How to Reduce Power Consumption of Pumping Stations by 5 Times: Solutions from Vector VS

05.03.2026

On February 19, 2026, the online talk show “NETWORKS IN SPOTLIGHT: Technological solutions for the sustainability of Ukrainian DSOs” took place. During the event, experts discussed not only power generation but also ways to radically reduce energy consumption by critical infrastructure.Stanislav Maliborsky, Product Manager of the “Industrial Automation” direction at Vector VS, presented effective solutions for modernizing pumping stations and water supply systems under unstable grid conditions.

Electric motors are the heart of any utility company (water utilities, heating networks, ventilation). They consume the lion’s share of all electricity on the market. Reducing their energy consumption by even 1% allows for the release of capacity to power thousands of additional consumers.

The Problem of Classical (Direct) Motor Startup

Traditionally, at many old facilities, electric motors are connected directly or using a “star-delta” scheme. This creates a series of critical problems:

• Enormous inrush currents: At the moment of startup, the current can exceed the nominal value by 8 times.
• Grid overload: A sharp voltage spike negatively affects other equipment and consumers (e.g., residential buildings) connected to the same substation.
• Mechanical wear: A sudden start creates water hammers in pipes and quickly wears out the pump mechanics.
• Problems with generators: To start a pump via direct-on-line start from a generator during a blackout, a generator with a massive (and expensive) power reserve is required, which will only be used in the first seconds of operation. Otherwise, the generator will simply “go into protection” and shut down.

Solution 1: Soft Starters (SS)

To solve the problem of peak loads, Vector VS offers soft starters from the British brand Motortronics. A soft starter reduces the inrush current from 8-fold to 2–3-fold. This makes the mechanism’s start “soft,” eliminates water hammers, and allows for the use of generators with significantly lower power ratings. The flagship VMX Synergy line is additionally equipped with an energy-saving algorithm. As Vector VS tests on a 23-kilowatt motor showed, this algorithm saved nearly 1.7 kW of power that was previously lost to heat.

Solution 2: Variable Frequency Drives (VFD)

While a soft starter is only needed for a correct startup, a frequency converter (VFD) provides full motor control 24/7. In a classical pumping station, the pump operates at full power (on/off), regardless of how much water the city actually consumes at that moment. A frequency converter with a connected pressure sensor measures the actual pressure in the system and automatically accelerates or slows down the pump according to real consumption.

The company offers the VDN (general purpose) and VDI (specialized for pumps/fans up to 250 kW) lines. Features of VFDs from Vector VS include:

• Localization: Fully Ukrainian-language interface (LCD display) and configuration software.
• EMC Filters (Category C1): The strictest European requirements, allowing industrial VFDs to be safely installed in the same network as household appliances.
• Specialized functions for water utilities: Functions such as “pump cleaning” for pipe blockages or “winter mode,” where water circulates slightly via a timer to prevent pipeline icing.
• Residential solutions: Single-phase converters allow for the efficient powering of heating circulation pumps in private houses from charging stations like EcoFlow.

Real Case Study: Payback in 9 Months

Stanislav Maliborsky cited an example from an energy audit in a city in the Dnipropetrovsk region. The pumping station operated old, powerful motors (over 600 kW) in an “on/off” mode. After implementing regulation using frequency converters, electricity consumption was reduced by almost 5 times. In annual terms, the savings for the utility company amounted to about 3,500 MWh. In this specific case, the full payback period for the modernization was just 9 months.

Vector VS offers professional energy audits for enterprises, providing clear payback calculations and the selection of optimal equipment for modernization.