Power Factor Correction Capacitors

Selection & Applications Of Power Factor Correction Capacitor For Industrial and Large Commercial Users

Ben Banerjee Power Quality Solution Group

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Agenda
Power Factor Fundamental The Need for Power Factor Correction Effects of Harmonics: TPF & DPF Correction Alternatives & Capacitor Locations PF Rate, Capacitor Sizing, & ROI Capacitor Applications To Motors Capacitor Switching Equipment Other Application Issues * Steady State VAR Correction * Dynamic VAR Correction Standards & Codes
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Power Quality Correction

Power Factor Fundamentals

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Power Quality Correction ACTIVE & REACTIVE POWERS

Most plant loads are Inductive and require a magnetic field to operate:

Motors Transformers Florescent lighting

The magnetic field is necessary, but produces no useful work The utility must supply the power to produce the magnetic field and the power to produce the useful work: You pay for all of it! These two types of current are the ACTIVE and REACTIVE components
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Power Factor Fundamental

Definitions: Working /Active Power: Normally measured in kilowatts (kW). It does the "work" for the system--providing the motion, torque, heat, or whatever else is required. Reactive Power: Normally measured in kilovoltamperes-reactive (kVAR), doesn't do useful "work." It simply sustains the electromagnetic field. Apparent Power: Normally measured in kilovoltamperes (kVA). Working Power and Reactive Power together make up apparent power.
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Power Factor:The Beer Analogy

kVAR
Reactive Power

Mug Capacity = Apparent Power (KVA) Foam = Reactive Power (KVAR) Beer = Real Power (kW) kVA
Apparent Power

Power Factor =

Beer (kW) Mug Capacity (KVA)

kW
Active Power

Capacitors provide the Foam (KVAR), freeing up Mug Capacity so you dont have to buy a bigger mug and/or so you can pay less for your beer !

Power Factor Fundamental

Power Factor : A measure of efficiency. The ratio of Active Power (output) to Total Power (input)
Active Power (kW)

Total Power (kVA)

Active (Real) Power Total Power Reactive = kW Power (KVAR) kVA = Cosine () = DISPLACEMENT POWER FACTOR

Power Factor

A power factor reading close to 1.0 means that electrical power is being utilized effectively, while a low power factor indicates poor utilization of electrical power.
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LEADING AND LAGGING

IC IR IL
G

IR V ILOAD

IC

KVARC KW KVARL

Division - Name - Date - Language

LEADING AND LAGGING

G G

KW

KVAR (LAG)

KW

KVAR (LEAD)

KW

KVAR (LAG)

KW

KVAR (LEAD)

INDUCTION MOTOR

OVER-EXCITED

SYN. MOTOR
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Typical Uncorrected Power Factor

(Use only as a Guide)
By Industry Auto parts Brewery Cement Chemical Coal mine Clothing Electroplating Foundry Forge Hospital Machine manufacturing Metalworking Office building Oil-field pumping Paint manufacturing Plastic Stamping Steelworks Textile Tool, die, jig
From IEEE Std 141-1993

Power Factor 75-80 76-80 80-85 65-75 65-80 35-60 65-70 75-80 70-80 75-80 60-65 65-70 80-90 40-60 55-65 75-80 60-70 65-80 65-75 60-65

By Operation Air compressor: External motors Hermetic motors Metal working: Arc welding Arc welding with standard capacitors Resistance welding Machining Melting: Arc furnace Inductance furnace 60Hz Stamping: Standard speed High speed Spraying Weaving: Individual drive Multiple drive Brind

Power Factor 75-80 50-80 35-60 40-60 40-60 40-65 75-90 100

60-70 45-60 60-65

60 70 70-75

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WHY DO WE CARE ABOUT POWER FACTOR

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MOTOR LOAD CHARACTERISTICS

NAOD PQCG US May 16, 2007 - English

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Why do we care about Power Factor?

In Industrial Facilities, Mostly Induction Motor loads Energy Efficient Motors not optimized for PF Low power factor is caused by oversized or lightly loaded induction motors Low power factor results in:
Poor electrical efficiency! Higher utility bills ** Lower system capacity On the Supply Side, Generation Capacity & Line Losses

Power Factor Correction Capacitors (PFCC) provide an economical means for improving Energy utilization
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Power Quality Correction

Why do we install Capacitors?

Before After

In this example, demand was reduced to 8250 kVA from 10000 kVA.

1750KVA Transformer Capacity Release.

The power factor was improved from 80% to 97%

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Harmonics
Displacement Power Factor

Total Power Factor

Effects of Harmonics on Capacitors
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Power Quality Correction

Linear vs Non-Linear

Until recently, most electrical equipment drew current in a linear fashion:

v

Current (i) & Voltage (v) are both Sinusoidal

Today, many electrical loads draw current in a non-linear fashion:

v
Current (i) is periodic, but not sinusoidal

i
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What produces Non-linear Current?

