Overcoming SCADA Limitations: Multiple Intelligence and Connectivity with Bridgemeter

Introduction: The Essentiality and Challenges of SCADA Systems

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

However, despite its 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: Although SCADA systems are effective in 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 requires the manual mobilization of field teams for corrections 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 makes it difficult to share data simultaneously between multiple SCADA systems—especially in scenarios involving different departments, partner companies, or regulatory agencies—restricting collaboration and interoperability between systems.

It is in this context that a new, complementary approach becomes essential—acting as an analytical intelligence layer 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 secure information sharing across 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 may indicate that a motor's current has increased, it rarely tells you why this occurred 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 onset of clogging or bearing wear—something that would be difficult to detect with data analyzed alone.
• Predictive Fault Detection: Based on historical patterns and subtle deviations in operational behavior, the system identifies potential failures before they occur. This enables truly predictive maintenance, based on the actual condition of the equipment—not just fixed schedules.
• Intelligent and Targeted Alerts: Instead of overwhelming Operational Control Center (OCC) operators with dozens of simultaneous alarms, the platform sends contextualized and relevant alerts directed to the responsible teams—such as maintenance, operations, or engineering. These alerts are often accompanied by preliminary diagnostics, suggested actions, and associated technical documentation. Furthermore, the solution can be integrated with the work order system, automating the opening of calls and significantly reducing the OC's time and workload.

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

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

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

One of the most significant technical challenges in multi-stakeholder environments is the limited connectivity between field controllers (PLCs) and SCADA systems. In most industrial architectures, a PLC only allows one SCADA system to connect at a time—and any attempt to connect simultaneously from a second system usually disrupts communication with the first.

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

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

• Single Connection to the Field: Establishes a secure and stable connection with the PLC, avoiding external interference.
• Centralized Reading and Processing: Collects operational data in real time, processing it in an intermediate intelligence layer.
• Secure and Concurrent Distribution: Forwards 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 cross-system collaboration , 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 previously unfeasible applications and collaborations.

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 think. Below are two common scenarios in which this capability is essential:

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 agencies require real-time sharing of sensitive operational data (such as pressure at delivery points or levels in shared reservoirs).

In these cases, each company needs access to data from its neighbor's network—both upstream and downstream—to make assertive operational decisions. Bridgemeter enables this information exchange securely, stably, and privately, meeting legal requirements and avoiding penalties.

2) Multi-Site Operations or Departments with Different Needs

A corporation with multiple plants may 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 often need to access the same data from different perspectives.

Hospitals are also a clear example: each unit operates its own 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.

Total Integration: From the Factory Floor to 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.

By detecting an anomaly or predefined operational trigger—such as critical inventory inferred from machine usage patterns or a vibration-based predictive maintenance condition—Bridgemeter can automatically trigger various workflows, such as:

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

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

Bridgemeter: A Smart, Unified, and Connected Platform

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

• Universal Connectivity: Compatible with the main 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 in a single, intuitive, and customizable interface, providing a 360° view of the operation.
• Advanced Operational Intelligence: Goes beyond data visualization: it applies algorithms and artificial intelligence to anticipate failures, generate intelligent alerts, and provide insights that traditional SCADAs cannot deliver.
• Multi-SCADA Connectivity: Eliminates the technical limitation of exclusive connection to PLCs, allowing multiple supervisory systems to access the same data simultaneously, with security and stability.
• 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 flows such as work orders, purchases and KPI updates.

Conclusion: Boost your SCADA and Advance Digital Transformation

SCADA systems remain essential components for monitoring and controlling industrial processes. However, given the growing challenges of efficiency, integration, and operational intelligence, it's necessary to go beyond simple data visualization.

Above-Net 's Bridgemeter emerges as a strategic layer that expands and enhances existing SCADA investments, adding predictive intelligence and resolving critical connectivity and integration limitations. The platform enables everything from regulatory compliance to multi-site operations optimization and full integration between the OT and IT worlds—fundamental pillars of Industry 4.0.

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

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

Talk to our experts and learn how to integrate intelligence into your current SCADA infrastructure. We're ready to help you overcome the barriers of the traditional model and accelerate your journey toward intelligent industrial automation.