Rapid Temperature Overfill Probe for Asphalt Loading Arms

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Solution Overview

Problem

Conventional overfill probes at asphalt terminals are unreliable and prone to false trips, leading to potential overfilling and product loss during the transfer of asphalt from tanker trucks to receiving tanks.

Innovation Solution

A rapid analogue pressure temperature overfill response probe with a 4-20 mA transmitter and programmable microprocessor system that detects temperature changes to prevent overfilling by sending a signal to the PLC to automatically shut down the loading process when the probe contacts hot asphalt, capable of operating across a wide range of asphalt products and temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional overfill probe is used to prevent overfilling, then overfill protection is provided, but the probe produces many false trips and is unreliable

Engineering Contradiction:

Improveoverfill probe reliabilityVSAvoidfalse trips during loading

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The invention changes the detection parameter from mechanical contact or level sensing to temperature detection. The probe measures temperature changes of the asphalt during loading, detecting when hot asphalt contacts the probe to indicate overfill condition. This parameter change eliminates false trips caused by mechanical probe issues while maintaining overfill protection.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention replaces the conventional mechanical overfill probe system with a temperature-based detection system. Instead of using mechanical contact or level sensors that are prone to false trips, the system uses a temperature sensor to detect thermal changes when hot asphalt contacts the probe, providing more reliable operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Speed

If a rapid temperature response probe is used to detect overfill, then response time is reduced and reliability is improved, but system complexity increases

Engineering Contradiction:

Improvetemperature detection response timeVSAvoidprobe system complexity

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The invention uses a temperature sensor with rapid thermal response capability to detect temperature changes in real-time during asphalt loading. The probe's thermal mass is minimized to achieve fast response, allowing immediate detection when hot asphalt contacts the probe. This rapid parameter detection improves response time without requiring complex mechanical moving parts.

Inventive Principle:

Principle #35Parameter changes

3Loss of substance

If conventional loading systems are used without temperature monitoring, then system simplicity is maintained, but overfill protection is insufficient and product loss occurs

Engineering Contradiction:

Improveasphalt product loss from overfillingVSAvoidloading system complexity

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The invention replaces conventional mechanical level sensors or contact-based overfill detection with a temperature-based detection system. The temperature probe provides continuous monitoring of thermal changes during loading, enabling early detection of overfill conditions before product loss occurs, while integrating smoothly into existing loading infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention implements a feedback control system where the temperature probe continuously monitors asphalt temperature during loading. When the probe detects a temperature change indicating contact with hot asphalt (signaling overfill condition), the system provides immediate feedback to shut down the loading process, preventing product loss and overfilling.

Inventive Principle:

Principle #23Feedback

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides reliable and fast-acting overfill protection, reducing the risk of overfilling, minimizing false trips, and lowering installation costs and downtime by using a simple design that integrates seamlessly with existing systems, ensuring consistent operation and automatic fail-safe controls.

Implementation Method 1

a temperature probe that has a very fast response time... As the gas inside of the temperature probe heats up, it will expand in a linear fashion for a specified range. The expansion of gas increases the pressure inside the cavity

Methodology Applied

Scientific EffectTemperature sensing: Thermal Expansion

Implementation Method 2

The expansion of gas increases the pressure inside the cavity, which is then converted by the 4-20 mA transmitter

Methodology Applied

Scientific EffectPressure to electrical signal conversion: Piezoresistive Effect

Data Source

PatentUS8789564B2Asphalt loading arm

Publication Date: 2014.07.29 MARATHON PETROLEUM COMPANY LP

AI summary

This asphalt loading arm is for dispensing fluids from a storage tank to a receiving tank. The loading arm includes an overfill probe to prevent overfilling during transfer from one tank in loading lanes at asphalt terminals. The overfill probe is a rapid temperature response probe. The rapid response temperature probe that has a very fast response time. Placing a transmitter on the probe uniquely allows a PLC to collect data from the probe.