Municipal water
Water-pump station monitoring
Replacing a planned DCS expansion with edge nodes for predictive maintenance across twelve remote pump stations.
−$180k
vs the DCS expansion quote
~3 days
mean failure warning
12
stations on one open stack
01 /THE CHALLENGE
Remote pump stations had no condition monitoring; failures meant emergency call-outs and overflow risk.
The incumbent DCS vendor quoted a large expansion to bring the stations online — capital the utility didn't have.
02 /WHAT WE DID
The approach
01
A Node Mini gateway per station reads vibration, current and flow, bridging legacy RTUs to MQTT.
02
Vibration and current-signature models flag bearing and seal failures days ahead.
03
One open, documented stack across all twelve stations — no per-station vendor licensing.
03 /THE OUTCOME
What changed
✓Failures now warn roughly three days ahead, turning emergencies into scheduled maintenance.
✓The rollout cost a fraction of the DCS expansion and runs on hardware the utility owns.
✓Safety and control stayed on certified gear; the Pi layer is monitoring-only.
WHAT WE DEPLOYED
12× Hyleon Node MiniRTU / Modbus bridgePredictive-maintenance modelsCellular uplinkCentral dashboard
“We were quoted a $180k DCS expansion. Twelve edge nodes did the monitoring job for a fraction, and we own every layer.”
Operations Lead
Municipal water utility