High-voltage cable systems ensure efficient power distribution across the UK’s rail network. At the heart of the system lies an essential yet often overlooked component, pressure switches. Since the 1970s, Pyropress pressure switches have played a crucial role in maintaining a major UK rail network’s infrastructure, preventing overheating, and ensuring the safety of both personnel and equipment.
A shared history of reliability
Pyropress has been a leading manufacturer of high-quality pressure switches for over 60 years, developing products known for their durability and resilience in industrial applications. In the 1970s, a UK rail network installed its high-voltage cable system, housed in oil-filled, pressurised pipes. This system was designed to protect critical power cables from environmental damage and overheating, and Pyropress pressure switches have played a crucial role in maintaining its reliability ever since.
To maintain system integrity, a stable pressure must be sustained within these oil-filled pipes. Any drop in pressure could result in insufficient cooling, leading to overheating and, in extreme cases, the melting of high-voltage cables. Pyropress pressure switches have been integral to ensuring this precise pressure control, providing a reliable solution that has withstood the test of time.
How Pyropress pressure switches maintain system safety
The primary function of Pyropress pressure switches in many rail network’s systems is to continuously monitor and respond to pressure fluctuations within the oil-filled, pressurised pipes. A sudden drop in pressure can compromise the insulation and cooling of the high-voltage cables, leading to serious operational risks. Pyropress pressure switches mitigate these risks through a series of automated responses.
When the pressure falls below a preset threshold, the switches trigger an alarm, alerting maintenance teams to the abnormal condition. This immediate warning allows engineers to investigate and rectify potential issues before they escalate. In some cases, the switches may activate backup pumps or auxiliary systems to restore the required pressure, ensuring continuous protection of the high-voltage infrastructure.
If the pressure drop is severe and poses a risk of electrical discharge or cable failure, the switches can also initiate an automatic shutdown of the power transmission system. This pre-emptive measure prevents further damage, minimises downtime, and protects both equipment and personnel from hazardous situations. By detecting and addressing pressure anomalies swiftly, Pyropress switches help prevent long-term deterioration caused by oil leaks, air ingress, or electrical faults that could lead to catastrophic failures.
The Pyropress Perseus™ range of pressure switches, used in the UK rail network’s system, are designed to deliver this level of reliability. Engineered for demanding environments, these industrial-grade pressure switches provide accurate pressure monitoring while withstanding harsh outdoor conditions.
Decades of performance with minimal maintenance
The high-voltage pressure system operates in all weather conditions, requiring components that can perform reliably over decades. Pyropress Perseus™ pressure switches are built to meet these exacting demands, featuring an IP67-rated enclosure that provides superior protection against dust and water ingress. This makes them ideal for outdoor railway applications, where exposure to moisture and fluctuating temperatures is inevitable.
Unlike switches designed for hazardous areas requiring ATEX certification, the Perseus™ switches used in the rail network’s system do not require explosion-proof ratings. However, they still meet rigorous industry standards, including SIL 2 IEC 61508 suitability, ensuring their reliability in safety-critical environments.
One of the most remarkable aspects of Pyropress pressure switches is their longevity. Many of the switches used in the UK rail network’s infrastructure have only been replaced once in the last 30 to 40 years, highlighting their exceptional durability. This longevity significantly reduces maintenance costs and minimises the risk of unexpected failures, which could lead to service disruptions across the railway network.
Pyropress designs its products with resilience in mind, ensuring they continue to function even in the harshest industrial environments. Whether exposed to constant vibration, extreme temperatures, or mechanical impacts, Perseus™ switches are built to last, keeping critical infrastructure operational with minimal intervention.
Supporting the future of railway infrastructure
As the UK rail network continues to modernise its systems, Pyropress remains a trusted partner in delivering robust and reliable pressure switch solutions. While technology evolves, the fundamental need for high-quality, long-lasting components remains unchanged. Pyropress’ commitment to engineering excellence ensures that its pressure switches will continue to play a vital role in the future of railway infrastructure.
For over 70 years, Pyropress has been at the forefront of industrial sensing technology, providing solutions that stand the test of time. By safeguarding the rail network’s high-voltage systems, Pyropress pressure switches are not just ensuring operational efficiency but are actively contributing to the safety and reliability of the UK’s railway network for generations to come.
