Modernising the UK’s water infrastructure

The UK Government’s new Water (Special Measures) Bill is imposing stricter measures on water companies to tackle pollution, against the urgent need for companies to modernise outdated systems, meet tough environmental standards and boost service reliability. Here, David Strain, technical director at the systems integrator Technidrive, explains that the new water infrastructure will need advanced drive solutions, with high-efficiency motors and specialised gear units enhancing pump performance, reducing energy costs and ensuring system reliability to meet the Bill’s goals.

During the State Opening of Parliament in July, the King outlined the Government’s priorities, including the new Water (Special Measures) Bill aimed at improving water quality and infrastructure. This Bill gives the water regulator new powers to ban bonuses for executives if environmental standards are not met and increases accountability for water company leaders.

Secretary of State for Environment, Food and Rural Affairs, Steve Reed, stated the Government’s commitment to reducing sewage pollution in waterways: “We will never look the other way while water companies pump record levels of sewage into our rivers, lakes and seas.”

The Bill strengthens regulations, ensuring water companies deliver for customers and the environment while attracting private investment for mandated infrastructure upgrades. However, water companies will face several significant challenges in meeting the objectives set by the new Water (Special Measures) Bill, particularly in modernising outdated systems, meeting tough environmental standards and boosting service reliability.

Costs and technical complexities

Modernising outdated systems invites high costs. Upgrading old infrastructure demands significant financial investment, as water companies must allocate substantial funds for modernising treatment plants, pipelines and other essential systems.

The technical complexity of implementing new technologies and integrating them with existing systems adds another layer of difficulty. This includes adopting advanced sensors, automation and data analytics tools. Additionally, modernisation projects can lead to temporary disruptions in water supply and services, inconveniencing customers and requiring effective communication and mitigation strategies.

Achieving sustainability goals while maintaining cost efficiency is a delicate balance, as companies need to implement eco-friendly practices and technologies that do not compromise their financial viability.

Fortunately, the adoption of advanced drive solutions can greatly enhance new water infrastructure. Using high-efficiency motors and specialised gear units can boost pump performance, lower energy expenses and ensure reliable system operation — helping water companies achieve the Bill’s ambitious targets.

Variable control of pumps

When it comes to energy consumption, centrifugal pumps are among the guilty culprits. For sectors like oil, gas, water and wastewater treatment, pumps can consume more than 15 per cent of a facility’s total energy use. A common cause is the use of traditional fixed-speed motors in pumping applications, which run consistently regardless of actual demand.

For most industries, the demand for fluid flow varies over time. For instance, water treatment plants might experience lower demand during off-peak hours. Fixed-speed pumps are unable to adapt to these changes, leading to wasted energy and increased costs. Installing a variable speed drive (VSD) is a no-brainer to better manage energy consumption in pumps.

A VSD’s core functionality lies in adjusting the frequency and voltage supplied to the motor, enabling precise control over its rotational speed. This allows for variable control of the pump’s output, meaning it never runs at full power unnecessarily. Moreover, many VSDs now come with smart technologies that can collect and analyse data from the drive, motor and pump, allowing operators to monitor energy consumption in real-time.

These systems bring substantial benefits compared to soft starters — equipment that facilitates a gentle ramp-up of the motor speed during the start-up phase. Thanks to the ability to set specific parameters, VSDs are a far better option for energy savings. Energy savings can also be made by deploying intelligent control software alongside a drive system. This technology can control pump performance through real-time monitoring and adjustments. Metrics such as pressure and flow are measured to ensure the pump speed adjusts correctly and efficiently.

Global motor and drive manufacturer and Technidrive partner, WEG, offers the Pump Genius platform for these applications. The system is available in three versions, Pump Genius Simplex, Multiplex and Multipump — each for a different scale of pumping operations. The tool enables a standard VSD to become dedicated for pumping systems and provides operators with greater opportunities for improving reliability and saving costs.

By equipping the inverter with intelligent features, the system can detect issues such as dry pumps and pump cavitation remotely. Upon identification, the drive sends an automated alert to the operator via the HMI and can shut down the motor if necessary. Likewise, the system can also react in instances of increased demand. Should an application require a larger pump, the system can automatically instruct the jockey pump to pause to enable the larger pump to continue operations.

For systems operating multiple pumps, the Pump Genius Multiplex enables forced rotation to ensure equal use of all pumps on site. Not only does this improve overall efficiency but it reduces excessive wear and tear on individual pieces of equipment.

Following installation, the efficiency of a pump should also be monitored over time since its overall effectiveness is likely to reduce. Regular maintenance, such as identifying and addressing leaks, clogs and other issues promptly, will ensure that the system is operating optimally. Again, using smart technologies to monitor the system digitally can give operators insight into efficiency. Another key advantage of WEG’s Pump Genius is its ability to perform some maintenance automatically. Cleaning of the impeller, also known as deragging, is particularly important in wastewater settings — both for pump efficiency, maintenance and spillage control.

Sustainable water management

As an example, let’s consider wet material processing in quarries. Such applications can face persistent issues in sludge settlement that can disrupt operations and pose significant risks of equipment damage, production downtime and increased maintenance during restart attempts.

A solution like WEG’s advanced Pump Genius software can be used to address these issues. WEG’s Pump Genius is a sophisticated pump process control software that offers enhanced system operation efficiency and reliability while reducing maintenance costs. This software is highly versatile and can be applied to any pump system requiring constant flow or pressure control. By integrating directly with the WEG CFW11 drive, Pump Genius eliminates the need for costly control panels and reduces overall installation costs.

The software supports both simplex and multiplex pump control, which is important for ensuring even wear and extending the lifespan of pump systems. It can manage up to five pumps, cycling them based on accumulated run times to distribute the workload evenly. This real-time monitoring and protection significantly reduce the risks of pump failure and the associated maintenance costs.

Furthermore, Pump Genius enhances energy efficiency by adjusting pump speed to meet system requirements, leading to substantial reductions in energy consumption. In wet material processing applications, the implementation of Pump Genius in the quarry thickener can allow for real-time adjustments of motor speeds based on dynamic data, ensuring optimal performance and preventing overload conditions.

Continuous monitoring of system parameters by the software can ensure efficient sediment settling and consistent water recycling, protecting the equipment from damage and improving overall process efficiency. In such an instance, Pump Genius can help reduce downtime and maintenance, supporting a proactive approach to sustainable water management.

The demands of the UK Government’s Water (Special Measures) Bill for companies to modernise their systems and reduce pollution will highlight the importance of high-efficiency motors and specialised gear units for improving pump performance and cutting energy costs. While these upgrades are costly, technologies like VSDs and intelligent control software will be essential for meeting new environmental standards and ensuring reliable service. These solutions will help water companies comply with regulations and support sustainable water management.

For more information on how advanced automation technologies are enhancing water resource resilience, visit Technidrive’s website.