INDUSTRIAL IOT AUTOMATION:

UPGRADING SCADA WITH IOT

INDUSTRIAL IOT AUTOMATION: UPGRADING SCADA WITH IOT

1
Introduction
Adoption of field management systems — also referred to as
supervisory control and data acquisition systems, or SCADA —
has exploded as enterprises seek solutions that allow legions of
field devices to be configured, maintained, and diagnosed from a
central location. In fact, according to Verified Research, the Field
Device Management Market size was valued at USD 1.24 Billion in
2020 and is projected to reach USD 1.82 Billion by 2028, growing
at a CAGR of 4.88%.1

Users across industries like energy and utilities, oil and gas,
metals and mining, and chemicals and pharmaceuticals are
utilizing smart field systems to monitor and control their devices
safely and remotely. Legacy protocols can create a reactive
and costly framework for any enterprise. But today, using
sophisticated field devices like sensors and controls enables
proactive and preventative monitoring and maintenance. In
the age of mass production and speedy product lifecycles,
sensor-based automation is crucial for optimizing assets already
installed in the field. An increase in adoption of these field
management systems has caused a drop in legacy technology use
and a massive uptick in automation and Internet of Things (IoT)
technology. In the Industrial IoT (IIoT), new technologies are ever Challenges with Industrial IoT Deployments
more robust to manage challenging conditions, while supporting Where does this leave automation engineers taking on enterprise-
the demand for extended communication range. scale IIoT projects? The most common barriers to starting IIoT
projects or converting to a new system are cost, security and
Legacy Industrial Solutions complexity.
Current legacy protocols simply cannot keep up with the rate at • Cost: Two of the biggest challenges that companies face when
which the IoT landscape is evolving. Modbus may come to mind starting an IIoT project are monetary and time costs. Traditional
when you think of "legacy" IIoT technology. Created in the 1970s, SCADA systems are very expensive and take months to configure
Modbus is the most highly deployed Industrial IoT protocol on for a company's specific needs as well as the added time of site
field devices like machinery, actuators and sophisticated sensors. deployment.
While this protocol offers attractive features such as no licensing When switching to a new system or software package, preparing
fees and easy deployment, Modbus comes with a number of for a learning curve and employee training time is inevitable.
limitations and security vulnerabilities. With a few exceptions, But choosing to stay with an insecure or outdated system will
Modbus is limited to how many devices it can address on one cost a company more in the long run for not meeting changing
data link and is limited by polling of slaves. Another challenge of business requirements. Legacy systems were designed with the
the Modbus protocol has traditionally been a lack of security from tools available at the time. Modern software comes with tools
outside data exploits. With cyberthreats increasing constantly, it that can help companies build more intelligent future-proof
is critical to leverage smarter and safer systems to connect your solutions that offer excellent ROI over time.
IoT devices and your enterprise's application platforms.

1
Field Device Management Market Size And Forecast
https://www.verifiedmarketresearch.com/product/field-device-management-market

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS

2
• Security: Traditional SCADA systems typically require a lot of • Wireless connectivity: Long Range Low Power Wide Area
middleware such as gateways, software, and licenses. The more Network (LoRaWAN) technology has become the fastest
middleware involved, the higher the risk of data accessibility, growing IoT connectivity standard and is fully supported by
and thus, a higher risk of a security breach. Industrial IoT Digi’s X-ON platform. Digi's Low Power Wide Area Network
protocols added security as an after-thought and often have (LPWAN) systems provide extended wireless range compared
none of these features enabled. to traditional monitoring systems like mesh or Wi-Fi. Whether
your company requires a new deployment or a retrofit, Digi can
• Complexity: A combination of complex technology
address your needs.
infrastructure, communications infrastructure, and immature
IoT standards creates a perfect storm for automation engineers. • Cost-effective: Tracking an entire supply chain of warehouses,
Additionally, standard SCADA and PLCs often require high distribution centers and manufacturing centers can be cost-
network bandwidth and cloud capacity to provide sub-second effective when using Low Power Wide Area Network systems.
monitoring. Avoid installing expensive copper for new installations and
wirelessly manage remote assets over multiple miles.
Digi XBee Intelligent Edge Controller vs.
SCADA • Short deployment time: What if your field deployment time
could be reduced by 95% over traditional SCADA and PLC
The Digi XBee® Intelligent Edge Controller (lEC) system brings
deployments? Legacy SCADA systems have a large footprint
together a networking architecture that closes the gap between
and can take multiple months to properly configure and
field devices and the cloud to provide powerful asset monitoring
deploy on site. Digi's systems can be deployed on site in mere
and control.
minutes, followed by remote, ongoing configuration. The key
• Seamless integration: The Digi XBee IEC system is compatible to shorter deployment times is simplified cloud/mobile-based
with 90% of the existing industrial sensors and machinery. provisioning and deployment testing.
It enables long-range wireless monitoring and control of
your industrial assets. The Digi X-ON cloud solution also
• Top-of-the-line security: IEC systems are built with Advanced
Encryption Standard (AES) security, so your company's data is
converts complex IIoT protocols into simplified data APIs so
safe from outside interference. Edge computing features create
communications can be disseminated easily to other tools and
a defined separation between data generated at the edge and
systems.
data generated in the cloud. This separation reduces the risk of
• Retrofit or new install security breaches during the transfer of data.

