How high temperature flow sensors increase reliability in harsh environments

When it comes to monitoring flow in harsh environments, there is no doubt that high-quality high-temperature flow sensors are a must. When operating temperatures begin to rise within an application, most sensors cannot cope and ultimately fail. In this article, we look at how high-temperature flow sensors can continue to operate under such conditions and deliver reliable and valuable results.

Typically, high-temperature applications can exceed temperatures as high as 2,500°C and beyond. The demands placed on the systems that work within these environments are extremely challenging and, without the correct devices, are prone to failure. Processes are often energy-intensive and expensive to manage, so lost reliability and additional maintenance costs are not things that are welcomed. This is where high-temperature flow sensors, such as the FlexFlow series from leading sensors and measurement device specialists, Baumer UK come into play.

How high temperature flow sensors differ

High-temperature flow sensors, such as those found in Baumer’s Flexflow series, operate under the calorimetric measuring principle. This is based on the physical laws of thermal conduction and transfer in liquids and gases. You can learn more about the calorimetric principle here.

To summarise, what this means is that a body with higher temperature releases energy into its environment in the form of heat. The quantity of this energy that is released into its environment is determined by the temperature difference and mass flow and a good high-temperature flow sensor performs this effectively, due to the liquid flowing through it acting as a coolant, the degree of which is directly dependent on the mass flowing past it.

What this does is reduce the number of measuring points within the application. It also reduces the effort needed for installation, service and storage. It is critical for the connections of the heating elements within the sensor to be cooled for reliable functioning. This is where breakdowns are avoided.

Why sensor selection is so important?

Selecting a suitable high-temperature flow sensor for use in harsh environments is of huge importance and there are several factors that have to be considered. These include:

Coolant temperatures

It is vital that the selected sensors can withstand temperatures exceeding 100°C. This is problematic for most run of the mill flow sensors and when these are used in bulk on an application, they often require regular replacement which ramps up considerable costs that are not sustainable.

Easy installation

For obvious reasons, it is important to choose a high-temperature flow sensor that is proven to be easy-to-install. The easy installation of a sensor within these environments enables the optimised performance and ensures that measurements are precise and most importantly, processes remain safe.

What makes Baumer's Flexflow series a great choice?

Baumer’s Flexflow series are proven as high-quality high-temperature flow sensors that flourish when used in extreme, hazardous environments. Not only that, but they are also incredibly easy to install thanks to their symmetrical centred design, regardless of the installation position.

Suitable for flow rates of up to 400cm/s and temperatures of +150°C, they are ideal for cooling systems operating within high temperatures and are available as analogue versions or with user-adjustable outputs. This is down to the use of IO-Link, which is considered to be the best option when it comes to applications that require the frequent change of batches or different process steps.

Its super reliable function enables the Flexflow sensor to handle transient temperature peaks with no performance dips and they are virtually maintenance-free due to the lack of mechanical parts. So, with the Baumer Flexflow series what you are guaranteed is a high-temperature flow sensor that guarantees the reliable monitor of flow and speed, though smooth operation.

For more information, check out the Baumer Flexflow sensor or contact Baumer UK directly for further assistance.