We designed and manufactured a unique system composed of 16 coupling & load capacitors for a European HVDC cable manufacturer.
At the end of 2020, a reputed European HVDC cable manufacturer has solicited CONDIS’ expertise for the development and production of a unique system aiming to equip the client’s laboratory. Composed of 16 coupling and load capacitors, split over 2 types of assembly, this project represents a premiere for CONDIS’ experts as it was the first time that we were mandated to design, produce, assemble and test such an impressively high and big testing equipment our facilities in Rossens. The products were successfully delivered to our customers in February 2022.
With the help of some of the team members that have worked on this exciting project, let’s make a retrospective of its milestones.
Yves Bonnefoy, as the Sales Manager, you were the first person in contact with the customer. How did you receive such a unique demand and how did you proceed to launch the project internally?
From the reception of the first request to the delivery of the components to the customer, through the finalisation of the design and the start of production, 18 months passed. It was a long-term project during which it was necessary to keep a continuous follow-up with the customer. My role was to be the voice of the customer within the project group: this project being a challenge, it was important to ensure that creative answers were provided to the customer.
I am very proud of this achievement which made CONDIS grow, such as myself, thanks to the many challenges that arose.
José Luis Bermudez, you are the Product Manager responsible for this project. What can you tell us about the design of these capacitors and their specificities? Could you identify some obstacles at the very early stages of the project?
It was an interesting challenge for us from the first discussion with the customer already. They requested great values of capacitance with very high voltage levels, including options to have super-imposed voltage tests, and a mobile structure. We create a pool of experts internally to do analysis in all branches; electrical, mechanical, manufacturability, transportation, and quality. We studied different possibilities, together with our customer, before finalising and accepting design. We are proud of the result of our studies and of the manufactured products. And we are, of course, ready to apply our expertise to overcome new challenges.
Sévérino Tehrani your role on this project was to ensure the mechanical and electrical performance of the assemblies by performing calculations and simulations. In your opinion, why is CONDIS the right partner to achieve such projects? Could you identify some obstacles at the very early stages?
CONDIS is able to provide tailor-made solutions thanks to the numerous multidisciplinary skills and the motivation of the people in the group. Obstacles were first identified and then resolved with the help of powerful tools and internal rules that help us solving them directly or proposing various solutions to the customer. Indeed, the products had to fulfil strict safety requirements (for the mechanical part, e.g. tipping stability or beam strength). The reports of the calculations and simulations were then provided to the client and verified at our facility during the product assembly. Electrical simulations were also carried out in order to optimise the corona-rings (dimensions and positions) while respecting the internal criteria avoiding any partial discharges.
Athos Grandi, in terms of Manufacturing process, could you tell us how this project has established a new basis for further projects of this kind to be accomplished within our facilities? How did you manage to expand our production capacities?
This project enabled us to invest in new equipment and to optimise our manufacturing processes for large capacitors (heavier than 1T and over 3m high). Indeed, we had to set up a new workstation and adapt some of our machines. An additional challenge was the assembly tests of these capacitors, but this let us gain experience in handling parts weighing over 1000 kg. We have expanded our lifting equipment to carry out the horizontal movement of these parts and have introduced a new procedure for vertical handling.
You have a similar project you would like to discuss with us? Or a new challenge for our team? Do not hesitate to contact us for further information at condis@condis.ch
