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Aerial view of a UK oil refinery and process plant with storage tanks
Industrial Process

From the sump plug to the stack.
Measurement that keeps the plant running.

Industrial sensing, gas engine controls, environmental measurement and UKAS-accredited calibration for process plants, utilities and combined heat and power.

1985
Building sensing technology in the UK
0
Moving parts in the level and position ranges
IP67
Gas engine control module rating
150+
Countries where Gill operates

Continuous operation leaves little room for weak measurement

A process plant is a network of interdependent systems. Level controls vessels and storage. Position feedback confirms that valves and actuators are where they should be. Oil condition can reveal machinery wear before failure becomes an outage. Environmental measurement supports emissions, weather and worker conditions. Gas engine controls influence ignition, efficiency and availability.

The measurement has to work within the process, not simply on the test bench. It has to survive its environment, communicate with the control system, provide useful information at the point of decision and remain defensible when performance, compliance or failure is under scrutiny.

Gill brings sensing, control, integration and calibration together across these requirements, from individual instruments through to connected measurement systems.

One process plant. Many measurement requirements.

Condition

Detect wear and developing mechanical problems before they become unplanned downtime, using oil debris measurement and other condition-monitoring technologies.

Level

Measure liquids, fuels and other media without relying on mechanical floats that can stick, foul or wear.

Position

Monitor the movement of valves, actuators and mechanical systems with non-contact position sensing designed for demanding environments.

Control

Support gas engine performance with sensing and control technologies for ignition, air-fuel management and engine protection.

Environment

Measure wind, rainfall and environmental conditions around plants, utilities, infrastructure and site boundaries.

Calibration

Maintain measurement confidence with independent UKAS-accredited calibration across six parameters, supporting both Gill and non-Gill equipment.

Process sensing map

Every process decision starts at a measurement point

A plant measures across the whole site. Level in vessels and bulk storage. Position on valves and actuators. Oil condition in rotating machinery, ignition and mixture on the engines, and wind at the stack, the flare and the fence line.

Explore 16 measurement points to see what is being measured, where the measurement happens and which sensing technology fits the application.

Get expert advice

Where measurement affects the process

Different parts of a plant fail in different ways. The measurement requirement changes with them.

Oil draining from a machine gearbox during a service
Condition monitoring

Rotating Machinery Condition

Move the detection point earlier

Mechanical wear rarely begins with a catastrophic failure. Oil can carry evidence of developing wear long before a machine stops. WearDetect provides continuous oil debris monitoring, helping identify developing problems while there is still an opportunity to plan intervention.

Engineering: Oil debris monitoring, level sensing, non-contact position feedback.

Explore WearDetect

Bulk storage silos at a process plant
Level measurement

Vessel and Bulk Tank Level

No float to stick

Level measurement in tanks, vessels and process systems can be exposed to particulates, viscous media, corrosive liquids and difficult access. Gill’s LevelPro, LevelSlick and LevelLite technologies provide continuous measurement options without mechanical floats in the measurement path.

Engineering: Capacitive level sensing, FEP-coated variants, local display.

Explore level measurement

Petrochemical plant with process stacks and storage tanks
Hazardous areas

Classified and Hazardous Areas

Certification before specification

In hazardous environments, the operating area can determine which sensing technologies can even be considered. Gill’s hazardous-area instrumentation includes certified wind measurement for applications where environmental monitoring has to coexist with classified-area requirements.

Engineering: Intrinsically safe wind sensing, sealed level sensing, hazardous-area experience.

Explore hazardous-area sensing

Gas engine installed with its pipework and controls
Power generation

Gas Engines and CHP

Availability is the whole business case

For combined heat and power and gas engine installations, sensing and control directly influence engine operation, efficiency and availability. Gill’s gas engine control technologies support ignition, air-fuel management and engine control across demanding operating environments.

Engineering: Gas engine ignition modules, air and fuel ratio control, CAN integration.

Explore gas engine controls

Plant stacks releasing a plume at dusk
Emissions

Emissions, Dispersion and Boundary Monitoring

Attribution happens at the fence line

Environmental conditions influence how emissions disperse and how measurements are interpreted. Wind and atmospheric data provide the context needed around process sites, helping connect what is happening within the plant with conditions beyond its boundary.

Engineering: 3-axis dispersion measurement, boundary stations, analyser integration.

