Overcoming SCADA Limitations: Intelligence and Multiple Connectivity with Bridgemeter

Introduction: The Essential Nature and Challenges of SCADA Systems

SCADA (Supervisory Control and Data Acquisition) systems are cornerstones of modern industrial automation and monitoring. They provide operators with a real-time view of the status of critical processes, equipment, and infrastructure, and are essential for operational supervision.

However, despite their relevance, many traditional SCADA implementations face limitations that can compromise efficiency, responsiveness, and integration with other systems or entities.

Two main limitations stand out:

1) Visualization without Intelligence: While SCADA systems are effective at displaying operational data (such as pressure, temperature, and equipment status), many still lack advanced interpretation capabilities. Generating predictive insights or automated diagnostics remains heavily dependent on operator experience. Detecting subtle faults and correlating variables requires continuous attention and often the manual mobilization of field teams for repairs and corrective actions.

2) Limited Connectivity: Most PLCs and SCADA systems operate with "one-to-one" connection architectures, which represents a significant bottleneck. This limitation hinders the simultaneous sharing of data between multiple SCADA systems—especially in scenarios involving different departments, partner companies, or regulatory bodies—restricting collaboration and interoperability between systems.

It is in this context that a new complementary approach becomes essential — acting as a layer of analytical intelligence and a robust integration hub, capable of leveraging existing SCADA systems and overcoming their structural limitations.

This additional layer not only enables intelligent interpretation of real-time operational data, but also facilitates the secure sharing of information between multiple systems and entities, promoting greater collaboration, predictive automation, and data-driven decision making.

Beyond Visualization: The Operational Intelligence that Traditional SCADA Doesn't Deliver

While a SCADA system might indicate that a motor's current has increased, it rarely explains why this happened or what it might mean . An advanced IIoT (Industrial Internet of Things) platform goes beyond simply collecting and displaying data: it incorporates algorithms and artificial intelligence to transform raw data into actionable insights .

• Correlational Analysis: The platform cross-references information from multiple sensors and assets. For example, it can correlate an increase in current in a pump with a slight increase in vibration or temperature, suggesting the beginning of a blockage or wear in the bearing—something that would be difficult to detect with data analyzed in isolation.
• Predictive Fault Detection: Based on historical patterns and subtle deviations in operational behavior, the system identifies potential faults before they occur. This allows for truly predictive maintenance, based on the actual condition of the equipment—and not just on fixed schedules.
• Intelligent and Targeted Alerts: Instead of overwhelming the OCC (Operational Control Center) operators with dozens of simultaneous alarms, the platform sends contextualized and relevant alerts, targeted to the responsible teams—such as maintenance, operations, or engineering. These alerts are often accompanied by preliminary diagnoses, suggested actions, and associated technical documentation. Furthermore, the solution can be integrated with the work order system, automating the opening of service requests and significantly reducing the time and workload of the OCC.

This layer of intelligence does not replace SCADA, but complements it — providing the "why" behind the data and enabling more proactive and efficient operational management.

So how do you add this advanced intelligence that correlates data, predicts failures, and guides actions with precision—all while integrating seamlessly with your current SCADA system?

Breaking the One-to-One Barrier: Multi-SCADA Connectivity with Bridgemeter

One of the most significant technical challenges in environments with multiple stakeholders is the limited connectivity between field controllers (PLCs) and SCADA systems. In most industrial architectures, a PLC allows the connection of only one SCADA system at a time—and any attempt at simultaneous connection by a second system usually interrupts the communication of the first.

This limitation becomes critical in scenarios where real-time data sharing is necessary for integrated operations between departments, partner companies, or regulatory bodies. This is where Above-Net 's Bridgemeter stands out—acting not only as a remote monitoring and intelligence platform but also as a integration hub for operational data.

To overcome this connectivity barrier, Bridgemeter offers an effective and scalable solution:

• Single Field Connection: Establishes a secure and stable connection with the PLC, preventing external interference.
• Centralized Reading and Processing: Collects operational data in real time, processing it in an intermediate intelligence layer.
• Secure and Simultaneous Distribution: Relays data to multiple SCADA systems or management platforms — in parallel, without access conflicts and with control over security, authentication, and latency.
• PLC Remote Access: Allows transparent remote access to the controller for adjustments, activation, or remote programming with proprietary software emulating local access.

