Why Motor Load Monitoring Matters: Insights from Charter Controls' Exclusive Interview

Motor-driven assets remain the backbone of the UK water sector. Pumps, blowers, mixers, and screening equipment all rely on stable load conditions to operate efficiently and avoid costly failures. As operational pressures rise and sustainability targets tighten, engineers are increasingly turning to real-time motor load monitoring as a practical and measurable way to protect equipment and extend system life.

To explore this topic in more depth, PBSI visited Charter Controls to interview Malcolm Greenhill, who discussed why the industry is shifting from traditional overload protection to true power measurement, and how this provides deeper insight into both motor behaviour and the mechanical health of the driven load.

Why Load Monitoring Matters More Than Ever

The water sector is transitioning toward a more data-driven model of asset performance. With tighter regulatory expectations, a push toward net-zero, and increasing pressure to eliminate unplanned outages, engineers are demanding greater visibility over pumps and rotating machinery.

Traditional overloads protect motors from excessive current, but they do not detect:

• Dry-running pumps
• Blocked impellers
• Mechanical wear
• Cavitation conditions
• Bearing degradation

Real power-based monitoring, such as the Unipower HPL500 series, delivers a far clearer picture of the mechanical load by measuring the motor’s true absorbed power (kW). As Malcolm highlights in the interview, this allows early detection of mechanical issues long before thermal overloads react.

A Practical Step Toward Energy Efficiency

Energy consumption remains one of the sector’s largest operational costs. When pumps drift out of expected load conditions, inefficiencies escalate. By visualising the motor’s real-time load, engineers can identify:

• Partially blocked pumps
• Flow-related deviations
• Wear-induced loading changes
• Opportunities for optimisation

These insights support the water industry’s drive toward energy reduction and help meet sustainability commitments.

Reliable Protection for Critical Assets

Malcolm emphasises that utilities want protection that works every time, without overcomplicating commissioning. Real power-based load monitors deliver:

• Fast response to abnormal conditions
• No need for external sensors
• Stable, repeatable measurements
• Reduced maintenance interventions

The result is a significant reduction in unplanned downtime—something water companies prioritise during AMP cycles.

Our Commitment to the Water Sector

Charter Controls continues to support UK and Irish water companies with dependable monitoring solutions, comprehensive technical support, and next-day availability from UK stock.

To learn more about motor load monitoring solutions, including the Unipower Motor & Machine Protection, please contact our engineering team.

Frequently Asked Questions

What is motor load monitoring?

It is the measurement of a motor’s real power (kW) to detect abnormal mechanical load conditions such as dry-running, jams, and wear.

Why is load monitoring important for the water industry?

It prevents pump failures, reduces downtime, and improves energy efficiency across pumping stations and treatment works.

How is real power measurement different from overload protection?

Overload relays measure current; load monitors measure true absorbed power. This allows much earlier detection of mechanical issues.

Which products does Charter Controls offer for motor load monitoring?

The Unipower HPL500 range provides industry-leading real power monitoring for pumps, mixers, conveyors, and general rotating equipment.