While many industries regard 0.95 power factor to be sufficiently high, concerned people here understood there are overpaying at 5% due to power factor. Ideally PF should be above 0.99 and it is economically possible to maintain it in most of the cases.
Tuning of APFC could only bring PF up to 0.96. Given the nature of the process with highly fluctuating loads, it was argued that active harmonic filters are required to achieve unity PF.
Powerbot was introduced just at the right time while this was going on. With Powerbot, continuous data was collected for a week for a detailed analysis.
The data was collected and analyzed by Powerbot. It was evident that indeed harmonics were high but that was not what caused low PF. There was substantial export of reactive energy (i.e. capacitive load). In other words, APFC had over corrected the power factor at certain power and PF levels.
The solution was evident and a small change in APFC design resolved the issue.
Here, Powerbot was installed in the single cost as that for harmonic analysis.