Why your installation is more vulnerable than you think

The demands on your electrical infrastructure are changing at an unprecedented rate. Whereas installations used to be linear, analogue and predictable, today's energy transition creates a complex mix of consumers and generators. The massive integration of power electronics, such as variable speed drives, LED lighting, EV chargers and heat pumps, introduces new challenges in your installation. Here we talk about Power Quality problems such as harmonic contamination, voltage dips, transients and reactive power.

These problems often remain invisible to the naked eye for a long time. They lurk in the background, meanwhile limiting the capacity of your transformers, unnecessarily heating cables through the skin effect and disrupting sensitive control electronics. The result? An installation that complies with NEN 1010 on paper, but is unreliable in practice. For sectors where failure is not an option - such as hospitals, heavy industry and data centres - this constitutes an unacceptable business risk. Grid congestion also plays an increasing role; you have to do more with the same connection, which reduces the margins for error.

At HyTEPS, we understand that as a technical manager, you need grip and control. You don't want to wait until the lights go out, a production line stops or a life-saving device fails. You are looking for certainty. Our approach is therefore always based on facts, data and standards. We do not guess at the cause, but make the invisible quality of voltage and current visible. Only when we have found the exact source of the instability through analysis and simulation do we look at the solution. This is how we transform a vulnerable infrastructure into a robust, reliable electrical installation.

Our integrated approach for optimal operational reliability

HyTEPS is distinguished by a unique combination of high-quality measurement technology, mathematical simulation models and practical engineering. We do not deliver standard products, but a guaranteed result for your installation.

Engineer measuring Power Quality

Measurement and monitoring

Everything starts with insight. Our engineers perform comprehensive Power Quality measurements at your site, without disrupting your business processes. We install advanced analysers that record voltage and power quality in detail. With these, we detect harmonics, voltage variations, imbalance and flicker. We do not just look at snapshots, but analyse trends over longer periods (e.g. a week or a month). This provides a crystal-clear picture of the 'health' and load capacity of your installation.

Analysis & Validation

Measuring is one thing, understanding is two. We process the collected measurement data in specialised software to digitally recreate your installation (Digital Twin). With this, we simulate various scenarios. What happens if you expand with new production lines? What is the effect of an Active Harmonic Filter on resonance points? By simulating, we avoid trial-and-error in practice and guarantee that the proposed solution actually works and is compliant with standards.

Engineers Analysis & Validation
Engineer Configures Engineering & Hardware

Engineering & Hardware

Based on the analysis and simulation, we engineer the best-fit Solution for your specific situation. This can range from setting up existing equipment correctly to implementing Active Harmonic Filters, capacitor banks or hybrid systems. HyTEPS supplies high-quality components and takes care of full commissioning and validation. Your installation manager is completely relieved of any concerns; we take responsibility for the technical result.

Training

A reliable installation also requires knowledge among your team. Through HyTEPS, we offer training and courses for your technical staff and installation managers. We teach your people how to recognise power quality problems early on and how to interpret measurement data. This way, we secure the accumulated knowledge within your organisation and increase the self-reliance and alertness of your technical department.

Sri giving training

The benefits of Power Quality optimisation

Investing in clean and stable voltage provides immediate technical and financial returns. It is not only about preventing breakdowns, but also about optimising your business processes and energy costs.

  • Maximum continuity: You minimise the risk of unexpected process and machine downtime. Your production continues, operating rooms remain operational and data servers remain online.
  • Extended equipment life: By eliminating harmonic contamination and voltage spikes, you reduce the thermal load on cables, transformers and motors. Equipment lasts longer and maintenance intervals can be optimised.
  • Reduction of energy losses: A fouled plant is inefficient. By reducing reactive power and harmonic losses (reactive current), you reduce energy bills and avoid fines from the grid operator for poor cos phi.
  • Compliance and safety: You demonstrably comply with relevant standards such as EN 50160 and your insurer's requirements. This provides peace of mind and legal certainty in the event of any calamities or inspections.
  • Capacity gain: By improving efficiency, you 'win back' capacity in your existing transformers and cabling. This creates room for new investments without expensive infrastructure reinforcements.

The impact of harmonics on your operational reliability

One of the biggest threats to reliable installation is the presence of harmonics. Harmonics are frequencies that are multiples of the fundamental mains frequency (50Hz). They arise from the use of non-linear loads, such as frequency converters, rectifiers and LED drivers. In practice, these harmonic currents cause a wide range of problems that directly and indirectly undermine the reliability of your installation.

A common consequence is unexplained tripping of protective devices, such as circuit breakers and earth leakage switches, precisely at times when this is operationally disastrous. Harmonics also cause extra heat generation in transformers and neutral conductors (the 'zero'), which can lead to insulation faults and, in extreme cases, even fires. The so-called skin effect increases resistance in cables, leading to unnecessary energy losses. In addition, harmonic voltages can interfere with the digital control of sensitive equipment, resulting in 'ghost faults': machines that stop without a clear error message.