Explore environmental monitoring

Cooling tower fans on a plant deck
Utilities

Utilities, Cooling and Drainage

The systems nobody watches until they fail

Cooling, drainage, water management and supporting infrastructure rarely attract attention when they work. Level, environmental and position measurement can provide the visibility needed to detect changing conditions before a supporting system becomes the cause of a wider interruption.

Engineering: Environmental monitoring, optical precipitation, capacitive level sensing.

Explore utility applications

Technical
insight

Why oil debris moves the detection point, and why that is the whole argument

Condition monitoring on a plant usually means vibration. Vibration is good at telling you that damage exists. It is much less good at telling you early, because the signature changes once a surface has already degraded.

Ferrous wear particles enter the lubricating oil before that point. WearDetect monitors the oil for that debris directly, which changes the question from how many hours the machine has run to what is actually wearing inside it.

That distinction matters because condition monitoring is only useful when it creates enough time to make a different decision. Earlier evidence means more options: investigate, schedule, inspect, repair or continue under observation.

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Sensing across the process

A modern process environment rarely depends on one measurement technology. It depends on multiple measurements working together.

Oil condition

Continuous debris detection for rotating machinery.

Level

Continuous measurement without floats for tanks, vessels, fuels and challenging liquids.

Position

Linear and rotary sensing for valves, actuators and mechanical systems.

Wind

Ultrasonic measurement for environmental monitoring, dispersion and hazardous-area applications.

Weather

Integrated measurement of wind and atmospheric conditions around operational sites.

Engine control

Sensing and control technologies for gas engines and CHP systems.

Third-party inputs

MetConnect provides a route for integrating additional measurement inputs into a connected monitoring system.

Calibration

Independent verification across multiple measurement parameters.

Industrial sensing, without the mechanical weak points

Some process environments are difficult enough without adding bearings, floats or other moving mechanisms to the measurement itself.

Gill’s core sensing technologies include solid-state and non-contact approaches designed to reduce mechanical wear points where the application demands it. That matters particularly where instruments are difficult to access, exposed to contamination or expected to operate for long periods between planned interventions.

The technology still has to be specified against the application. Media, temperature, pressure, ingress protection, hazardous-area requirements, installation conditions and required outputs all affect the instrument specification.

Explore Gill industrial technologies

Industrial process technologies

Products and services engineered for process environments, spanning condition monitoring, level and position sensing, gas engine controls, environmental measurement and calibration across Gill.

Industrial Sensors and Controls

Gill WearDetect oil debris sensors
Condition monitoring

WearDetect

Oil debris sensor

Monitors lubricating oil for ferrous wear particles, moving the detection point earlier than vibration monitoring can reach.

Measures : Ferrous wear debris in oil-lubricated equipment
Use : Compressors, gearboxes, engines and hydraulic systems
Options : Available with a local display

View WearDetect

Gill LevelPro, LevelSlick, LevelDefend, LevelLite capacitive level sensors and the DD1615 display
Level measurement

Level sensing

Capacitive liquid level sensors

Continuous level with no moving parts and fully sealed solid-state electronics, including a FEP-coated variant for the liquids that defeat mechanical devices.

LevelPro : Stainless steel, IP66 and IP68, 0-10 V or 4-20 mA, RS232 for configuration
LevelSlick : FEP coated for particulate, viscous and corrosive liquids, -40 to +85 degrees C
LevelLite : Lightweight aluminium, IP68, voltage or current output

Explore level sensors

Gill Blade non-contact position sensors
Valves and actuators

Blade position sensors

Non-contact inductive position sensing

Linear and rotary position feedback with nothing in contact, for actuators that cycle continuously between turnarounds.

Principle : Non-contact inductive, no wearing parts
Types : Linear and rotary, including dual output for redundancy
Range : Blade25, Blade60, Blade360 and Blade Dual Output

Explore position sensors

Gill gas engine controls
Power generation

Gas engine controls

Ignition modules and air/fuel ratio control

Ignition timing and energy from the module, mixture control from the AF120. Configured with the SparkZ and GillFire software.

GS8 and GS12 : Up to 8 and 12 cylinders; GS12 spark duration to 3000 microseconds
GT6 : 1 to 6 cylinders, gas engines up to 13 litres
AF120 : Closed loop on a Bosch UEGO lambda sensor; CAN, 4-20 mA and RS232

Explore engine controls

Meteorological Technology

Gill WindObserver ultrasonic anemometers
Hazardous areas

WindObserver

Heated 316 stainless open-head 2-axis anemometer

The WindObserver IS is the certified option for classified areas around flares, tank farms and process units.

