Optimizing Tank Management with HMI and Overfill Alarms

Our confidential lubricant and additives customer out of Pittsburg, PA, faced a significant challenge with its tank management process. Operators and bulk material unloading truck drivers lacked real-time visibility into tank levels, which often resulted in overfilling. The consequences were costly and time-consuming, involving wasted products, extended cleaning durations, and operational inefficiencies. To address these issues and streamline their workflow, we implemented an innovative solution that transformed their operations.

The core issue revolved around the lack of localized visualization for tank levels. Operators would begin unloading bulk material into tanks without knowing how much capacity was available. This led to:

• Overfilled tanks that caused spillage and product waste.
• Extended cleanup times resulting from product overflow contaminating pumps, tubing, and surrounding infrastructure.
• Increased operational downtime as staff addressed spills instead of focusing on production.
• Unnecessary costs, not only in cleaning labor but also in wasted material.

Our customer adopted a Human-Machine Interface (HMI) visual dashboard integrated with an overfill alarming system to tackle these challenges. This solution was specifically designed to provide a clear and accessible view of tank levels, enabling operators to manage bulk unloading processes with precision.

Key Features of the Solution:

1. HMI Visual Dashboard – A user-friendly interface allows operators to view real-time product levels in all tanks at a glance. This ensured accurate capacity monitoring before and during unloading.
2. Overfill Alarming System—Advanced alerts are activated whenever tanks approach capacity limits, giving operators sufficient time to stop unloading and prevent overflow.

The implementation of the HMI visualization and overfill alarming system delivered remarkable results. By addressing the root cause of overfilling incidents, the company achieved significant operational improvements:

1. Reduced Cleanup Time: The prevention of overflows eliminated the need for extensive cleaning of pumps, tubing, and equipment. This improvement freed up operators to focus on priority tasks and reduced the downtime associated with spill recovery.
2. Minimized Product Waste: By eliminating overfilling, Additive & Lubricant Customer drastically reduced wasted materials. The improved accuracy in tank monitoring conserved critical product inventory and reduced unnecessary costs.
3. Enhanced Operator Efficiency: Real-time tank monitoring and alarms empowered operators with the tools they needed to make informed decisions during the unloading process. This improved workflow efficiency and bolstered confidence in daily processes.
4. Cost Savings: Reduced cleanup costs and conserved materials translated to a measurable expense reduction, delivering clearer ROI from the implemented system.
5. Improved Safety: By preventing overflows, the system also helped maintain a cleaner and safer work environment, mitigating risks related to spills and contamination.