HyTEPS analyses this pollution in detail. We look at the Total Harmonic Distortion (THD) of both voltage and current and test it against your equipment limits and standards (such as the IEC 61000 series). By actively filtering with advanced Active Harmonic Filters, we bring the current form back to a pure sine wave. The result is a 'clean' voltage on which your equipment operates as the manufacturer intended: interference-free, cool and efficient.

Results from practice:

1.75 MW of power released and direct cost reduction at SNB

Despite own generation, SNB was struggling with high costs due to reactive power. HyTEPS optimised the installation with capacitor banks. The result: 1.75MW less grid load and a payback time within one year.

Grid analysis at PLB Group prevents unnecessary battery investment

An independent Power Quality measurement at PLB Group exposed unused spare capacity. Through targeted optimisations, we avoided the purchase of an expensive battery storage system. This provides the customer with enormous cost savings, while maintaining security in every kilowatt.

Communication stability ensured by elimination of EMI at Schiphol Airport

HyTEPS eliminated electromagnetic interference in the Schiphol T2000 network after an integral EMC study. This approach restored system integrity and guaranteed uninterrupted communication for emergency services.

Continuity in passenger flows through EMC control

Harmonic contamination threatened the continuity of Schiphol's security lanes. HyTEPS analysed the risks and installed seven active filters to restore grid quality. The result is a stable installation and guaranteed operational security for millions of passengers.

National security of supply secured with large-scale Power Quality monitoring

HyTEPS continuously analyses and validates Power Quality data from the entire Dutch power grid. Our customised software transforms this complex data stream into reliable control information for optimal security of supply.

Production outages eliminated by stable Power Quality at Mannesmann

HyTEPS solved the failure of air compressors at Mannesmann by immediately eliminating harmful harmonic contamination. With active filtering and continuous monitoring, precision tube production is now fully stabilised.

Maximum grid capacity through targeted reactive power compensation at Xella

HyTEPS restored installation capacity at Xella by targeting reactive power with capacitor banks. The solution offers Xella an immediate cost reduction and sustainable security in every kilowatt.

100% operational reliability for taxiway lighting at Schiphol Airport

HyTEPS identified the risks to the taxiway lighting at Schiphol Airport through accurate measurements. With the subsequent solution, the continuity and safety of this critical installation is fully guaranteed.

Halving harmonic contamination increases operational reliability at Thialf

Thialf was struggling with unexplained failure of critical variable speed drives. HyTEPS implemented Active Harmonic Filters, which successfully reduced the harmonic pollution (THDu) present to below 4%. Supplemented by permanent monitoring, this now ensures an extremely stable and reliable installation.

Optimal operational reliability through data-driven energy monitoring

HyTEPS implemented an advanced monitoring system that gives CurTec real-time grip on energy consumption and Power Quality. This data-driven solution prevents blind power penalties and ensures a stable, climate-neutral future.

Real-time Power Quality insight secures production of 290,000 tonnes of zinc

By tackling unexplained outages with high-end monitoring, HyTEPS ensured continuity at Nyrstar. Real-time insight into Power Quality now prevents unnecessary downtime.

Full operational reliability through elimination of grid contamination at Sappi Maastricht

Sappi Maastricht eliminated costly production downtime by targeting harmful harmonics with a Power Quality diagnosis and active filtering. This investment fully restored operational reliability and paid for itself within a year due to the guaranteed continuity.

Extra production capacity through Cos Phi optimisation at Naber Plastics

HyTEPS increased installation capacity at Naber Plastics by targeting reactive power. With a 400kVAr capacitor bank, our engineers immediately created space for additional machinery. This results in optimum power utilisation and maximum operational reliability.

Safe innovation: Arc calculation for the world's fastest charging battery

Our engineers performed specialist arc simulations to ensure the safety of InMotion's unique battery pack. Thanks to this concrete analysis, the team is now working on ultra-fast charging technology with the right protective equipment and complete certainty.

Sustainable expansion without grid reinforcement at Clondalkin Flexible Packaging

HyTEPS ensures continuity at Clondalkin with a system that combines energy insight with automatic HACCP recording. This eliminates risky manual checks and maximises operational reliability.

5MW plant safely expanded without grid congestion risk

To prevent downtime at the new 5MW plant, HyTEPS preventively implemented two Active Harmonic Filters. This assures ARN Recycling of a stable energy network and maximum business continuity.

75% Faster shutdown times for safe battery storage at iwell

For iwell's battery system, HyTEPS conducted an Arc Flash Compliance study to ensure electrical safety. The new settings reduced shutdown times by 75%, reducing dangerous arc flash energy to safe levels.

Preventing unplanned downtime by eliminating harmonic pollution at Nyrstar

HyTEPS eliminated high-risk harmonic contamination at Nyrstar. Our specialist measurements provided an exact diagnosis and a guaranteed stable production environment.

550 Amp released power: from capacity problem to growth space

Nijsen was struggling with high costs and lack of capacity due to reactive power. Our active capacitor banks eliminated the penalties and immediately created 550 amps of extra space on the transformers.

