When Emballator decided to install an additional painting line, an existing transformer stood in the way, and in any case greater low-voltage capacity was needed. The solution was to place stations outside the building and make holes in the wall.
Pär Claesson is process development manager at Emballator Metal Group. He also acted as project manager when the factory in Ulricehamn was extended with a new painting line, while, at the same time, an old high-voltage facility was replaced with a new one that offered greater personnel safety.
“When we were planning the project for a new painting line, an uninterrupted stretch of more than 60 metres was required. However, the only area we could use with reasonable logistics contained a transformer station with its associated low-voltage switchgear,” explains Claesson.
Flexibility
“Our old receiving station also needed updating as it had been there ever since the factory had been built in 1978. To find space for it on the existing premises seemed impossible. But I got a tip to contact Holtab to see what solution they might offer,” recalls Claesson.
Claesson contacted Holtab to discuss how the new station should be equipped as well as to find construction and logistics solutions. After a period of discussion, it was agreed that Emballator needed a HMICC receiving station and a HMICP transformer station.
“It quickly became obvious that Emballator did not want to give up any production and storage areas, so we began to look for a solution that could be located outside. To make the installation as smooth as possible, the transformer station was built directly against the existing factory facade.”
“The cables from the substation could be run directly into the production hall through holes made in the wall. It was a smart and creative solution,” says Anders Haglund, who was Holtab’s salesman for the delivery.
Thorough tests
Another aspect that made this assignment unlike many others was the time factor. The new receiving station had to be energised a week or so after delivery, which made it imperative that the installation was thoroughly inspected even before it left Holtab’s factory.
“We are naturally used to this kind of thing, adds Haglund. When we build our stations at our factory in Tingsryd, the process includes thorough checks, configuration and testing. So when we finally deliver the stations they must be ready for immediate commissioning. But in the case of Emballator, it was imperative to do a sterling job in view of the tight schedule before the new equipment could be commissioned and supply the whole factory.”
But everything went exactly according to plan. Holtab delivered complete and turnkey units which Emballator’s electricians then installed and commissioned.
And Claesson is satisfied with the collaboration and notes that everything worked really smoothly.
“I had not worked together with Holtab before, but they made a good impression from the beginning. They were responsive to our requirements and came up with ideas as to how we could resolve all our challenges. We came to them with changes to the renovation plan quite late in the project, but Holtab also managed to deal with this in a really good way. It’s obvious that they have extensive experience in delivering these types of products.”
The delivery comprised:
One complete 12 kV HMICC receiving station with:
- A concrete foundation and installation floor of 800 mm
- 12 kV ABB SafeRing Air switchgear containing incoming compartments for the grid operator, metering acc. to IBH14 and four outgoing power switches with state-of-the-art relay protection for cables to new and existing transformers
- 110 VDC DC cabinet with batteries for control and monitoring
- Alarm panels
- General power, heat, lighting etc.
One completely assembled walk-in HMICP transformer station containing:
- A building with an insulated concrete pad and separate areas for the switchgear and transformer
- A hardwearing floor mat from Tarkett in the control room
- A dry-type insulated transformer 11/0.42 kV, 1,600 kVA with low losses from GBE
- Holtab 400 V industrial switchgear of type CMS 2500 A Form 4A
- Power switches from Schneider Electric with integrated metering for optimal monitoring of how much energy each part of the facility consumes
- A de-tuned automatic capacitor 300 kVAr
- General power and lighting.
