Case Finnsementti: Improved operational reliability through main power distribution modernization

Finnsementti is a Finnish cement manufacturer with more than 100 years of experience in cement production. The company is part of the international CRH Group, one of the world’s largest building materials companies. A significant share of Finland’s cement supply is produced at Finnsementti’s plants in Parainen and Lappeenranta.

In a recently completed, extensive project, Insta modernized the main power distribution system at the Parainen plant. Over the approximately three‑year project, the remotely operated main distribution equipment of the old power plant was renewed, including the pneumatic disconnectors and circuit breakers of the dual‑busbar system, protection relays, current transformers, and auxiliary equipment. The project also included the implementation of a backup connection.

Integrating multiple voltage levels poses challenges

The cooperation between Finnsementti and Insta dates back to 2014. KMJ‑Engineering, Insta’s subsidiary prior to its merger with the parent company, has long been responsible for network calculations and electrical system documentation at the Parainen plant. The same experts were also responsible for electrical design, calculations, and documentation management in the recently completed modernization project.

“Our plant operates with relatively high power levels and uses nearly all standard distribution voltages, including some that many facilities abandoned long ago. Integrating all of them is challenging. Insta has provided us with a great deal of support,” says Jari Rantanen, Electrical Engineer at Finnsementti.

The main power distribution is divided into two sections. One section had been modernized earlier in several phases, while the modernization of the other section began with Insta in 2019.

Some of the equipment on the non‑modernized side had already become unreliable in operation. In addition, maintenance expertise and spare parts for the 1950s‑era pneumatic circuit breakers were increasingly difficult to source.

“When components started to fail, we had to consider renewal on a larger scale. When one of the circuit breakers became stuck in a problematic situation, it caused enough issues that we decided to accelerate the remainder of the project,” Rantanen explains.

Implementation without a single unplanned outage

“Insta renewed the outgoing feeder circuit breakers and disconnectors, as well as protection relays and current transformers with auxiliary equipment, bringing the system fully up to date. The challenge was that the open‑cell switchgear of the old power plant was retained, and the plant remained in operation throughout the cell‑by‑cell renewal process. Only the cell being replaced was de‑energized,” Rantanen explains, continuing:

“In addition to the cement plant, mining operations and a Weber plant also receive power through our facility, so everything had to remain operational without any disruptions.”

Thanks to the dual‑busbar system used at Finnsementti, the modernization could be carried out through switching changes while production continued.

“In that sense, the project was absolutely perfect, the plant did not experience a single unplanned shutdown due to this project,” Rantanen emphasizes.

The project also included the installation of a backup connection, consisting of a 20‑kilovolt switchgear and an intermediate transformer. This enables uninterrupted power transfer to a backup system when needed.

“During annual maintenance, we realized that our old backup connection was undersized, and maintaining the basic infrastructure alone required so much effort that further development was impossible. We had a 20‑kilovolt connection to our neighboring company Paroc’s substation, which effectively served as their backup supply. We came up with the idea of converting the connection to operate in both directions, providing us with a five‑megawatt backup connection. Insta designed the solution based on my initial concepts, and the result was a robust system that allows switching to and from the backup connection without a power outage,” Rantanen explains.

Everything starts with strong cooperation

Mika Salonen, Head of Insta’s Power Distribution Unit, describes the project as extensive, but not one that involved insurmountable challenges.

“Everything starts with good cooperation, including electrical design carried out together with KMJ‑Engineering. Without continuous interaction with the customer, this project would not have been possible,” Salonen says.

“The expertise of the power distribution installation team must also be highlighted. They worked seamlessly together with the customer.”

“Communication worked very well. We could call at any time if something required clarification or confirmation,” Rantanen adds.

“All required changes were known in advance on both sides, and there was no need for extensive discussions beyond agreeing on how and when things would be done. Everything worked perfectly,” Rantanen praises.

With the introduction of new technologies, both personnel safety and fire safety have improved. Rantanen notes a clear increase in system reliability and confirms that the plant has not experienced a single power outage caused by equipment failure in the past two years.

Salonen adds that avoiding system‑related disturbances requires systematic and regular preventive maintenance to keep equipment in proper condition.

Rantanen concludes that trust in Insta’s expertise grew even further during the project.

“There is truly an impressive level of expertise behind everything,” he summarizes.

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