Combining IoT and SCADA: Benefits, Challenges, and Process Explained

Supervisory control and data acquisition (SCADA) systems have been the cornerstone for managing, monitoring, and automating industrial processes for decades. However, everything changes and moves to a combination of SCADA and IoT. In fact:

A modern SCADA system cannot help but incorporate IoT approaches. Still, it’s impossible to disregard local solutions like PLCs and RTUs, tried and tested in this field over the years.

Kostiantyn Oliynyk, Head of IoT at WebbyLab

Offering IoT product development services, we know what it takes to create custom SCADA software solutions. Our very own product, 2Smart Standalone, initially an automation platform, has evolved to complement the needs of SCADA systems perfectly.

Using 2Smart Standalone as an example, we’ll explore:

• What modern SCADA systems look like;
• How to use the Internet of Things in SCADA systems;
• The benefits of integrating IoT with the SCADA systems;
• The challenges of the IoT and SCADA integration.

A 2Smart Standalone automation platform developed by WebbyLab

SCADA Systems Evolution: From Time Relays to IoT Adoption

Before SCADA systems emerged, industrial processes relied on simple dials displaying pressure, temperature, utility meter data, and other equipment indicators. Controlling these required a physical presence — engineers constantly monitoring devices and manipulating wired control panels with switches and buttons.

Needless to say, ensuring 24/7 operation meant a dedicated team on-site.

A simple dial and control buttons for managing industrial processes

Maintenance cost reduction was the driving force behind SCADA’s development. Early systems incorporated existing solutions like time relays, offering a taste of automation. However, this approach introduced new challenges during maintenance, replacement, and reconfiguration.

Time relays automated some tasks and reduced the need for manual intervention with the dials remaining

The rise of microprocessors in the 1950s was a turning point. These compact devices became the perfect solution for automation and monitoring in SCADA systems.

Architecturally, SCADA comprised a set of sensors and controls connected to factory equipment. The equipment was linked to PLCs or RTUs and further integrated into a single network. A server running specific software was connected to this network for data collection and analysis. The PLC or RTU performed automation logic. Physical human-machine interfaces (HMIs) were and are still being used for manual control.

Kostiantyn Oliynyk

Head of IoT at Webbylab

Helped dozens of startups create effective IOT products.

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Before integrating IoT in SCADA, these systems were proprietary and didn’t allow combining equipment from different manufacturers into one ecosystem. However, with the growth of the IT industry in the 2000s, they started implementing open protocols and approaches. This shift enabled industrial businesses to combine various hardware sets into cohesive SCADA systems.

A diagram depicting a SCADA system featuring two solutions from one manufacturer and one from another

Now, as technology advances, SCADA’s reliance on wired connections between system components is decreasing. More solutions for remote control and monitoring appear.

A modern SCADA system with an RTU/PLC and HMI near each equipment piece, connected wirelessly to the central RTU/PLC and the SCADA server

It’s at this point using the Internet of Things in a SCADA system becomes prevalent. Many industrial businesses are now looking at comprehensive enterprise IoT solutions to streamline device integration, ensure scalability, and optimize overall operations across multiple facilities.

8 Benefits of Using the SCADA System in IoT

Using IoT in SCADA offers plenty of benefits for improving industrial processes. Let’s explore how this combination impacts your operations:

Overall Equipment Effectiveness

Overall equipment effectiveness, or OEE, shows how well your equipment is used compared to its full potential. Using IoT and SCADA lets you better understand equipment health, ultimately tackling performance bottlenecks and optimizing production efficiency.

Machine-to-Machine Communication

Owing to the connectivity technologies in IoT, you combine all your devices and equipment into a single ecosystem. As a result, you get a seamless data exchange and next-level automation.

Data Acquisition

Traditional SCADA systems rely on a limited set of data points. IoT, instead, captures info from previously inaccessible areas. This makes process optimization and decision-making even easier.

Remote Management and Monitoring

IoT and SCADA integration enables real-time monitoring and management of your operations from anywhere. This is especially beneficial in situations that require quick response.

Security

Combining SCADA and IoT lets you access additional security features. Those include advanced monitoring, access controls, intrusion detection, and threat detection software.

Scalability

As your business needs evolve, so too can your SCADA system. Given the modular nature of IoT devices and platforms, Scaling IoT devices and platforms is a relatively simple process.

