Model of a Cyber-physical System for Monitoring and Controlling Liquid Levels in Tall Storage Tanks
Year: 2025
Type: article
Abstract: Accurate monitoring of liquid levels in tall storage tanks is a critical issue in the oil and gas sector and related industries. Traditional PLC–SCADA systems, although widely used, are limited to monitoring and signaling functions without implementing adaptive closed-loop control, double feedback, or predictive analytics. These limitations create risks in environments characterized by foams, vapors, and density fluctuations. This paper presents a conceptual design of a cyber-physical system (CPS) for liquid level monitoring and control. The system integrates heterogeneous sensors—radar, ultrasonic, hydrostatic, and vibrating fork—into a unified framework. Radar sensors serve as the primary source of measurements, hydrostatic sensors provide confirmation, ultrasonic devices validate dynamic changes, while vibrating forks act as safety triggers in emergency conditions. Such multi-sensor integration improves accuracy, reliability, and robustness. The algorithmic subsystem processes signals through filtering, normalization, and data fusion. Adaptive self-tuning methods and elements of machine learning allow dynamic adjustment to variations in liquid properties. Control commands generated by the system regulate pumps and valves, supporting both basic operations and advanced modes, such as selecting the required liquid type. An analytical layer is added through a database that stores all measurement results, control actions, and historical data. This enables trend analysis, prediction of potential risks, and prevention of critical states like overflow or equipment overuse. Additionally, remote monitoring via a web interface allows engineers to track data in real time, review historical trends, and adjust parameters. The proposed CPS integrates measurement, data processing, prediction, and actuation into one coherent solution. Although the paper focuses on system description rather than prototype validation, the results demonstrate significant potential for improving adaptability, accuracy, and reliability in industrial liquid storage. The practical application and capabilities of a cyber-physical system for monitoring and controlling liquid levels are examined using the example of a petroleum tank farm. The system’s operation in normal mode utilizing radar and hydrostatic sensors, along with emergency response mechanisms based on vibration sensors is described. Principles of adaptive self-tuning based on historical data analysis are also outlined. The importance of remote monitoring and the ability to adjust parameters via a web interface are emphasized. This demonstrates the system’s capacity for comprehensive, reliable, and autonomous management.
Source: Municipal economy of cities
Authors: V. Kropyvnytska, B. Merenko
Language: English
Subfield: Control and Systems Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: diamond
OpenAlex ID: W7089489576