Build Your Own Smart Industrial Tank Level Monitoring and Pump Control Solution

4 Reasons to Create a Smart Tank Monitoring and Pump Control System

#1. A smart solution allows operators to remotely manage tank levels and pump operations from anywhere, preventing common issues such as tank overflows, pump dry-running, and treatment process disruptions. The ability to monitor systems in real-time reduces the risk of costly emergencies by enabling early detection of potential problems, providing timely data for decision-making.

#2. In terms of maintenance and usage, access to real-time data allows operators to optimize system performance. Data on pump operations and operating hours can be leveraged to support predictive maintenance, reducing downtime and extending the lifespan of equipment. This also ensures consistent water quality by making informed decisions based on continuous monitoring.

#3. When based on versatile products like Arduino’s, inspired by open-source principles, a smart tank monitoring system is highly adaptable and scalable, allowing it to fit various industrial needs. It can be integrated with existing equipment and third-party systems, ensuring seamless incorporation into a facility’s operations. This flexibility makes it ideal for a range of industrial applications, from small-scale plants to complex systems.

#4. By automating the monitoring process, the solution minimizes the need for frequent manual checks, reducing human error and cutting operational costs. Automated alerts and precise monitoring help maintain optimal chemical dosing and flow rates, while reducing any costs associated with equipment damage, process disruptions, and regulatory non-compliance.

Technical Overview of the Solution

A flexible and cost-effective solution for tank monitoring and pump control can be based on an easy-to-use micro PLC such as the Arduino Opta. The complete tutorial is available on Arduino Docs.

In this case, the system employs a variety of sensors – such as float switches, ultrasonic transducers, and pressure transducers – to continuously track liquid levels. Data from flow meters is used to measure pump discharge rates and overall system flow. This information is then transmitted to a cloud-based SCADA (Supervisory Control and Data Acquisition) system for real-time access, allowing operators to visualize and manage tank levels, pump status, and system flow rates through an intuitive dashboard.

Additionally, the system includes configurable alarms that send alerts for critical scenarios such as abnormal flow rates or high/low tank levels. These alarms can be customized and sent via multiple channels, including email and SMS, preventing unnecessary notifications and ensuring only critical alerts are triggered.

The solution is compatible with a variety of sensors and supports industry-standard protocols, such as Modbus RTU over RS485 and Modbus TCP/IP. 

Adding Vision-Based Liquid Monitoring

In situations where conventional sensors are not practical, a vision-based monitoring system can be deployed. A module such as the Arduino Nicla Vision, which is equipped with a 2 MP color camera, has the intelligence to visually assess the current liquid level in a tank: applying so-called “blob detection”, the liquid’s surface can be identified and the tank’s fill level calculated. This data can be relayed to the control system to trigger appropriate actions, such as opening or closing valves.

This vision-based approach offers a non-invasive method to monitor tank levels, making it suitable for systems where physical sensor installation is difficult or impossible. It can also be retrofitted to almost any existing system without significant modifications.

Unlocking Smart Industrial Solutions with the Arduino Ecosystem

The flexibility and adaptability of the Arduino platform make it an excellent choice for creating smart industrial systems, such as tank level monitoring and pump control solutions. Whether you're integrating traditional sensors or implementing innovative vision-based methods, Arduino’s open-source tools and broad compatibility with industry standards offer a versatile foundation for any project. Explore the Arduino ecosystem to find the right tools for your next industrial challenge, and see how it can accelerate your path to smarter, more efficient operations.