Tank Fill Switch Feedback Control for Overfill and Overpressure
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Solution Overview
Problem
Tanks used 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 to prevent overfilling and overpressure, including a tubular body, float, and rod system to detect liquid levels and communicate with a control unit for valve control or alert signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If tanks are filled automatically without close observation, then productivity is improved, but reliability deteriorates due to overfilling and overpressure conditions
Solution Approach 1:
The patent implements automatic feedback control by installing liquid level sensors (float indicators, capacitive sensors, or radar sensors) that continuously monitor the liquid level in the tank and send signals to the control system. When the liquid level reaches a predetermined maximum level, the system automatically shuts off the fill operation or generates an alarm, eliminating the need for continuous human observation while preventing overfilling and overpressure conditions.
Solution Approach 2:
The tank fill system is equipped with self-monitoring capabilities through integrated sensors and control logic that automatically detect liquid level conditions and regulate the fill operation without external intervention. The system serves itself by detecting its own state (liquid level) and taking corrective action (shutting off fill or alarming), thereby maintaining safety during unattended automatic operation.
2Reliability
If manual monitoring is used to ensure tank fill safety, then reliability is improved, but productivity deteriorates due to the need for close observation
Solution Approach 1:
The patent replaces the mechanical system of manual visual monitoring with automated sensing systems including float indicators, capacitive sensors, or radar sensors coupled with electronic control logic. These electronic systems continuously monitor liquid level and automatically control the fill operation, eliminating the need for human operators to maintain constant visual surveillance while improving both safety and operational efficiency.
3Device complexity
If no liquid level monitoring system is installed, then device complexity is reduced, but harmful factors increase due to spills and overpressure damage
Solution Approach 1:
The patent applies preliminary action by installing liquid level sensors and control systems that detect and respond to liquid level conditions before dangerous overfilling or overpressure conditions occur. The system proactively shuts off the fill operation or generates alarms when approaching maximum safe levels, preventing spills and damage before they happen rather than reacting after problems occur.
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 apparatus effectively prevents overfilling and overpressure conditions by providing real-time monitoring and control, reducing spills and tank damage, and allowing for safe and efficient fill operations.
Implementation Method 1
a float in and moveable along a length of the tubular wall
Data Source
AI summary
Tank-installable switches for installation through a thief hatch port on a tank. In some embodiments, the switch may comprise a tubular body and a liquid level sensor. The liquid level sensor may include: 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 may be 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.