Power Factor Correction Bristol for Sharpak, Yate

Sharpak Yate in Bristol, a member of the Guillin Group is a long-standing PFC maintenance client of Power Efficient Solutions.

The company is the leading manufacturer and supplier of food-quality PP packaging solutions to retailers and the food industry in the United Kingdom. It supplies trays to professionals in the poultry and hospitality sectors for their production of fresh produce and ready meals.

The production facility utilises 6 off incoming LV supplies, with all benefiting from Power Factor Correction.  However, one of the LV supplies had not been as efficient as it should be, due to excessive capacitor deterioration, caused by ‘harmonic distortion’.

We identified this during the annual PFC maintenance visit and recommended the existing ‘standard’ PFC was replaced for ‘detuned’.  The existing standard PFC unit was around 40-years old and was showing its age.  Due to the introduction of non-linear loads, such as inverters, over the last 20-years, the harmonic distortion on site had risen significantly.  This had caused the PFC capacitors within the standard unit to deteriorate to the point of failure, causing the Power Factor to drop to 0.70 (lag).

Rather than just replace the failed capacitors, only for them to fail again in the next few years, we recommended the PFC unit was replaced and a 350kVAr Detuned PFC Unit installed, to ensure trouble-free operation.  Detuned PFC contains filters that absorb excess harmonic distortion and protect the capacitors from the damaging effects.

The client agreed and placed the order to remove the old standard units and replace with the detuned alternative.

Power Factor Correction Installation

The installation went smoothly, however wasn’t without its challenges.  The main issue we had to overcome was that there was no suitably rated switch to facilitate connection to the LV switchgear, and the client needed to avoid any shutdown and loss of production time, to install a suitably rated switch.  We therefore had the 350kVAr unit manufactured as a 150kVAr (Master) & 200kVAr (Slave) units.  This would enable us to utilise 2 off existing 400Amp fused switches on the LV switchgear and avoid the need to isolate the main supply to install a new fused switch.

The whole installation was completed in 2-days, without the need for any loss of power and the clients’ operations continued as normal, without disruption.

The results were that the average Power Factor improved from 0.70 (lag) pre-works to 1.00 (unity) post-works.  The improved Power Factor will not only save the client money, but it will also significantly reduce current draw on the main incoming electrical supply, freeing up more capacity, and will have a beneficial effect on the motors utilised in their manufacturing processes, improving reliability, and reducing future maintenance costs.

Client Testimonial

“Power Efficient Solutions have been servicing our PFC for several years.  We had an issue with an old PFC unit, explained in detail by Steve.  We looked at all options available to the company and moved toward replacing the old ‘standard’ PFC unit for a new ‘detuned’ PFC unit.  From receiving the detailed quotation to installation, Steve kept us fully informed with updates and lead times for project completion.  This project did come with some challenges, which Steve’s team over came with no impact to the company, production, or delay on project completion.  I would recommend Power Efficient Solutions to companies looking for solutions on energy saving.

Power Efficient Solutions are professional, reliable, and trustworthy.”

Justin O’Sullivan

Engineering & Technical Manager

Sharpak, Yate