Eliminating the risk of extended down time for a leading European glass manufacturer in France
16 July | Castlet
Our client, a leading European power station, manufactures glass containers for high end consumable products.
Electrostatic Precipitators (ESPs) are used in glass manufacturing to control emission outputs by removing fine particulate matter from furnace exhaust gases before they are released into the atmosphere.
Castlet has supplied the glass manufacturing industry with bespoke ESP solutions for over five decades. We provide reliable power and control solutions for Transformer Rectifier (TR) units in ESPs, ensuring they provide continuous particulate collection.
THE PROBLEM
We were commissioned by our glass manufacturing client to make upgrades to their ESP control system to replace obsolete equipment, as they were at risk of extended down time.
To avoid extended down time, the client required two new control cubicles within just eight weeks. These control cubicles needed replacing to ensure reliable power and control for their TR units, to ensure the system returned to operating efficiently.
Alongside designing, manufacturing and commissioning two new control cubicles, we needed to perform testing on the existing TR units, to ensure they were still performing to the desired standard. The new control cubicles needed to integrate with the existing systems, while minimising operational disruption and ensuring long-term reliability.
“Working on this project for a leading European glass manufacturer in France was extremely rewarding as we successfully implemented new cubicles that delivered stable and consistent power control”
Ian Fox
Our Solution
Designing a solution
Facing the challenge of an extremely short lead time, the Castlet team identified the components they needed that were on long lead times before the client placed the order, enabling us to prepare for immediate ordering.
Our engineers designed a comprehensive turnkey solution within the eight-week timeframe. We designed two new cubicles to meet the dimensions of the original TR units and site layout, ensuring that all on site cabling could be reconnected without any modifications when it came to installation.
On-site installation and testing
The control cubicles were manufactured and assembled in our UK facility, before being shipped for installation by our team of dedicated engineers on site. We tested the performance of the existing TR units to validate their operational integrity and compatibility with the new controls. Our team completed installation and commissioning with minimal disruption to ongoing plant operations.
The outcome
As a result of our expertise and quick response time, the upgraded ESP control system was fully operational within the eight-week period from order placement to on-site installation, avoiding any unplanned downtime.
The new cubicles delivered stable and consistent power control to the TR units, significantly improving ESP performance and emission control. By replacing obsolete components, our client reduced the risk of future system failures and gained greater confidence in system reliability.
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