The Problem in Detail
The site was operating with ageing Power Factor Correction (PFC) equipment that no longer reflected the facility’s operating demands. Performance varied across the network, and power factor values reduced significantly during low-load conditions. A seven-day survey identified deteriorating capacitor banks and switching components, alongside increasing concerns around reliability and future maintenance requirements.
Finding the Solution
Enspec carried out detailed power quality analysis across all seven transformer incomers to understand how the network behaved under changing site conditions. Active, reactive and apparent power demand were monitored throughout the survey period. Harmonic levels remained within acceptable planning limits, allowing the power factor correction upgrade to proceed without the need for harmonic detuning.
Making it all Work
The power factor correction upgrade was engineered using measured site data rather than nominal design assumptions. Each PFC unit was designed around actual operating demand and low-load performance requirements. Installation works were completed during a planned shutdown using pre-engineered equipment, allowing the full upgrade to be delivered without interruption to manufacturing operations.
The Value Enspec Added
Enspec's Site Services Team planned and delivered the power factor correction upgrade during a scheduled site shutdown, allowing all installation works to be completed without disrupting manufacturing operations. This reduced the risk of unplanned downtime and avoided unnecessary operational costs associated with extended outages. The final system design also introduced a consistent architecture across the site, simplifying future maintenance and ongoing support requirements.
What that means for the project now
The completed power factor correction upgrade now provides stable performance across all seven transformer incomers. The site benefits from improved network utilisation, lower maintenance risk and greater confidence in the long-term reliability of the electrical infrastructure.
Power Factor Correction Upgrade Delivered Within Planned Shutdown
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