We designed a fully wireless, solar-powered tank overfill prevention system using a self-healing mesh network. This architecture enabled reliable communication across tanks spread throughout the large plant, routing data through multiple sensor nodes back to a single central point—without requiring direct line-of-sight or extensive infrastructure.

In a mesh network, each sensor unit acts as both a data source and a repeater. If one path is blocked by distance, obstacles, or interference, the system automatically reroutes information through alternative nodes, creating redundant pathways for high reliability and extended coverage. This eliminated the need for long conduit runs and heavy wiring, delivering significant cost savings to the customer while simplifying installation in a large facility.

Powered by solar panels, each unit operated independently and sustainably. The system polled sensors every few minutes, reporting critical data including float switch status (triggering high or high-high alarms), sensor battery levels, and temperature.

The result was real-time remote monitoring that gave the customer complete peace of mind during tank filling operations, preventing overfills and enhancing safety across the site. This was a customed designed solution from ECM that is in use today.