Case note ABB drives cut lifecycle costs for Yorkshire Water

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While Yorkshire Water Services' specification for the new system would ... commissioned, the project is supported by an
Case note ABB drives cut lifecycle costs for Yorkshire Water

ABB medium voltage AC drives, ACS 2000, replaced a DC drive system at Yorkshire Water’s Blackburn Meadows water and sewage treatment works

Yorkshire Water supplies its customers with around 1.24 billion litres of drinking water each day as well as collecting, treating and disposing of about one billion litres of waste water safely back into the environment. The company operates over 700 water and sewage treatment works and 120 reservoirs and maintains 62,000 miles of water and sewerage mains. Yorkshire Water needed to upgrade the pumping control system at its Blackburn Meadows Wastewater Treatment Works in Sheffield. The site uses six pumps to transfer wastewater 25 metres below ground to the head of the treatment works. The existing DC drive system used dry-type cast-resin indoor transformers feeding DC drives controlling the DC motors.

No transformer needed The solution chosen included six ABB ACS 2000 drives, with motors rated at 2 x 645 kW, 2 x 505 kW and 2 x 300 kW. Medium voltage drives were selected instead of low voltage drives due to the long cable lengths and overall project costs including the electrical distribution system, variable-speed drives and motors. While Yorkshire Water Services’ specification for the new system would permit indoor transformers, they would need to be integrated into the new variable-speed drives and would, therefore, not be free-standing. The ACS 2000 was selected as it can be used without an input isolation transformer, thereby allowing a direct connection to the 6.6 kV line supply (direct-to-line). The active front end (AFE) enables the transformerless operation with reduced harmonic loadings.

Reduced costs Yorkshire Water is benefiting from lower energy consumption and reduced maintenance costs. The existing system was rated at 1750 kW, whereas the new system is reduced to 1450 kW. This means the overall operating capacity is lower but the flow characteristics and performance are much greater. The old system required a lot maintenance effort, with engineers needing to check the condition of the brushes on the DC motors at least every month. The new solution requires only an annual visit to each drive. Full engineering service As with most medium voltage projects of this nature, ABB provided a full engineering service. At the start of the project, ABB works with the customer and the end-user to provide the interface to the product, exactly as they need. In this project, the customer needed an additional earth switch and some Castell interlocks fitted, both of which ABB were able to provide. Once the solution is installed and the drive has been commissioned, the project is supported by an ABB service contract. This ensures a fast response to any problems on site to do any diagnostic or any repair work on the product itself.

Challenge – Update pumping control system for waste water plant – Upgrade form DC to AC based system Solution – Six ABB ACS 2000 drives controlling six AC motors – Transformerless solution – Customised scope to meet user’s exact needs – Service contract included – Training provided for staff Benefits – Transform less solution allows direct-to-line connection, cutting costs – Lower energy consumption – Lower heat losses – Reduced maintenance

For more information please contact: ABB Limited Daresbury Park Daresbury Warrington Cheshire WA4 4BT Tel: +44 (0) 1925 741 111 Fax: +44 (0) 1925 741 212 www.abb.co.uk/energy

© Copyright 2013 ABB. All rights reserved. Specifications subject to change without notice.

Ref: YW Blackburn Meadows Factfile/Sep2013

Highly modular drive “The ACS 2000 has a lot of benefits over drives from other companies in that it is very interactive and highly modular,” says David Batty of ETM, Aecom Design Build. “To change a component is very straight forward: you just pull out a drawer and put in a new drawer. Each of the drawer modules takes only about five minutes to change.