Grid congestion is making it increasingly difficult for industrial end-users to purchase or return the power they require. The consequences range from power constraints and the (dis)connection of generation to voltage issues, long waiting times for splicing and contractual limits or penalties if exceeded. Our company, a large enterprise in the manufacturing industry, independently received the same advice from two external consultants: a large-scale battery storage system would be needed to smooth peaks and prevent overruns. However, we decided to get more clarity first by commissioning measurements.
The research focused on three key questions. First, there was a need for detailed insight into actual plant loads and the locations of any bottlenecks. It also examined whether and how loads could be moved, including to another hall, without exceeding contractual and load capacity limits. Finally, it needed to be conclusively established whether a battery pack would actually be necessary and effective, and if so, where it would have the greatest effect.
HyTEPS combined a contractual review with thermal and security engineering analysis. The contracted transmission capacity was assessed based on 15-minute averages according to the GTV standard, in accordance with EN 50160. This established whether there was actual excess capacity at the grid connection. At the same time, 1-second measurement data was used to look for short-term spikes that could cause tripping of fuses or other protection devices. This twin-track approach provides both a system perspective (grid connection and contract) and a component perspective (behaviour of protections and internal distribution).
The measurement results provided a clear picture of internal load profiles and connection utilisation. All measured power values remained well within the contractual limits, so there was no structural overrun. The installation proved to have sufficient spare capacity, while internal bottlenecks could be located and eliminated with targeted optimisations. By deploying optimal reactive power compensation, apparent power can be reduced towards active power. This leads to direct savings on grid and capacity costs and avoids cos φ penalties.
Based on the analyses, HyTEPS recommended installing a capacitor bank to free up additional capacity and optimise energy consumption. It also proved possible to relocate specific activities to the intended hall responsibly, without creating new bottlenecks or exceeding limits. This eliminated the need for a battery storage system and avoided an investment of hundreds of thousands of euros.
A battery storage system is often seen as a quick solution to peak smoothing and capacity limits. In practice, the underlying bottlenecks regularly turn out to be blind current, unfavourable load scheduling or unbalanced distribution within the installation. Measuring and modelling first provides insight into the nature and origin of peaks and the operational measures that have the greatest impact. In this case, blind current compensation and organisational optimisations proved sufficient to meet the operational goals, without overinvestment.
Quarterly readings provide insight into compliance with contracted transmission power, while higher-resolution analysis reveals precisely which short-term spikes can lead to the triggering of protection devices. Blinding current compensation and internal optimisation are a logical first step; only when these measures prove insufficient does it make sense to consider large-scale storage or grid reinforcement. Load shifting becomes data-driven by using measurement profiles per hall or section, and minimise kVA by optimising the power factor to avoid cos φ penalties.
An independent Power Quality and capacity measurement led to the informed decision not to invest in a battery storage system, but to optimise with reactive power compensation and relocation of specific activities. The measurements showed that all power values were well within limits and there was even spare capacity. By reducing apparent power (kVA) towards active power (kW), grid and capacity costs could be reduced and cos φ penalties avoided. Without HyTEPS' objective measurements, decisions would have been made based on assumptions and commercial interests.
