Utility Monitoring

Three men wearing PPE gear viewing something on an iPad.

Interstates worked with a large consumer goods company on a solution for capturing data from utility W.A.G.E.S. (water, air, gas, electric, steam) meters. We started by walking through the plant’s distribution of water and electricity, documenting where meters were located and what potential network connectivity would be available if not already present. Once meters were connected to the plant’s network, we could then collect data off the meters at different collection frequencies. Data was stored in a time-series database for an intended duration of 400 days. This allowed the end users to have data to reference for over a year. Additionally, base statistics and event-driven captured data can be stored for a longer period of time.

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Interstates’ Utility Monitor Solution Key Features

Alerting when a value crosses a threshold for a period of time

Automated reporting on a timely basis, which allows for signature and operation input

Forecast utility consumption based on selected timeframes: monthly, quarterly, seasonally

Data collection and historization on a wide range of existing metering hardware


The biggest challenge on this project was getting all the meters connected to the plant network. Connecting all the meters provides the best opportunity to complete a full plant analysis. However, it may be impractical or difficult for each meter to be connected to the plant network. This could be due to switch locations, running cables, or the layout of the plant itself.


Interstates’ Utility Monitor services focuses on capturing data from networked W.A.G.E.S. meters connected to a manufacturing site. At this client’s site, Utility Monitor allowed them to keep a historical record of metered data and use it for advanced analysis such as anomaly detection, operation classifications, accountability to utility suppliers, and further understanding of consumption trends.

Our approach to setting up this solution is to first complete a network audit of existing and planned utility metering at a site. The intent is to outline utility distribution systems and provide a hierarchical utility flow diagram for data collection. This product partners with solutions our engineering team provides, such as additional site audits, like power or arc flash studies.

Return on Investment

Monitoring the current, voltage, power, and harmonic distortion of a utility switchgear can provide valuable information to a manufacturing site in several ways:

Power Quality Monitoring: By monitoring voltage and current, a manufacturing site can identify voltage sags, swells, interruptions, and harmonic distortions that can cause equipment damage and downtime. With real-time data on power quality, the site can take corrective actions to prevent equipment failures and improve productivity.

Energy Management: Monitoring power and current can provide insight into energy usage and help identify energy-saving opportunities. By analyzing the data, the plant owners and operators can determine the most efficient operating conditions and optimize the use of energy resources.

Load Management:
By monitoring the current, operators can identify peak demand periods and take steps to reduce the load during these times. This can help to avoid peak demand charges and reduce overall energy costs.

Equipment Maintenance:
Monitoring voltage and current can provide insight into the health of equipment and identify potential maintenance issues before they become major problems. This can help plant operators schedule maintenance more efficiently, reduce downtime, and extend the life of equipment.

Monitoring harmonic distortion can help plant maintenance personnel ensure compliance with regulatory standards for power quality. This may avoid penalties and legal issues related to non-compliance.

Overall, monitoring the current, voltage, power, and harmonic distortion of utility switchgear provides valuable insights to a manufacturing site, improving energy efficiency, reducing costs, and ensuring reliable equipment performance.

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