System Architecture and Data Flow

As part of the Variance Project, the dashboard has been designed and implemented in a structured two-stage process to ensure reliability, accuracy, and real-time insights. The solution leverages Plant SCADA, industrial-grade sensors, and a web-based dashboard application to deliver end-to-end visibility of tank operations.

Stage 1: Data Acquisition via SCADA

The first stage begins with the Plant SCADA system, which acts as the primary data collection layer. The SCADA system continuously gathers raw data from:

• Flowmeters – capturing the precise measurement of liquid inflow and outflow.
• Level Sensors – monitoring tank stock levels in real time.

Once collected, this sensor-driven data is automatically recorded and stored in a centralized database, forming the foundation for further analysis and reporting.

Stage 2: Dashboard and Reporting

In the second stage, a web-based dashboard application interfaces directly with the centralized database. It reads the incoming real-time SCADA data and transforms it into a structured and consolidated format. Key functionalities include:

• Displaying real-time tank levels across all 12 monitored tanks.
• Providing a variance view of input and output flows to identify discrepancies quickly.
• Generating organized reports for operational teams and management review.
• Ensuring data accuracy by aligning dashboard figures with SCADA sensor readings.

This two-tier process ensures seamless integration between hardware (sensors and flowmeters), data acquisition (SCADA), and analytics (dashboard and reporting). The outcome is a comprehensive, real-time variance monitoring system that provides KNPL stakeholders with actionable insights and greater confidence in operational decision-making.