What is grid congestion and what does it mean for you?

Grid congestion is best described as congestion on the power grid. At peak times, the demand for power or the supply when feeding back generated renewable energy is greater than the grid operator's physical cables and transformers can handle.

For you as a Technical Manager or Installation Manager, this has direct consequences. As a result, grid operators are increasingly refusing new connections or the reinforcement of existing contracts to companies. You cannot solve the congestion on the public grid yourself, but you can optimise efficiency within your own installation.

The automatic reflex when there is a power shortage is often to immediately invest in costly battery systems. However, waiting for a grid connection takes too long and batteries are not always the most efficient first step. A structural alternative is much closer at hand: 'breaking in' within your own electrical installation. Indeed, measurements in industry, hospitals and data centres, among others, show that hardly any installation makes 100% efficient use of its contracted capacity.

The technical bottleneck: kW versus kVA

Your grid operator's bill and hard limit are based on apparent power (kVA) or amperes. This is the sum of the useful, active power (kW) actually running your machines, and the 'lost' power (kVAR) created by reactive current and harmonic contamination.

When the Power Quality (the quality of voltage and current) of your installation is not optimal, you fill your cabling and transformers with this unusable power. As a result, you reach the grid operator's contract limit, when in reality you could still be running significantly more machines. This inhibits your operations unnecessarily and causes higher grid costs.

Freeing up space by optimising Power Quality

When internal power quality is restored, the unnecessary, 'idle' load on your cables and transformers immediately decreases. In practice, this process of cleaning up often results in significant capacity gains within the existing infrastructure. You achieve this efficiency gain through three fundamental interventions:

  • Eliminating harmonic contamination: Deploying modern electronics (such as variable speed drives and LED lighting) is energy-efficient, but often causes distortions in the current, known as harmonics. This distortion increases the effective current value and causes unwanted heat build-up in your components. Installing Active Harmonic Filters (AHF) neutralises this harmonic contamination and directly reduces the overall current load.
  • Blinding power compensation: Components that build up magnetic fields, such as heavy electric motors, continuously draw reactive power from the grid. This current does not cause physical work on the shop floor, but it does claim part of your contracted kVA capacity. Offsetting this power locally stops the unnecessary commutation of power towards the grid operator. The kVA load on your main connection decreases, allowing you to immediately use this freed-up space for additional useful power (kW).
  • Peak Shaving and Load Balancing: Often, your average power demand is not the actual bottleneck, but short-lived peak moments exceed the limits of the connection. By intelligently controlling energy flows (load balancing), you distribute the load evenly across the phases and available capacity. Combined with targeted switching or peak absorption, you stay safely within the limits of your contract capacity.

Why a battery is not always the first step

System solutions that store electrical energy for later use decongest the power grid and provide greater flexibility. Yet placing a battery in an internally contaminated installation is risky. Power electronics in an environment with harmonics or voltage dips can lead to resonance, accelerated wear and inefficiency. By optimising Power Quality first, you avoid these problems and it turns out that a battery can often be much smaller (or even completely redundant).

Security in every kilowatt

In practice, optimising Power Quality is often accompanied by a significant reduction in structural energy losses. The capacity this frees up gives you room to expand or realise desired sustainability initiatives without having to wait for the grid operator. At the same time, you can further prepare for local power storage and consumption optimisation.

This ensures you have a robust and efficient installation. After all, no one should have to worry about the reliability and safety of electricity.

Want to dive deeper into the subject matter?

Want to know exactly how to understand and exploit this hidden capacity yourself? Then follow our Power Topic: Create extra capacity: Power Quality as an answer to grid congestion. In it, our engineers share practical analysis and real-life examples.

Map your hidden capacity today

Waiting for grid reinforcement costs you valuable time. Here's a clear look at the situation around your grid capacity: the space you are looking for is often already there. Let us explore how we can optimise Power Quality for you, so that you can move forward with your expansion or sustainability plans straight away.

HyTEPS

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5653 MA Eindhoven