Modeling and Simulation of a Digital Twin for SCADA-Based Industrial Pumping Systems

This paper presents the development and simulation of a digital twin model for an industrial cooling-water pumping system operated under a SCADA environment. The model was built in MATLAB/Simulink and includes pumps, pipelines, and valve behavior using real design data. Simulation results were compared with actual SCADA measurements, showing a difference of 6.6–10%, which confirms good agreement between the model and real system. The study shows how a digital twin can be used to analyze system performance, verify instrument accuracy, and improve control logic before implementation. It also outlines the steps for data collection, PLC–SCADA connection, and performance validation. The developed model provides a useful base for future predictive monitoring, design improvement, and real-time optimization in industrial automation.