Drives, motors + switchgear
The Vyeboom pump station upgrade Vyeboom Irrigation Board operates one of the region’s largest pump stations, drawing from the Theewaterskloof Dam, near Villiersdorp in the Western Cape, a key source for regional, agricultural irrigation. A planned upgrade of the pump station raised a diicult question: how to modernise while safeguarding ongoing supply. In this case study, ElectroMechanica (EM) sets out the approach adopted and the success achieved.
approach that adds cost in most irrigation systems. The result was limited resilience during grid outages.
Ineicient pumping Operating a mix of pump sizes on a shared line made flow optimisation challenging. Instead of maximising flow, energy was lost in turbulence, meaning more power was used without delivering more water. The solution What turned a complex upgrade into a workable plan was not a single specification but a coalition that knew where its responsibilities overlapped. The irrigation board carried the pressure of keeping crops watered on time, supported by a consulting engineer who carefully evaluated technical and financial factors. On-site support was provided by system integrator WJ Cotter, who was responsible for installation and PLC/SCADA integration. Bridging disciplines To support them, partners stepped in with complementary expertise. EM’s engineers in Cape Town and Johannesburg tested electrical assumptions against the hydraulic redesign commissioned from a leading pump manufacturer. At the same time, WJ Cotter handled site integration and controls, ensuring the upgrade meshed with day-to-day board operations. That study confirmed that larger, more eicient pumps could be matched with medium voltage drives to work in step rather than at odds with each other. When scheduling challenges arose near the end of the shutdown window, EM helped keep the project on track by holding the equipment. Closing eiciency gaps Delta’s role was equally critical. Its MVF2000 drives, each rated for 800 kW and configured to take 11 kV input while delivering 6.6 kV output, replaced the station’s step-down transformers and closed a long-standing eiciency gap. With more than 96% eiciency, low harmonic distortion, and tolerance for the voltage disturbances common in South Africa, the upgrade delivered technical assurance and operational resilience. The integration ensured the drives were embedded into the control environment seamlessly, giving the board confidence in everyday operation. “The MVF2000 drives are proven worldwide, but at Vyeboom, it was EM’s local support and expertise that made sure they delivered real results for the board,” said Sergey Zubov, IABG Country Manager (CIS), Delta Electronics. Moving forward with confidence A site visit to a previous EM project allowed the board and the consulting engineer to see medium-voltage drives in operation – and that progressed the discussion from specifications to practical outcomes. They observed smooth starts and stops, spoke directly with operators, and confirmed how the technology
It was clear that the Vyeboom pump station needed an upgrade, but it needed to be completed within a narrow shutdown window to ensure farmers would have reliable water when the season opened.
T he decision was not simply about equipment. The upgrade was about ensuring farmers would have water when the season opened. The irrigation board faced a narrow shutdown window, a station operating under demanding conditions, and two very dierent options. So¡ starters were the familiar choice in medium-voltage systems, and drives carried the perception of added complexity. On paper, the drives promised smoother starts, lower energy use, and generator compatibility, but the board needed more than a specification sheet. They needed confidence that the upgrade would deliver reliably when it mattered most. The challenge The upgrade had to be completed within the short seasonal shutdown. Missing that window would have delayed the project by a year and extended the risks to infrastructure and supply. Equipment wear and downtime Traditional starting methods placed a significant load on the pumps, as is common in long-serving stations. Bearings and seals wore out faster, increasing the need for more frequent maintenance. Breakdowns raised the risk of interrupting water deliveries during critical periods. Water hammer also damaged valves, reducing their service life by half and driving up replacement costs. Limited backup options Pumps of this scale draw high current on start-up, even when fitted with so¡ starters. This made the use of generators impractical without significantly oversizing the sets, an
10 Electricity + Control MAY 2026
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