Modern pumps, SCADA automation, VFD controls, remote monitoring, and backup power transformed a 1947-era facility into a resilient stormwater management system designed for decades of reliable operation.

The transformation of Saginaw County Michigan’s Gage Drain Pump Station demonstrates what’s possible when aging stormwater infrastructure meets modern automation.

Once reliant on time-consuming manual inspections, unsafe confined-space entry and deteriorating electrical equipment, the nearly 80-year-old facility is now a fully remotely operable stormwater management system. Powered by advanced pumps, SCADA technology, remote monitoring, and backup power, the upgraded station delivers greater reliability, improved safety, and stronger flood resilience for a 4,500-acre watershed.

Designed by Spicer Group and supported by Kennedy Industries, the project turned an aging, high-risk facility into a modern stormwater asset built for long-term performance.

Completed in December 2024, the project transformed a declining facility originally built in 1947 into a modern, data-driven operation capable of monitoring and responding to changing stormwater conditions in real time. Kennedy Industries supplied and commissioned critical components including the KISM SCADA system, Cascade axial-flow pumps, motor control center, instrumentation, and monitoring technologies that now enable operators to manage the station remotely while reducing maintenance demands and operational risk.

For municipal utilities evaluating aging infrastructure, the Gage Drain Pump Station upgrade offers a compelling example of how pump station automation, remote monitoring solutions, and modern controls can strengthen stormwater infrastructure resilience, improve operator safety, and support long-term asset management goals.

From Manual Operations to Remote Control

For nearly eight decades, the Gage Drain Pump Station played a critical role in managing stormwater runoff throughout a watershed that encompasses farmland, residential neighborhoods, industrial facilities including Nexteer, as well as key transportation corridors including I-75, M13, M46, M81, and active rail lines.

By the time modernization efforts began, however, the facility had reached the limits of its operational life. Repeated Saginaw River flooding had corroded key infrastructure components, electrical systems had deteriorated, and maintenance activities posed increasing safety concerns. Operators lacked remote visibility into system performance and were required to conduct manual inspections to assess operating conditions.

Maintenance was particularly challenging. The original station design required removing the roof for pump service, creating labor-intensive maintenance procedures and increasing operational downtime. Combined with the absence of automation and remote monitoring capabilities, the aging facility could no longer provide the level of reliability required for modern municipal stormwater management.

Engineering a Modern Stormwater Management System

Recognizing the need for a long-term solution, the Saginaw County Public Works Commission engaged Spicer Group in 2016 to develop a modernization strategy focused on reliability, safety, and operational efficiency. The resulting design incorporated many of today’s leading stormwater infrastructure resilience strategies, including automation, remote monitoring, redundancy, and improved maintainability.

The project included:

• Construction of a new pump station building
• Installation of a self-cleaning trash rack system
• Three new 150 HP Cascade Axial Flow Pumps
• A Primex Motor Control Center with Variable Frequency Drives (VFDs)
• Kennedy Industries’ KISM SCADA System
• A 500 kW standby generator
• Advanced instrumentation and monitoring technologies

Throughout the project, Kennedy Industries collaborated closely with Spicer Group and county stakeholders to supply, integrate, and commission the pumping, controls, instrumentation, and automation systems that serve as the foundation of the station’s new remote operating capabilities.

How SCADA Improves Municipal Pump Station Operations

At the heart of the modernization is the implementation of the Kennedy Industries KISM SCADA System, which gives operators real-time visibility into pump station performance and allows key operational functions to be monitored and controlled remotely.

For utilities evaluating how SCADA improves municipal pump station operations, the benefits are substantial:

• Real-time system monitoring
• Remote operational control
• Faster response to alarm conditions
• Reduced field visits
• Improved operational oversight
• Enhanced asset management
• Increased reliability during storm events

These capabilities have fundamentally changed how the Gage Drain Pump Station is operated. Rather than relying solely on routine site visits and manual checks, operators now have immediate access to critical system information, allowing faster decision-making and more proactive management of stormwater infrastructure.

As staffing challenges continue to affect public works agencies across North America, remote monitoring solutions for pump stations are becoming increasingly important tools for improving operational efficiency and maximizing available resources.

Advanced Pumping Technology Drives Reliability

The modernization project also included installation of three new 150 HP Cascade Axial Flow Pumps equipped with inverter-duty motors. These pumps provide the capacity needed to manage stormwater flows throughout the watershed while delivering greater operational flexibility through integrated VFD technology.

How VFDs Improve Pump Station Efficiency

One of the most frequently asked questions among engineers and operators evaluating modernization projects is: How do VFDs improve pump station efficiency?

