Power factor
The power factor survey process
A power factor survey is the critical first step in maintaining the efficiency and longevity of a PFC system. The process evaluates financial viability from your municipal bill, then runs a thorough onsite inspection and health report. Fixing component issues proactively helps you avoid costly demand charges and equipment failure, backed by data-driven maintenance and continuous monitoring.
- A power factor survey is the first step to an efficient, long-lived PFC system.
- It starts with your municipal bill, to confirm the financial case for correction.
- An onsite inspection tests every component and records its condition, including dust and heat marks.
- A detailed health report and continuous monitoring keep the system effective.
Phase 1: consultation and financial viability
A survey is the first step in confirming the financial case for correction. It begins by:
- Evaluating the municipal bill to determine whether the site is on a demand-based tariff, which confirms the viability of correction.
- Assessing load and capacity where the site is not on a demand-based tariff, to see whether correction is needed to use its full available capacity.
- Consulting to identify how many systems are installed, their operating voltage and their current status.
From this, a detailed quotation is provided for the full inspection and survey, tailored to the equipment onsite.
Phase 2: onsite inspection, testing and safety
- Test critical components: capacitors, fuses, contactors, reactors and controllers, so each is operating correctly and the risk of failure is reduced.
- Controller setup: verify and configure settings to match the system and the site's load conditions.
- Safety parameters: confirm all protection and safety settings to prevent degradation and hazards.
- Dust and heat marks: record dust, debris and discolouration that can cause overheating or shorts. The panel is cleaned with the repairs that follow the survey.
Neglecting PFC maintenance in the high-dust, high-heat environments common in South Africa significantly raises the risk of electrical fires and prolonged downtime. Given the severe cost of demand charges, professional annual surveys protect both finances and safety compliance.
Phase 3: data-driven next steps and monitoring
After the survey, a comprehensive health report details the condition of every component, flags any issues, and sets out actionable recommendations, including a panel clean where dust is found. Continuous monitoring then keeps the system efficient between visits, so correction stays effective as the load changes.
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What does a power factor survey involve?
Three phases: an initial consultation that checks financial viability from your municipal bill, a detailed onsite inspection and component-level testing, and a health report with data-driven next steps and continuous monitoring.
How is financial viability assessed?
By evaluating your municipal bill to see whether you are on a demand-based tariff. If you are, correction reduces demand charges. If you are not, the survey assesses whether correction is needed to use your full available capacity.
What is tested during the onsite inspection?
Capacitors, fuses, contactors, reactors and controllers are all tested, controller settings verified, safety and protection parameters confirmed, and dust and heat marks recorded. The panel is cleaned with any repairs that follow the survey.
Why are regular surveys important in South Africa?
In high-dust, high-heat industrial environments, neglecting PFC maintenance raises the risk of electrical fires and downtime. Given the cost of demand charges, annual surveys protect finances and help satisfy insurance and health-and-safety requirements.
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