In this article, you will learn:
- what data from the SCADA system is useful for maintenance,
- what can be achieved by combining SCADA and CMMS.
SCADA systems, including AVEVA InTouch HMI, are mainly associated with production halls, visualization and process control, but their capabilities are much broader. InTouch, in combination with CMMS systems, opens new perspectives for technical departments, especially in maintenance management. It allows you to collect and use industrial data for automated monitoring, planning and process improvement.
Table of contents
What SCADA data is useful for maintenance?
AVEVA InTouch HMI communicates directly with sensors and machines using industrial protocols such as OPC UA, Modbus TCP/RTU, MQTT and Ethernet/IP. This allows for:
- collecting alarms and events (e.g. overheating, motor failure, thermal trip),
- counting the operating hours and number of cycles of equipment (pumps, mixers, compressors),
- collecting real-time machine operating parameters (temperature, pressure, speed),
- measuring energy and other media consumption (e.g. number of litres pumped).
This data is archived in AVEVA Historian, which allows for historical analysis and failure prediction.
InTouch also has its own REST API interface, which enables flexible and bidirectional integration with external systems such as CMMS. This allows not only data transfer but also control of system operations and confirmation of task completion.
Capabilities and mechanics of integrating InTouch SCADA with CMMS
Integration is easy and flexible because it is based on open standards and ready-made tools:
- The OPC UA protocol enables seamless real-time data exchange between systems.
- MQTT/Modbus offers a lightweight and fast way to transfer alarm and measurement information.
- REST API allows developers to create dedicated integrations, mapping any variables and triggering processes in CMMS.
How does such a connection work?
It requires preliminary mapping of technical objects, defining critical thresholds in SCADA, and configuring the CMMS API to automatically receive and process requests. This is a task that even an intermediate automation engineer should be able to handle.
- SCADA receives information from sensors and PLCs on machines (e.g., pump temperature or number of agitator cycles).
- When defined thresholds are exceeded or an alarm occurs, InTouch sends the appropriate signal/command to the CMMS system (e.g., repair order, inspection plan).
- CMMS generates a service request with a detailed description of the problem and a link to the specific device.
- After the repair, the status is updated in CMMS, and the update can be sent back to SCADA via API, closing the information loop and automatically updating the data for the visualization application.
What can be achieved by combining SCADA and CMMS?
Automation of service requests
Errors and alarms from machines (e.g. motor protection activation, pump leak, inverter overheating) immediately become orders in CMMS, eliminating delays and the risk of human error.
Planning based on meter data
CMMS automatically creates maintenance orders based on operating hours and cycles calculated by SCADA independently of the operator.
Example: after a pump has worked for 1,000 hours, an automatic maintenance order is generated approximately 48 hours before the limit is reached, with full historical data from InTouch.
Accurate OEE and MTBF reports
The data collected by the SCADA system goes directly into efficiency reports (OEE with micro-downtime times, accurate MTBF failure-free operation report) and allows you to quickly detect bottlenecks and implement data-driven countermeasures.
Analysis and optimization
Failure trends, consumption indicators and operating parameters (e.g. energy, flow, pressure peaks) are analyzed on an ongoing basis. This enables the implementation of predictive maintenance – predicting potential events and proposing solutions.
Implementation examples
- Waterworks: monitoring of submersible pumps, pumping stations, number of cycles and motor hours. SCADA transmits alarms about dry running, pressure drops or failures to CMMS Profesal Maintenance, which automatically creates reports for the maintenance department. In addition, reports show energy consumption and pump optimization.
- Chemical plant: data from dispensers and pneumatic valves (monitored by SCADA) generate automatic orders in CMMS Profesal Maintenance for preventive maintenance when thresholds are exceeded. The system also records temperature alarms and equipment failures, automating communication with the technical department.
The integration of the AVEVA InTouch HMI SCADA system with a CMMS system (e.g. Profesal Maintenance) is a modern solution that allows maintenance departments to achieve real process automation, accurate machine condition monitoring and effective activity planning. Open architecture, communication protocols and flexible APIs make this combination ideal for manufacturing plants seeking digital transformation and cost optimization.
If you are interested in how AVEVA InTouch HMI and CMMS Profesal Maintenance can help your technical department, please contact the author of this article.
