Unexplained failure of rectifiers posed a risk to process continuity at zinc producer Nyrstar. Thanks to HyTEPS' implementation of advanced monitoring, the cause is now always visible and operational reliability guaranteed. We brought peace of mind back to the plant.
As the only zinc producer in the Netherlands, Nyrstar bears responsibility for an annual production of approximately 290,000 tonnes of high-quality zinc. In a process of this size, continuity is not a wish but a hard requirement. Yet the organisation was faced with a technical conundrum: the inexplicable, short-term failure of rectifiers with thyristors. For the technical managers and plant managers, this not only posed production risks, but also the gnawing uncertainty about the cause. Was it wear and tear? An internal fault? Or did the problem lie deeper in the plant's power supply?
This uncertainty is disastrous for a production environment where safety and reliability are paramount. During the internal investigation, it was suspected that the quality of electricity - Power Quality - played a role at the time of failure. Because regular measuring equipment is often not fast enough to capture momentary events, the 'smoking gun' remained invisible. Patrick Emmers, Reliability Engineer E&I at Nyrstar, clearly articulates the move towards certainty:
"When the word Power Quality came up, we immediately approached HyTEPS, our in-house supplier in the field of Power Quality."
To restore operational reliability, it is not enough to simply look at the voltage; an in-depth Power Quality analysis is necessary. HyTEPS analysed the situation and recommended the deployment of the SATEC EM720T. This is not just any meter, but an advanced instrument capable of recording all possible Power Quality events at lightning speed. Where standard meters fail, this technology brings transients, peaks, dips, flicker and harmonics into razor-sharp focus.
HyTEPS' strategy rests on facts and data. Our engineers recommended the placement of four of these meters, specifically positioned on each of NYRSTAR's 10 kV supply lines. In doing so, we created a conclusive measurement network that does not miss a single anomaly. By deploying this technical expertise, we transformed a vague suspicion of 'bad power' into a concrete, measurable parameter set. This enables Nyrstar to see exactly what the status of the power supply was at the millisecond a thyristor failed.
At HyTEPS, responsibility does not stop with the delivery of a box; we ensure its operation in practice. Our engineers configured the meters and associated software in close cooperation with the team at NYRSTAR. This decisive implementation ensures that the data is not only collected but also directly usable by the people on the floor. The objective was clear: the customer must be able to act independently and immediately in case of calamities.
The result is total control. This eliminates guesswork. HyTEPS has thus drastically reduced the search area for the cause of outages. Moreover, the analyses now provide insight into long-term trends, allowing NYRSTAR to proactively maintain before an incident occurs.
Like Nyrstar, you can eliminate downtime risks through insight. Don't wait until a failure shuts down your process. Our specialists are ready to analyse and protect your installation.
HyTEPS
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