Water availability is a global requirement; however, ensuring it is managed effectively on a local level worldwide is a significant challenge. The water and wastewater industries consume 4% of global electrical energy, which is equivalent to Australia’s total energy consumption. Given the persistently high and growing cost of energy, waterworks must meet increasing demand, operate as efficiently as possible, and strive to achieve Net Zero.
ABB’s product portfolio, featuring digitalisation, automation and measurement solutions, provides more efficient and sustainable operations that support local water cycle performance, regardless of the situation. This blog explores the most prominent ABB products used in industrial water works and water treatment facilities and how they support efficiency in water systems.
ABB’s role in hospitals extends far beyond the mechanical, as their products control hospital-wide ventilation and keep lab automation operating with surgical precision. Their motors and drives support the very systems that enable healthcare professionals to do their work with confidence.
Waterworks and Wastewater Treatment Challenges
As demand for clean water grows, waterworks and wastewater treatment facilities face the pressure of delivering more, often with less. Many water facilities still function with outdated manual processes and fragmented systems, and this lack of integration limits visibility and makes maintenance difficult and repairs slow. Much of the current infrastructure is decades old, with ageing pipes and inefficient pumps that contribute to water loss and higher energy bills, making modernisation a pressing concern.
ABB Solutions for Water Systems Management
The pressures on modern water systems are undeniable, but with the right technologies, they are also highly solvable. Pumps and other motor-driven applications all use energy, and optimising their procedures while maintaining their dependability is key to improving water systems. ABB is actively helping utilities and treatment facilities address critical infrastructure and energy challenges with scalable solutions tailored for the water sector.
ABB Variable Speed Drives Modernise Infrastructure
ABB’s variable speed drives (VSDs) and high-efficiency motors are valuable tools for upgrading outdated infrastructure, as integrating them does not require a complete system overhaul. Many older treatment plants rely on pumps and fans that operate without sophisticated speed control, which means they run at a constant speed; however, very few applications require this. Being able to adjust the motor’s speed based on real demand can save a significant amount of energy, up to 50% in some situations. ABB’s VSDs are a relatively inexpensive solution that allows operators to adjust motor speeds in real-time based on actual demand, to reduce energy consumption and lower operational costs.
For example, ABB’s ACQ580 drive is specifically engineered for water and wastewater applications and features built-in pump-cleaning, soft pipe fill, and level control functions. These enhancements allow older systems to run more efficiently with relatively simple upgrades.
Water and Energy Saving
One of the most important aspects of water management is making sure that water processing facilities operate as effectively as possible. ABB utilises control systems and process automation to enable water facilities to operate at their optimal level. For larger facilities, the ABB Ability System 800xA distributed control system can integrate all plant-wide control systems, which allows engineers to have precise control over intricate processes, such as desalination, from a single command centre. This allows for fast response and coordinated action during weather-related events such as flooding or plant overloads.
ABB variable speed drives can reduce energy usage by up to 50% in pumping applications, which contribute a significant portion of power consumption in the water treatment industry. Additionally, ABB motors, especially those meeting IE3 and IE4 premium efficiency standards, offer superior energy performance with low lifecycle costs.
In wastewater treatment plants, ABB’s Ability Smart Solution for Wastewater enables continuous performance monitoring and process optimisation. By analysing real-time data from across the facility, this system helps operators to fine-tune aeration and pumping processes, which are the biggest energy consumers, to achieve energy reductions of up to 25%.
Supporting Scalability
ABB understands that many utilities operate under tight budget constraints. That’s why many of its water solutions are designed for easy retrofit and a fast return on investment. For example, replacing a fixed-speed motor with a high-efficiency motor and VSD can dramatically improve performance without the need to redesign the entire system. ABB also provides simulation tools and engineering support to help operators identify where upgrades will have the greatest impact, so funds are spent wisely and results are measurable.
Facilities that supply water in urbanised areas need to maintain reliability even when they are making improvements to their systems. ABB’s automation and control systems support modular growth and integration into existing networks. The ABB Ability Symphony Plus SCADA platform is particularly well-suited for this, offering remote and distributed control solutions that can manage complex and geographically diverse systems.
ABB Maintenance Solutions
Bridging the Digitalisation Gap
ABB offers a range of digital solutions that connect people, assets, and processes, closing the digital divide that many utilities face. ABB Ability digital services collect and analyse performance data from drives, motors, and control systems, and deliver actionable insights to improve efficiency. Importantly, these solutions are designed to be user-friendly and modular so that they can be accessible for plants with limited technical resources or budgets. ABB’s condition monitoring and remote access tools give operators real-time visibility into system health and performance from any location.
Condition Monitoring
Condition monitoring is a growing modern maintenance strategy, and ABB’s drives have been using it for years. As well as controlling a pump motor, a drive can constantly monitor how that motor is performing. Some advanced drives also track the condition of other connected components, like gearboxes or bearings, giving operators a clearer picture of the whole system.
An innovative feature built into ABB’s variable speed drives is the ability to create a “torque curve” during setup. This curve shows the normal range of torque on the motor shaft at different speeds. Once the drive knows this baseline, it can monitor actual torque during operation and spot when it goes outside expected limits. If this happens, the drive can send an alert to the system controller to prompt further inspection. This is all accomplished without requiring additional sensors, as the drive itself handles monitoring using its built-in intelligence.
Early Detection and Prevention
Leaks in water distribution networks, which are often undetected, make it more challenging to provide sufficient potable water for everyone. ABB’s AquaMaster electromagnetic flowmeters measure and record water flow data in real time to pinpoint the precise amount of water flowing through a pipe. These flowmeters are dispersed within a distribution network’s pipes and identify changes in flow or small leaks that could lead to water loss.
ABB Water Solutions from Beta Power Engineering
ABB understands the real-world pressures facing the water industry and is helping to tackle them head-on. With professional knowledge of how the sector operates and a catalogue of smart, forward-thinking technologies, ABB is not just offering equipment; it is providing real support. By combining industry expertise with innovative technology, ABB helps water and wastewater facilities address everyday challenges and achieve steady, long-term improvements in their operations.
With ABB’s global expertise and trusted local partners like Beta Power Engineering, water and wastewater operators have access to reliable, forward-thinking solutions backed by decades of engineering know-how. To find out how ABB technologies can support your water management goals, get in touch with Beta Power Engineering today.