Industrial gas flow measurement requires specialized sensor physics to overcome unpredictable velocity profiles, wide temperature swings, and low-pressure drop constraints. Fluid Components International (FCI) addresses these extreme process environments by engineering advanced thermal dispersion instrumentation. Instead of relying on mechanical moving parts that clog, wear, and drift over time, FCI designs highly accurate thermal mass flowmeters, flow conditioners, and multipoint sensing arrays. This rugged design philosophy ensures absolute measurement repeatability, minimal maintenance overhead, and exceptional durability across heavy industrial air, gas, and aeration piping networks.
By focusing on precision calibration, explosion-proof housings, and ultra-sensitive thermal sensors, FCI guarantees that complex gas flows and liquid levels are monitored with absolute stability. Integrating FCI thermal mass technologies provides facilities with direct access to highly certified flow configurations, backed by dedicated application expertise to solve demanding extraction, combustion, and aeration measurement challenges on the plant floor.
In the realm of gas flow dynamics, the specialized ST series of thermal mass flowmeters sets the global benchmark for monitoring compressed air, flare gas, biogas, and complex industrial gas mixtures. These instruments utilize two matched platinum RTD sensors—one reference sensor and one heated sensor—to measure mass flow directly without requiring separate pressure or temperature compensation hardware. This solid-state design delivers exceptional low-flow sensitivity and high turndown ratios, providing the deterministic, real-time data required for critical flare gas monitoring, combustion air control, and strict regulatory environmental reporting.
Managing low-flow gas injection and chemical additive dosing requires specialized instrumentation designed for tight tolerances. FCI’s compact mass flowmeters, such as the ST100L and inline micro-flow configurations, are engineered with built-in flow conditioning and precision-machined tubes to handle minute flow rates with surgical accuracy. By completely eliminating the mechanical wear common in miniature rotameters or turbine meters, these rugged solid-state tools empower operators to maximize process efficiency, protect continuous pilot-plant operations, and execute precision dosing under volatile pressure conditions.
Beyond gas dynamics, FCI provides certified plant defense loops with its rugged FLT93® series of flex-switch level and temperature monitors. Utilizing advanced thermal dispersion technology within a single sensor element, these multi-variable switches detect liquid level, slurry interface, and low-flow or no-flow piping conditions simultaneously. Because they feature no moving parts to seize or coat, they remain completely immune to the sticky or abrasive characteristics of heavy oils, wastewater slurries, and demanding cooling loops, providing reliable, real-time telemetry to protect expensive pumps from running dry.
Irregular piping geometries, tight elbows, and valves create turbulent swirl profiles that distort standard flowmeter accuracy. FCI resolves these layout constraints natively by pairing its instrumentation with high-efficiency VORTAB® flow conditioners. Utilizing specialized tab-type geometries, these inline conditioners profile incoming gas streams instantly, eliminating swirl and velocity distortions within a fraction of the straight pipe run normally required. This integrated system approach allows facilities to install highly accurate flow loops in cramped spaces, drastically reducing installation costs while safeguarding long-term measurement integrity.
Everest Automation is an authorized partner providing specialized application knowledge, expert technical support, and lifecycle services across Eastern Canada.
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