Building a Tank Monitoring SCADA with ThingsBoard

Monitoring storage tanks requires reliable instrumentation, intuitive dashboards, and robust alarms. Here’s how I build a ThingsBoard-based solution that operations teams trust.

1. Instrumentation and Data Capture

• Connect level transmitters and temperature probes to PLCs or edge devices.
• Publish telemetry to ThingsBoard via MQTT or HTTP using JSON payloads:

{
  "tank_id": "TK-104",
  "level_percent": 78.2,
  "temperature_c": 42.5,
  "volume_liters": 35000,
  "timestamp": "2025-05-09T12:45:00Z"
}

2. Asset Hierarchy

• Create an asset for each facility, then define tank entities with attributes (capacity, product type, safe ranges).
• Store maintenance contacts and inspection schedules as server-side attributes.

3. Dashboard Design

• Combine level gauges, trend charts, and alarm tables.
• Add floor plan overlays showing tank status at a glance.
• Provide quick filters (by product, temperature range) so operators find issues fast.

4. Alarm Configuration

• Set thresholds for high/low levels, rapid changes, and temperature deviations.
• Configure escalation: first notify operators, then maintenance if unresolved.
• Log acknowledgements and resolution notes directly in ThingsBoard.

5. Reporting and Analytics

• Use widgets to calculate dwell time within optimal ranges.
• Export telemetry to data lakes for forecasting and inventory reconciliation.
• Schedule automated PDF reports for daily shift handover.

6. Mobile Access and Security

• Enable responsive dashboards for tablets and smartphones used on the plant floor.
• Implement role-based access to ensure only authorized staff can acknowledge alarms or change setpoints.
• Use TLS certificates and SSO for secure authentication.

7. Integration with Operations

• Push work orders to the CMMS when tank levels cross critical thresholds.
• Share data with ERP systems to support production planning.
• Provide APIs for third-party logistics partners to view inventory status securely.

With a solid instrumentation backbone and thoughtful ThingsBoard configuration, tank monitoring becomes proactive rather than reactive. Operators gain real-time visibility and actionable insights to keep production flowing smoothly.