The Challenge
Electrical monitoring identified elevated harmonic distortion on feeders serving critical production equipment. Harmonic levels exceeded recommended limits, creating concerns around electrical compliance, transformer and conductor heating, and long-term asset reliability. The facility required a solution that would correct harmonics at the source without interrupting production or requiring changes to existing drives or process equipment.
The Solution
XCT deployed Xeco ECBS units on selected nonlinear loads responsible for the majority of harmonic generation. The system dynamically mitigated harmonics at the load level, preventing distortion from propagating upstream into the facility’s electrical distribution system. Installation was completed without production downtime and required no operational changes.
The Results
Post-installation measurements showed a significant reduction in total harmonic distortion, bringing the system back within acceptable operating thresholds. Reduced harmonic content lowered electrical losses and thermal stress across upstream infrastructure while improving overall system stability under varying production conditions.
The Impact
By addressing harmonic distortion at its source, the facility avoided costly infrastructure upgrades and restored confidence in electrical system performance and compliance. The project demonstrated a scalable, repeatable approach to power quality correction for industrial manufacturing environments with high nonlinear loading.
