Case Study On Power Factor Improvement

Abstract

Electrical Power constitutes a major component of the manufacturing cost in industry. In an electrical installation, power factor may become poor because of induction motors, welding machines, powertransformers, voltage regulators, arc and induction furnaces, choke coils, neon signs etc. A poor power factor for the plant causes huge amount of losses, leading to thermal problem in switchgears. However power factor is controllable with a properly designed power factor improvement capacitors system. The power factor correction obtained by using capacitor banks to generate locally the reactive energy necessary for the transfer of electrical useful power, allows a better and more rational technical-economical management of the plants. This paper describes different aspects of power factor improvement in a typical industrial plant with the help of a casestudy.

Full text

Case Study On Power Factor Improvement
Samarjit Bhattacharyya, Dr. A Choudhury, Prof H.R. Jariwala
Department of Electrical Engg, S.V.National Institute of Technology, Surat-395007, India
Phone: 91-261-2201564 , Email address: samarjit.bhattacharyya@gmail.com
M.S. Shetty, Reliance Industries Limited, Surat , India
Abstract- Electrical Power constitutes a major component of the manufacturing cost in industry. In an electrical
installation, power factor may become poor because of induction motors, welding machines, power
transformers, voltage regulators, arc and induction furnaces, choke coils, neon signs etc. A poor power factor for
the plant causes huge amount of losses, leading to thermal problem in switchgears. However power factor is
controllable with a properly designed power factor improvement capacitors system. The power factor correction
obtained by using capacitor banks to generate locally the reactive energy necessary for the transfer of electrical
useful power, allows a better and more rational technical-economical management of the plants. This paper
describes different aspects of power factor improvement in a typical industrial plant with the help of a case
study.
Index Terms— Power factor, Capacitor, Nomogram, Reactive power
1. Introduction
Most of the electric energy used in world is generated, distributed and utilised in sinusoidal form. Sources of
this type are frequently called alternating current ( ac) source. The figure-1 shows the typical voltage and
current vectors in an ac circuit. The angle θ between voltage and current is called power factor angle and the
cosine of this angle is called the power factor. The cosine θ depicts that component of current which is in
phase with voltage.
Fig-1, Vector diagram for ac voltage & current
The resistive loads in an electric circuit has a power factor of unity,whereas for a purely inductive load the
power factor is zero. However, in practice, the actual loads in an electric circuit are partly resistive and partly
inductive. This combination of inductive and resistive loads makes the power factor of the plant to a value
between zero and one. Lower the power factor, more are the losses, or in other words for an efficient operation
of the plant, the power factor should be close to unity.
To improve the power factor, shunt capacitors are used. The value of capacitance required is a function of the
type of electrical load in the plant. In view of the capital cost involved for installation of capacitors, a reasonably
high power factor of the order of 0.8 to 0.9 is considered while designing the capacitors for power factor control.
Voltage
Current
θ
A typical vector diagram for ac voltage & current
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2. Working Principle
Reactive power can be described as a by-product of electrical energy system. It circulates through the
generators, transmission lines and transformers, but it is not delivered anywhere. It must be recognised and
accounted for, however, since it plays an important role in the stability, cost of power and voltage control of the
system.
Reactive power is measured much like active power, that is, through a vector product of current and voltage.
Reactive power does not dissipate any energy other than the losses it creates through current circulation in the
equipment and the transmission lines. Every kind of load except a perfect heating load generates reactive power.
Reactive power can be leading ( current vector leading the voltage vector) or it can be lagging ( current vector
lagging the voltage vector). Since reactive power can be leading or lagging, the total balance must be zero. The
leading power is because of capacitance in the power circuit. Similarly, the lagging power is because of
inductance in the power circuit.
Motors, transformers in the industries are large source of lagging ( inductive) power. In order to control
excessive lagging (inductive) power, capacitors may have to be connected in the power circuit. Since capacitors
are the source of leading power, they compensate the lagging power created by common equipment in the
industries like motors and transformers.
Capacitors should be located as near to the load as possible. However, this is not practically possible because of
the cost, availability of space and other environmental conditions. Capacitors can be located as in :
i. Individual Compensation
In such installations capacitors are installed parallel to the equipment and are controlled by a common
switch. This is generally suited for high output induction motors, furnaces, transformers.
ii. Group compensation
This method resorts to compensation of the group of loads fed from the same bus bar. This is particularly
useful when small loads are connected to a common bus bar.
iii. Central Compensation
This can apply to HT and/or LT capacitors. The output of capacitors has to be divided in a number of steps
with auto / manual control depending upon the initial power factor of the load and its variation.
