Reducing maintenance costs in a Turkish denim factory

Challenges in the customer’s denim factory

Loads at the factory were fed by several transformers, and a 2500 kVA transformer feeding the yarn manufacturing machinery was facing high maintenance costs. The problems experienced by the customer included frequent burning of the electronic cards and excessive heating of the electrical equipment such as cables and transformers.

A power quality audit at the factory was conducted by Merus Power’s local partner, ST Tekno. Power factor at the factory was reasonably ok and was above 0.94. Though voltage harmonic distortions were also within the limits, measurements revealed that the current harmonic distortions were excessively high and were exceeding 31% which is well above the safe limits set by IEEE 519 standards.

Our Merus® Solution

The active harmonic filtering solution was sized as per the customer’s requirements, which were to bring high current harmonic distortions under the IEEE 519 limits. Installation and commissioning of Merus® A2-series Active Harmonic Filtering solution at the site were carried out by our local partner, ST Tekno.

As power quality data showed that there were several individual harmonics that were exceeding the limits, the Merus® Active Harmonic Filtering solution was configured to selectable compensation mode.

Results after installation

After the successful commissioning, the Merus® Active Harmonic Filtering solution brought current harmonic distortions well below the limits defined in IEEE 519. The reduction of harmonic distortions provided a safe environment for the reliable operation of the sensitive control circuitry of electronic cards.

Unexpected breakdowns of the electronic cards reduced significantly which helped the plant optimize its maintenance costs. As harmonic currents from the network were mitigated, the I2R in the cables and transformers also went down. This helped to mitigate the excessive heating of equipment and extended their operational lifetime.

Segment / Application

Textile industry – denim manufacturing

Location

Türkiye

Power quality issue

  • High current harmonic distortion

Merus® Solution

Customer Benefits

  • Reduced maintenance costs and burning of electronic cards
  • Reduced heating of electrical equipment
  • Long lifetime of electrical equipment
  • No unexpected machinery breakdown

Do you have any questions?

Please contact one of our salespeople with questions and inquiries.

Markus Ovaskainen

Director,
Sales

+358 40 539 2145 markus.ovaskainen@meruspower.com

Riku Kalliomaa

Head of Sales,
Regions & Channels

+358 50 3323 020 riku.kalliomaa@meruspower.com

Jaakko Poutamo

Sales Manager,
Energy Storage, Europe

+358 50 918 0012 jaakko.poutamo@meruspower.com

Mikko Zavertkin

Sales Manager,
Key Accounts & OEMs

+358 40 5908 858 mikko.zavertkin@meruspower.com

Viktoria Mansikkala

Sales Manager,
Baltics & Eastern and Southern Europe

+358 44 9 735 737 viktoria.mansikkala@meruspower.com

Juhani Jaatinen

Senior Sales Manager,
DACH, Benelux, France,
Asia-Pacific

+49 160 762 4909 (DE) juhani.jaatinen@meruspower.com

Venkatesh Ramachandra

Regional Sales Manager,
Middle East

+971 50 55 38 465 venkatesh.ramachandra@meruspower.com
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