Power Factor Solution
POLARIS offers comprehensive power factor correction solutions designed to improve electrical system efficiency, eliminate reactive power penalties from utilities, and reduce overall electricity costs for industrial and commercial facilities. Poor power factor is one of the most common and costly electrical inefficiencies — causing higher current draw, increased cable and transformer losses, voltage drops, and stiff utility penalties. POLARIS approaches power factor correction as a complete engineered solution — starting with a load profile analysis and harmonic assessment, followed by system design (capacitor bank sizing, APFC controller selection, detuned reactor specification), supply and installation of the APFC Panel, and verification testing to confirm PF improvement. POLARIS also offers retrofit capacitor bank upgrades for existing panels, and thyristor-based fast-switching solutions for fluctuating loads.
Key Features
- End-to-end power factor correction from load analysis and system design to installation and testing.
- APFC Panel supply with automatic capacitor switching for continuous PF maintenance above 0.95.
- Harmonic assessment and detuned reactor sizing to prevent capacitor resonance issues.
- Thyristor-based fast-switching solutions for rapid load fluctuation environments.
- Retrofit capacitor bank additions to existing LT panels and distribution boards.
- Power quality analysis and energy audit services to identify PF improvement opportunities.
- Capacitor bank installation with proper protection, earthing, and discharge provisions.
- Post-installation verification testing and PF improvement report for utility compliance.
- Solutions for single-point installation or distributed capacitor placement strategies.
- Applicable for manufacturing, commercial buildings, pumping stations, and utilities.
Frequently Asked Questions
What causes poor power factor in industrial facilities?
Poor power factor is mainly caused by inductive loads such as induction motors, transformers, welding machines, and induction heating systems. These loads draw reactive (magnetising) current from the supply in addition to active (useful) current — increasing the total current and reducing power factor.
How much can POLARIS's power factor correction solution reduce electricity bills?
Savings depend on the existing power factor and the utility's tariff structure. Typically, industries with a power factor below 0.85 can save 5-15% on electricity costs by correcting it to 0.95+. In addition, PF penalty charges are eliminated, and transformer capacity is freed up for additional loads.
What is the process POLARIS follows for power factor correction projects?
POLARIS starts with a site assessment and load profile analysis using power quality meters. Based on reactive power demand and harmonic levels, the capacitor bank is designed with appropriate KVAR rating, staging, and detuned reactors. After supply and installation of the APFC Panel, post-commissioning PF verification is done and documented.
Is a harmonic study necessary before installing capacitor banks?
Yes, especially for facilities with non-linear loads like VFDs, UPS systems, and rectifiers. Capacitors can resonate with system inductance at harmonic frequencies, causing overloading and failure. POLARIS performs harmonic analysis and includes appropriately rated detuned reactors in the design to prevent resonance.
Can POLARIS retrofit power factor correction into existing electrical panels?
Yes. POLARIS can design and install capacitor banks as a retrofit addition to existing LT panels, main distribution boards, or as standalone APFC Panels installed alongside existing switchgear. This avoids the need to replace existing infrastructure while achieving significant PF improvement.