Case study · Manufacturing
Leading power factor at Chet Chemicals.
In September 2026 we surveyed the power factor correction panel at Chet Chemicals in Germiston. The site read a power factor of 0.92 leading, and the panel was delivering 188.7 of its 238 kVAr. We found a worn contactor, a blown fuse and capacitors losing capacitance on two steps. The repair was quoted the next day at R4,184 ex VAT.
- The panel was delivering 188.7 of its 238 kVAr, and the site read a power factor of 0.92 leading.
- Four steps had a fault, a noisy contactor, a blown fuse, uneven capacitance and low capacitance.
- A panel short of kVAr that still reads leading points to switching or settings, not size.
- The repair was quoted at R4,184 ex VAT, most of it four 30 kVAr capacitors.
By Oliver Nesbitt, Sales & Client Relations, Augos Energy
What does a leading power factor mean?
Most plants have a lagging power factor. Motors draw reactive power and the PFC bank puts capacitive kVAr back to cancel it. When the bank puts in more than the load needs, the site goes leading. It's still a power factor below 1.0, so it still raises kVA.
At Chet Chemicals the panel was short of kVAr overall, but the site was still reading leading. That points to switching, not size: steps staying in when they should drop out, or a controller setting that doesn't match the load.
What did the survey find?
The panel has a Lovato DCRL8 controller on a 1250/5 CT. We tested each step on 2 September 2026:
- Step 1: the contactor was noisy and deteriorating.
- Step 2: the HRC fuse on the blue phase had blown. All three fuses were removed so the step couldn't run on two phases.
- Step 4: capacitance readings were uneven across the phases.
- Step 5a: capacitance was low.
Total measured output was 188.7 kVAr against 238 kVAr installed, about 21% short.
What did the repair cost?
The quote went out the next day, 3 September, at R4,184 ex VAT:
| Item | Amount |
|---|---|
| 4 × 30 kVAr 440 V capacitors | R1,999 |
| 12.5 kVAr contactor | R220 |
| 3 × 63 A fuses | R35 |
| Travel | R430 |
| Labour | R1,500 |
| Total, ex VAT | R4,184 |
What was the saving?
The site isn't metered on our platform, so I can't give a measured rand saving. We'd need the utility bills before and after the repair, or a meter on the incomer.
What I'd tell any plant engineer
A leading power factor isn't a sign your PFC is doing extra well. It means something in the panel isn't switching the way it should. Get the contactors and controller settings checked along with the capacitors.
Figures from the Augos PFC survey report of 2 September 2026 and quote of 3 September 2026.
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A bank that lost a quarter of its capacity without tripping.
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Why a good controller reading doesn't mean a healthy panel.
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Questions
What does a leading power factor mean?
The site has more capacitive kVAr switched in than its load needs, so current leads voltage instead of lagging it. It usually means capacitors are staying in when the load drops, or the controller is set wrong.
Is leading power factor a problem?
It can be. A power factor below 1.0 raises kVA whether it is leading or lagging, and too much capacitance on a lightly loaded site can push voltage up. Whether your tariff penalises it depends on the utility.
What does a noisy contactor tell you?
The contacts or coil are wearing. A contactor that chatters or buzzes can fail to switch a step in or out, which is one way a panel ends up over- or under-correcting.
Why were the fuses removed from a step?
One HRC fuse on the blue phase had blown. The other two were removed so the step couldn't run on two phases until it was repaired.
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