Supervisory Control and Data Acquisition (SCADA) systems and Industrial IoT (IIoT) devices often perform the same tasks ” like data collection, monitoring, altering and report creation. Therefore, many are looking to expand the functionality of existing SCADA systems with IoT devices as a result. However, default settings and software can sometimes prevent interoperability with legacy technology, like facility SCADA.
Leaving these systems unlinked puts companies at risk of siloing data or building parallel infrastructures, doubling IT investment to create new systems that perform work existing ones may already handle.
Linking these networks can improve connectivity, boost access to information and streamline data gathering, automation and remote plant management strategies. These methods for connecting SCADA systems with new IoT technology ensure facilities adopting smart technology won’t leave legacy tech behind.
Creating a Combined SCADA IoT Platform
Several strategies for linking SCADA and IoT are possible, depending on the size and complexity of the fleet and what functions it’s performing.
Often, organizations attempting a comprehensive retrofit may use a dedicated IIoT system that integrates the SCADA system by collecting and reporting relevant data. This IIoT network would bridge sensors and other devices that gather critical information with SCADA systems that perform similar tasks. It would then report these details to the cloud, where IoT and intelligent systems can use it.
This approach does not directly integrate the SCADA system with other IoT devices, but it makes the data it collects available to these devices and offers some level of interoperability.
For example, connecting an IoT module or intelligent network controller to a SCADA remote terminal unit or PLC could enable one to transfer data gathered by SCADA-connected sensors to other smart devices. This system would allow users to adopt IoT analyzers that collect information without replacing existing equipment.
Many IIoT developers, aware of the growing need to link legacy and Industry 4.0 equipment, are also developing intelligent gateways and controllers that can enable the delivery of sensor data to the cloud. This technology can provide users with more cohesive access to information, potential interoperability with IoT devices and reduced risk of data silos.
A replacement of legacy hardware may be necessary in the future. However, this approach allows facilities to use SCADA computer systems and IoT hardware simultaneously without the risk of creating parallel data infrastructures or losing information one system may gather.
Integration may also be more straightforward in facilities using modern SCADA systems, often equipped with open database connectivity (ODBC) that can help connect it with cloud-based technology.
Common Pitfalls and Challenges of IoT-Based SCADA
When integrating IoT and SCADA systems, facilities may need to navigate a few common challenges. They may need to integrate IoT devices to let them control systems the SCADA network may already be able to handle. In some cases, it may be necessary to add IoT-connected switches to achieve this functionality.
Creating a power-control system that shuts off unnecessary devices or hardware to conserve energy may require additional IoT switches to perform tasks the SCADA system can’t manage.
Cybersecurity can also become more of an issue due to IoT connectivity. Integrating devices doesn’t necessarily make systems less secure, but it will introduce new paths for unauthorized network access. As a result, different practices may be needed to protect the network against attacks.
Many existing SCADA systems rely on industrial security techniques like obscurity (STO) and air gapping. If systems had proprietary or secretive designs, they would naturally be harder to hack. Air-gapped networks disconnected from the internet have less of an attack surface than cloud-based systems that rely on internet connectivity to function.
These strategies have never entirely defended industrial systems against digital attacks. Certain types of malware specifically target SCADA systems that are often protected by STO and air-gapping.
Modern systems rely on technology that is well-documented outside of the organization and can be understood by a hacker with network access. IoT systems cannot be air-gapped, as they need to connect to the cloud to transmit and receive data. Integrating IoT with a SCADA system may also expose it to the internet or make it much more accessible than it was previously.
For these reasons, understanding the basics of IoT security is essential for facilities that integrate smart technology with their legacy SCADA systems. Effective device configuration, strong passwords, update schedules and network segmentation are common strategies that can help managers protect industrial IoT systems from attack.
Working with IoT suppliers to create effective security programs can also help ensure integration does not make its SCADA system more vulnerable to a cyberattack.
Long-Term IT Strategies for SCADA Systems With Integrated IoT
When choosing to integrate legacy hardware with new IoT systems, it’s import to prepare for a phase-in period. During this time, workers can adjust to using the latest technology, and IT staff will have time to troubleshoot early issues with the IoT-SCADA integration.
This phase-in period also provides the organization with an opportunity to start small and scale up. Reducing the scope of early IoT-SCADA projects will give the company more opportunities to experiment and identify how IIoT devices can interface with SCADA hardware, like PLCs and RTUs.
Integrating Legacy SCADA Systems and IoT Devices
As IIoT devices become more popular, businesses may need to find ways to integrate IIoT technology with existing SCADA systems. Otherwise, they may risk creating data silos or developing parallel IT infrastructures.
New IoT modules can be used to connect SCADA PLCs and RTUs with cloud-based systems. This will enable a company’s IIoT network to take advantage of data collected by their SCADA network.
Businesses that integrate SCADA and IoT will need to prepare for particular challenges, like securing new internet-connected SCADA hardware. However, the advantages of integration will likely outweigh the cost of these difficulties.
