Tank Fill Level Switch With Valve Control for Overfill Prevention
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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 technologies 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 tanks are filled manually by operators monitoring the fill operation, then flexibility and adaptability are maintained, but the risk of human error leading to overfilling and spills increases
Solution Approach 1:
The tank fill control apparatus enables the system to monitor and control its own filling operation automatically. The liquid level sensor continuously monitors the tank level and automatically triggers alerts or shutdowns when maximum levels are reached, eliminating the need for constant manual monitoring while improving safety and reliability.
Solution Approach 2:
The system incorporates continuous feedback through the liquid level sensor that provides real-time information about the tank fill status. This feedback loop allows the control system to automatically respond to changing conditions by generating alerts or modifying fill operations, thereby preventing overfilling without requiring complex manual intervention systems.
2Productivity
If tanks are filled automatically without close observation, then productivity increases, but the risk of overfilling and spills increases
Solution Approach 1:
The automatic fill control system incorporates continuous feedback through the liquid level sensor that monitors tank levels in real-time. When the maximum liquid level is reached, the sensor automatically triggers alerts or shutdowns, enabling high-speed automated filling operations while maintaining high reliability and preventing spills through automated safety mechanisms.
Solution Approach 2:
The system replaces manual mechanical monitoring with automated electronic sensing and control. The liquid level sensor and control unit automatically detect and respond to fill conditions, substituting human observation with reliable electronic detection that maintains both high productivity and spill prevention capability.
3Ease of manufacture
If simple tank designs are used, then ease of manufacture and maintenance are improved, but the capability to prevent overpressure conditions and spills deteriorates
Solution Approach 1:
The tank system is segmented into functional modules: the simple tank structure itself, the separately installed liquid level sensor, and the independent control unit. This segmentation allows the tank to maintain its simple, easy-to-manufacture design while adding protective monitoring and control capabilities through separate, easily installed components that prevent overpressure and spills.
Solution Approach 2:
The liquid level sensor and control unit act as intermediary components between the simple tank structure and the filling operation. These intermediary devices provide the intelligence and control needed to prevent overpressure and spills without requiring complex modifications to the basic tank design, maintaining ease of manufacture while improving reliability.
4Reliability
If liquid level monitoring is implemented, then overfilling prevention is improved, but device complexity and installation requirements increase
Solution Approach 1:
The tank fill control apparatus is designed as a universal system that can be applied to various tank types and sizes. The liquid level sensor and control unit serve multiple functions: monitoring liquid levels, generating alerts, and controlling fill operations. This multi-functionality reduces overall system complexity by consolidating multiple protective functions into a single integrated apparatus that can be installed on standard tank configurations.
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 by providing real-time monitoring and control, reducing spills and tank damage through alert signals and valve control functions.
Implementation Method 1
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
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.