Certification : WindObserver IS: ATEX, IECEx and UKEX, with EN 60945:2002 for EMC
Range : WindObserver 90 measures 0 to 90 m/s; 75 measures 0 to 75 m/s
Build : 316 stainless steel, IP66, heated on the standard models

View WindObserver

Gill MaxiMet compact weather stations
Boundary and worker safety

MaxiMet

All-in-one weather station, no moving parts

One unit, one cable, one output string. The GMX552 adds WBGT heat stress for operators working beside hot plant.

Heat stress : GMX552 measures WBGT alongside wind, temperature, humidity and pressure
Wind : 0 to 60 m/s across the range, WindSonic-based
Rainfall : GMX603 carries optical rainfall to 0 to 200 mm/hr, 5 percent or better

View MaxiMet

Gill MetConnect weather stations
Emissions and analysers

MetConnect

Separable weather station with third-party inputs

Brings existing analysers and probes into one record, and separates sensors by height where the permit or the standard requires it.

Inputs : Pt100 to IEC 60751, two analogue inputs, contact closure for rainfall
Outputs : RS232, RS422, RS485, Modbus and SDI-12; ASCII, NMEA 0183, SDI-12 v1.3
Accuracy : Temperature 0.2 degrees C, humidity 1.5 percent RH, pressure 0.5 hPa

View MetConnect

Not sure which product fits?Tell us whether it is for a process line, a tank or a plant boundary, what it has to survive and the system the data has to reach. Our team will narrow the range down with you.

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Built to connect to the system around it

A sensor is only useful if its measurement can reach the system that needs it.

Gill technologies support industrial interfaces including 4-20 mA, 0-10 V, RS232, RS422, RS485, Modbus and CAN, depending on the instrument. Applications can integrate measurement into PLC, DCS, SCADA, engine control and wider data systems.

For installations combining Gill and third-party measurement, MetConnect provides additional input and communication options, helping bring different sources of environmental and process data into one monitoring architecture.

Outputs and options

  • 4-20 mA & 0-10 V : Level and position into existing analogue loops
  • Modbus & RS485 : Environmental measurement into DCS and historian
  • CAN : Engine control modules and the AF120 controller
  • Analogue & Pt100 : Third-party analysers and probes on one station
Need certification detail, output options or a level sensor sized to a vessel?ATEX and IECEx documentation, output and interface options, sensor lengths and drawings. Direct from our engineering team.

Request information

Calibration that stands up to scrutiny

Measurement confidence does not end when an instrument leaves the factory.

Labcal, the independent calibration laboratory within the Gill Group, is UKAS accredited to ISO/IEC 17025:2017 and provides calibration for Gill and non-Gill equipment across six parameters: gas and air flow, liquid flow, pressure, temperature, humidity and air velocity.

That gives process operators, utilities and engineering teams access to an independent calibration service across a mixed measurement estate, with traceability where it matters.

01 · Gas and air flow

Gas meters · Mass flow controllers · Dispensing systems · Low-flow laboratory to higher-flow industrial

02 · Air velocity

Anemometers · Pitot tubes · Thermal probes

03 · Liquid flow

Flow meters and sensors · Process control equipment · Water used for the accredited capability

04 · Pressure

Gauges · Transducers · Manometers · Transmitters

05 · Temperature

Thermometers · Probes · Thermocouples · Data loggers

06 · Humidity

Hygrometers · Probes · Transmitters

One laboratory. Six UKAS-accredited parameters.Equipment from any manufacturer.
Explore Calibration Services

What changes when the measurement is engineered properly

01

Earlier detection

Measurement can move the point of detection closer to the beginning of a developing failure, creating more opportunity for planned intervention.

02

Fewer mechanical failure points

Non-contact and solid-state technologies can remove mechanical components from applications where wear, contamination or access make them a concern.

03

Hazardous-area capability

Certified instrumentation is available for applications where environmental and process measurement must operate within classified environments.

04

Sensing and control

Gill’s capability extends from measurement into gas engine control, connecting sensing with the systems that act on it.

05

Designed for integration

Industrial outputs and communication protocols support connection into existing control, monitoring and data architectures.

06

Independent calibration

UKAS-accredited calibration provides an independent route to measurement verification across Gill and non-Gill equipment.

Specifying for an industrial plant?Talk through approvals, mounting, power and integration with our team before the specification is fixed.

Discuss your requirements

Process measurement questions, from area classification to the historian

Measurement and technology

Ferrous wear particles in the lubricating oil. Those appear while surfaces are degrading, ahead of the point where the damage is developed enough to change the vibration signature.

