Summary:
Predictive maintenance is no longer an abstract goal, it's a practical reality. This blog outlines how utilities are phasing in continuous monitoring solutions with a scalable “crawl, walk, run” roadmap. Learn how to start small, build value, and position your utility for grid intelligence.
How Utilities Are Phasing in Continuous Monitoring to Unlock Long-Term Grid Intelligence
Every utility understands the value of predictive maintenance: fewer outages, lower costs, better asset performance. But turning that vision into action can feel overwhelming.
Where do you begin? How much change is needed? What about legacy infrastructure?
The good news: you don’t have to modernize everything at once.
Many leading utilities are adopting a crawl-walk-run approach to grid modernization. This phased strategy starts with simple thermal monitoring, builds toward multi-modal asset visibility, and ultimately enables predictive analytics, digital twins, and autonomous decision-making.
In this article, we will break down each phase of the roadmap, show how real utilities like Southern Company are using it, and explain how your utility can scale modernization with confidence.
The Crawl-Walk-Run Framework Explained
This strategy is outlined in the white paper "Beyond Manual Inspections: How Continuous Monitoring Systems Enable Proactive Grid Management." It was developed in response to the needs of utilities seeking to modernize without overwhelming field teams, breaking budgets, or disrupting existing operations.
Here’s how it works:
Step 1 - Crawl: Begin with Thermal Monitoring
Most utilities start by deploying thermal sensors on high-risk or high-value assets. These sensors provide real-time, non-contact temperature readings of:
- Transformer bushings
- Breaker terminals
- Switchgear connections
- Cables and buswork
This data is streamed every 60 seconds into SCADA or historian systems, offering a much higher fidelity than annual inspections.
Why it's low-risk:
- Minimal infrastructure changes
- Easy integration via IEC 61850 or Modbus
- Immediate return through fault detection and reduced truck rolls
Key benefits:
- Early detection of thermal anomalies
- Improved safety and awareness
- Less reliance on periodic manual inspections
Step 2 - Walk: Add Visual Monitoring and Cloud Intelligence
Once thermal data is flowing and field teams see the value, many utilities expand into visual monitoring.
Cameras with intelligent edge analytics are installed to capture:
- Physical damage (e.g., arcing, corrosion)
- Wildlife interference or vandalism
- Obstructed gauges or misaligned indicators
- Weather-related risks (flooding, ice, fire)
This stage also introduces cloud dashboards that aggregate sensor feeds, automate alerts, and allow centralized monitoring from anywhere.
Why it builds momentum:
- Visual data adds context to thermal anomalies
- Edge analytics reduces false alarms and improves response accuracy
- Centralized dashboards streamline operations
Key benefits:
- Multi-sensor correlation improves fault detection
- Remote verification reduces site visits
- Teams can prioritize maintenance based on real asset condition
Step 3 - Run: Enable Predictive Maintenance and Analytics
With thermal and visual monitoring in place, utilities can unlock the full potential of predictive operations. This phase enables:
- Trend analysis across fleets and asset classes
- Predictive alerts based on degradation patterns
- Digital twin integration for simulation and planning
- Semi-autonomous operations (e.g., automated fan activation or load rebalancing)
This is where continuous monitoring evolves from a tactical tool to a strategic capability.
Why it's transformative:
- Real-time and historical data empower AI tools
- Outage prevention becomes proactive, not reactive
- Maintenance becomes optimized and strategic
Key benefits:
- Reduced emergency maintenance
- Longer asset lifespans
- Foundation for grid automation and resilience
Real-World Results: Southern Company’s Crawl-Walk-Run Success
Southern Company used this phased approach to enhance substation operations and reduce manual inspections. Starting with thermal monitoring, they:
- Detected multiple faults in real time
- Prevented catastrophic flashovers
- Integrated monitoring into their PI System and CMMS
Now, instead of relying on annual inspections, their teams receive real-time alerts, complete with thermal images and asset metadata.
The result? Lower O&M costs, improved safety, and a foundation for predictive operations.
You Don’t Need a Full Overhaul to Get Started
One of the biggest barriers to modernization is perceived scale. But with the crawl-walk-run strategy, utilities can:
- Start with a pilot site or high-priority transformer
- Expand based on ROI and internal readiness
- Avoid overloading field teams or IT infrastructure
Deployment of SWI’s Touchless™ Monitoring solutions is designed to be incremental, with minimal disruption and immediate impact. Each phase delivers its own value while building toward long-term goals.
Why This Matters Now
Grid modernization isn’t a future project. It’s a present-day imperative.
- Aging infrastructure is becoming more vulnerable
- Skilled labor is becoming harder to find
- Regulatory and customer demands are increasing
Waiting means missed savings, higher risks, and lost ground to more proactive utilities.
Want to see how this roadmap works in practice? Download the white paper: "Beyond Manual Inspections: How Continuous Monitoring Systems Enable Proactive Grid Management" to explore the crawl-walk-run framework in detail, view real deployment outcomes, and begin planning your path to predictive maintenance.