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In refinery and energy applications, level measurement is rarely as simple as selecting a standard instrument and installing it in the field. Process conditions, piping specifications, maintenance access, vessel design, and site standards can all influence whether a level measurement solution will work reliably in practice.
A recent magnetic level indicator application completed by Westech Industrial’s partner, Clark Reliance, highlights how a technical challenge can often be solved through thoughtful engineering rather than a one-size-fits-all product approach.
The Challenge: Long-Length Level Measurement with Site-Specific Piping Requirements
A refinery in the Southeast United States required magnetic level indicators for an application with an exceptionally long span — approximately 300 inches centre-to-centre. For many facilities, long-length level measurement can create challenges related to mechanical support, process connections, installation constraints, and long-term reliability.
In this case, the customer wanted to maintain the use of an internal retention spring, while also needing the ability to connect process piping to the drain. At the same time, they wanted to keep a standard side-connected gauge arrangement.
This combination of requirements created a unique challenge. The refinery had strict piping specifications related to gauge length and the number of allowable connections. The level indication solution needed to meet those internal specifications without compromising functionality, support, or maintainability.
Why Support and Connection Design Matter
In refinery environments, equipment specifications are often built around safety, reliability, maintenance efficiency, and consistency across the site. Long level gauges can require additional consideration because of their size, weight, and exposure to operating conditions.
For magnetic level indicators, support and connection design can directly impact installation success. If the gauge does not align with site piping standards, the facility may be forced to modify surrounding piping, add supports, or request a custom configuration. These changes can increase installation complexity, extend timelines, and create additional cost.
In this application, the challenge was not simply measuring level over a long distance. The real issue was finding a configuration that would satisfy multiple requirements at once:
The customer needed a long magnetic level indicator, wanted to retain the internal retention spring, required drain connection flexibility, and still needed the gauge to align with site piping specifications.
The Solution: A Custom Flow-Through Plate Design
To solve the issue, Clark Reliance developed a special flow-through plate solution. This allowed the customer to maintain the internal retention spring while still connecting process piping to the drain.
By adapting the design in this way, the solution was able to meet the refinery’s specification requirements without forcing the customer to move away from their preferred gauge arrangement. The custom design helped address the support concern while preserving the functionality and configuration the site required.
This type of engineered solution is a good example of how level measurement challenges are often solved through application knowledge, not simply product selection. Understanding the process conditions, mechanical requirements, and site standards is critical when designing equipment for refinery and energy applications.
The Value of Application-Specific Thinking
For Canadian energy facilities, this case study is a useful reminder that level instrumentation must often be evaluated beyond the datasheet. While standard equipment may work well for many applications, certain projects require additional review to ensure the final installation meets operational, safety, and maintenance requirements.
Applications involving long-span level measurement, custom piping layouts, hazardous or demanding process conditions, and strict site specifications may benefit from early technical discussions. Involving knowledgeable partners before finalizing equipment selection can help identify potential installation concerns before they become field issues.
In this example, the solution was not about replacing the customer’s requirements with a different approach. Instead, the design was adapted to meet the requirements already in place. That is often the difference between a product that works in theory and a solution that works in the field.
Supporting Canadian Energy Facilities with Practical Solutions
Westech Industrial works with Canadian energy producers, refineries, and industrial facilities to help match level measurement applications with practical, reliable solutions. Through our partnership with Clark Reliance and our experience in instrumentation, service, and integrated systems, Westech can support customers in reviewing application requirements, identifying potential installation challenges, and sourcing equipment suited to demanding operating environments.
In addition to product support, Westech’s service and integration teams can assist with broader project needs, including custom fabrication, instrumentation support, system integration, and field service. Whether the requirement is a standard level indication application or a more complex engineered solution, Westech helps customers find an approach that fits the application, the site, and the long-term operational goals. For more information visit our website at https://westech-ind.com or call us today at 1-800-912-9262.
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