Model Workers Help Enterprises Solve Tough Problems! Henan Provincial Model Worker Hu Changqing Offers On-Site Solutions to Assist Two Companies in Overcoming Pain Points in Reactive Power Compensation Equipment

“We’re fined 3,000 yuan every month for failing to meet the power factor standard, and when the equipment breaks down, we still can’t pinpoint the problem. At this rate, we simply won’t be able to absorb the rising production costs!”

Recently, the heads of two enterprises in Xiaoguan Town and Xinzong Town shared their “power-use challenges” with Hu Changqing, a model worker from Henan Province: their reactive power compensation devices are not functioning properly, resulting in power factors that consistently fail to meet the State Grid’s standard of 0.9 to 1. This not only exposes them to ongoing fines but also presents difficulties in fault diagnosis and frequent recurrence after repairs, casting a “safety shadow” over their production operations. Upon learning of the situation, Hu Changqing promptly visited both companies, conducted an on-site “diagnosis,” and provided tailored renovation recommendations, thereby alleviating their urgent predicament.

The equipment is operating while faulty, with problems deeply concealed.

“As you can see, this compensation device always ‘lets us down’ during peak production periods—the power-factor meter needle stubbornly hovers around 0.85, and the power-supply bureau’s penalty notices arrive on time every month,” the person in charge said helplessly, pointing to the reactive-power compensation unit inside the distribution room of a small enterprise in Xiaoguan. Hu Changqing put on his hard hat, bent over to carefully inspect the equipment’s operating condition, used a multimeter to measure the capacitor values, and simultaneously asked the electrician about routine maintenance: “How do you normally troubleshoot faults? How often should vulnerable components like capacitors and contactors be replaced?” After a half-hour on-site inspection, Hu Changqing quickly identified the company’s core pain points: first, fault diagnosis lacks a systematic approach—electricians rely solely on visual inspection and auditory cues to pinpoint problems. When faced with hidden faults such as capacitor failure, contactor contact burnout, or loose wiring terminals, they often fail to locate the root cause, resulting in ad-hoc repairs that involve dismantling and replacing parts here and there, which not only wastes time but also drives up costs; second, the switching strategy is imprecise, and the equipment does not…

Adjusting the number of capacitors put into service in response to changes in production load results in “under-compensation” (low power factor) during peak daytime operations and “over-compensation” when nighttime loads are low, which not only degrades power quality but also accelerates component aging. Thirdly, spare-parts inventory management is unscientific: the company fails to stockpile critical emergency spares. During the last equipment failure, the delay caused by waiting for new capacitors to arrive amounted to two days, during which the power factor remained below the required standard, resulting in an additional penalty payment.

At another enterprise, Hu Changqing encountered similar problems—and even instances of “incomplete repair”: the contactor contacts were merely wiped down without being sanded to remove the oxide layer, resulting in poor electrical contact after power was applied and causing the equipment to fail again within a week of operation. “These issues may seem minor, but over time they not only undermine the company’s economic performance but also create safety hazards for the power supply system,” Hu Changqing stated sternly.

Three-Step Transformation: Precise Breakthrough

In light of the common challenges faced by the two companies as well as their specific differences, Hu Changqing drew on his many years of experience in the operation and maintenance of electrical equipment to provide on-site “three-step” renovation recommendations, each of which adheres strictly to the principles of practicality, low cost, and easy implementation:

Step 1: Develop a “Simplified Troubleshooting Checklist” to expose faults for what they really are. “You don’t need to rely on complex diagnostic equipment—just a checklist and a multimeter are enough to pinpoint the problem,” says Hu Changqing. On site, he hand-wrote a “Troubleshooting Checklist for Reactive Power Compensation Devices,” outlining three core inspection items: First, use a multimeter to measure the compensation capacitors, noting that “the actual capacitance must be within ±10% of the rated value; if there is no capacitance or leakage, the capacitor must be replaced.” He also provided hands-on instruction on how to read the measurements and determine whether a capacitor is good or bad. Second, inspect the contactor contacts, emphasizing that “if you find signs of burning or oxidation, immediately sand them down; if the damage is severe, replace the contactor outright—each replacement costs only about 50 to 100 yuan, so don’t let a small issue lead to a major problem.” Third, examine the wiring terminals, requiring that “every time you perform an inspection, tighten the connections with a wrench and affix a ‘Inspected’ label afterward to avoid redundant work.” He further recommended that companies assign responsibility for these inspections to the electricians on each shift, having them spend just 10 minutes before starting work to complete the check, thereby reducing failures at the source.

Step 2: Customize a “Time-Phased Capacitor Switching Schedule” to Ensure Power Factor Compliance. “When the load changes, the number of capacitors put into service must change accordingly; otherwise, the system will be operating inefficiently,” says Hu Changqing. Based on the production patterns of the two enterprises, he tailored individual “Capacitor Switching Schedules.” Taking the production period from 8:00 a.m. to 6:00 p.m. as an example, he recommends that the enterprises use clamp-on ammeters to measure actual current: when the current exceeds 80% of the rated current, 6 to 8 sets of capacitors should be switched in; during the non-production hours from 6:00 p.m. to 8:00 a.m. the next day, only 2 to 3 sets of capacitors should remain in operation. In addition, he advises the enterprises to install a “large-dial power-factor meter” (with a dial diameter of at least 10 cm) on the control panel, with the compliance range of 0.9 to 1 marked in green, so that operators can instantly read the value. If the power factor falls below 0.9, capacitors should be manually added immediately; if it rises above 1, the number of capacitors in service should be reduced—thus completely resolving the problems of under-compensation and over-compensation.

Step 3: Stock an “Emergency Spare Parts Kit” to ensure repairs are carried out without delay.

“The biggest challenge in fault repair is waiting for spare parts; it’s essential to stock ‘life-saving’ spares in advance.” Hu Changqing recommends that the two companies, based on the models of their respective equipment, each maintain a reserve of 2–3 sets of compensation capacitors (priced at RMB 200–300 per set) and two contactors, stored in a dedicated toolbox in the distribution room and clearly labeled “Emergency Spare Parts.”

Model worker offers advice—now I feel confident.

After hearing Hu Changqing’s recommendations for improvement, the furrowed brows of the two company leaders finally relaxed. One of the companies’ electricians remarked on the spot: “In the past, troubleshooting felt like groping in the dark; now that we have a checklist, we can complete the inspection in just 10 minutes, and we’ll have a clear roadmap for future repairs.”

Currently, the two companies have initiated the retrofit in accordance with Hu Changqing’s recommendations, promptly procuring multimeters, large-dial power-factor meters, and emergency spare parts. Meanwhile, the electrical maintenance team has begun conducting routine inspections based on the “Troubleshooting Checklist.” “We expect to complete the entire retrofit within one week, and next month our power factor will definitely meet the standard—no more fines!” said the company’s head with full confidence.

This “Model Worker Assistance to Enterprises” initiative led by Hu Changqing not only resolved practical challenges for the Xiaoguan and Xinzong enterprises, but also demonstrated, through professional and pragmatic actions, the exemplary role of model workers in mentoring, supporting, and solving problems. Moving forward, the local authorities will continue to leverage the talent advantages of model workers by establishing a dedicated platform for connecting model workers with enterprises, enabling more companies to overcome production bottlenecks under their guidance and thereby fostering high-quality enterprise development.

(Writer: Wu Lihui; Photographer: Wu Lihui; Reviewer: He Jihua)