Spills and overflows are more than operational inconveniences—they can damage equipment, trigger environmental violations, and bring costly downtime. AEC’s ControlCORE automation platform is built to prevent these events through reliable tank level monitoring, intelligent diverter logic, and real-time control.
Why Spills & Overflows Happen
Common causes include:
- Manual monitoring or float-only level controls
- Misconfigured diverter valves or pump sequencing
- Sensor failure, communication loss, or clogged discharge lines
- Lack of system integration for alarms, cutoffs, or fail-safes
How ControlCORE Prevents Spills
-
Continuous Level Monitoring
- Uses reliable sensors (ultrasonic, radar, pressure)
- Real-time thresholds and smart alerts
- Trigger logic before limits are breached
-
Automated Diverter Logic
- Dynamically redirect flow based on tank availability
- Automate valve actuation, pump control, and fill sequencing
- Prioritize safety over manual reaction time
-
Centralized Control & Visibility
- Connect to SCADA/HMI for live level and diverter status
- Full dashboard views of all connected tanks
- Integration with alarm systems and auto-shutdown logic
-
Failsafe Redundancies
- Backup controls to prevent spillage if primary logic fails
- Time-based shutoff if abnormal fill rate detected
- Secondary containment integration
Real-World Impact
A facility using ControlCORE:
- Reduced switch-over time from 45s (manual) → under 10s (automated)
- Prevented 3 previously common overflow events within 6 months
- Set up remote tank monitoring across multiple sites
Implementation Tips
- Choose the right sensor type (ultrasonic, radar, hydrostatic) based on fluid, tank geometry and environment.
- Create diverter logic flows: e.g., Tank A high → divert fill to Tank B → if Tank B high → stop fill and alert.
- Integrate with your existing PLC/SCADA or install ControlCORE as a dedicated module.
- Establish alarms with escalation and define actions: e.g., “If level > 95% for 30 sec → stop fill & send alert.”
- Maintain the system: sensors should be cleaned, verified, and logic periodically tested.
Spills and overflows don’t have to be part of your process. With ControlCORE, you gain precision control and real-time automation that keeps your operations clean, safe, and compliant.
Talk to the AEC team today to learn how ControlCORE can help safeguard your tank and diverter systems.
