Project Description
Client: Anglian Water
Location: Wivenhoe, Essex
Date: April 2025
Project Type: VSD Upgrade & Control Panel Modifications
Products Used: x3 18.5kW ABB ACQ580 Variable Speed Drives
Overview
Gibbons Engineering Group recently completed VSD installation at a remote pumping station in Wivenhoe for Anglian Water. The project involved the installation of three 18.5kW ABB ACQ580 Variable Speed Drives (VSDs), designed to improve the energy efficiency and operational flexibility of the site’s pump systems.
Project Objectives
The upgrade was initiated to provide:
- Enhanced speed control of existing pump sets
- Soft ramp-up and ramp-down functionality to reduce mechanical stress
- Reliable sequencing and remote operation through telemetry integration
Challenges
One of the key challenges was the absence of electrical drawings for the site’s three existing pump control panels. This meant that all modifications had to be carefully planned and carried out with extra caution to ensure safety and system integrity.
Our Solution
Our engineering team mounted the new VSDs adjacent to each of the existing pump control panels. New cabling was installed in conduit between the VSDs and control panels, with all terminations carefully routed and labelled to allow for ease of future maintenance.
Each pump and VSD setup was individually tested for correct functionality in both Hand and Auto modes, and their operation was validated against telemetry inputs shown on the Anglian Water common control HMI screen.
This sequential approach ensured that:
- Each system was proven fully operational before progressing to the next
- The stop/start logic and sequencing of all three pumps worked seamlessly
- No disruption occurred to the site’s operational flow
Once commissioning was complete, a backup of the VSD parameters was taken and securely stored for future reference.
Ongoing Support
Gibbons Engineering Group is currently producing a complete set of electrical drawings to document the modifications made to the site. These will be provided alongside a comprehensive end-of-job report for Anglian Water’s records.
Outcome
The new VSD installation has resulted in improved pump efficiency, reduced mechanical wear, and enhanced control visibility for the client, with the added assurance of modern, documented infrastructure.
