Discover how our customization in mechanical pressure switches helped a global steel producer improve reliability, stabilize high-temperature operations, and reduce maintenance.

How Barksdale Enabled Reliable Pressure Monitoring in a High-Temperature Industrial Process

A coke oven plant is a critical part of many large steel manufacturing facilities. In simple terms, it is a system where coal is heated in an oxygen-limited environment to produce coke, a fuel used in steelmaking. During this process, valuable gases are also generated and reused throughout the plant for heating and energy. These gas systems operate under high temperature and continuous pressure. They must remain stable to keep production running safely and efficiently. Even small pressure fluctuations can create operational risks. Learn how Barksdale delivered a customized pressure monitoring solution using B2T and D2T pressure switches to improve reliability in a coke oven plant environment.

The Customer and the Challenge

The customer is one of the world’s leading steel producers, operating large, integrated manufacturing facilities. Its operations span multiple stages of production, from raw material processing to finished steel output. Efficiency, safety, and uptime are critical at this scale. Any instability in one process can impact the entire production chain and this makes reliable instrumentation essential for maintaining continuous operations. 

Coke oven plants are among the most demanding areas within a steel facility. They involve:

• High-temperature operations

• Continuous gas generation and flow

• Flammable process media

The existing pressure monitoring system was not delivering consistent performance. The environment exposed equipment to rapid pressure fluctuations, high thermal stress, and mechanical vibration. Standard pressure switches were not designed for this level of demand.  The customer needed a solution that could handle real-world operating conditions without constant intervention.

Barksdale's Approach to a Customized System Design

Barksdale focused on delivering a complete, application-specific solution by first gaining a detailed understanding of the process environment. This involved evaluating pressure behavior, temperature exposure, and the overall system layout. At the core of the solution were the Barksdale B2T and D2T mechanical pressure switches, both designed for industrial environments and known for their accuracy, repeatability, and long service life. However, the real value came not just from the products themselves, but from how they were integrated into a broader, engineered system tailored to the application.

To ensure reliable performance, the pressure switches were combined with carefully selected components. A diaphragm seal isolated the sensing element from process gases, improving durability. A pigtail siphon reduced the impact of high temperatures, while a snubber stabilized pressure fluctuations and minimized sudden spikes. Custom fittings ensured secure integration into the existing system. Once installed, the solution delivered immediate improvements. Pressure readings became stable, equipment handled fluctuations without disruption, and overall performance increased. Maintenance requirements decreased significantly, reliability improved, and reduced downtime ultimately led to repeat business and continued collaboration.

Why Barksdale Made the Difference

Barksdale delivered more than a product by providing a complete, application-specific solution built around the B2T and D2T pressure switches, enhanced with components designed for real operating conditions. This system-level approach ensured that each element worked together to improve performance, stability, and long-term reliability. In demanding environments such as coke oven plants, where precise pressure control is critical to steel production, standard products alone are often not sufficient. By incorporating protective components like diaphragm seals, siphons, and snubbers, the solution improved durability and reduced operational stress. The result was a customized system that minimized downtime, lowered maintenance requirements, and delivered consistent performance. Based on this proven performance, the customer placed a repeat order, reinforcing confidence in the solution and establishing a strong foundation for ongoing collaboration, while highlighting the importance of combining proven products with application-specific engineering to achieve lasting value.

Learn more about our Mechanical Pressure Switches

-> Terminal Block Diaphragm Switch: D1T, D2T

-> Stripped & Housed Bourdon Tube: B1T, B2T