High Temperature Flow Switches & Flow Meters for Combustion Air
Accurate and dependable flow monitoring in extreme temperature applications up to 450°C where conventional technologies fail.
Over 45 Years in Operation
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High temperature processes such as combustion air systems, furnaces and thermal oxidisers present significant challenges for flow measurement and switching.
In these environments, temperatures can exceed 400°C, placing extreme demands on instrumentation. Many conventional flow technologies struggle or fail under these conditions, leading to unreliable measurement and increased maintenance.
Thermal flow switches and meters from Allison Engineering, based on proven FCI technology, are specifically designed to operate in these environments, providing reliable performance at process temperatures up to 450°C.
The Problem
Measuring or detecting flow in high temperature environments is difficult due to both process conditions and equipment limitations.
Common challenges include:
- Extreme temperatures damaging standard flow instrumentation
- Drift and instability in measurement at high temperatures
- Failure of mechanical components due to heat stress
- Limited technology options capable of operating above 300°C
- Harsh environments with dust, contaminants and fluctuating conditions
- Critical need for reliable monitoring in combustion systems
In many cases, operators are forced to compromise on measurement accuracy or reliability due to lack of suitable technology.
The Solution
Thermal dispersion flow switches and meters provide a robust and reliable solution for high temperature applications.
With no moving parts and an all-welded sensor design, these instruments are able to withstand extreme process conditions while delivering stable and repeatable performance. They are widely used in combustion air systems where both measurement and flow detection are critical.
This application closely links to Combustion Air Flow Measurement for Industrial Processes and SIL & SIS Compliant Process Control Instrumentation, where reliable flow monitoring is essential for both efficiency and safety.
From experience, these systems are often the only viable solution in high temperature environments where other technologies cannot operate reliably.
Technical Insight
High temperature capability
FCI thermal flow technology is designed to operate at process temperatures up to 450°C, making it suitable for the most demanding industrial applications.
No moving parts
Unlike mechanical flow switches, thermal devices have no moving parts, eliminating wear and improving reliability in extreme conditions.
Rugged sensor design
All-welded stainless steel or Hastelloy sensor construction provides durability and resistance to thermal stress and corrosion.
Stable measurement performance
Thermal dispersion technology provides consistent performance even in fluctuating temperature and flow conditions.
Suitable for gas applications
Particularly well suited to combustion air, process air and other gas flow applications at elevated temperatures.
Integration into safety systems
These devices are often used in safety-critical systems, including burner management and flow protection applications, with SIL-rated options available.
Recommended Products
Flow Switches
SIL-rated thermal flow switches for detecting flow, low flow and no-flow conditions in high temperature applications.
Thermal Mass Flow Meters
Reliable gas flow measurement solutions designed for high temperature environments and demanding industrial processes.
Key Benefits
- Reliable operation at process temperatures up to 450°C
- Suitable for applications where other technologies fail
- No moving parts for long-term reliability and low maintenance
- Accurate flow detection and measurement in harsh environments
- Supports combustion efficiency and process control
- SIL-rated options available for safety-critical systems
Need information or advice?
Speak with our friendly, expert team to discuss your requirements and find out how we can help you.
High Temperature Flow Measurement FAQs
Explore common questions about high temperature flow measurement, including technology selection, limitations and best practices.
What is the maximum temperature for flow switches and meters?
Thermal flow switches and meters from FCI can operate at process temperatures up to 450°C, making them suitable for extreme industrial environments.
Why do standard flow meters fail at high temperatures?
From experience, many conventional technologies rely on components that degrade or become unstable at high temperatures, leading to drift, failure or reduced accuracy.
What is the best technology for high temperature flow measurement?
Thermal dispersion technology is one of the most reliable options, due to its simple design, lack of moving parts and ability to operate in extreme conditions.
Can flow switches be used in combustion air systems?
Yes. Flow switches are commonly used to detect airflow in combustion systems, ensuring fans and air supply systems are operating correctly. Not all flow switches are the same and many are simply not reliable in harsh environments, which is where the FCI product range stands apart.
Are these devices suitable for safety systems?
Yes. Many models are SIL-rated and are used in safety instrumented systems for applications such as burner management and process protection.
What industries use high temperature flow measurement?
Common industries include oil & gas, chemical processing, power generation, waste-to-energy and industrial manufacturing.
Relevant Links
Why Trust Allison Engineering
We are committed to delivering the highest standards across the specialist areas we support, combining proven products with practical engineering knowledge and dependable service.
Need a Flow Solution for High Temperature Applications?
Speak to our team to identify the right high temperature flow switch or meter for your application and ensure reliable performance in extreme conditions.