
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.
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.
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.
Stack emissions and dispersion
A permit is written around where the plume goes, and where it goes is decided by wind and stability rather than by the stack.
- WindMaster Pro 3-axis to 32 Hz for dispersion and stability
- MetConnect THP two analogue inputs for third-party gas analysers
- WindObserver 75 long-duration wind reference at stack height
Flare stack and elevated release
Flare performance and radiation contours both move with the wind, and the sensor sits in the one place on site nobody wants to visit.
- WindObserver 90 0 to 90 m/s, 316 stainless, no moving parts
- WindObserver IS ATEX, IECEx and UKEX certified for classified areas
- WindSonic 75 0 to 75 m/s at a secondary elevated position
Process vessels and columns
Level in a vessel is a control variable and a safety case at the same time, and a float that sticks is invisible until it matters.
- LevelPro capacitive, stainless steel, IP66 and IP68, no moving parts
- LevelSlick FEP coated for viscous, particulate or corrosive liquids
- DD1615 level display local indication alongside the output
Bulk storage tanks
Stock reconciliation and overfill protection both come off the same measurement, and the tank is usually the last thing anyone recalibrates.
- LevelPro +5 to +32 V DC, 0-10 V or 4-20 mA output, RS232 for configuration
- LevelLite lightweight aluminium, IP68, voltage or current output
- LevelSlick operating -40 to +85 degrees C for difficult liquids
Classified and hazardous areas
In a zoned area the certification decides what can be installed, and nothing about the specification matters until that question is closed.
- WindObserver IS ATEX, IECEx and UKEX, with EN 60945:2002 for EMC
- LevelPro fully sealed solid-state electronics
- MetConnect THP sited outside the zone, feeding the same record
Gas engine ignition
Combined heat and power only pays while the engine runs, and ignition is where availability is won or lost.
- GS12 Ignition Module up to 12 cylinders, spark duration to 3000 microseconds, IP67
- GS8 Ignition Module up to 8 cylinders, static and non-static, IP67
- GT6 Ignition Module 1 to 6 cylinders, engines to 13 litres, IP67
Air and fuel ratio control
Gas composition drifts, and an engine tuned to yesterday’s gas runs rich, runs hot or trips.
- AF120 Air/Fuel Ratio Controller closed loop on a Bosch UEGO lambda sensor, IP67
- GS12 Ignition Module ignition timing and energy alongside mixture control
- AF120 interfaces CAN, 4-20 mA and RS232 outputs
Rotating machinery oil condition
Compressors, gearboxes and engines fail from wear that is already in the oil while the vibration signature still looks normal.
- WearDetect oil debris sensing for ferrous wear particles
- WearDetect with display local indication alongside the output
- LevelPro lubrication level in the same machine
Hydraulic and lubrication systems
A hydraulic reservoir dropping slowly is a leak somewhere, and the first sign is usually the level rather than the puddle.
- LevelPro capacitive, no moving parts to stick
- LevelLite lightweight option for skid-mounted plant
- DD1615 level display local display at the machine
Valve and actuator position
A valve that reports the command rather than the position is a control loop running on an assumption.
- Blade position sensors non-contact inductive, no wearing parts
- Blade60 contactless linear position feedback
- Blade Dual Output a second independent channel where redundancy is required
Cooling towers and plume
Cooling capacity derates with wet bulb temperature, and plume visibility is a neighbour complaint before it is an engineering one.
- MetConnect THP temperature 0.2 degrees C, humidity 1.5 percent RH
- MaxiMet GMX500 wind, temperature, humidity and pressure in one unit
- WindSonic 60 local airflow reference at the tower
Worker heat stress on the plant
Operators work in coveralls beside hot equipment, and air temperature alone understates what that does to them.
- MaxiMet GMX552 WBGT heat stress with wind, T, H and P, 1.29 kg, IP66
- MaxiMet GMX500 wind, temperature, humidity and pressure
- MetConnect One where third-party sensors join the same station
Site boundary and neighbour monitoring
Odour, noise and dust complaints are argued at the fence line, and without wind data at the boundary there is nothing to argue with.
- MaxiMet GMX551 wind, T, H, P, solar and rainfall in one housing
- WindMaster Pro 3-axis for dispersion and source attribution
- MetConnect THP analogue inputs for boundary analysers
Bunding, drainage and interceptors
A bund only works if somebody knows it is filling, and rainfall is usually what fills it.
- LevelPro capacitive level with no moving parts to foul
- LevelSlick FEP coated for contaminated or oily water
- TruMet PW100 optical rainfall, 0 to 200 mm/hr, nothing to block
Control room and plant historian
A measurement that does not reach the historian in a protocol the DCS accepts is a measurement nobody will ever look at.
- MetConnect One Modbus RTU and ASCII, SDI-12 v1.3, NMEA 0183
- WindObserver 75 RS422 and RS485, Modbus RTU variant available
- AF120 CAN, 4-20 mA and RS232 into plant control
Calibration and compliance
Permit reporting, safety cases and stock reconciliation all rest on instruments somebody has to prove are right.
- UKAS-accredited calibration six parameters under one accreditation
- Multi-parameter calibration equipment from any manufacturer
- Recalibration scheduling intervals, reminders and turnaround
Where measurement affects the process
Different parts of a plant fail in different ways. The measurement requirement changes with them.

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.

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.

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.

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.

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.

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.
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.
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.
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

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

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.

Blade position sensors
Non-contact inductive position sensing
Linear and rotary position feedback with nothing in contact, for actuators that cycle continuously between turnarounds.

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.
Meteorological Technology

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.

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.

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.
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
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
What changes when the measurement is engineered properly
Earlier detection
Measurement can move the point of detection closer to the beginning of a developing failure, creating more opportunity for planned intervention.
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.
Hazardous-area capability
Certified instrumentation is available for applications where environmental and process measurement must operate within classified environments.
Sensing and control
Gill’s capability extends from measurement into gas engine control, connecting sensing with the systems that act on it.
Designed for integration
Industrial outputs and communication protocols support connection into existing control, monitoring and data architectures.
Independent calibration
UKAS-accredited calibration provides an independent route to measurement verification across Gill and non-Gill equipment.
Go deeper
Explore the engineering challenges behind industrial measurement, from machinery condition and level sensing to gas engine control, hazardous-area applications and environmental monitoring.
- ApplicationWind sensors and weather stations for environmental monitoring at chemical plants
- ApplicationInstruments for environmental monitoring at oil refineries
- ApplicationEnvironmental monitoring at public utility sites / waste treatment plants
- ApplicationConveyor drive condition monitoring
- ApplicationSpecialist level sensing in cement and mining
- ApplicationWater pumping station operational monitoring
- ApplicationWater pumping station level monitoring
- ApplicationWastewater level monitoring
- ApplicationBearing wear monitoring in production lines
- ApplicationProcess fluid level monitoring
- Application note AN0037WindObserver monitors Christmas Island Phosphates for stevedore operations
- Application note AN0042WindObserver monitoring at nuclear power plants in Sweden
- Application note AN0056Spray Painting Control On Vehicle Production Lines Using WindObserverIS
Process measurement questions, from area classification to the historian
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.
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.
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.
The WindObserver IS, which is certified to ATEX, IECEx and UKEX, with EN 60945:2002 for EMC.
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.
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.
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.
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