3. Installation Guidelines
capacitors for overhead distribution system can be pole-mounted in banks of 300 to 3600 kVAr at nearly any
primary voltage up to 34.5 kV phase to phase. Pad mounted capacitor are used for underground distribution
system in the same range of sizes and voltage ratings.
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Common Capacitors Connections
Single Phase
Ground to Neutral
Delta
Ungrounded Wye
Grnd
Grounded Wye
Common Methods for connecting Power
Factor Capacitors
Fig-2, Common capacitor connections
The above figure-2 shows four of the most common capacitors connections : 3-phase grounded wye, 3-phase
ungrounded wye, 3-phase delta and single phase. Grounded and ungrounded wye connections are usually made
on primary circuits whereas delta and single phase connections are usually made on low voltage circuits.
The majority of the power capacitor requirement installed on primary distribution feeders is connected grounded
wye. There are a number of advantages from this type of connection. With the grounded wye connection, switch
tanks and frames are at ground potential. This provides increased personnel safety. Grounded wye connections
provide faster operation of the series fuse in case of capacitor failure. Grounded capacitors can bypass some line
surge to the ground and therefore exhibit a certain degree of self protection from transient voltages and lighting
surges. The grounded wye connections also provide a low-impedance path for harmonics. If the capacitors are
electrically connected ungrounded wye, the maximum full current would be limited to three times the line
current. If too much fault current is available, generally above 5000 A, the use of current limiting fuses must be
considered.
4. Estimation of KVAR required to improve power factor:
A quick estimate of capacitive KVAR required for improvement of power factor at a given load can be made
from the Nomogram shown in the figure. However in most cases the capacitor bank rating has to be carefully
selected after due consideration of rated voltage of the system, system over voltages, harmonics in the system,
rating of series reactor etc. A Nomogram ( fig-3) is used for calculating the necessary capacitor rating QC
(kVAr) required to improve the power factor of a load P (KW) :
QC = K x P
Example :
for a load P of 1500 KW, to improve power factor from 0.6 to 0.85, the factor K from Nomogram is 1.4.
QC = 1.4 x 1500 = 2100 kVAr
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Fig-3,Nomogram
Nomogram
Present
Power Factor Desired
Power Factor
0.4
o,45
o.5
0.55
0.6
0.65
0.7
0.75
1.0
0.9
0.8
0.7
0.6
0.5
0.4
2.3
2.2
2.1
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.1
1.0
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
K
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Case Study:
Here in this case study we are considering a industrial installation where there is one HT switchgear with two
incomers and four LT switchgear with two incomers. We have calculated resistance of power cables and busbars
which is required to calculate power loss in the existing power factor. We have taken desired power factor as
0.95 and again calculated the losses at new power factor. The difference between the two is 4.5 kilowatt per
hour. In one year this gain will be 39420 kwhr . If we take Energy cost as Rs 6.5per kwhr, there will be saving
of gain will be Rs 2.56 lakhs. In addition there will be considerable reduction in heating in these switchgears
which will improve the reliability of the switchgear and the power system. Total reactive power required to
improve power factor to 0.95 is 967 Kvar
Parameters with Existing Power Factor
P.F. kW kVAR kVA I(LV) I(HV)(line) I(HV)(phase)
PMCC2
IC1 0.784 342 270 437 607.975 38.22871 22.07200196
