From Voltage Drops to Stable Operation: Vector VS Technologies Strengthening Critical Infrastructure

On February 19, Energy Club will host the Energy Freedom online talk show “Networks Under Fire: Technological Solutions for the Resilience of Ukrainian DSOs”, dedicated to practical technologies for increasing the reliability and adaptability of energy infrastructure under wartime challenges. Among the speakers is Stanislav Maliborsky, Product Manager of the “Industrial Automation” direction at Vector VS, who will present solutions for modernizing pumping stations using frequency converters and soft starters.

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Stanislav Maliborsky

In an interview with the Energy Club media department, he discussed the key risks to pumping equipment under unstable power supply conditions, the practical advantages of using modern motor control tools to prevent accidents and water hammers, the possibilities for phased modernization of existing facilities without large-scale reconstruction, the economic impact of automation, and the role of industrial technologies in ensuring the resilience of life-support systems during crisis situations.

– Mr. Maliborsky, your presentation focuses on the modernization of pumping stations. What are the key problems that arise in their operation under unstable or damaged power grids?

– The main challenge is the mismatch between power supply parameters and equipment requirements. When operating from backup sources (generators, cogeneration units) or a damaged grid, several issues occur:

• Startup overloads: Inrush currents during direct motor starts are 5–7 times higher than nominal, causing critical voltage “sags” or generator shutdowns.
• Frequency instability: This leads to motor winding overheating and premature equipment failure.
• Water hammers: Sudden stops and starts due to voltage interruptions destroy stop valves and pipelines.
• Operating voltage drops: Reduced voltage leads to increased current and motor failure.

– How does the use of frequency converters and soft starters help ensure stable water supply and reduce the risks of accidents or downtime?

• Soft Starters (SS): They minimize startup currents, ensuring a smooth acceleration of the motor. This allows for the use of lower power (and lower cost) generators.
• Variable Frequency Drives (VFD): In addition to the benefits provided by soft starters, VFDs allow for precise pressure maintenance in the system by adapting motor speeds to actual water consumption. This completely eliminates water hammers and ensures a stable water supply even with fluctuations in input voltage.

– How complex is the implementation of such solutions at already operating facilities—does it require large-scale modernization, or are gradual integration steps possible?

– We offer a flexible approach depending on the community’s budget:

• Spot modernization: You can start with the most critical or energy-intensive nodes. Installing a VFD on even one main pump already yields a noticeable result.
• Comprehensive approach: Full replacement of control systems. Modern solutions integrate easily into existing circuits without the need for a complete replacement of the pumping units themselves.

– Equipment automation is also a matter of energy efficiency. What economic effect or optimization of electricity consumption can infrastructure operators expect from these technologies?

– Automation is an investment that returns exceptionally quickly. On outdated facilities without automation tools, investments in new equipment typically pay back within approximately 12 months.

– Speaking more broadly about the resilience of critical infrastructure: what role, in your opinion, does industrial automation play in the reliability of life-support systems during crisis situations?

– Electric motors consume about 70% of all electricity in the industrial and utility sectors. In a time of energy crisis, every percentage of savings means:

1. Grid unloading: Reducing the power deficit on a national scale.
2. Autonomy: The ability to operate longer on batteries or a limited supply of generator fuel.
3. Survivability: Automated systems can respond independently to emergency situations, preventing failures from cascading at times when human resources are limited.

The participation of industry experts in the Energy Club talk show highlights the growing attention to applied technological solutions capable of increasing infrastructure resilience under unstable power supply. The presented approaches to pumping station modernization demonstrate that automation and professional electric drive management can not only reduce accident rates and energy costs but also strengthen the autonomy of water supply systems—one of the key elements of community life support.