A close look at the high-voltage manufacturing process

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An overview of high-voltage equipment manufacturing

In the heart of the energy sector lies a world where innovative ideas, lean processes, and strong collaboration come together. Welcome to the high-voltage factory, an exciting place where brilliant and creative minds forge the technologies of tomorrow.

High-voltage manufacturing is a critical yet often unseen cornerstone of our infrastructure. It involves precise engineering and careful assembly to produce essential components that power our daily lives. It’s undeniable how high-voltage manufacturing is quietly but significantly shaping the backbone of our grid.

In this blog, we will uncover the ins and outs of the high-voltage manufacturing process, from the intricacies of lean design principles to the practicalities of production.

Discover everything you need to know about the high-voltage manufacturing process in the latest episode of the Power Pulse podcast: The wonders of a switchgear factory.

Step-by-step guide to producing high-voltage equipment

High-voltage equipment manufacturing is a meticulous process. This step-by-step guide will take you through the journey from concept to integration into our electrical grids.

• Material selection and procurement
  High-voltage equipment demands robust materials that can withstand extreme electrical stresses and environmental conditions. Suppliers are chosen based on quality, reliability, adherence to industry standards, and sustainability. On-time procurement strategies ensure that materials arrive precisely when needed, minimizing storage costs and waste.
  
  As an example, Hitachi Energy’s EconiQ^TM switchgear uses an eco-efficient gas mixture that essentially eliminates CO2 equivalent emissions of the insulation medium compared to sulfur hexafluoride (SF₆). In our gas-insulated switchgear (GIS) factory in Zurich, we installed new robust tanks where we pre-mix the gases that we need for our EconiQ line.
  
  
• Manufacturing and assembly
  This phase is the foundational step in producing quality high-voltage equipment. It involves the careful planning and detailed modelling to ensure the final product meets all requirements. Manufacturing in the Feeder Factories and at our external suppliers involves creating the individual parts that which include fabrication processes such as cutting, machining, stamping, and molding. Once the individual components are viable, assembly teams meticulously integrate these components, following strict protocols to maintain product integrity and safety.
• Quality assurance and testing
  All components undergo rigorous testing to verify performance under simulated operational conditions. Electrical, mechanical, and environment tests identify any defects or deviations from the set requirements. Only components that meet stringent criteria proceed to the next phase.
  
  The Digital Passport System (DPS) underscores Hitachi Energy’s commitment to excellence. DPS enables seamless traceability of all components within our high-voltage portfolio. It is a digital repository of critical product information, from test records and certificates to supplier documents.

Quality is our license to operate in Hitachi Energy.

• Certification and compliance
  Before deployment, high-voltage equipment must adhere to regulatory standards and certifications. Compliance with international safety protocols ensures reliability and compatibility across global markets. Certifying bodies validate adherence to standards such as the International Electrotechnical Commission (IEC) and Institute of Electrical and Electronics Engineers (IEEE), affirming the technology’s safety and performance.
• Packing and shipment
  Once certified, the equipment must be carefully packaged to ensure it stays intact, free of damage, and secure during transit. Custom-designed crates and shock-absorbent materials safeguard delicate components. Efficient logistics networks ensure timely deliveries, minimize downtime and optimize project timelines.
  
  One of the most iconic deliveries Hitachi Energy has ever done was back in January 2024, when we delivered 12 bays of GIS in an astonishing transatlantic journey from Zurich, Switzerland, to California, US. Designed to safely and efficiently deliver long-range cargo, an Antonov AN-124 strategic aircraft transported 64 tons of high-voltage equipment in a 9,500 km journey across the Atlantic Ocean.

Listen to the latest Power Pulse podcast episode, where I share the wonders of operating a modern high-voltage factory.

Essential skills and training for high-voltage manufacturing workers

Training programs and expertise development

Behind every groundbreaking high-voltage masterpiece is a workforce adept in a symphony of skills that made it possible. Here, we delve into the core competencies and training that propel individuals towards continued innovation on the factory floor.

Training programs

1. Technical training programs: Institutes and industrial training centers offer specialized courses in manufacturing technologies. These programs equip individuals with hands-on experience in operating machinery, understanding industrial automation, and implementing lean manufacturing principles.
2. Certifications and credentials: Industry-recognized certifications validate proficiency in specific areas such as quality control, process optimization, and safety protocols. These credentials not only boost credibility, but also open doors to advanced career opportunities.
3. Continuous learning: The pursuit of innovation is a journey, not a destination. Continuous learning through workshops, seminars, and online courses keeps factory professionals abreast of emerging trends and best practices. It fosters a culture of lifelong learning and adaptation.
   
   Ochibo Hiroi is deeply embedded in Hitachi Energy’s quality culture. It is designed to learn from failures in day-to-day work, linking them to improvements, preventing failure recurrence, and continuously making processes, products, solutions, and services better.
4. Cross-functional collaboration: Innovation thrives in diverse and collaborative environments. Factory teams benefit from cross-functional training initiatives that promote interdisciplinary skills, enabling adaptability and flexibility to new challenges, market demands, and technological advancements.
   
   At Hitachi Energy, we live by the powerful equation “Diversity + Collaboration = Great Innovation.” We believe in the power of diversity of thought and that it’s everyone’s job to build a workplace that fosters it.

Expertise development

1. Technical proficiency: Mastery of machinery, understanding of industrial processes, and proficiency in handling advanced tools are essential in maintaining a safe work environment and enabling a culture of continuous improvement. For these reasons, technical skills are the backbone of operational excellence.
2. Problem solving: Factories are breeding grounds for challenges with its advanced machinery and processes. Effective problem-solving skills ensure product quality and maintain smooth sailing operations. These skills include the ability to analyze, diagnose, and solve problems efficiently and effectively.
3. Attention to detail: Precision is not a luxury but a necessity in manufacturing. A keen eye to detail ensures that products achieve high standards of quality and performance. It fosters reliability and great customer satisfaction for every service and product.

Overcoming challenges and pioneering innovations

Key innovations revolutionizing high-voltage manufacturing

The high-voltage manufacturing sector is undergoing a transformation fueled by innovations that push the boundaries of what’s possible in energy transmission. Here are some of the breakthroughs driving this transition.

• Energy storage solutions
  In high-voltage factories, these energy storage solutions play a pivotal role in stabilizing the power supply even during peak demand or grid fluctuations. By storing excess energy during low demand periods and releasing it during high demand, these solutions optimize energy usage and reduce waste. It can also act as a backup during power outages or disruptions, minimizing downtime and maintaining continuous operations.
• Digital twins
  A digital twin is a virtual replica of a physical system, allowing engineers to stimulate, analyze, and optimize performance in a digital environment. Digital twins enable the simulation of high-voltage systems under various conditions, enabling engineers to identify potential issues before physical implementation. By integrating real-time data from sensors, digital twins also provide a comprehensive view of a system’s performance. This capability allows for more informed decision-making and proactive maintenance.

By embracing these advancements, the high-voltage manufacturing process can enhance its capabilities while contributing to broader societal goals, such as reducing carbon emissions and supporting the energy transition.

Conclusion: The future of high-voltage manufacturing

In high-voltage equipment manufacturing, each step – from initial design to assembly and testing- represents a testament to innovation. These critical components not only power our grid but also embody a commitment to safety, reliability, and sustainability.

As technology evolves and global energy demands grow, innovations in high-voltage production remain at the forefront, driving progress towards a sustainable energy future, and people of diverse backgrounds, skills, and expertise are at the core of these transformative efforts.