Computers

Variable Frequency Drives Electronic Ballasts Almost anything electronic

Fax Machines

Copiers

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Power Quality Correction

Time vs Frequency
Time Domain
f1 = 60 H z

Frequency Domain
1 0.5 0 1 3 5 7 9 1 1

60 Hz

f1
f3 = 3 x 60hz = 180 hz

+
180 Hz

1 0.5 0 1 3 5 7 9 1 1

f3
f5 = 5 x 60 hz = 300 hz

+
300 Hz

1 0.5 0 1 3 5 7 9 1 1

f5
f7 = 7 x 60 hz = 420 hz

+
420 Hz

1 0.5 0 1 3 5 7 9 1 1

f7
D isto rted Wave = f1 + f3 + f5 + f7

1 0.5

0 1 3 5 7 9 1 1

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Power Quality Correction

Total Harmonic Current Distortion Is Same As

Total Demand Distortion (TDD)

I
TDD

2 2

+ I

+ I
1

2 4

+L

100 % =
h
= 2

Ih

100
1

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Power Quality Correction

Total or True Power Factor (TPF)

TPF = (DPF) x (Harm Coefficient)
KW DPF = KVA = Cos f 1 1 + TDD2
TPF = Total or true power factor DPF = Displacement power factor Harm coefficient = Harmonic power factor = Cos d
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Harm Coefficient =

Total Power Factor Example

VFD ( Six Pulse ) DPF = .95 TDD = 90% ( No Line Reactor)

Harm coefficient =
1 1 + .92 = .7433

TPF = .95 x .7433 = .7061

Power Quality Correction

Applying Capacitors:

Caps at Motors or at SWBD / MCC:

Disadvantage: If Drives are present anywhere, the harmonic currents they produce can flow back to the point of lowest impedance: the capacitor! This will cause premature failure of the capacitor.

VFD

M M M M
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How Harmonics Affect Capacitors

Capacitors are naturally a low impedance to high frequencies:
Caps absorb harmonics Caps do not generate harmonics

As capacitor absorbs harmonics, the capacitor heats up

Reduced life expectancy

Voltage harmonics stress the capacitor dielectric

Reduced life expectancy

Parallel combination of capacitors with motor or transformer can cause resonance condition

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Resonance

The installation of standard capacitors can magnify harmonic currents on the network

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How Harmonics Affect Capacitors:

Resonance:
fr = f 1 XL XC

Resonance XL
( XL-Xc )

X L = 2fl

XC =

1 2 fc

fr

XC

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Capacitor Resonance
Resonant Point likely to amplify dominant harmonic (typically 5th)

Magnification of Harmonic Current when Standard Capacitor are Added to the Network
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Power Factor Correction With Harmonics:

De-tuning a network:
Force the resonant point away from naturally occurring harmonics
4.2 Harmonic (252 Hz)

I<h5>
Z

Ih5
f
A

f1

f3

f5

f7

f9

We control the impedance of these two elements

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UTILITY RATE & PFCC

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Most utilities penalize for bad Power Factor...

If the consumer does not correct the power factor, the utility may have to Build more power plants Install New/ Large transformers Use larger utility cables/ Wires, Switchgear,etc. Many different rate structures across the country. Typically, penalties are imposed for PF < 95%. Thousands of Customers across the country are currently unaware that they are being penalized for low power factor!!!

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How do utilities charge for Power Factor?

Utilities recoup the cost of providing reactive power in different ways..
kVA billing: utility measures and bills every ampere of current including reactive current. kW demand billing with Power factor adjustment: utility charges according to kW demand and adds a surcharge for power factor, typically in the form of a multiplier applied to kW demand. kVAR Reactive Demand charge: A direct charge for use of magnetizing power. (example:$ 4.50/kVAR) Two utilities recently introduced substantial Power Factor Penalties TXU (Texas) $3.50 - $5.50 per kW Demand to 95% pf TVA (Tennessee) $1.46 per kVAR lagging, $1.14 per kVAR leading (April 1, 2004)
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MOST COMMON POWER FACTOR RATE CLAUSE

BILLING KW DEMAND =
ACTUAL KW DEMAND X BASE PF/ ACTUAL PF

Penalty Calculation From Utility Bills In TX

BILLING DEMAND (apfa) = KW2 & ACTUAL DEMAND = KW1

Due to PF Adjustment, KW2 > KW1 *Distribution System Charge *Nuclear Decommission Charge *Transition Charge-1 *Transition Charge-2 *Transmission Service Charge *Transmission Cost Recov Factor = (KW2-KW1) x $3.55 / apfa = M1 = ( KW2-KW1) x $0.044/apfa = M2 = (KW2-KW1) x $0.177/ apfa = M3 = (KW2-KW1) x $0.272 / apfa = M4 = (KW2-KW1) x $1.19 / apfa = M5 = (KW2-KW1) x $0.27103 /apfa =M6

