Location: Pasadena, TX, USA
Partner: Enhanced Electrical Sales
Industry: Water and Wastewater
Timeline: 2020
Background
Inframark is a leading independent American-owned company specializing in water and wastewater operations. In Pasadena, Texas, Inframark operates the Vince Bayou Wastewater Treatment Plant, a critical facility with a permitted average daily capacity of 14 million gallons per day (MGD) and a peak capacity of 40 MGD. This plant plays a vital role in managing wastewater for the surrounding community, ensuring reliable and efficient treatment processes.
The plant, originally reliant on a two-speed soft starter system housed within an elevated Motor Control Center (MCC) building, was due for an upgrade. The aging system needed to improve its operational efficiency and process control while complying with IEEE 519 harmonic distortion standards. To address these challenges, Inframark contacted Enhanced Electrical Sales, a regional partner of Comsys', which proposed using Comsys' Active Dynamic Filters (ADF) as the ideal solution.
Challenge
The Vince Bayou Wastewater Treatment Plant faced multiple challenges that needed to be addressed to ensure reliable and efficient operation. The existing system was outdated and lacked precise process control, making it difficult to achieve optimal operational efficiency. Additionally, harmonic distortion levels at the facility exceeded the limits set in the IEEE 519 standard, which posed a risk to compliance and could compromise the reliability of the plant’s operations.
Adding to these technical challenges were logistical constraints associated with the facility’s layout. The Motor Control Center (MCC) building, which housed the existing system, was located 20 to 30 feet above the ground. This elevated positioning made it particularly difficult to relocate or replace equipment. A solution was needed that could work with the existing MCC setup and avoid significant changes to the plant’s structure or operations.
Solution
To overcome these challenges, Enhanced Electrical Sales conducted a comprehensive harmonic study using Comsys' ADF sizing calculator. The study revealed that the plant's needs could be met with two ADF P300 filters, strategically installed adjacent to the MCC building. This solution allowed direct integration into the existing electrical bus without requiring the MCC to be relocated.
Additionally, six Variable Frequency Drives (VFDs) were installed to improve process control and the plant's overall energy efficiency. The combination of Comsys' ADF filters and VFDs not only addressed the harmonic issues but also modernized the facility’s control systems.
Results
The implementation of Comsys' ADF technology brought significant improvements to the Vince Bayou facility. Harmonic distortion was reduced to meet IEEE 519 standards, ensuring full compliance. Enhanced process control and operational efficiency translated into substantial cost savings. The return on investment (ROI) for the project was achieved in under one year, a clear example to the efficiency of the chosen solution.
The project also showcased the flexibility of Comsys' ADF filters, in fact, by installing them adjacent to the existing MCC building, the team overcame logistical constraints.
The whole project was very positive. I was told by one of the maintenance managers at the plant that their ROI for this project was less than one year.