Structural cost reduction through elimination of reactive power penalties at VDL Parree

By deploying a 300 kVA capacitor bank, HyTEPS stopped monthly reactive power penalties at VDL Parree. This intervention increased efficiency and created additional capacity immediately, so the investment paid for itself within a year.

Fault-free LED transition for De Kuip stadium

In an environment where tens of thousands of spectators count on continuity, downtime is not an option. HyTEPS secures Power Quality at Stadion Feijenoord, so that the transition to LED lighting leads directly to guaranteed performance without invisible risks.

Maximum operational reliability for offshore giant: ground loops eliminated

HyTEPS eliminated years of cable insulation damage on the Bumblebee due to a hidden ground loop in the complex offshore installation through a focused Power Quality. This proactive approach restores operational continuity and provides Allseas with the maximum reliability their operation requires.

100% care continuity through optimal Power Quality at Rivierenland Hospital

Hospital Rivierenland ensures safe care by working with HyTEPS to eliminate harmonic contamination in the installation. The deployment of Active Harmonic Filters now guarantees optimum Power Quality and maximum operational reliability.

Optimisation of grid capacity and operational reliability at OVET B.V.

Grid congestion and complex Power Quality issues threatened to stall OVET B.V.'s expansion plans. HyTEPS implemented an advanced monitoring system that provides exact insight into consumption and peaks. This allows OVET to safely expand and make maximum use of existing capacity without the risk of outages.

Rijkswaterstaat ensures tunnel safety with 40% spare capacity

HyTEPS eliminates harmonic pollution in the Ruhr Tunnel by implementing four active filters. Thanks to 40% spare capacity, technical safety for Rijkswaterstaat is guaranteed under all circumstances.

4MW solar panels integrated without grid pollution at KLM

HyTEPS integrated 4 MW of solar panels at KLM Schiphol without risk. By eliminating grid pollution with Active Harmonic Filters, we ensure maximum operational reliability and a stable installation in Hangar 14.

No room for error: how Zentrys guarantees 24/7 continuity

HyTEPS ensures the operational reliability of Zentrys through targeted arc scanning and selectivity testing. With digital simulations, we eliminate invisible risks for maximum continuity and a safe working environment.

500 amp extra capacity and complete elimination of blind current penalties at Mauser

Through targeted measurements and active filtering, HyTEPS eliminated grid contamination and blind current penalties at Mauser Packaging Solutions . This immediately provided 500 amps of extra capacity, allowing production to scale up safely without investing in a heavier grid connection .

Maximum operational reliability for Amphia: 100% grip on Power Quality

Our engineers analysed Power Quality with continuous waveform recording to ensure maximum safety. Thanks to continuous monitoring, all risks are now under control and care continuity is guaranteed.

From unexplained outages to maximum operational reliability: Power Quality at Vencomatic Group

Conservation at Vencomatic inadvertently led to harmonic contamination and failure of critical equipment. After a proactive Power Quality measurement, our engineers implemented Active Harmonic Filters, which successfully stabilised the plant and ensured operational reliability.

Direct cost savings and extra capacity for Van Munster Recyclers

Van Munster Recyclers eliminated the reactive power penalty and immediately created additional capacity with a HyTEPS capacitor bank. Thanks to the immediate cost savings, this solution paid for itself within one year.

Frequently asked questions about installation reliability

Answer:

We understand that downtime costs money. Our organisation is set up for flexibility and decisiveness. For acute problems, we aim to have an engineer with measuring equipment on site as soon as possible to identify the cause.

Answer:

Electronic components and insulation materials wear faster due to heat and voltage spikes. By stabilising the voltage and keeping it 'clean', you avoid these stressors, making equipment last years longer.

Answer:

Our engineers analyse the installation using measurements, simulations and modelling to target the cause.

Answer:

Operational reliability is our priority. We plan measurements and the implementation of a solution in such a way that your business processes experience minimal disruption, with safety and continuity being paramount.

Answer:

There are several standards such as EN 50160 (for voltage at the transfer point) and the IEC 61000 series (for EMC and Power Quality within installations). HyTEPS tests your installation against these standards through advanced measurements. We deliver a clear report that indicates in understandable language where you are at risk and how to become compliant again.

Answer:

Absolute. In addition to preventing downtime, you reduce energy losses (I²R losses) in your cables and transformers. This contributes directly to the water board's CO2 reduction targets.

Answer:

Yes, harmonics can cause cables and transformers to overheat, posing a fire hazard. They can also cause protective devices to trigger unintentionally, leading to acute and dangerous machine failure.

Answer:

Yes. Without measurement, you are guessing; you do not know whether your capacity problem is due to actual consumption or pollution. A measurement prevents you from investing in the wrong solutions (such as an overweight battery).

Answer:

Absolutely. We are not an inspection agency that just diagnoses a problem. We recommend concrete solutions, such as harmonic filters or capacitor banks, and can also supply and commission them for you.

Choose security and continuity

Don't leave the reliability of your installation to chance. Avoid surprises and regain control of your electrical energy. Our engineers are ready to work with you to find a structural solution.