Case study · Food & Beverage
A burned contactor behind a 0.99 power factor at Eagle Springs.
On 31 August 2026 we surveyed the power factor correction panel at Eagle Springs. The controller read a power factor of 0.99, but the panel was delivering 147.1 of its 180 kVAr. The step 1 contactor had burned contact points on the red phase, and that step was giving 12.9 of its 30 kVAr. The fix was quoted at R1,908 ex VAT.
- The controller read 0.99, but the panel was delivering 147.1 of its 180 kVAr.
- The step 1 contactor had burned contact points on the red phase, leaving that step at 12.9 of 30 kVAr.
- The other steps were covering for it, with less in reserve for a heavier load.
- Caught on the annual survey, the fix was quoted at R1,908 ex VAT including travel and labour.
By Oliver Nesbitt, Sales & Client Relations, Augos Energy
Why isn't a good power factor reading enough?
Because the controller only tells you the result, not what it's costing the panel to get there.
At Eagle Springs the panel has a Lovato DCRL5 controller on an 800/5 CT, and on 31 August 2026 it read a power factor of 0.99. On the annual survey we measured every step. The step 1 contactor had burned contact points on the red phase, and that step was giving 12.9 of its 30 kVAr. Across the panel, 147.1 of 180 kVAr was working, and step 1 accounted for 17.1 kVAr of that 32.9 kVAr shortfall. The other steps were covering for the weak one, but with less in reserve for a heavier load.
What does an annual survey check?
For every step in the panel, the technician records:
- Rated kVAr
- Current on each phase
- Measured kVAr
- Contactor condition
- Fuse condition
- Capacitor condition, including capacitance where needed
For the panel as a whole, they record total installed against total measured kVAr, the controller make and model, the target and operating power factor, the CT ratio and the supply voltage on each phase.
What did it cost to fix?
One contactor, quoted at R1,908 ex VAT including travel and labour. Left alone, a burned contactor can fail completely, and then the whole step is gone.
What I'd tell any plant engineer
A good number on the controller is the start of the conversation, not the end of it. Get every step tested once a year, while the fix is still one contactor.
Figures from the Augos PFC survey of 31 August 2026 and its quote.
In this story
The tools behind the result.
Power factor correction
How power factor is measured, priced against your tariff and kept corrected.
Explore ›Blown fuses and tired capacitors at In2Foods
A bank that lost a quarter of its capacity without tripping.
Explore ›Leading power factor at Chet Chemicals
A panel short of kVAr that was still reading leading.
Explore ›The rest of Augos Energy
Energy management
Each site metered, priced on its own tariff and every bill checked against the meter.
Explore ›Bill verification
Every bill rebuilt from your own meter and the tariff, line by line.
Explore ›Tariff optimisation
Your metered load priced on every tariff your site qualifies for.
Explore ›Tenant billing
Each tenant sub-metered and billed on what they used.
Explore ›Energy procurement support
Wheeling, PPA and solar offers replayed on your own 30-minute load.
Explore ›Energy reporting
Measured data by site and period, as downloads, by API or as AI-ready exports.
Explore ›More case studies
More results, with their basis.
Questions
My power factor is 0.99. Do I still need a survey?
Yes. A panel can read 0.99 and still have a failing step. This one was delivering 147.1 of its 180 kVAr with a burned contactor.
What does an annual PFC survey check?
Every step in the panel: current on each phase, the kVAr it delivers against its rating, the fuses, the contactor and the capacitors. It also records the controller model and settings, the target and operating power factor, the CT ratio and the supply voltage.
Why do contactors fail in PFC panels?
Every time a step switches in, the contactor carries a surge of current. Over time the contact points burn, and the step delivers less than its rating or stops switching altogether.
Do I need Augos metering to get a survey?
No. The survey is done at the panel with test instruments. Metering adds a monthly view of power factor and cost between surveys, but it isn't needed.
Free site assessment
Assess your measurement point and get a quote.
Tell us the site type, supply size and number of sites, photograph the measurement point, and we quote. Electricity now; water, gas and fuel next.