- June 12, 2025
Pressure Switches for High Temperature Applications: What You Need to Know
Pressure switches are mechanical or electronic devices that open or close a circuit when a specific pressure level is reached. They are widely used to monitor and control pressure in hydraulic, pneumatic, and process systems across various industries. In normal operating conditions, standard pressure switches perform effectively, but when exposed to extreme heat, their internal components can degrade, leading to malfunction or failure.
This is where high temperature pressure switches come into play. Designed specifically for demanding environments like furnaces, boilers, and chemical reactors, these switches are built with heat-resistant materials and thermally stable components to ensure reliable performance. They maintain accuracy and safety under elevated temperatures, making them a critical choice for applications that push the limits of conventional pressure sensing technology.
Key Challenges in High Temperature Applications
Operating in temperatures above 100°C (212°F) presents several engineering challenges:
- Thermal drift: Measurement accuracy can shift due to expanding materials.
- Component degradation: Seals, diaphragms, and electronics may fail or degrade over time.
- Material fatigue: Prolonged exposure to heat affects mechanical resilience.
To overcome these issues, pressure switches designed for high temperature environments must be built with:
- Heat-resistant materials like stainless steel or ceramic
- Thermally isolated sensing elements
- Enclosures rated for extreme temperatures and environmental stress
Features of High Temperature Pressure Switches
If you’re selecting a pressure switch for high heat conditions, look for these critical features:
- High Temperature Ratings
Models designed to withstand temperatures at temperatures of 700 °C (1300 °F) and up to 1000 °C (1830 °F) on short term. - Remote Mounting with Capillary Tubes
Allows the sensing element to be placed away from heat sources, extending the switch’s life. - Rugged Enclosures
Industrial-grade housings that resist oxidation, corrosion, and mechanical damage under heat. - Adjustable Set Points
Fine-tune the activation and deactivation thresholds even in fluctuating thermal conditions. - Hermetically Sealed Contacts
Prevent internal contamination and ensure long-term reliability.
Common Industries and Applications
Pressure switches designed for high-temperature environments play a critical role in maintaining operational safety and efficiency across a range of demanding industries:
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Power Generation
In steam and gas turbines, pressure switches monitor steam and gas pressures within boilers, turbines, and heat recovery systems. These switches ensure proper pressure levels are maintained to prevent overheating or pressure build up, helping avoid catastrophic failures in power plants. -
Oil & Gas
Refineries and drilling operations operate in extremely harsh and high-temperature conditions. Pressure switches are used in systems like downhole tools, wellheads, and processing lines to monitor and control pressure in real-time, ensuring safe extraction, transport, and processing of hydrocarbons. -
Chemical Processing
Reactors, heat exchangers, and other chemical processing equipment often involve high temperatures and aggressive chemicals. High-temperature pressure switches provide reliable monitoring to help maintain process stability, prevent overpressure incidents, and ensure compliance with strict safety standards. -
HVAC Systems
In industrial-grade boilers and high-efficiency furnaces, pressure switches regulate burner operation and monitor pressure within sealed combustion chambers. Their role is crucial for energy efficiency, emission control, and system longevity. -
Food Processing
Equipment like autoclaves, industrial ovens, and pressure cookers operate at high pressures and temperatures to sterilize or cook food products. Pressure switches in these systems maintain the correct internal pressure to meet food safety standards and process requirements.
Key Factors to Consider
When choosing a pressure switch for high temperature applications, consider:
- Pressure range and accuracy requirements
- Ambient and process temperature limits
- Electrical contact ratings
- Certifications (ATEX, IECEx) for hazardous areas
It’s also wise to consult with manufacturers that specialize in industrial-grade sensing solutions to ensure proper configuration for your specific needs.
MeasureX High Temperature Sensor & Transmitter Solutions
In addition to mechanical pressure switches, MeasureX offers cutting-edge high temperature pressure switch that deliver exceptional accuracy and durability under extreme conditions. These solutions are ideal when both precision and low power consumption are required, even in highly humid or water-exposed environments.
MeasureX’s high temperature pressure sensors can measure at constant temperatures up to 700°C, and some models are engineered to withstand spikes of up to 1000°C. Their robust build ensures low noise operation and high-resolution output for precise monitoring and control.
Key Features:
- Highly accurate readings with minimal power consumption
- Long battery life for remote or continuous monitoring
- Compact, rugged design for industrial-grade reliability
- Ideal for machine construction and process control testing
- Equipped with electrical connectors for seamless integration
MeasureX also provides customised solutions for unique application requirements. Our pressure and temperature transducers are trusted in sectors including marine, food and beverage, HVAC, and process automation. Whether off-the-shelf or tailor-made, MeasureX sensors are designed for high performance in hazardous and demanding environments.
Need help selecting the right pressure switches for your application?
Contact MeasureX to speak with our experts about your requirements, and we’ll help you find the best solution or provide flexible, customised options for your application.
