Design reference
Power factor explained
Power factor is the difference between the power a load actually converts into work and the power the cable and protective device have to carry. Get it wrong in a design and the current you calculate is too low — which means the cable, the device and the volt drop are all wrong with it.
The three powers
Alternating current loads that store energy in a magnetic or electric field — motors, transformers, ballasts, some switch-mode supplies — draw current that is out of step with the voltage. That out-of-step current still flows in the cable, still heats it, and still counts towards the protective device rating, but it does no useful work.
- • True power (kW) — the part that does work: heat, light, torque. What the energy meter bills.
- • Reactive power (kVAr) — the part that shuttles back and forth charging and discharging fields. Does no work, but occupies capacity.
- • Apparent power (kVA) — the vector sum of the two. This is what the cable, the MCB and the supply actually see.
Formulae
power factor = kW ÷ kVA = cos φ
Single phase: Ib = P ÷ (Uo × pf)
Three phase: Ib = P ÷ (√3 × U × pf)
kVA = √(kW² + kVAr²)
Why it changes the design
Take a 3 kW load on a 230 V single-phase supply:
- pf 1.00 (resistive heater)
- 13.0 A
- pf 0.95 (mixed / good LED)
- 13.7 A
- pf 0.85 (heat pump)
- 15.3 A
- pf 0.70 (uncorrected fluorescent, small motor)
- 18.6 A
- pf 0.50 (cheap LED driver, welding set)
- 26.1 A
Same kilowatts, double the current. At pf 0.5 that 3 kW load has moved from a comfortable 16 A circuit in 1.5 mm² to needing 32 A protection and 4 mm² — and volt drop, which is proportional to current, has doubled with it. This is the single most common way a paper design under-sizes a real installation.
Typical values by load type
Use the equipment data plate or manufacturer's data wherever it exists. The figures below are design guidance only, for use when nothing better is available.
| Load | Typical pf | Notes |
|---|---|---|
| Resistive heating — immersion, storage heater, panel heater | 1.00 | Purely resistive; kW = kVA. |
| Electric shower | 1.00 | Resistive element. Size on full rated kW, no diversity. |
| Cooker / oven / hob (resistive elements) | 1.00 | Induction hobs draw slightly lower — allow 0.95. |
| GLS / halogen lighting | 1.00 | Legacy filament lamps are resistive. |
| LED lighting — good quality driver | 0.90 – 0.95 | Driver data sheet states it. Cheap drivers can be 0.5. |
| LED lighting — low-cost / retrofit lamps | 0.50 – 0.70 | Often non-linear too; watch neutral currents on three-phase. |
| Fluorescent, magnetic ballast (uncorrected) | 0.50 – 0.60 | Capacitor-corrected fittings reach ~0.90. |
| EV charge point (mode 3, 7.4 kW) | 0.98 – 1.00 | Modern on-board chargers are near-unity by design. |
| Air source heat pump / air conditioning | 0.85 – 0.95 | Inverter-driven units are better than fixed-speed. |
| Single-phase induction motor (pump, fan, compressor) | 0.60 – 0.80 | Worst at part load. Check the nameplate. |
| Three-phase induction motor at full load | 0.80 – 0.90 | Falls to ~0.4 at no load. |
| Welding set, small transformer | 0.50 – 0.70 | Highly inductive and intermittent. |
| Mixed domestic final circuits (sockets, general use) | 0.95 | A reasonable design assumption where the load is unknown. |
| Mixed commercial / small industrial supply | 0.85 – 0.90 | Use measured data from a supply analyser where possible. |
Leading, lagging and distortion
- • Lagging — inductive loads (motors, transformers, ballasts). Current lags voltage. By far the most common in UK installations.
- • Leading — capacitive loads, or over-correction. Current leads voltage. Over-corrected banks on lightly loaded sites can cause voltage rise and upset generator or UPS control.
- • Distortion power factor — with switch-mode supplies, LED drivers, VSDs and IT loads the current is not a clean sine wave at all. The true (total) power factor is displacement × distortion, so a load that looks like cos φ 0.98 can have a total pf nearer 0.6. Third-harmonic currents from these loads add in the neutral of a three-phase circuit, which is why the neutral is sized as a current-carrying conductor and Table 4Ab derating applies.
Correction — when it's worth it
Domestic installations are not billed for reactive power, so correction is almost never justified in a house. On commercial and industrial supplies the DNO or supplier may levy an availability or reactive charge, and poor power factor eats transformer and cable capacity you have already paid for.
- • Fixed capacitors at the load — simple, cheap, best for a single large motor running continuously. Never fit across a motor fed by a VSD.
- • Automatic capacitor banks — switched steps at the main panel, controlled by a relay measuring site pf. Standard for varying commercial loads.
- • Detuned / harmonic-filtered banks — required where there is significant harmonic content, otherwise the capacitors and supply impedance can resonate and destroy the bank.
- • Active harmonic filters — electronic correction of both displacement and distortion. Expensive, but the only real answer on heavily non-linear sites.
BS 7671:2018+A4:2026 Chapter 81 and Appendix 17 treat power factor correction as part of the energy efficiency assessment of an installation, alongside load profiling, transformer sizing and conductor selection.
Mistakes to avoid
- • Assuming pf 1.0 for everything because the domestic examples in the books do.
- • Using the kW figure from a motor nameplate as the input power — that figure is output power; divide by efficiency as well as pf.
- • Correcting a motor fed through a variable speed drive — the drive already presents its own input characteristic and capacitors can damage it.
- • Ignoring distortion pf on LED and IT loads, then finding the neutral running hotter than the lines.
- • Over-correcting a site that runs light out of hours, producing a leading pf and voltage rise.
Need a circuit designed properly?
Paul designs and installs new circuits across Brighton, Hove and Sussex — sized on measured load and real power factor, not guesswork.