Client: Alliance Seed Cleaning Plant
Industry: Agriculture
Location: Alberta
Project Type: Targeted Power Factor Correction – Motor-Based Capacitor Banks
Scope: Power Quality Recording | Utility Bill Analysis | Capacitor Bank Design | Installation | Commissioning
Project Overview
Alliance Seed Cleaning Plant was experiencing electrical strain, recurring utility penalties, and overloading concerns on its transformer bank. ATCO Electric noted that the feeding transformer was consistently running above its rated capacity, with phase currents averaging 213 A on equipment rated for 180 A.
Current Group was brought in to investigate the issue and deliver a complete power factor correction solution. Following onsite measurements, engineering analysis, and targeted capacitor installation, the plant now operates with lower electrical stress, reduced kVA demand, and a significantly improved power factor.
Identifying the Problem
ATCO’s field measurements and billing data revealed two core issues:
- The transformer was overloaded by approximately 18 percent during peak operation.
- The plant’s power factor averaged only 68 percent, creating both safety concerns and monthly financial penalties.
Current Group’s power quality recording confirmed that the facility was drawing as much as 115 kVA during peak conditions, far above the transformer’s designed 75 kVA capacity. The majority of this excess load came from reactive demand generated by key motor systems, including the dust collector, air compressor, main leg, and gravity fan.
Engineering the Solution
The project team determined that a motor-based correction strategy would deliver the most accurate and efficient results. Rather than install a single large capacitor at the service entrance, Current Group engineered dedicated capacitor banks sized for the four major motors responsible for the bulk of reactive load.
This approach ensured that capacitors only activated when their associated motors were running, preventing over-correction and ensuring reliable ongoing performance. The installation also reduced loading on the plant’s main fused switch, bringing it safely back below its continuous operating limits.
An optional real-time power meter was added to allow the facility to monitor kW, kVA, kVAR, and power factor remotely, providing transparency and long-term performance verification.
Results & Impact
The project delivered measurable improvements in efficiency, reliability, and electrical safety.
| Project Focus | Outcome |
|---|---|
| Power Factor | Improved from 62–72% to 90%+ after correction |
| Utility Penalties | Eliminated, saving $2,200–$2,800 per year |
| Electrical Loading | Reduced transformer loading and conductor temperatures |
| Main Switch Performance | Load reduced from approximately 203 A to about 151 A |
| Equipment Longevity | Lower thermal stress and reduced risk of future failures |
| System Capacity | Increased available headroom without utility service upgrade |
With the power factor correction project, Alliance Seed Cleaning Plant is operating with improved electrical stability, lower operating costs, and greater long-term reliability. Current Group’s targeted motor-based capacitor strategy corrected the reactive load at its source, resolved ATCO’s safety concerns, eliminated monthly penalties, and strengthened the plant’s electrical infrastructure for future growth.
