers at least once every 6 months to keep them working right. That means pick it up, rotate it upside-down, and let the stuff inside slide to the top, then turn it back over. I learned this from a fire inspector that I had to guide through a datacenter once.
It really depends on the kind of fire extinguisher as to whether that matters. That said, my understanding is that if it is a dry powder that has settled it would be visible on the pressure gauge.
Really, that is about actually checking the pressure gauge every six months. If you tell someone to look, they never will. If you tell someone they have to do something, they might. Its the same logic behind "testing" a smoke alarm. The electronics are simple enough that you would REALLY need to try to damage them (and they are set up to piss you off with incessant beeping when failing anyway). But by pushing the button every six months, you actually check if there is a battery in it and so forth. Rather than hearing it beep in the morning, telling yourself you'll fix it when you get home, and never doing so.
How does powder settling affect a pressure gauge? There has been no change to the internal pressure of the vessel, the change loose vs compacted powered will not change the volume of materials inside the extinguisher. The only way the pressure should change is if there’s a leak.
It very much depends on the specific materials which is why it is a "let's not get into this and just say 'better safe than sorry'" situation but: Even if the powder is settled, it is going to almost immediately get kicked up and re-mixed once you start spraying. Probably don't test this for yourself for obvious reasons, but that is why a "fresh" can of spray paint will basically always work. It might not be even for the first few sprays but it rapidly becomes even.
Over simplifying (because molecular dynamics and shit) but think of it like a really crowded room. You basically can't sit down, let alone lie down, if it is crowded enough. And even if you try, someone will nudge you (or kick you) and you will get going.
As the pressure decreases, the settled powder is less likely to be disturbed and you are more likely to wake up from your nap wondering why nobody else is waiting for the new Star Wars with you. And that is why paint cans have the shaker and so forth.
So if your fire extinguisher has settled/compacted to the point that it is not viable? It is almost guaranteed to be because of a pressure leakage and that would be reflected on the gauge.
Now, there is probably some variant where this can happen regardless. But that would be a bad product anyway because these need to work even if nobody can ever be bothered to find the key to the glass box.
Your logic is not correct. Powder and people are not the same. Volume is volume, and particles of fire retardant are not changing size or quantity. If pressure drops substantially in an extinguisher, it’s leaking.
A can of fresh spray paint works because the seals are all still good and the nozzle isn’t clogged, and cans of used spray paint can leak out pressure or have the nozzle or other plumbing jammed up with dried spray paint.
You're right, the pressure gauge shouldn't change without a leak or temperature change (Boyle's Law and such). But it's hard to have a 100%, no-leak extinguisher. There's plenty of points of failure to keep the thing pressurized, and the leak could be imperceptible (over months) or a rapid failure
And you wanna keep contents from settling as well, so you don't just spray gas when trying to use it. So you mix it a bit and inspect the gauge every so often, because you don't want it to fail when you need it most
Ideally, it shouldn't lose pressure. But also ideally, you don't have a fire that requires an extinguisher in the first place
But yes, you're right on that one. "Settling" of the fire-retardent wouldn't cause a pressure change. It's just part of the safety inspection to check the gauge as well as to "mix" it... keeping it ready to go