SensorsONE

High Range Pressure Sensors

High range pressure sensors are essential components in industrial and research settings where precise measurement of extreme pressures is critical. These rugged sensors are designed to withstand the rigors of hydraulic systems, pneumatic systems, and other high-pressure environments, providing reliable and accurate data for process control, safety, and analysis.

Find out more about High Range Pressure Sensors to determine which product options and capabilities will best meet your application requirements.

High range pressure sensors are engineered to deliver accurate and reliable pressure measurements in environments where conventional sensors would falter. They are specifically designed to handle the extreme pressures encountered in hydraulic and pneumatic systems, often reaching hundreds of bars or thousands of psi. These sensors are built to withstand not only the high pressure levels but also the rapid pressure fluctuations and potential shock loads common in such applications.

Hydraulic Systems and High Pressure

Hydraulic systems rely on high pressure to generate significant forces and torques, making them indispensable in heavy machinery, construction equipment, and industrial processes. High range pressure sensors play a crucial role in monitoring these systems, ensuring operational efficiency, and preventing catastrophic failures that can result from overpressure. The robust design of these sensors enables them to endure the demanding conditions of hydraulic systems, including pressure spikes, vibrations, and potential hydraulic fluid contamination.

Pneumatic Systems and High Pressure

While pneumatic systems generally operate at lower pressures than hydraulic systems, certain applications demand high pressure pneumatic control. High range pressure sensors are employed in these instances to monitor and regulate pressure, ensuring safe and efficient operation. Although pneumatic systems lack the “hammer effect” of hydraulic systems, the potential for high-velocity projectiles due to escaping high-pressure gas necessitates careful monitoring and control.

Pressure Units and Ranges

High range pressure sensors are calibrated to measure pressure in various units, including bar (bar), megapascals (MPa), pounds per square inch (psi), and kilopounds per square inch (ksi). The choice of unit depends on the specific application and industry standards. It’s crucial to select a sensor with an appropriate pressure range to ensure accurate measurement and prevent sensor damage. Exceeding the sensor’s maximum pressure rating can lead to inaccurate readings or even sensor failure.

Applications

Oil and Gas Exploration and Production

  • Downhole Pressure Monitoring: High range pressure sensors are critical for monitoring pressure in oil and gas wells during drilling, completion, and production operations. These sensors provide real-time data on downhole pressures, helping to optimize drilling parameters, prevent wellbore instability, and ensure safe and efficient extraction.
  • Pipeline Pressure Monitoring: High range pressure sensors are deployed along pipelines to monitor pressure and detect potential leaks or blockages. This is crucial for maintaining pipeline integrity, preventing environmental damage, and ensuring the safe transportation of oil and gas.
  • Wellhead Pressure Monitoring: Accurate measurement of wellhead pressure is essential for optimizing production rates and preventing equipment damage. High range pressure sensors provide reliable data for wellhead control systems, ensuring efficient and safe operation.

Hydraulic Systems

  • Heavy Machinery and Equipment: High range pressure sensors are used extensively in hydraulic systems for heavy machinery such as excavators, cranes, and bulldozers. These sensors monitor hydraulic pressure to ensure safe operation, prevent equipment damage, and optimize performance.
  • Industrial Presses: High pressure hydraulic presses rely on accurate pressure measurement for precise control and to prevent damage to the press and the workpiece. High range pressure sensors provide the necessary data for safe and efficient operation.
  • Actuators and Cylinders: Hydraulic actuators and cylinders are used in a wide range of applications, from robotics to manufacturing. High range pressure sensors monitor the pressure within these components to ensure smooth operation, prevent overpressure, and optimize performance.

Pneumatic Systems

  • High-Pressure Air Compressors: High range pressure sensors are used to monitor and control the pressure in high-pressure air compressors, ensuring safe operation and preventing damage to the compressor and associated equipment.
  • Pneumatic Tools: Pneumatic tools, such as impact wrenches and nail guns, rely on high-pressure air for operation. High range pressure sensors are used to monitor and regulate pressure, ensuring safe and efficient tool performance.
  • Automated Systems: High-pressure pneumatic systems are often used in automated manufacturing and assembly processes. High range pressure sensors provide precise pressure measurement for control systems, ensuring accurate and reliable operation.

Process Industries

  • Chemical Reactors: High range pressure sensors are used to monitor pressure in chemical reactors, ensuring safe operation and preventing runaway reactions or explosions.
  • Pressure Vessels: Pressure vessels, such as storage tanks and autoclaves, require accurate pressure monitoring to ensure structural integrity and prevent hazardous conditions. High range pressure sensors provide reliable data for safety and process control.
  • Pipelines: High range pressure sensors are used to monitor pressure in pipelines transporting various fluids and gases, ensuring safe and efficient transportation and preventing leaks or blockages.

Research and Development

  • Materials Science: High range pressure sensors are used in materials science research to study the behavior of materials under extreme pressure conditions. This research helps develop new materials with improved strength, durability, and performance.
  • Chemistry: High-pressure chemical reactions are often used in research and development to synthesize new compounds and study reaction mechanisms. High range pressure sensors provide accurate pressure measurement for these experiments.
  • Physics: High-pressure physics research explores the behavior of matter under extreme pressure, contributing to our understanding of fundamental physical phenomena. High range pressure sensors are essential tools in these investigations.