By eliminating the limitation of one-to-one connectivity, Bridgemeter enables collaboration between systems , greater operational transparency, and secure integration between different layers of the production chain—all without compromising the stability of the original control environment.

This unique data sharing capability opens doors to applications and collaborations that were previously unfeasible.

Essential Use Cases for Multiple Connectivity

The need to connect multiple SCADA systems to a single measurement point is more common—and critical—than one might imagine. Below are two recurring scenarios where this capability is indispensable:

1) Regulated Sector (e.g., Post-Privatization Sanitation)

Following concession auctions, such as the CEDAE blocks in Rio de Janeiro, new operators began managing interconnected sections of the same water supply and sewage network. To ensure the integrated and safe operation of the system, regulatory bodies require the real-time sharing of sensitive operational data (such as pressure at delivery points or levels in common reservoirs).

In these cases, each company needs access to data from the network operated by its neighbor—both upstream and downstream—to make assertive operational decisions. Bridgemeter enables this exchange of information with security, stability, and privacy, meeting legal requirements and avoiding penalties.

2) Multi-Site Operations or Departments with Distinct Needs

A corporation with multiple plants might use a local SCADA system for operational control and another, at headquarters, for strategic monitoring or consolidation into BI platforms. The same applies to departments such as Engineering, Maintenance, Operations, and Quality, which frequently need to access the same data from different perspectives.

Hospitals are also a clear example: each unit operates its system locally, but central management requires a unified view. Bridgemeter allows all these systems to access, in real time and without conflicts, a single, reliable source of field data.

Full Integration: From the Factory Floor to the ERP

Bridgemeter 's integration capabilities extend far beyond SCADA systems. The platform acts as a strategic link between the Operational Technology (OT) Information Technology (IT) systems — connecting the factory floor directly to ERPs such as SAP, TOTVS, Oracle , and others.

Upon detecting an anomaly or a predefined operational trigger—such as a critical inventory inferred from the machine's usage pattern or a predictive maintenance condition based on vibration—the Bridgemeter can automatically trigger various workflows, such as:

• or purchase approval request
• Issue a purchase order for parts based on actual usage analysis and predictive need;
• Automatically update KPIs in Business Intelligence dashboards, promoting real-time visibility.

This OT/IT integration eliminates manual steps, accelerates response to operational events, and enables fully automated workflows , making Digital Transformation a tangible and measurable reality for the industry.

Bridgemeter: An Intelligent, Unified, and Connected Platform

Bridgemeter positions itself as a strategic solution for companies seeking to elevate their digital maturity. Below is a summary of the platform's main capabilities and differentiators:

• Universal Connectivity: Compatible with major industrial protocols (Modbus, OPC-UA, MQTT and others), it integrates with a wide variety of PLCs, sensors and equipment already installed on the market.
• Real-Time Data Consolidation: Centralizes and organizes information from multiple sources into a single, intuitive, and customizable interface, providing a 360° view of operations.
• Advanced Operational Intelligence: Goes beyond data visualization: applies algorithms and artificial intelligence to anticipate failures, generate intelligent alerts, and provide insights that traditional SCADA systems cannot deliver.
• Multi-SCADA Connectivity: Eliminates the technical limitation of exclusive connection to PLCs, allowing multiple supervisory systems to access the same data simultaneously, securely and stably.
• Native OT/IT Integration: Establishes a secure and efficient bridge between the factory floor and corporate systems (ERPs such as SAP, TOTVS, Oracle), automating critical workflows such as work orders, purchases, and KPI updates.

Conclusion: Maximize your SCADA system and advance your digital transformation

SCADA systems remain essential components for monitoring and controlling industrial processes. However, given the increasing challenges of efficiency, integration, and operational intelligence, it is necessary to go beyond simply visualizing data.

Bridgemeter , from Above-Net and enhances existing SCADA investments, adding predictive intelligence and addressing critical connectivity and integration limitations. The platform enables everything from meeting regulatory requirements to optimizing multi-site operations and full integration between the OT and IT worlds—fundamental pillars of Industry 4.0.

Don't just observe your data. Transform it into intelligent decisions. With Bridgemeter, your operation gains proactivity, enhanced connectivity, and a new dimension of digital value.

Want to discover how Bridgemeter can integrate and add intelligence to your existing SCADA infrastructure?

Speak with our experts and discover how to integrate intelligence into your current SCADA infrastructure. We are ready to help you overcome the barriers of the traditional model and accelerate your journey towards intelligent industrial automation.