SCADA System in Water Storage Tanks With NI Vision LabVIEW
SCADA System in Water Storage Tanks With NI Vision LabVIEW
Kartika1, Misriana2, M. Fathan Naqi1, Asran1, Misbahul Jannah1, Arnawan Hasibuan1, Suryati2
1
Department of Electrical Engineering, Faculty of Engineering, Universitas Malikussaleh, Lhokseumawe, Indonesia
2
Department of Electrical Engineering, Politeknik Negeri Lhokseumawe, Lhokseumawe, Indonesia
Corresponding Author:
Kartika
Department of Electrical Engineering, Faculty of Engineering, Universitas Malikussaleh
Lhokseumawe, Indonesia
Email: [email protected]
1. INTRODUCTION
Water is vital for various human activities, including drinking, bathing, washing, and industrial
processes [1]. However, ensuring its availability to meet these demands often poses challenges [2]. To address
this, water is typically stored in tanks and pumped through electricity-powered pipes using pumps [3], [4].
Manual filling of reservoirs, however, can lead to waste when tanks are left unchecked, resulting in unnecessary
water and electricity consumption if pumps are not turned off once the tank is full [5], [6]. Proper water
conservation is achieved through regulated usage, ensuring taps are turned off when not in use [7]. Maintaining
the correct liquid level in industrial settings is critical for meeting production demands [8]. Insufficient real-time
monitoring and control may result in manual operation, which, while cost-effective, presents challenges,
particularly when accessing water reservoirs located remotely or at elevated positions [9], [10].
Effective water level control in storage tanks is essential for proper distribution [11]. A well-designed
control system prevents overflow during tank filling, ensuring a consistent water supply [12] while enabling
real-time monitoring and control [13]. Control techniques range from basic on/off systems to more advanced
methods like proportional integral derivative (PID) control [14], which is commonly used for regulating
induction motor speeds [15]. However, determining the correct gain values for Kp, Ki, and Kd can be
challenging [16]. In water level control, PID systems regulate the speed of water pumps, controlling the flow
into storage tanks while monitoring the water level [17]. This requires an integrated system with a human-
machine interface (HMI), which facilitates communication between the user and machine [18]. The HMI
displays system status, enhancing usability and ensuring efficient interaction through intuitive controls and
status information [19].
HMIs enable real-time monitoring, direct control, and alarm notifications for hazardous conditions
[20]. Integrating data acquisition, monitoring, and control, SCADA systems are widely used to address water
level monitoring challenges, providing an easy-to-use interface for remote real-time observation [21]. SCADA
enhances efficiency by delivering real-time data and automating water tank management, including monitoring
and controlling water parameters [22], [23]. Effective system control, however, requires the right software and
actuators. LabVIEW facilitates rapid measurement, monitoring, and data storage, while microcontrollers like
Arduino are necessary for implementing control settings [24].
This study focuses on developing a water level control and monitoring system for tanks using an HMI-
based SCADA system. The system aims to automate water filling and distribution to prevent waste and
optimize electricity use [25]. The HMI interface enables real-time monitoring, while SCADA integrates
tracking, control, and data collection. Users can view water levels on an intuitive display, with alarms for
abnormal conditions. Integrating LabVIEW with an Arduino microcontroller improves performance
visualization. This research is significant for advancing efficient water management solutions, especially in
industrial environments where managing tank liquid levels is crucial.
2. METHOD
The flowchart facilitates the analysis and implementation of the designed tool, namely the SCADA
system on the water storage tank, with NI-VISA LABVIEW. The research flow can be seen in Figure 1. The
flowchart serves as a valuable tool for analyzing and implementing the SCADA system on the water storage
tank, which is designed using NI-VISA LABVIEW. It provides a clear overview of the necessary steps and
processes involved in developing and executing the system. The research flow, illustrating each stage of the
project, is depicted in Figure 1 for better visualization and understanding.
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HX710 pressure sensor, and YF-S201 flow sensor. LabVIEW commands Arduino R3, the central controller,
to manage the L298N driver module, which activates water pump 1 to transfer water to storage tank 1. The
solenoid valve regulates the water flow from the pump to the tank. Once the water is stored in storage tank 1,
the distribution water pump moves it to storage tank 2, the final storage location, with Solenoid valve 2
controlling the distribution flow. The sensors measure water level (HC-SR04), pressure (HX710), and flow
(YF-S201), sending data back to Arduino R3. LabVIEW continuously monitors and adjusts the system to
maintain the water flow at the setpoint.
(a) (b)
Figure 3. Overall mechanics used in this stud: (a) storage tank and tower and (b) control box
No
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discharge setpoint at four p.m. Then, run the monitoring and control system on the run icon, which can be
directly seen on the LabVIEW monitor screen display, as shown in Figure 9.
Figure 9. Test results for monitoring water level and water pressure in the tank
The figure illustrates the successful integration of LabVIEW with Arduino to monitor the water
levels in two tanks in real-time. The display includes several key components, such as performance graphs
for tracking the present value (PV) and set point (SP) values. In this configuration, the water level setpoint is
established at 40 cm, indicating that the system is designed to maintain the water level around this value.
