Float-Based Tank Fill Control for Overfill and Overpressure
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Solution Overview
Problem
Liquid tanks in oilfield operations often experience overfilling and overpressure issues, leading to spills and potential damage, as existing systems lack effective monitoring and control mechanisms.
Innovation Solution
A tank fill control apparatus comprising a tank-installed switch with a liquid level sensor and a control unit that generates alerts or modifies fill operations when a maximum liquid level is reached, preventing overfilling and overpressure conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring of tank fill operations is used, then operational simplicity is maintained, but overfilling and overpressure conditions occur leading to spills and damage
Solution Approach 1:
The patent implements automatic feedback control by installing a float-based liquid level sensor inside the tank that continuously monitors liquid level and sends signals to a control unit. When the liquid reaches a predetermined maximum level, the system automatically generates an alert signal or activates a valve control to stop the fill operation, eliminating the need for continuous manual monitoring and preventing overfilling and overpressure conditions.
Solution Approach 2:
The tank fill control system performs self-monitoring and self-regulation through the installed liquid level sensor and control unit. The system automatically detects when the liquid level reaches the maximum threshold and autonomously triggers the alert or valve control mechanism, enabling the tank to regulate its own fill operation without external human intervention.
2Productivity
If automatic fill operations are used without close observation, then productivity increases, but overfilling occurs leading to spills and environmental contamination
Solution Approach 1:
The patent applies preliminary action by pre-setting the maximum liquid level threshold through the float-based sensor positioning before the fill operation begins. The control system is pre-programmed with the maximum level parameter, and the valve control mechanism is pre-positioned to automatically activate when the threshold is reached, ensuring that overfilling is prevented before it can occur during automated operations.
Solution Approach 2:
The automatic feedback control system continuously monitors the liquid level during fill operations and provides real-time feedback to the control unit. When the liquid level approaches the predetermined maximum, the system automatically triggers an alert or activates the valve control to stop filling, thereby preventing spills and environmental contamination while maintaining high productivity during automated operations.
3Strength
If no liquid level monitoring is installed, then device complexity remains low, but overpressure conditions exceed the upper port closure handling capacity causing damage
Solution Approach 1:
The patent implements feedback control by installing a liquid level sensor that continuously monitors the liquid level and provides real-time information to the control unit. When the liquid reaches the maximum level, the system automatically triggers an alert or activates valve control to stop the fill operation, preventing overpressure conditions that could damage the upper port closure while maintaining relatively simple device architecture.
Solution Approach 2:
The system applies preliminary action by pre-configuring the maximum liquid level threshold through the float sensor positioning and control unit programming before operation begins. This predetermined threshold ensures that the fill operation automatically stops before the liquid level can generate overpressure conditions that would exceed the upper port closure handling capacity, thereby protecting the structural integrity without requiring complex real-time pressure calculation systems.
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 effectively prevents overfilling and overpressure in liquid tanks, reducing the risk of spills and damage by providing real-time monitoring and control of fill operations, ensuring safer and more reliable tank filling processes.
Implementation Method 1
a float in and moveable along a length of the lower end
Data Source
AI summary
A tank fill control apparatus comprising: a tank-installed switch, including: a tubular body including an upper end, a lower end, and an annular mounting flange on an outer surface between the upper end and the lower end; a liquid level sensor including a detector, a float in and moveable along a length of the lower end and a rod connecting the float to the detector, the liquid level sensor configured to sense a liquid level relative to the lower end and further configured to generate a signal when at least a maximum selected liquid level is sensed; and a control unit in communication with the tank-installed switch including: a liquid level monitoring function for receiving the signal from the liquid level sensor; and a control function for generating at least one of (i) an alert signal indicating that the maximum selected liquid level is sensed and (ii) a valve control to modify a fill operation from a tank fill system.