Efficient Tank Monitoring: Automated Fill Level Control and More

In process industries, reliable monitoring of liquid containers is a critical task. Overfills can lead to costly environmental damage, dry running damages expensive pumps, and undetected leaks cause not only economic losses but also significant safety risks. This case study demonstrates how ootb automation GmbH developed an intelligent tank monitoring system for an industrial client that combines maximum operational safety with maximum user autonomy.

The Initial Situation: Complex Tank Infrastructure Without Central Monitoring

Our client operates an industrial facility with numerous tanks of varying sizes for different media. The existing infrastructure had grown over years and consisted of a heterogeneous collection of sensors, pumps, and valves from various manufacturers. No central monitoring existed – fill levels had to be checked manually at regular intervals, which was labor-intensive and error-prone.

Management recognized the need to invest in a modern monitoring system. The requirements were clearly defined: the system should not only display current fill levels but also actively prevent hazardous situations. Three critical scenarios had to be automatically detected and prevented:

Overfill Protection: Each tank needed a configurable maximum level. When this limit is reached, inlet pumps should be automatically shut down and responsible personnel notified.

Dry-Run Protection: Pumps that transfer media from tanks must be protected from dry running. The system should detect when the fill level drops below a critical value and shut down the corresponding pumps in time.

Leak Detection: Particularly critical are unnoticed leaks in piping. The system should detect unusual fill level changes that cannot be explained by normal operations and trigger alarms.

A key requirement was integration with existing infrastructure. The existing sensors and actuators should continue to be used to minimize investment costs. At the same time, the client placed great emphasis on independence: adjustments and extensions should be possible without external service providers.

The Development: Modular, Scalable, and User-Friendly

ootb automation developed a solution that combines technical capability with exceptional user-friendliness. The system is based on a modular architecture that seamlessly integrates into existing infrastructure.

Flexible Sensor Integration The heart of the system is universal sensor connectivity. Regardless of whether fill levels are captured via pressure sensors, ultrasonic measurement, capacitive, or radar-based methods – the system supports all common measurement principles. Connection is made either via industrial standard protocols like Modbus/TCP or modern IoT protocols like MQTT.

This flexibility proved to be a decisive advantage. While some of the large tanks were already equipped with modern 4-20mA sensors, smaller containers only had simple float switches. The system could process both sensor technologies in parallel and derive consistent monitoring functions from them.

Intelligent Threshold Monitoring Up to eight different thresholds can be defined individually for each tank: from “critically empty” through “reorder required” and “optimal operating range” to “critically full.” Each threshold can be linked to different actions: notification via email or SMS, pump shutdown, activation of warning lights, or system logging.

The threshold logic considers intelligent hysteresis to avoid alarm oscillations. For example, if an overfill alarm is triggered at 95 percent fill level, the reset only occurs at 92 percent – not already at 94.9 percent, which would lead to constant switching on and off.

Leak Detection Through Intelligent Algorithms Detecting pipe leaks presented a particular challenge. A simple fill level drop is not a reliable indicator, as this can also be caused by normal withdrawals. The developed system therefore analyzes fill level changes in context: if pumps and valves are closed and a continuous fill level drop is still observed, this indicates a leak.

The algorithms also consider temperature-related volume changes and evaporation effects. Machine learning components learn the normal operating behavior of each tank and can detect anomalies with high reliability.

User-Friendly Configuration An outstanding feature of the solution is its easy configurability. The system has an intuitive web interface through which new tanks can be added, thresholds adjusted, and alarm recipients configured – all without programming knowledge. For more complex adjustments, a well-documented scripting language is available, enabling the customer to implement their own automation logic.

Implementation and Commissioning

Installation occurred gradually over a three-month period. First, the most critical tanks were connected – those containing particularly hazardous media or whose failure would cause the greatest economic damage. After successful validation of this pilot phase, additional tanks were successively integrated.

A training program ensured that the client’s employees fully mastered the system. In addition to operating standard functions, configuration options and the scripting language were also taught. After completing the training, the client was able to integrate new tanks independently and adapt the system to changing requirements.

Measurable Success and Operational Experience

The introduction of the tank monitoring system led to significant improvements in several areas:

Operational Safety: Since system commissioning, there has not been a single overfill or pump dry-run. Multiple times, the system was able to detect potential leaks at an early stage, avoiding costly consequential damage.

Personnel Efficiency: Manual fill level control is completely eliminated. The freed personnel resources could be deployed for value-adding activities.

Optimized Logistics: Precise knowledge of all fill levels enables optimized ordering disposition. Express deliveries with premium charges could be drastically reduced.

Documentation: All fill level histories are recorded without gaps. This enables not only analysis of past incidents but also optimization of process parameters through data-based evaluations.

Customer Testimonial

The client’s sustained satisfaction is reflected in this statement:

“For many years we have used the software of ootb automation GmbH and are very satisfied in all aspects of this collaboration. We particularly appreciate the fact that we can maintain and expand the system independently. When we recently installed three new tanks, we were able to integrate them into the monitoring system without external support – this not only saves costs but also makes us independent of external service providers’ availability.”

Rick Mandt, Infrastructure Group Leader

Conclusion: Intelligent Automation for Greater Safety

This case study exemplifies the approach of ootb automation GmbH: we develop automation solutions that combine technical excellence with practical manageability. Instead of complex systems that create lifelong dependence on the manufacturer, we deliver tools that empower our customers to take control themselves.

The tank monitoring system shows how through thoughtful software architecture, safety can be increased, efficiency improved, and operational complexity reduced simultaneously. If you also face similar challenges – whether in process industries, warehousing, or other areas with monitoring needs – contact us for a non-binding consultation.