Cost Reduction

The Internet of Things cuts operational costs by improving efficiency, reducing energy consumption, and offering predictive maintenance. Wonder how much an IoT prototype will cost? Check out our recent article on IoT prototype cost estimation.

Predictive Analysis

The IoT and SCADA combination lets you leverage predictive analysis for your equipment. You can study data from IoT sensors to tackle equipment failures before they occur.

How 2Smart Standalone Can Be Used as a SCADA System?

WebbyLab’s product, 2Smart Standalone, can be used as a form of SCADA software. 

Only after implementing 2Smart Standalone did we realize that this product could serve as excellent SCADA software. Though it requires specific modifications for this field, its flexible architecture makes it absolutely ready for this.

Kostiantyn Oliynyk, Head of IoT at WebbyLab

Here is how 2Smart Standalone can be used as SCADA in IoT:

1. The product offers multiple deployment options. We can install it on-site near the equipment on a small physical server, run it in the cloud, or launch it on a remote physical server. Communication between equipment can be organized using wired and wireless connections, either locally or in the cloud.
2. Accessing the product interface is possible through a web browser, both remotely and locally, a mobile application, an API, or a physically connected HMI. It’s also feasible to use HMIs connected to the RTUs or PLCs of each equipment.
   

   

   
   
   Control interfaces of 2Smart Standalone: a web application, mobile app, and physical HMI

    

   3.  The product is highly versatile and flexible in terms of connecting devices. These could be off-the-shelf devices using Modbus or KNX protocols, or any devices with communication interfaces like MQTT or REST API.

   
   Thanks to the built-in bridge architecture, we can integrate with any device. This is currently a must-have task for SCADA systems to avoid limitations in equipment from one manufacturer.

   Yehor Fedorov, IoT Project Team Lead at WebbyLab

    

   
   Integrating an MQTT-enabled device using an MQTT adapter with 2Smart Standalone

4. The admin panel offers centralized management and monitoring of all devices through a universal interface. Additionally, customizable dashboards allow for specific equipment monitoring and the creation of tailored widgets.

An admin panel with access to all devices monitoring and management

Dashboards with pre-built and custom widgets for monitoring and management

5. Out of the box, the product captures all device data into a historical database. This data is accessible via API or through a historical data visualization system. For example, Grafana can be installed for creating historical dashboards.

Grafana dashboard for visualization of collected data in the system

6. The built-in automation feature enables the configuration of alerting scenarios and maintenance predictions, and, if necessary, automatic equipment control.

Challenges of SCADA and IoT Systems

The potential benefits of using SCADA and the Internet of Things are highly promising. Still, there are several challenges to consider:

• Lack of standardization. Current custom IIoT solutions might lack unified standards. This inconsistency can create compatibility issues, slowing down the company’s processes.
• Latency. Certain industrial processes require real-time, split-second decisions. Cloud-based solutions can introduce latency due to data transmission times, so using edge-based controls for critical applications is more suitable.
• Security concerns. IoT systems offer numerous tools to ensure security. But with a growing number of interconnected devices, your business is at risk if proper security measures are not implemented.
• Scalability requirements. IoT makes it easy to scale, but it also brings some challenges in handling this growth. Unlike traditional SCADA systems, the design must be horizontally scalable to accommodate more connected devices.

Embrace IoT for Your SCADA System

Using the SCADA system in IoT leads to the next level of industrial automation, monitoring, and control. Promising enhanced efficiency, improved decision-making, and optimized operations, you cannot but adopt IoT solutions.

Having been delivering IoT software development services for over five years, WebbyLab experts know how to use of IoT in SCADA. As seen in 2Smart Standalone, we don’t just build isolated IoT products — we excel at integrating them with SCADA systems and other solutions.

With over 10 successful projects and 3 of our own products behind our backs, we worked in such industries as HVAC, access control systems, consumer electronics, smart homes, EV charging, and beyond. We can also cover everything from IoT devices development to end-to-end IoT development and consulting. Check out our portfolio for more.

In case you need a partner who’ll integrate your SCADA system with IoT, you can safely count on WebbyLab. With relevant experience in such solutions, we’re ready to drive you toward intelligent automation. Don’t wait — reach out to us for a consultation.