IC2 0.765 345 342 445 619.105 38.92855 22.47606607
PMCC3
IC1 0.762 365 307 475 660.842 41.55294 23.99130648
IC2 0.852 367 223 432 601.018 37.79131 21.81946189
PMCC4
IC1 0.909 98 45 109 151.646 9.535307 5.505373487
IC2 0.86 88 52 101 140.516 8.835468 5.101309378
PMCC5
5E 0.874 930 518 1065 1481.68 93.16607 53.79103453
PMCC8
IC1 0.8 40 30 49 68.1711 4.286514 2.474892668
IC2 0.67 37 39 55 76.5185 4.811393 2.77794075
Main IC1 0.686 1385 1476 2020 176.709 35.34187 20.40523751
Main IC2 0.85 4785 2975 5620 491.637 98.32738 56.77100733
Chart:-1 Parameters with existing Power Factor
Parameters with Desired Power Factor
P.F. kW kVAR kVA I(LV) I(HV) I(HV)(phase)
Required
Reactive
Power
PMCC2
IC1 0.95 342 112.409964 360 500.8487 31.49276 18.1828849 157.590036
IC2 0.95 345 113.3960163 363.1578947 505.2421 31.76901 18.3423839 228.6039837
PMCC3
IC1 0.95 365 119.9696984 384.2105263 534.5315 33.61069 19.4057105 187.0303016
IC2 0.95 367 120.6270666 386.3157895 537.4604 33.79486 19.5120432 102.3729334
PMCC4
IC1 0.95 98 32.21104231 103.1578947 143.518 9.02424 5.21030035 12.78895769
IC2 0.95 88 28.92420126 92.63157895 128.8733 8.103399 4.67863705 23.07579874
PMCC5
5E 0.95 930 305.6762178 978.9473684 1361.957 85.6382 49.444687 212.3237822
PMCC8
IC1 0.95 40 13.14736421 42.10526316 58.57879 3.683363 2.12665321 16.85263579
IC2 0.95 37 12.16131189 38.94736842 54.18538 3.407111 1.96715422 26.83868811
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Chart:-2 Parameters with Desired Power Factor
R(ohm/k
m)at
70de
g
C
CABLE
LENGTH(
meter
)
RESISTANCE
(ohm)
THICKN
ESS(m
m
)
WIDTH(
mm)
LENG
TH(m
eter
)
RESISTANCE(
ohm)
HV(ohm) LV(ohm) HV(ohm) LV(ohm)
PMCC2
IC1 0.198 70 0.01386 10 150 7 0.00017808 0.257 0.000365 0.27086 0.00054308
IC2 0.198 75 0.01485 10 150 7 0.00017808 0.257 0.000365 0.27185 0.00054308
PMCC3
IC1 0.198 65 0.01287 10 150 8 0.00020352 0.257 0.000365 0.26987 0.00056852
IC2 0.198 70 0.01386 10 150 8 0.00020352 0.257 0.000365 0.27086 0.00056852
PMCC4
IC1 0.198 65 0.01287 10 150 7 0.00017808 0.257 0.000365 0.26987 0.00054308
IC2 0.198 60 0.01188 10 150 7 0.00017808 0.257 0.000365 0.26888 0.00054308
PMCC5
5E 0.198 70 0.01386 10 150 7 0.00017808 0.257 0.000365 0.27086 0.00054308
PMCC8
IC1 0.198 280 0.05544 10 150 6 0.00015264 0.257 0.000365 0.31244 0.00051764
IC2 0.198 275 0.05445 10 150 6 0.00015264 0.257 0.000365 0.31145 0.00051764
HT
IC1 0.0582 1500 0.0873 10 160 7 0.00016695 0.318 0.003505 0.4053 0.00367195
IC2 0.0582 1500 0.0873 10 160 7 0.00016695 0.318 0.003505 0.4053 0.00367195
CABLE HV(630sq mm Al.)
NET RESISTANCE
Calculation for resistance
CABLE HV(185sq mm Al.) BUSBAR LV(Al. ρ=.03816(Ωsq.mm)/m at
20degC TRANSFORMER
RESISTANCE
Chart-3: Calculation of resistance
Total
Losses(before)
HVt/f(ohm) HVline(ohm) LV(ohm) HVline(amp) HVphase(amp) LV(amp) HV(watts) LV(watts) (watts)
PMCC2
IC1 0.257 0.01386 0.00054 38.2287074 22.07200196 607.97462 436.377 602.2211 1038.598122
IC2 0.257 0.01485 0.00054 38.92854643 22.47606607 619.10459 457.0013 624.4722 1081.473499
PMCC3 0
IC1 0.257 0.01287 0.00057 41.55294282 23.99130648 660.84198 510.4402 744.8387 1255.278904
IC2 0.257 0.01386 0.00057 37.791308 21.81946189 601.01839 426.4484 616.0877 1042.536087
PMCC4 0
IC1 0.257 0.01287 0.00054 9.535306879 5.505373487 151.64584 26.87885 37.46676 64.34560213
IC2 0.257 0.01188 0.00054 8.835467842 5.101309378 140.51587 22.84626 32.16887 55.01513542
PMCC5 0
5E 0.257 0.01386 0.00054 93.1660718 53.79103453 1481.6773 2591.78 3576.781 6168.561154
PMCC8 0
IC1 0.257 0.05544 0.00052 4.286514102 2.474892668 68.171068 7.778445 7.216877 14.99532124
IC2 0.257 0.05445 0.00052 4.81139338 2.77794075 76.518545 9.731244 9.092483 18.82372692
HT 0
IC1 0.318 0.0873 0.00367 35.34187137 20.40523751 176.70936 724.3462 343.9831 1068.329265
IC2 0.318 0.0873 0.00367 98.3273847 56.77100733 491.63692 5606.813 2662.607 8269.419376
