TankScan Helps Migrate Legacy Tank Monitoring Software

KBC Technology

KBC Technology is a leader in Digital Energy Management & Carbon Emissions Management. We innovate with award-winning technologies for low and no-carbon processes, and deliver robust and proven automated surveillance to meet your sustainability goals.

Applications: Tank Level Monitoring

Market: Chemical

Challenge

The Remote Tank Monitoring application was deployed across multiple clients, each with many locations and multiple tanks per location. The company faced high costs of operation, and they needed to exit the business. They were interested in partnering with TankScan because of the common hardware, diverse experience with sensors, experience in the chemical industry, and focus on world-class customer service. The global energy consulting company wanted to offer a migration plan for their existing customer base with the best support and lowest risk. The system needed to be secure, while at the same time available to personnel after business hours and on weekends. They also needed the entry cost to be low with minimal costs associated with engineering, integration, and installation services. Lastly, they wanted the system to be able to scale in size and to mix and match sensor hardware and connectivity of cellular and wired ethernet technologies, all while using the same provider for software and setup support.

Previously, this global energy consulting company developed their own software platform. But, ongoing support proved expensive and cumbersome. Their existing systems had been deployed over the last 10 years on multiple edge devices, including wireless and wired gateways, PLCs, and 4-20mA level sensors, including ultrasonic, radar, and submersible pressure. Additionally, some installations had added HMIs and deployed Intrinsically Safe Barriers to meet plant hazardous area needs. The major concerns were the continuation of the remote level monitoring service, while reducing or eliminating unnecessary migration costs and service interruption.

Solution

In 2025, this global energy consulting company partnered with TankScan to offer a migration plan for their clients. The intent was to retain the hardware and redirect the data from the old cloud software to the TankScan software platform. Their new monitoring system leverages easy integration tools to adapt to the incoming data formats, including Rest API, formatted emails, and formatted ftp files. The data updates range from once per hour to once per day and benefit from exception reporting, which reduces data usage and extends battery life. In addition to monitoring the remote tanks' level, the new monitoring system automatically monitors the conditions of the hardware and connectivity system and notifies through email and text messages when an alert condition or anomaly is detected. The user is provided notifications with accurate readings to mobile devices or PC’s and requires no software installation. Rather, it is all driven through the intelligence platform hosted in the cloud. The image below shows the overview screen, showing the measurement list, which is automatically sorted by the most critical alerts at the top of the list.

Results

The supplier and end users have seen numerous benefits from level and system health monitoring including:
• Reduced labor associated with auditing the health of the tank sensors
• Improved reliability of their operations with reliable, remote visibility to off-site and on-site personnel
• Improved confidence and reduced risk of level monitor failure

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