Gill engineering insightThe value is not better detection, it is earlier detection. On continuous plant that is the difference between scheduling an outage and being given one.

Capacitive sensors have no moving parts. Floats, guides and mechanical switches stick, scale and foul in viscous, particulate and corrosive liquids, which describes most real process fluids.

LevelPro is stainless steel at IP66 and IP68 with 0-10 V or 4-20 mA output, RS232 for configuration. LevelSlick is FEP coated for the difficult liquids and operates from -40 to +85 degrees C.

With a sensor whose measurement is not affected by coating and fouling. LevelSlick is FEP coated specifically for conductive liquids with particles, suspended matter or high viscosity.

Because a position sensor with contacting parts wears, and on a plant it wears on equipment that only comes out of service at a turnaround. The Blade range is non-contact inductive in linear and rotary formats, with a dual-output variant where redundancy is needed.

Gill engineering insightThe other reason is that it reports actual position rather than commanded position, which is a different piece of information when a loop is misbehaving.

Wind speed, direction and an indication of atmospheric stability, recorded alongside the concentration measurement. A 3-axis sensor such as the WindMaster Pro gives the vertical component that stability and dispersion work depend on.

As wet bulb globe temperature, which combines air temperature, humidity and radiant heat. Air temperature alone understates exposure beside hot equipment and in coveralls. The MaxiMet GMX552 measures WBGT alongside wind, temperature, humidity and pressure.

Gill engineering insightMeasure where the work happens. A reading from the site weather station on a grass plot will not represent a platform beside a fired heater.
Specification and integration

The WindObserver IS, which is certified to ATEX, IECEx and UKEX, with EN 60945:2002 for EMC.

Gill engineering insightThe IS is not a drop-in for a standard WindObserver. It uses its own certified power supply and interface, reads as unheated, and has factory calibration traceable to national standards but no individual calibration certificate. Decide that at specification, not at commissioning.

LevelPro offers 0-10 V or 4-20 mA, with RS232 for configuration, and the 4-20 mA output needs a 250 Ohm load resistor across the output. LevelLite gives voltage and current outputs, with CAN on bespoke sensors. Position sensors and the engine controls offer CAN, and the AF120 adds 4-20 mA and RS232.

Yes, through the protocol the system already accepts. MetConnect outputs RS232, RS422, RS485, Modbus and SDI-12; the WindObserver range outputs RS422 and RS485, with a Modbus RTU variant on the 65 and 75; level and position sensors offer analogue and CAN.

Liquid level, ideally with rainfall intensity nearby so the rate of fill can be related to the event rather than guessed at.

Tipping buckets block with dust and debris and under-read in light rain. The TruMet PW100 measures optically with no moving parts, 0 to 200 mm/hr at 5 percent accuracy and 0.1 mm resolution, and outputs one pulse per 0.1 mm so it replicates the gauge it replaces.

Up to 8 cylinders, the GS8. Up to 12 cylinders and the longest spark duration, the GS12, which goes to 3000 microseconds of continuous spark. For compact engines up to 6 cylinders and 13 litres, such as gensets and compressors, the GT6. All are IP67.

The ignition module sets timing and spark energy. The AF120 controls the air and fuel mixture, closed loop, using a Bosch UEGO lambda sensor and driving a stepper or current-controlled bypass valve. They are complementary rather than alternatives.

Gill engineering insightThe case for closed-loop mixture control is gas composition drift. An engine mapped to one gas quality runs progressively richer or leaner as the supply changes, and the losses accumulate quietly.
Calibration and engineering

Set by the operator, the permit and the safety case. Where a measurement supports permit reporting or an overfill protection function, an annual traceable calibration is common.

Labcal is UKAS-accredited to ISO/IEC 17025:2017 and calibrates gas and air flow, air velocity, liquid flow, pressure, temperature and humidity.

Gill engineering insightGas and liquid flow are in that accreditation, which matters here more than on most sites. It means flow meters, gas meters and mass flow controllers can go through the same laboratory as everything else.

Six: gas and air flow, air velocity, liquid flow, pressure, temperature and humidity. Labcal is an independent UKAS-accredited laboratory, Lab 0625, and calibrates equipment from any manufacturer, not only equipment supplied by Gill.

Yes. Alongside the standard ranges, Gill engineers develop embedded and custom solutions where an off-the-shelf product does not fit the machine, the fluid or the control architecture.

Question not answered here?Ask our experts directly. You will speak to someone who knows the instruments and where they are used.

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