During testing, the pump activates to fill the water until it reaches a height of 40 cm, while the valve control
automatically adjusts the water flow. The system relies on data from a water level sensor connected to the
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Arduino, which is transmitted to LabVIEW for processing. As the water level approaches the 40 cm setpoint,
the control system stabilizes the water level around this target. This test demonstrates the system’s ability to
maintain the water level at the specified setpoint, ensuring that each component, including the pump, valve,
and sensor, functions properly to preserve the system’s stability around the setpoint. The results of the system
test shown in Table 1 confirm that the water level remains at the 40 cm setpoint.
The system test data for maintaining a 40 cm water level set point is summarized in Table 1,
showing pump and valve statuses and the water levels in both tanks at specific time intervals. From 0 to 31
seconds, the water level in both tanks increases steadily. During this period, pumps one and two remain
“On,” and valves one and two stay “Open,” ensuring a continuous water flow. At 31 seconds, the water level
reaches approximately 3.6 cm in tank 1 (with a pressure of 0.17 Psi) and 3.9 cm in tank 2 (with a pressure of
0.17 Psi). This consistent rise in water levels confirms the system’s ability to maintain a smooth flow,
moving steadily towards the 40 cm set point.
In tuning the PID parameters, this method consists of Kp, Ti, and Td, where:
a. Kp (proportional gain) is 60% of the proportional value calculated by comparing T and L.
b. Ti (integral time) 50% of Tu, where Tu equals the time constant T.
c. Td (derivative time) 12.5% of Tu. This helps with smooth changes in system response.
So, the PID tuning obtained by the Ziegler-Nichols method is as follows.
a. Proportional (P) control
𝑇 7,59
𝐾𝑝 = = = 13,77
𝐿 0,551
𝐿 0,551
𝑇𝑖 = = = 1,83
0,3 0,3
c. PID control
𝑇 9,50
𝐾𝑝 = 1,2 = 1,2 = 16,52
𝐿 0,551
After PID tuning with the Ziegler-Nichols method, the parameters obtained are Kp = 16.52, Ti =
1.102 seconds, and Td = 0.2755 seconds. Furthermore, the PID value obtained from the tuning results using
the Ziegler-Nichols method shows the system response by looking at the step response of the S curve
produced.
A step change in response to PID control of the water flow rate. The image also gives data on the
rise time of 0.296 seconds, an overshoot of 10.5%, and settling time of 1.49 seconds. The value shows a
gradual decrease from the overshoot value point. This is a result of the Td value of 12.5% of Tu, which acts
to help smooth the change in the system response.
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accurately, as well as the water pressure readings, indicating that when the water level in tank 1, 2.04 cm, the
sensor reads a water pressure of 0.1 Psi, as well as the water level in tank 2, 2.21 cm, the sensor reads a water
pressure of 0.1 Psi. The table shows that the sensor reads the parameters in the tank accurately until the water
level in Tank 1 is 40 cm, as well as in the tank, the water pressure sensor reads a water pressure of 1.88 Psi in
tank 1 and 1.77 Psi in tank 2. Overall, the system consistently maintains a flow rate close to the setpoint
without significant fluctuations until the end of the test at 325 seconds. At that point, the flow rate on both
sensors, flow 1 and flow 2, was consistently at 4.0 l/m without any additional overshoot or significant
fluctuations, indicating the system’s stability in a steady state. These results suggest that the PID parameters
that are set are compelling enough to achieve and maintain flow stability at the desired setpoint
4. CONCLUSION
This research introduces a water management system based on SCADA, which integrates LabVIEW
and Arduino for monitoring and controlling water levels and flow rates in a storage tank. The system
employs ultrasonic sensors for measuring water levels and pressure sensors for pressure measurements. Pulse
width modulation (PWM) regulates the water flow rate, ensuring stability. The SCADA system minimizes
water and energy waste, promoting sustainable water management in industrial and environmental contexts.
The HC-SRF04 ultrasonic sensor achieves a water level measurement accuracy of 99.77%, with the
LabVIEW human-machine interface (HMI) displaying these readings. Water pressure in both tanks is
measured by the HX710 sensor, with an accuracy of 98.54%, and the corresponding data is also shown on the
LabVIEW HMI. The Ziegler-Nichols method tunes the PID controller, which adjusts the PWM to regulate
the water flow rate. The optimized PID parameters are 𝐾 𝑝 = 16.59, 𝑇 𝑖 = 1.102, and 𝑇𝑑 = 0.2755 seconds,
resulting in optimal flow control. The YF-S201 sensor measures the water flow rate on both pumps,
accurately detecting the flow. The PID control successfully maintains a flow rate setpoint of 4 l/m, with
minimal fluctuations around the target, initially exceeding by 2.5% before stabilizing within approximately
10 seconds. The SCADA system efficiently transmits sensor data to LabVIEW, facilitating a reliable real-
time monitoring and control interface, ensuring effective water level management, and reducing water and
electricity waste.
FUNDING INFORMATION
We will jointly bear the costs incurred in conducting this research, without involving any other
parties, whether individuals, groups, or institutions.
Name of Author C M So Va Fo I R D O E Vi Su P Fu
Kartika ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Misriana ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
M. Fathan Naqi ✓ ✓ ✓ ✓ ✓
Asran ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Misbahul Jannah ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Arnawan Hasibuan ✓ ✓ ✓ ✓ ✓ ✓ ✓
Suryati ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
INFORMED CONSENT
We have obtained informed consent from all individuals included in this study.
DATA AVAILABILITY
Derived data supporting the findings of this study are available from the corresponding author
Kartika ([email protected]) on request.
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BIOGRAPHIES OF AUTHORS
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