Total Losses = 20077.37619
Loss Calculation before pf correction
NET RESISTANCE CURRENT(before) LOSSES(before)
Chart-4: Loss calculation at existing power factor
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Vol. 3 No.12 December 2011
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Loss Calculation after pf correction
NET RESISTANCE CURRENT(after) LOSSES(after) Total
Losses(after)
HVt/f(ohm
) HVline(ohm
) LV(ohm)
HVline(amp
) HVphase(amp) LV(amp) HV(watts) LV(watts) (watts)
PMCC2
IC1 0.257 0.01386 0.000543 31.4927567 18.18288491 500.8487 296.1447 408.6938 704.8385687
IC2 0.257 0.01485 0.000543 31.7690089 18.3423839 505.2421 304.3606 415.8954 720.2559244
PMCC3 0
IC1 0.257 0.01287 0.000569 33.6106906 19.4057105 534.5315 333.9613 487.3192 821.2805341
IC2 0.257 0.01386 0.000569 33.7948588 19.51204316 537.4604 341.0232 492.6743 833.6975418
PMCC4 0
IC1 0.257 0.01287 0.000543 9.02424021 5.210300355 143.518 24.07479 33.55815 57.63294526
IC2 0.257 0.01188 0.000543 8.10339938 4.678637053 128.8733 19.21722 27.05897 46.27618754
PMCC5 0
5E 0.257 0.01386 0.000543 85.638198 49.44468704 1361.957 2189.867 3022.121 5211.987262
PMCC8 0
IC1 0.257 0.05544 0.000518 3.68336335 2.126653206 58.57879 5.743457 5.328806 11.07226282
IC2 0.257 0.05445 0.000518 3.4071111 1.967154216 54.18538 4.879769 4.559459 9.439227911
HT 0
IC1 0.318 0.0873 0.003672 25.5072912 14.72707345 127.5365 377.3078 179.1788 556.4866145
IC2 0.318 0.0873 0.003672 88.1244682 50.88017795 440.6223 4503.603 2138.706 6642.308767
Total
Losses 15615.27584
Chart-5: Loss calculation after improved power factor.
It is evident from the above charts that power factor of PMCC-8 , I/C-2 and main I/C-2 are very low in
comparison to other switchgears. Immediate steps are to be taken to improve the power factor of both the
switchgears. KVAR required to design the capacitor bank can be taken from chart-2 or using Nomogram as
discussed in the chapter-4 of this paper.
5. Conclusion
The low power factor is highly undesirable as it causes an increase in current, resulting in additional losses of
active power in all the elements of power system from power station generator down to utilisation devices. In
order to ensure most favourable conditions for a supply system from engineering and economical standpoint, it
is important to have power factor as close to unity as possible.
6. References
[1] Marcos, T.Galelli, Marcio, S.Vilela, “Proposal of a timer controller with constant switching frequency and power factor correction”,
IEEE, 2005.pp, 102_109 International Journal of Computer and Electrical Engineering, Vol. 1, No. 2, June 2009 1793-8163 - 187 -
[2] Oscar GarcíaJosé A. Cobos, Roberto Pedro Alou, and Javier Uceda, “Single Phase Power Factor Correction:A Survey”, IEEE
Transactions on Power Electronics, Vol. 18, No. 3, May 2003.
[3] Bhim SinghBrij N. Singh, Ambrish Chandra, , Kamal AHaddad, , Ashish Pandey, , and Dwarka P. Kothari, “A Review of Single-
Phase Improved Power Quality AC–DC Converter”, IEEE Transactions on
[4] Industrial Electronics, Vol. 50, No. 5, October 2003.
[5] Martin F.Schlecht, Brett A.Miwa, “Active Power Factor Correction for Switching Power Supplies”, IEEE Transactions on Power
Electronics, Vol.PE-2, no.4, October 1987.
[6] A.Pandey, Prof B.Singh, “Comparative Evaluation of Single-phase Unity Power Factor ac-dc Boost Converter Topologies”, IEEE
proc, November 30, 2004.pp, 102-109
[7] ‘POWER ELECTRONICS - Converters, Applications and Design’, Mohan, Under land, Robbins, John Wiley & Sons
[8] POWER ELECTRONICS – Circuits, Devices and Applications’, Muhammad H. Rashid, Prentice Hall of India Private Limited
[9] ‘POWER ELECTRONICS’, M D Singh, K B Khanchandani, Tata McGraw – Hill Publishing Company Limited.
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