Plant Managers’ Big Mistake: Power Factor vs Power Quality

I met someone at a power conference in Orlando recently and he asked what I did.  As I explained he said “oh, power factor!”   I paused and gently but firmly corrected him by saying “no, power quality, not power factor.”

This is a common misconception, but the confusion and assumptions are costing companies money and time as plant managers are forced to cope with outdated information or, in most cases, misinformation about power factor.

Power Factor is NOT Power Quality.   They are not interchangeable, nor should you make any assumptions about either.  This point was also driven home by an encounter last month at a large Toronto auto manufacturing facility.  They suspected a power problem and when I arrived, everyone looked to power factor for a solution.  But, to be honest, power factor is the last thing I would look at.  In fact, we spend more time lately actually removing power factor correction capacitors than we do installing them, as they often make the situation worse.  That’s because plants are modernizing their equipment inventories, creating harmonics that interact with the old-style power capacitors, amplifying the problem.

The answer lies with an inverter-based solution, a piece of equipment that has no capacitors so we don’t amplify the harmonic issue.  Power factor doesn’t lower the energy costs, it lowers the penalty you pay the utility.  The problem is solved with modern technology and an open-minded approach to finding the problem.  People will tell you all you have to do is this, and it will save you money.  Often, they’re wrong, because it’s not a power factor issue.

Poor power quality can impact the performance and lifespan of equipment, causing malfunctions, damaging sensitive electronics and leading to production downtime.  On the other hand, a low power factor primarily affects the efficiency and cost of power consumption.  It indicates that a higher amount of power needs to be supplied to achieve the same amount of work, leading to increased energy costs and potential penalties from power suppliers.

Both power quality and power factor are critical for efficient operations at large industrial facilities, but they require different strategies for monitoring, analysis, and correction to ensure optimal performance and cost-effectiveness.

Got questions on Power Quality or Power Factor? Let’s start a conversation! Happy to provide insights and help you navigate your power management challenges! Drop a comment below, DM or reach our to us at @Encompass Power Solutions.