Sheboygan Regional Wastewater has five remote wastewater pumping stations throughout the city of Sheboyganwww.cechina.cn, WI. These pumping stations are monitored remotely with a SCADA system that does not monitor motor load conditions. ThereforeCONTROL ENGINEERING China版权所有, maintenance personnel routinely go 30 ft. below ground to check the health of the pumps and motors.
　　“The average daily flow at the facility is about 11 million gallons,” explains Dale Doerr, Sheboygan Regional Wastewater superintendent. “If we have a rain event or substantial snow melt, we can reach peak flows of 64 million gallons. This makes it essential for all our pumps to operate at capacity, to ensure that we can manage the increased flow levels and avoid adverse sewer problems for the 68,000 people we serve.”

www.cechina.cn, Sheboygan Regional Wastewater monitored its pumping stations remotely with a SCADA system, but the system was unable to detect motor load conditions. The facility turned to overload and monitoring relays to obtain real-time information." src="http://www.cechina.cn/upload/article/c6900e5f-a339-4fdf-800b-58cb370dec00/1.jpg">

　　With its pumps typically located 30 ft. below groundwww.cechina.cn, Sheboygan Regional Wastewater monitored its pumping stations remotely with a SCADA system, but the system was unable to detect motor load conditions.  The facility turned to overload and monitoring relays to obtain real-time information.
　　If a pump is partially restrained, the pump and motor would still run, albeit inefficiently, until the bi-metallic overloads eventually trip. This happens if current draw is sustained at a level above 115% full load amperage (FLA) for a period of time.
　　Lift station retrofit
　　With this motor issue in mind, Doerr looked into using Eaton’s Motor Insight overload relay. Eaton explained that these relays would allow Sheboygan Regional to monitor its entire system including line, loadwww.cechina.cn, and motor from a headquarters location, thus avoiding the manual pump checks. With real-time data, maintenance personnel would only need to be sent to a location when data suggested there was a problem.
　　Sheboygan Regional agreed to be a beta site and retrofit its Indiana Avenue lift station with Motor Insight relays, remote displays控制工程网版权所有, and Modbus communication modules on the station’s three 60 hp pump motors.
　　Impact of early detection
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