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Nexisense Pressure Sensor High-Temperature Measurement Solutions: Installation Protection for Accuracy and Longevity
In industrial automation, pressure sensors are core measurement instruments for monitoring gas or liquid pressure changes, supporting process control and safety warnings. Many processes involve high-temperature media, such as steam, thermal oil, or molten materials, where direct sensor use can damage cores, PCBs, or components. Nexisense sensors are known for durability and flexibility, effectively handling high-temperature challenges through scientific installation protection measures. This article analyzes high-temperature measurement principles, structural design, advantages, and practical applications to help optimize configuration, ensuring measurement accuracy and device longevity.
Definition and Function of Pressure Sensors
A pressure sensor converts physical pressure signals into standard electrical signals, used in industrial process monitoring, equipment diagnostics, and automation control. It captures pressure changes in real-time and outputs 4-20mA current or RS485 digital signals for PLC or SCADA systems. In high-temperature measurements, its role is crucial: providing pressure data while preventing thermal damage and ensuring system stability.
Nexisense products support wide temperature applications in chemical, energy, and metallurgical fields, enabling precise control in high-temperature environments.
High-Temperature Measurement Principle Analysis
Pressure sensors operate based on deformation of sensitive elements: medium pressure acts on an isolation diaphragm, causing strain changes in internal silicon or strain-resistive elements. Amplified circuits output the signal. High temperatures amplify thermal noise, causing zero drift, sensitivity reduction, or permanent damage (e.g., silicon softening or solder melting).
To handle high temperatures, the core principle is thermal isolation and cooling: heat is dissipated before reaching the sensor. Typical methods include heat sinks for convective and radiative cooling, condensate rings for phase-change heat absorption, extended impulse tubes to lengthen heat conduction paths, and capillaries to reduce heat flux. Together, these measures keep sensor temperature within -40°C to 85°C, with some models extending to 130°C safely.
Internal Structure Analysis
Nexisense pressure sensors feature modular, protective design: stainless steel isolation diaphragm, diffused silicon core, signal processing PCB, and housing. The diaphragm contacts the medium, preventing corrosion; the core converts pressure with integrated temperature compensation; the PCB handles amplification and linearization; housing is IP67-rated, shock- and vibration-resistant.
For high-temperature applications, the structure supports flexible connections: threaded or flanged, allowing heat sinks or condensate rings. Core materials use high-melting alloys, PCB coated against thermal aging. Compact yet robust design facilitates field retrofits, ensuring long-term stability under high temperature.
Key Advantages
Nexisense pressure sensors offer significant advantages in high-temperature measurement: heat-resistant materials and compensation maintain ±0.1%-±0.5% FS accuracy even in hot media. Fast response (millisecond level) suits dynamic process control. Strong impact and overload resistance (150%-200% FS) adapts to high-temperature vibration. Protective measures extend lifespan 2-5 times, reducing replacement costs.
These advantages translate into higher system reliability, preventing unexpected failures and improving overall production efficiency.
High-Temperature Measurement Application Scenarios
High-temperature measurement occurs in chemical reactors, steam boilers, thermal oil circulation systems, and metallurgical furnaces. In steam lines, sensors control valves to prevent overheating and explosions; in petroleum refining, monitor hot oil pump stations; in food processing hot-melt adhesive systems, prevent blockages.
Nexisense products perform reliably, e.g., in 200°C steam, condensate rings enable continuous monitoring with remote data analysis and alerts.
High-Temperature Measurement Methods
Standard method is direct contact with protective measures. Depending on temperature:
70°C–80°C: add a heat sink between sensor and pressure port to dissipate heat via surface area, reducing core temperature.
100°C–200°C: heat sink alone insufficient; install a condensate ring (U-shape or coil) at pressure port, medium cools via phase change, then further cooling via heat sink before reaching sensor.
If space allows: extend impulse tube (0.5–2 m stainless steel) for heat dissipation, or use capillary tube combined with heat sink to reduce heat conduction.
Ensure pipe slope (gas up, liquid down) to prevent condensation accumulation. Sensor location should be ventilated and avoid direct sunlight.
Maintenance Guidelines
High-temperature maintenance is crucial. Regularly clean heat sink surfaces with a soft cloth for efficiency. Condensate rings require drainage valves to avoid measurement lag. Calibrate sensors annually to verify zero and full-scale drift. Avoid over-temperature operation; empty medium when stopped. Store in dry, room-temperature environment. These practices extend lifespan from months to years.
Technical Specifications
| Parameter | Specification |
|---|---|
| Medium Temperature | Standard -40°C to 85°C, high-temp type -40°C to 130°C (up to 200°C with protection) |
| Pressure Range | -100 kPa to 100 MPa |
| Accuracy | ±0.1% to ±0.5% FS |
| Response Time | <10 ms |
| Output | 4-20 mA / RS485 |
| Overload | 150% FS |
| Protection Rating | IP67 |
| Material | 316L Stainless Steel |
Additional Optimization
For higher performance, use specialized high-temperature models with internal insulation or dual temperature sensors. Software compensation corrects residual thermal drift. For extreme temperatures (>300°C), consider remote capillary systems to avoid direct contact.
FAQ
Is a heat sink enough for 100°C steam?
No, condensate ring + heat sink is recommended to prevent direct steam impact.
Does extending the impulse tube affect response?
Slightly slower, suitable for static measurement; for dynamic processes, use condensate rings.
What if accuracy drops at high temperatures?
Enhance protection and calibrate regularly with compensation.
Where are capillaries suitable?
Compact spaces or high-temperature vibration environments, e.g., boiler lines.
Does Nexisense offer high-temperature models?
Yes, customizable, supporting core temperature up to 130°C.
Conclusion
High-temperature measurement challenges pressure sensors with thermal damage, but heat sinks, condensate rings, extended impulse tubes, and capillaries effectively isolate heat, ensuring accuracy and longevity. Nexisense provides advanced structure and reliable performance for complete solutions. From principle understanding to installation, each step contributes to industrial safety and efficiency. In modern high-temperature processes, scientific protection is critical to continuous production, ensuring longer-lasting and more precise measurements.
