Optimization of pumping station operation using a variable frequency drive system

M.Y. Ikimbayev, A.T. Tikebayev

2025

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DOI 10.37878/2708-0080/2025-6.15
Data confidence 70 medium
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Abstract

This article presents the results of a study on optimizing pumping station operation using variable frequency drive (VFD) systems. An analysis of technical, operational, and economic factors demonstrates the high efficiency of VFD implementation for stations with variable loads. Practical application of the discussed methods using the NS-5 pumping station (Almaty) as an example demonstrated significant improvements in key performance indicators: specific energy consumption was reduced by 32.4% (from 1.45 to 0.98 kWh/m³), the number of emergency shutdowns was reduced by 87.5%, and the period between repairs was increased from 6 to 18 months. The economic benefit from implementation for a 100-kW station amounted to approximately 18.5 million tenge per year, with a payback period of 1.35 years. The paper systematizes the criteria for selecting and configuring VFDs, proposes a PID controller tuning algorithm, and a decision matrix for selecting the optimal control system configuration (single pump with VFD, cascade control, all pumps with VFDs) based on the station's characteristics. Promising areas for technology development are identified, including integration with Industrial Internet of Things (IIoT) systems and the use of artificial intelligence algorithms for predictive optimization of operating modes. The research results can be used in developing industry energy efficiency standards, creating energy-saving programs, and in educational programs for training engineering personnel. The widespread implementation of VFDs at pumping stations in Kazakhstan has the potential to save 1.2–1.5 billion kWh of electricity annually.