• Compatible with RS-485 and 4-20 mA sensors and controls

• Sub-second alarms and events

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS

3
• Improved efficiency: Digi XBee IEC edge compute technology the bandwidth and connectivity requirements that come with
improves responsiveness and capacity of your IIoT systems. traditional SCADA systems. The numbers speak for themselves:
Distributed agents monitor assets for faults and changes in real bandwidth and storage efficiency is improved by >99.7% with
time, adjacent to the asset. This proximity eliminates most of Digi XBee IEC solutions.

Traditional SCADA Systems Digi XBee Intelligent Edge Controller

Polling interval 15 min 0.1 seconds (or user-defined)
Capacity
Message size 100+ bytes 11 bytes
Cost Fiber/LTE ($$$$$) LPWAN ($)
Network Traffic High Low (99.99% reduction)
Security TLS AES encryption and rotating keys
Detection speed Delayed Rapid (sub-second)
Polling method Static polling interval Dynamic polling interval (on demand/rule-based)
Operational
Configuration On-site only Over-the-air (OTA)
Benefits
Deployment staging Required Not required
Installation Large and complex Small and simple (scan and go)

• Sub-second notifications: SCADA systems and PLCs require • Edge computing: The Digi X-ON platform provides edge
massive network bandwidth to provide sub-second monitoring computing capabilities to improve monitoring and alarm
needed to build a proactive environment. Meanwhile, Digi XBee reporting. The major benefit is increased network efficiency by
IEC brings sub-second notifications and control to the sensor only transmitting valuable information. An example is shown
and gateway level empowering sub-second monitoring at a below where the Digi XBee IEC or gateway can run intelligent
fraction of the cost and bandwidth of centralized SCADA / PLC edge rules to operate cloud-independent process control using
systems. wireless sensor input and wireless actuator control. When
sensors and control devices are connected via a single IEC,
this can be done locally. When sensors and control devices are
far apart, intelligent edge rules can be implemented on the
gateway.

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS

4
Digi XBee IEC System in Digi XBee IEC System in
Action: Case Study 1 Action: Case Study 2
Digi's system can empower enterprises across numerous A city in the north Dallas-Fort Worth area required a new solution
industrial use cases. Here are a few highlights of what the to provide monitoring and control of water towers and multiple
Intelligent Edge Controller system can do when deployed in pump stations. Digi XBee IEC was retrofitted to the existing system
verticals such as energy and utilities, oil and gas, metals and to provide remote monitoring and control, as well as important
mining, and chemicals and pharmaceuticals. historical data of the water usage information for regulatory
reporting.
Off-shore Oil and Gas Test Wells
Problem: An oil and gas company had a single-staffed offshore Smart City Water Management
platform with 22 surrounding unmanned platforms up to 20 Problem: For a water tower and pump deployment, a city needed
kilometers away that needed to schedule production testing for connectivity to two water towers and four pump locations that
their government regulatory agency. would provide monitoring and control functions. The city also
needed a basic dashboard for monitoring, control and historical
Approach: Digi stepped in to develop a system for offshore oil data.
and gas production. Digi XBee IEC was the smallest, lowest-power
option at the time. Using Digi X-ON, the test procedure workflow Approach: Digi developed a system for the city that was robust
was fully automated. Each IEC connected 11 different industrial in connectivity and monitoring features, but with an interface
control and monitoring devices, including actuated valves. simple enough for non-technical city employees to gather and
understand data.
Benefits:
• Retrofit to existing equipment Benefits:
• Converged utility network with multiple services
• Long-range secure wireless
• Automated water level/pump process control
• Real-time monitoring and control of pressure sensors and
actuators • Extended pump lifetime and reduced electricity consumption
• Simple installation • Real-time monitoring and control of water system status
• Dramatically reduced on-site visits • Real-time alerts and notifications
• Real-time detection of equipment failure or issue • Historical data for compliance reporting

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS

5
 within seconds. This is particularly important for measuring the
impact of weather, fires and accidents often before an outage
even occurs in an electrical transmission network.

