Forecourt Automation System
Project Overview
Designed and engineered a comprehensive forecourt automation system for fuel stations, achieving full compliance with CSA C22.2 standards. The system monitors fuel levels, controls dispensing equipment, and prevents hazardous conditions through integrated safety mechanisms.
Key Challenges
- Strict compliance with explosive atmosphere regulations (Class I, Division 1)
- Precision measurement of fuel levels (±0.5% accuracy requirement)
- Integration with multiple legacy dispensing systems
- 24/7 operational reliability in harsh environmental conditions
Design Process
Requirements Analysis
Conducted field surveys at 12 operational fuel stations to identify pain points and operational requirements. Documented 87 functional requirements and 23 safety-critical constraints.
Hazardous Area Classification
Developed zone classification diagrams for forecourt areas, specifying appropriate equipment for each zone per CSA C22.1-18. Implemented intrinsic safety barriers for all electronic components in Division 1 areas.
Mechanical Design
Created 3D models of containment housings using explosion-proof enclosures rated for Class I, Group D atmospheres. Designed mounting systems for ultrasonic sensors with environmental protection.
Prototype Testing
Conducted 400+ hours of accelerated life testing on prototypes, including temperature cycling (-40°C to +70°C) and vibration testing per IEC 60068-2-6 standards.
Technical Specifications
Materials
- 316L stainless steel for all wetted components
- NEMA 4X rated fiberglass enclosures
- PTFE-insulated wiring for chemical resistance
Performance
- 0.3% volume measurement accuracy
- 500ms emergency shutdown response
- IP67 environmental protection
Compliance
- CSA C22.2 No. 30-M1986
- UL 913 (Intrinsic Safety)
- ATEX Zone 1 certification
Results & Impact
Innovative Features
Multi-layer Safety
Implemented triple-redundant shutdown systems with SIL 2 rated components
Real-time Monitoring
Continuous tank level measurement with 1-second refresh rate
Legacy Integration
Developed 14 different interface protocols for existing dispensers