Busbar design for a backup transformer-rectifier

In the competitive world of zinc production, efficiency and production continuity are essential. In 2022, a major multinational zinc producer with an annual capacity of 150,000 tons needed to find a solution to ensure that any issues with their transformer-rectifiers would not affect their production. The reason was clear: failures in the transformer-rectifiers could cause production stoppages, which would have a significant impact on their operations. The company sought the help of Gecsa to find a solution to this problem.

Starting Situation:

The company had two transformer-rectifiers, but the possibility of failures in these equipment posed a constant threat to their production. The goal was to ensure the continuity of their operations and avoid costly unplanned downtime.

Goal:

The main goal of the project was to prevent interruptions in production caused by failures in the transformer-rectifiers. The company needed a solution that would guarantee the integrity of its production process. At the same time, this solution would allow the company to perform maintenance on the transformer-rectifiers without affecting its production.

Customer's Adopted Solution:

The solution adopted by the customer was to install a new backup transformer-rectifier. This measure would ensure that, in case of failure in one of the transformer-rectifiers, the other could take over the load and keep production running.

Gecsa´s Work:

Gecsa, as an expert in electrical and engineering solutions, took responsibility for designing a new aluminum busbar for a current intensity of 130 kA. Gecsa worked closely with the client to define the section and plant layout of the busbar.

The main complexity of this project lay in defining the arrangement of the switches. To enable the startup of the backup transformer-rectifier, Gecsa installed 8 switches of 40 kA each. The connection between the transformer and the rectifier was also successfully executed by Gecsa.

In addition to planning and design, Gecsa also took care of manufacturing the busbar and installing all its elements, including on field weldings. This comprehensive solution ensured that the system was ready for operation and allowed the zinc production company to achieve its goal of production continuity.

Result:

Thanks to the successful collaboration between the zinc production company and Gecsa, production stoppages have been avoided. The installation of the new backup transformer-rectifier, the design of the high-current busbar, and the arrangement of the switches allowed for quick connection in case of failure in one of the transformer-rectifiers. The company was able to maintain its operations uninterrupted, resulting in increased efficiency and ultimately greater success in its highly competitive sector.

At Gecsa, we are proud to have played a crucial role in this success story, and we remain committed to offering innovative and reliable solutions to our customers at all times.