• Previously not commercially feasible with SCADA or legacy O&M

systems deployed in high-value utility operators’ active stations.

Digi XBee IEC System in

Action: Additional Use Cases
Digi XBee IEC System in  EMOTE ASSET PREDICTIVE
R
Action: Case Study 3 MAINTENANCE —
Automated predictive and
The electricity transmission grids are increasingly becoming the
planned maintenance for
primary source of energy for transport, industry, commercial and
distributed assets using real-
retail as the economy decarbonizes. The increased demands on
time IoT data.
reliability are in stark contrast to the challenges in the industry of
remote, inaccessible infrastructure, increasing natural disasters
IOT/SCADA UPGRADE —
and an aging workforce.
Suitable for most traditional
industrial PLC systems as an
Electrical Grid Smart Operations
alternative to expensive SCADA
Problem: Traditionally, the electrical grid infrastructure is
solutions.
managed annually or on a post-incident, reactive basis. The
addition of Industrial Internet of Things (IIoT) monitoring WATER MANAGEMENT —
using Digi XBee IEC is revolutionizing electricity infrastructure, Water treatment plants currently
operations and maintenance. The goal of smart grid operations consume 1% of the United
is to increase reliability of the grid through proactive and reactive States' electrical grid. Manage
monitoring of the underlying infrastructure on a continuous basis. and optimize wastewater
treatment plants to save power.
Approach: Digi XBee IEC is being deployed for real-time
monitoring of electrical towers using maintenance drones. This
 IL AND GAS TANK FARMS —
O
makes it possible to perform upgrades and maintenance without
Monitor chemical or feed levels
switching off power or using expensive equipment and personnel,
in tanks in real time.
which saves costs and prevents loss of revenue.

UTILITIES —
Benefits:
Monitor remote assets, networks
• Integrated real-time sensing to monitor and report on tower
and tank levels in real time for
angle, vibration and shock in real-time.
optimized maintenance response
• Real-time status on towers, allowing utility customers the and reduced site visits.
ability to see where the network is under stress or has failed

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS

6
Why Digi? security using highly efficient network operations for mission-
critical functions such as mass configuration and firmware
Digi is a complete IoT solutions provider, supporting every updates, as well as system-wide monitoring with dashboards,
aspect of your project, from mission-critical communications alarms, and performance metrics.
equipment to design and deployment services to get your
application designed, installed, tested, and functioning Company Background
securely, reliably and at peak performance.
• Digi has been connecting the “Internet of Things” — devices,
Digi builds its products for high reliability, high performance, vehicles, equipment and assets – since 1985
security, scalability, and versatility so customers can expect • Digi is publicly traded on the NASDAQ stock exchange: DGII
extended service life, quickly adapt to evolving system
• Headquartered in the Twin Cities of Minnesota, Digi employs
requirements, and adopt future technologies as they
over 700 people globally, and has connected over 100 million
emerge. Digi embedded modules, routers, gateways, and
devices worldwide
infrastructure management solutions support the latest
connected applications across verticals, from the enterprise As an IoT solutions provider, Digi puts proven technology to work
to transportation, energy, industrial and smart cities use for our customers so they can light up networks and launch new
cases. products. Machine connectivity that’s relentlessly reliable, secure,
scalable and managed — and always comes through when you
Our solutions enable connectivity to standards-based and need it most. That’s Digi.
proprietary equipment, devices, and sensors, and ensure
reliable communications over virtually every form of wireless Learn more on our About Digi page.
or wired systems. Our integrated remote management
platform helps accelerate deployment and provide optimal

Contact a Digi expert and get started today

PH: 877-912-3444
www.digi.com

Digi International Worldwide Headquarters

9350 Excelsior Blvd. Suite 700
Hopkins, MN 55343

/digi.international @DigiDotCom /digi-international

© 2024 Digi International Inc. All rights reserved. 91004542 A5/1124

INDUSTRIAL
MISSION IOT COMMUNICATIONS
CRITICAL AUTOMATION: UPGRADING
FOR TRAFFICSCADA WITH IOT
MANAGEMENT SYSTEMS
While every reasonable effort has been made to ensure that this information is accurate, complete, and up-to-date, all information is provided “AS IS” without warranty of any kind.
We disclaim liability for any reliance on this information. All registered trademarks or trademarks are property of their respective owners. 7