Project Overview
Project Type: Critical Power Quality Enhancement for Semiconductor Production Line
Completion Date: January 2024
Location: Tampines Industrial Park, Singapore
Client: Leading Global Semiconductor Manufacturer (Singapore Facility)
Technical Challenge & Solution
Challenge: To eliminate harmonic interference, voltage transients, and ground loop currents affecting sensitive lithography and testing equipment in a Class 1000 cleanroom environment. The solution required ultra-stable, electrically isolated power with minimal electromagnetic interference (EMI) and compact footprint due to space constraints in the facility's technical galleries.
Solution: TSTYNICE supplied and installed specially engineered three-phase isolation transformers with enhanced shielding and indoor-optimized thermal management systems.
Equipment Supplied
3-Phase Isolation Transformer (High-Precision): 300 kVA, Delta-Wye Configuration
3-Phase Isolation Transformer (Process Power): 575 kVA, Delta-Wye Configuration
Voltage Ratio (Both Units): 400V ±1% / 400V (Floating Secondary Neutral)
Quantity: 1 unit each (300 kVA & 575 kVA)
Enclosure: IP31-rated indoor casing with anti-corrosion coating (RAL 7035)
Cooling: ONAN + Forced Air (Integral Thermostatically Controlled Fans)
Mounting: Indoor, floor-mounted with vibration damping pads
Key Technical Features & Specifications
Electrostatic Shielding (Faraday Shield): Triple-layer, copper-foil electrostatic shielding between primary and secondary windings to suppress common-mode noise and high-frequency transients (>60 dB attenuation).
Low Stray Magnetic Field: Core and winding design optimized to minimize stray magnetic flux (<5 mT at 1m), preventing interference with adjacent sensitive instrumentation.
Enhanced Insulation (Class H): 180°C rated insulation system for high thermal endurance and reliability in Singapore's tropical climate.
Precision Voltage Regulation: Tight impedance matching (±2%) and use of high-grade, grain-oriented silicon steel cores to ensure voltage regulation better than 1.5% from no-load to full-load.
Silent Operation: Fans equipped with EC (Electronically Commutated) technology for variable speed control, ensuring noise levels below 55 dB(A) during normal operation.
Integrated Monitoring: Built-in PT100 sensors for winding temperature monitoring, with alarm and trip contacts. Local digital display for voltage, current, and temperature.
Compliance: Designed and tested to meet or exceed SS 323 (Singapore Standards), IEC 61558-1, and IEEE C57.12.01.
Project Execution
Phased Delivery & Installation: Coordination with the client's plant shutdown schedule to install the 575 kVA unit for the process line first, followed by the 300 kVA unit for the precision instruments, minimizing production disruption.
Custom Interface Integration: Secondary terminals configured with insulated copper busbars for direct connection to the client's existing PDU (Power Distribution Unit), eliminating cable lugs and reducing connection points.
Site-Specific Adaptations: Casing design included front and rear removable panels and top cable entry options to align with the facility's tight cable routing pathways.
Comprehensive Testing: Pre-delivery tests included routine tests, special impulse tests, heat run tests, and most critically, shielding effectiveness tests and THD measurement under load to validate performance specifications.
Operational Results
Power Quality Dramatically Improved: Measured reduction in common-mode noise by over 85%, eliminating sporadic faults in the wafer inspection systems.
Equipment Uptime Enhanced: The photolithography tool's Mean Time Between Failures (MTBF) related to power issues increased by over 30%.
Stable Thermal Performance: Forced air cooling system maintains winding temperatures within 65°C rise even during sustained 90% loading in an ambient temperature of 28°C.
Space Efficient: The compact, integrated casing design saved approximately 15% floor space compared to the client's initial separate-transformer-and-ducting plan.