Variable Frequency Drives allow pump speeds to automatically adjust based on system demand rather than operating at full speed continuously. Benefits include:

• Lower energy consumption
• Reduced equipment wear
• Improved hydraulic performance
• Lower maintenance costs
• Extended asset life
• Enhanced operational flexibility

These advantages make VFDs a critical component of modern stormwater pumping solutions and pump station modernization projects.

Building Resilience Into Critical Infrastructure

Across the water and wastewater industry, communities are increasingly investing in infrastructure that can withstand severe weather events and support long-term operational sustainability.

The upgraded Gage Drain Pump Station demonstrates how municipalities can improve critical infrastructure resilience through strategic investment in modern equipment and controls. The project incorporates multiple layers of redundancy and operational safeguards, including:

• Backup power generation
• Redundant monitoring technologies
• Radar level instrumentation
• Pressure transducers
• Float systems
• Monitoring cameras
• Weather station integration

The facility also includes three Flygt mixers designed to reduce ice buildup and maintain year-round performance, as well as Fontaine flap gates, DeZurik valves, and other critical infrastructure components that contribute to long-term reliability.

Together, these improvements help protect residents, businesses, industrial facilities, and transportation networks throughout the watershed while supporting broader flood mitigation infrastructure objectives.

ESG Highlights: Delivering Measurable Value

The Pump Station modernization also delivers significant Environmental, Social, and Governance (ESG) benefits.

Environmental

• Improved stormwater management protects surrounding waterways and ecosystems.
• VFD technology helps reduce energy consumption.
• Enhanced flood management reduces environmental impacts associated with uncontrolled runoff.
• Modern instrumentation supports more efficient system operation.

Social

• Improved flood resilience protects homes, businesses, and public infrastructure.
• Enhanced maintenance access improves worker safety.
• Reduced confined-space maintenance requirements lower operational risk.
• Reliable stormwater management supports community resilience during severe weather events.

Governance

• SCADA-enabled monitoring improves operational transparency.
• Remote visibility supports better decision-making and asset management.
• Redundant monitoring systems improve reliability and risk management.
• Modern controls support long-term infrastructure planning objectives.

These municipal infrastructure ESG benefits increasingly influence how communities prioritize infrastructure investments and evaluate project success.

Recognized for Excellence

The success of the project has already earned industry recognition. The upgraded Gage Drain Pump Station received the Michigan Association of County Drain Commissioners 2025 Award, highlighting its innovative approach to stormwater infrastructure modernization and public service.

The recognition reinforces the project’s status as an award-winning stormwater infrastructure project and a model for municipalities considering similar upgrades.

A Blueprint for Future Pump Station Modernization

The Gage Drain Pump Station upgrade demonstrates that modernizing aging infrastructure is about more than replacing stormwater management equipment. It is about fundamentally improving how critical assets are operated, maintained, and managed.

By transforming a manually operated facility into a remotely operable stormwater management system, Saginaw County has improved reliability, enhanced safety, strengthened flood resilience, and positioned the station to serve the region for decades to come. For municipal operators, engineers, contractors, and public works leaders, the project offers a compelling example of how automation, remote monitoring, and modern pumping technologies can deliver measurable operational and financial benefits.

Frequently Asked Questions

What was the primary goal of the Gage Drain Pump Station modernization?

The project aimed to replace aging infrastructure and transform the facility into a remotely operable stormwater management system with improved reliability, safety, and operational efficiency.

What role did Kennedy Industries play in the project?

Kennedy Industries supplied and commissioned critical equipment including the KISM SCADA system, Cascade axial-flow pumps, motor control center, instrumentation, monitoring technologies, and control systems.

How does remote monitoring improve pump station operations?

Remote monitoring provides operators with real-time visibility into system performance, enables faster response to changing conditions, reduces field visits, and improves overall operational efficiency.

Why were VFDs included in the upgrade?

Variable Frequency Drives improve energy efficiency, reduce equipment wear, optimize pump performance, and extend equipment life by matching motor speed to system demand.

What infrastructure supports year-round reliability?

The upgraded station includes backup power generation, Flygt mixers to reduce ice buildup, redundant monitoring systems, weather monitoring, and advanced controls that help maintain reliable operation throughout the year.

Learn More About Pump Station Modernization

Municipalities, engineering firms, and contractors looking to improve reliability, enhance operational visibility, and strengthen stormwater infrastructure resilience can benefit from the expertise Kennedy Industries brings to every project.

From advanced pumping systems and SCADA integration to instrumentation, controls, and field services, Kennedy Industries helps utilities modernize critical infrastructure with solutions designed for long-term performance.

Learn More

To learn more about pump station modernization, remote monitoring technologies, stormwater pumping solutions, and SCADA systems, visit www.kennedyind.com or contact Kennedy Industries today.

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