Unplanned downtime is not an option in precision tube manufacturing. HyTEPS analysed the invisible risks in the grid and restored stability, so that Mannesmann can now blindly rely on their installation. We brought peace and security back to the electrical system.
Production at Mannesmann leaned on eight huge machines, but the plant showed worrying instability. Plant manager Walther van Boekel was faced with an acute problem: air compressors were failing when running at low speed, while the drawing belt was running at full speed. This uncertainty about the cause and the fear of unexpected production stops posed an immediate risk to security of supply to the automotive and chemical industries.
Harmonic problems were suspected, but without hard data, the true cause remained invisible. HyTEPS was called in to remove this technical uncertainty. We did not start with a product, but with getting to the bottom of the problem to ensure the safety and continuity of the installation.
Our engineers immediately carried out extensive on-site measurements to map Power Quality. This analysis showed that six-pole rectifiers, used for DC drives, were causing spikes in the voltage waveform. This resulted in severe contamination of voltage and current and high total harmonic pollution.
The measurements confirmed it immediately: harmonic contamination was the cause of the outage. This not only posed an acute problem, but also caused accelerated wear and tear and fire risk. Thanks to our simulations, we knew exactly which solution would guarantee operational reliability.
To stabilise the plant, our engineers implemented an Active Harmonic Filter that directly compensates for harmful pollution. In addition, we installed a thyristor-controlled capacitor bank. This reacts at lightning speed during the extrusion process to correct the high reactive power, which directly increases the capacity of the system and minimises losses.
To ensure this new security, we implemented comprehensive monitoring. With this, we continuously monitor the status of equipment and Power Quality parameters. The installation is now stable: PLCs no longer interfere, LED lighting no longer breaks down and compressors continue to run undisturbed.
Mannesmann has regained control of their installation. Do you also want to be sure that your production process is protected against invisible Power Quality risks? Our engineers are ready for a clear diagnosis.
HyTEPS
Beemdstraat 3
5653 MA Eindhoven
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