In the complex environment of industrial production, the stable operation of pneumatic systems is a crucial prerequisite for safe production. By detecting pressure changes in gases or liquids, pressure switches automatically trigger circuit switches, thereby preventing equipment from overpressure, underpressure, or abnormal operation, and effectively avoiding safety accidents. From reaction kettles in chemical workshops to pneumatic equipment in underground mines, the precise response of pressure switches can often resolve potential crises within milliseconds. This article will analyze the key role of pressure switches in ensuring safe production through several typical industry cases.
1.Application of Pressure Switches in Explosion-Proof Positive Pressure Cabinets
In flammable and explosive industrial environments, explosion-proof positive pressure cabinets are vital safety equipment. These cabinets monitor internal pressure via pressure switches and control the operation of fans and compressors according to preset logic. When the internal pressure drops, the pressure switch initiates an air supplement procedure and sends an alarm signal to remind operators to take timely measures.
Case Study
A chemical plant utilized explosion-proof positive pressure cabinets to protect its electrical equipment during production. During a routine inspection, an abnormal drop in internal cabinet pressure was detected. The pressure switch promptly triggered an alarm and activated the air supplement procedure. Subsequent inspection revealed that the air leakage was caused by the aging of a sealing component inside the cabinet. Timely repairs prevented equipment damage and potential explosion accidents that could have resulted from insufficient pressure.
2.Mining Industry: "Safety Line of Defense" for Underground Pneumatic Equipment
Underground mining equipment such as pneumatic rock drills and pneumatic winches rely on high-pressure air sources for operation, with their working pressure typically ranging from 0.5 to 0.6MPa. If the air source pressure exceeds 0.7MPa, it may cause overload fracture of equipment components; a sudden pressure drop can lead to abrupt equipment shutdown, interrupting underground operations. A coal mining enterprise installed intelligent pressure switches in its underground compressed air system, which not only monitor the main pipe pressure but also sense pressure changes in individual equipment through shunt sensors.
In the winter of 2022, a pneumatic bolt machine in the west wing mining area of the mine experienced a local pressure rise to 0.72MPa due to pipeline blockage. Upon detecting the anomaly, the pressure switch immediately sent a signal to the control system, cutting off the equipment's air supply and notifying maintenance personnel via the underground broadcasting system. When the maintenance team arrived at the scene, they discovered slight cracks at the pipeline elbow. Continued operation could have resulted in high-pressure air spraying and causing injuries. According to mine statistics, since the installation of this air pressure monitoring system, the number of fault shutdowns of underground pneumatic equipment due to abnormal pressure has decreased by 68%, and there have been no more work-related accidents caused by air pressure issues.
3.Application of Pressure Switches in Gas Leakage Prevention
In gas systems, pressure switches are employed to monitor the pressure in gas pipelines. When abnormal pressure is detected, the pressure switch triggers an alarm and shuts off the gas valve, preventing explosion accidents caused by gas leakage.
Case Study
A food processing plant once encountered a gas leakage incident. Leakage occurred due to corrosion of the flange gasket in the workshop's gas pipeline. The pressure switch promptly detected the pressure drop and activated the alarm system. Operators quickly closed the gas valve and initiated the emergency response plan. Timely handling averted a potential gas explosion.
4. Ensuring Stable Operation of HVAC Systems
In heating, ventilation, and air conditioning (HVAC) systems, pressure switches are used to monitor air duct pressure, ensuring the normal operation of fans. If filters are clogged or air ducts are obstructed, pressure switches can trigger alarms or adjust fan speeds to prevent system overload.
Case: Prevention of Air Conditioning System Failures in Commercial Buildings
The central air conditioning system in an office building experienced airflow obstruction due to dust accumulation on the filter screen. After detecting abnormal high pressure, the pressure switch automatically reduced the fan speed, preventing motor overheating and energy waste.
Conclusion
Although pressure switches are small industrial components, they serve as "the last line of defense" in safe production. They not only ensure the safe operation of equipment but also take timely measures in emergency situations to avoid accidents. As requirements for safe production become increasingly stringent, selecting appropriate pressure switches and establishing sound maintenance mechanisms are not only technical safeguards but also concrete manifestations of enterprises' fulfillment of their main responsibility for safe production. In the future, with the advancement of intelligent technology, pressure switches will further enhance industrial safety levels and provide protection for various industries.
