Introduction #

Poor power factor costs industrial plants through higher demand charges, transformer stress, and reduced system capacity. This guide shows how to diagnose low power factor, select the right correction approach, and verify results safely.

What Is Power Factor and Why It Matters #

  • Power factor (PF) is the ratio of real power (kW) to apparent power (kVA).
  • PF below 0.9 typically triggers utility penalties and forces larger upstream gear.
  • Improving PF frees capacity, reduces losses, and stabilizes voltage.

Common Causes of Low PF #

  • Induction motors running lightly loaded
  • Welders and arc furnaces
  • Older fluorescent lighting ballasts
  • Large HVAC compressors

Measuring and Baselining #

  • Use a power meter that reports kW, kVA, and PF at main and key feeders.
  • Capture load profiles over shifts to see worst-case PF.
  • Note harmonic content; heavy harmonics may need detuned filters.

Sizing Capacitors (kVAR) – Step by Step #

kVAR = kW × (tan φ₁ – tan φ₂)
  • φ₁: angle of existing PF; φ₂: angle of target PF (e.g., 0.95).
  • Example: Improve from 0.78 to 0.95 on 500 kW load
    tan φ₁ (0.78) ≈ 0.79 - tan φ₂ (0.95) ≈ 0.33 - kVAR = 500 × (0.79 – 0.33) ≈ 230 kVAR
### Where to Place Capacitors
  • Main bus: Simplest, helps system-wide PF.
  • At large motors: Reduces feeder currents and voltage drop.
  • Automatic banks: Best for variable loads; steps switch in/out.

Avoid Overcorrection #

  • Target 0.95–0.98 to avoid leading PF that can trip generators or UPS.
  • Use stepped banks with contactors or thyristor switching for fast-changing loads.

Harmonics and Detuned Banks #

  • If THD(V) > 5% or many VFDs exist, use detuned capacitor banks (series reactors) to avoid resonance near 5th/7th harmonics.
  • Specify tuning (e.g., 189 Hz for 50 Hz systems) per utility/IEC guidance.

Protection and Switching #

  • Provide fusing per bank step; consider breaker + contactor for each step.
  • Use discharge resistors; verify safe touch voltage before maintenance.
  • For large banks, add temperature sensors and ventilation.

Verification Checklist #

  • Re-measure PF at main incomer under peak production.
  • Confirm feeder currents drop proportionally.
  • Check voltage rise; ensure within code limits.
  • Trend PF over a week to validate automatic switching logic.

Integration With Calculators #

Maintenance Tips #

  • Inspect capacitor banks quarterly for bulging or discoloration.
  • Verify step contactors for wear every 12–18 months.
  • Clean enclosures; dust raises temperature and shortens life.
  • Re-check PF after major load changes or motor additions.

Conclusion #

Improving power factor is a high-ROI project: it lowers utility penalties, frees capacity, and stabilizes voltage. Start by measuring baseline PF, size kVAR properly, use detuned banks where harmonics are present, and monitor results continuously.