VSD Retrofit for Storm Pump Station

Client: Anglian Water
Location: Stifford Corran Way
Date: 29 April 2026

The project involved the safe isolation, removal, and replacement of the existing VSD system, along with full installation and commissioning of a new drive.

Key tasks included:

• Isolation of the Storm Pump 2 control section
• Documentation of all existing electrical connections
• Removal of mains and motor cables from the faulty VSD
• Disconnection and removal of the existing control card
• Safe extraction of the faulty module using an overhead crane
• Delivery and positioning of the new ABB ACQ580 drive
• Installation of the new VSD into the MCC panel
• Reconnection of motor and control cabling
• Installation of new mains cabling from the switch fuse
• Fitting of a new keypad interface to the panel door

Once installed, the new drive was fully programmed and commissioned. The system was tested to ensure correct motor rotation and performance, including a controlled test run in hand mode under site supervision.

During commissioning, it was identified that the existing current transformer (CT) was undersized for the upgraded mains cabling. A replacement CT was recommended to ensure accurate current monitoring moving forward.

The retrofit was successfully completed within the scheduled timeframe, restoring full functionality to Storm Pump 2. The new VSD provides:

• Improved energy efficiency
• Enhanced control over pump operation
• Increased system reliability
• Future-ready compatibility with site infrastructure

This project highlights Gibbons Engineering Group’s capability to deliver end-to-end VSD retrofit solutions within the water industry. From safe isolation and removal through to installation, commissioning, and optimisation.