Solution for harmonics and more power at Mauser Packaging Solutions

HyTEPS immediately understood what we needed. They not only removed reactive current, but also freed up extra power and made our power network healthier. We are now looking at how we can possibly make even more power available through smart sizing.
Reinier Goorden, Installation manager, project engineer and energy coordinator at Mauser’s Oosterhout

5 x 1600 kVAR transformers, 1x 2000 kVAr transformers

13 outgoing feeders main distribution box

Up to 500 Amps additional power possible

Challenge

Globally operating company Mauser Packaging Solutions offers a wide range of (industrial) packaging solutions and services throughout the packaging lifecycle. Reinier Goorden is the installation manager, project engineer and energy coordinator at Mauser’s Oosterhout site. This production site houses six transformers, 20 blowers and 19 injection molding machines, and everything that goes with such equipment.

“A monthly reactive power penalty from the energy supplier led us to look for the causes of reactive power. Spread over a number of years, conventional compensation had already achieved a great deal and also significantly reduced penalties. Among others, 500 kVar compensation cabinets were installed behind Transformers 1, 2 and 6. With this, HyTEPS had already helped us immensely. On one of the other transformers, HVK3, the situation was somewhat different. Behind this distributor were a number of machines with motors and controllers causing extra pollution on our grid. In fact, it got so bad that we were also seeing it on other main distributors. To find a solution, we needed HyTEPS’ expertise, of course!”

Goal

Mapping reactive power per feeder on main distributor.
Resolve problems with harmonics and Cos Phi
More capacity to scale up production

Solution

“Mauser wanted to map the reactive power per feeder in the main distributor (HKL3),” says Christan van Dorst, Manager Technical Engineering, HyTEPS. “At the company’s request, HyTEPS performed a Power Quality (PQ) measurement on 13 outgoing feeders from the main distribution box powered by transformer #3.” Mauser also used Satec Expertpower meters to continuously map the Power Quality.

Powers generally remained constant and stable during the measurements. Several meters were used simultaneously – any discrepancies would indicate that new measurements would have to be taken. However, that wasn’t necessary. In the case of feeders HKL3-1 and HKL3-2, harmonic power was found to be even higher than reactive power.

“Measurement results and our analysis of existing and expected reactive power showed that harmonic filters were required at the transformer level. The problem needed to be addressed locally, but also between several machines. To solve such a complex problem, it is important to map the entire installation properly, including all dependencies between devices.”

Result

“By solving problems with harmonics and Cosinus Phi, we were able to free up a great deal of capacity,” explains Reinier. “In the most favorable case, we could even gain almost 400-500 amps. Much better than requesting a bigger connection, which can take a very long time, or partially or completely replacing machinery. It was also recommended that the outgoing cables of cabinet HVK-3 be tagged, to make it easier to identify the different phases.”

Reinier: “HyTEPS immediately understood what we needed. They not only removed reactive current, but also freed up extra power and made our power network healthier. We are now looking at how we can possibly make even more power available through smart sizing. We have also placed HyTEPS Power Quality meters behind the main distribution transformer. By doing this with more and more devices, we gain optimum insight into our installation, and we see where we could perform even better. For example, if we have always set a screw for extrusion at 220 degrees, we could now find out at what times we could set it a few degrees lower to save energy.”