Total / Month = M1+M2+M3+M4+M5+M6 = $ / Month

CAPACITOR LOCATION & TYPE

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Power Quality Correction

Capacitor Locations

Three Options for Applying Power Factor Capacitors:

A) Fixed capacitors @ individual motors or @ MCC B) Automatic Banks at Main Switch Board C) De-tuned Automatic Capacitor Bank at Main Switch Board

M A B C A

M M M M

Harmonic Source e.g. Variable Speed Drive

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Fixed Capacitors - Low Voltage

Main Benefit
pf correction

Side Benefit
voltage support Small I2R reduction

Usage
Correcting pf on individual loads such as motors

Disadvantages
Overcompensation (correct past unity) Not to be used on non-linear loads Unable to track minute by minute load changes occurring on non-compensated feeders

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Standard Automatic Capacitor Systems

Main Benefit
pf correction

Side Benefit
voltage support Small I2R reduction

Usage
Correcting pf on entire MCCs or substations

Application alert
Not to be used on nonlinear loads

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Anti-Resonant Automatic Cap. Bank

Automatic Cap. Bank with a reactors in series Reactors tuned to 4.2 or 4.4 Use where Non-Linear Loads less than 50% of total loads.

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Transient Free De-Tuned Automatic Cap. Banks

For sensitive networks Similar to Antiresonant Automatic Capacitor System except solid state switching Reactor tuned to 4.2 or 4.4 Response time < 5 sec Use where NonLinear Loads < 50% of Total Loads.
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Electronic Switch Transient Free

L1
Fuses SCR-Diode

L2

L3

De-tuned Inductor

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Power Quality Correction

Rule Of Thumb For PFCC Applications

* When Non-Linear Loads < 15% Of Total Loads Select Standard Automatic Cap. Bank * When Non-linear Loads >15% But < 50% Of Total Loads Select Anti-Resonant (Detuned) Auto. Cap. Bank * When Non-Linear Loads > 50% Of Total Loads Select Active Harmonics Filter For VAR Correction

When Transformer KVA To Cap. KVAR Ratio < 3 Select Anti-Resonant ( Detuned) Auto. Cap. Bank

* When Soft-Starters are present, select Detuned Auto. Cap. Bank

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ACTIVE FILTER in VAR Correction Mode

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Cyclical Loads & Loads With Dynamic VAR Movements

CAUSES
WELDING OPERATIONS LARGE HP MOTOR STARTING PROCESS LOADS (i.e. MIXERS, CRUSHERS, CHIPPERS, SHREDDERS) ARC FURNACES

RESULTING IN
VOLTAGE FLICKER VOLTAGE SAGS POOR POWER FACTOR INABILITY TO START MOTORS

Division - Name - Date - Language

4 2

Active Filter (AHF)

For Power Factor Correction For System where Non-Linear Loads > than 50% of Total Loads. When Fast VAR Movements Necessary AHF-New breed of power quality product Harmonics cancellation Power factor correction VAR compensation Resonance elimination Independent or simultaneous modes of operation

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Active Harmonics Filter

Electronic filtering up to the 50th harmonic
I source I load Power source Non-linear load
I conditioner
Active Harmonic Conditioner

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Hybrid Filters
Combination of passive & active technologies

+
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MV HVC Banks General Layout

MAIN INCOMING INTERFACE WITH CUSTOMER'S NETWORK

15kV HVL LINEUP NEMA 3R

4000kVA, 13.8kV/480V NEMA 3R

5000A, 480V MAINS NEMA 1

2000A, 480V NEMA 1

4x300A ACCUSINE 6000kVAR, 13.8kV, 60Hz FIXED, DE-TUNED NEMA 3R

4x300A 4x300A ACCUSINE ACCUSINE

4x300A ACCUSINE

4x300A 4x300A ACCUSINE ACCUSINE

POWER ZONE HOUSE 1

POWER ZONE HOUSE 2

24X300A ACCUSINE -> 6000kVAR

PASSIVE

ACTIVE

Division - Name - Date - Language

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HVC Banks General

Marriage of two technologies Fixed capacitor banks and AHF Auxiliaries: MV/LV SWGR

HVC
15000

Vars Leading/Lagging

10000 Fixed Kvar 5000 0 Load Accusine Result Kvar

10

12

14

16

-5000 -10000

Time in cycles

Division - Name - Date - Language

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Cyclical Loads & Loads With Dynamic VAR Movements

CAUSES
WELDING OPERATIONS LARGE HP MOTOR STARTING PROCESS LOADS (i.e. MIXERS, CRUSHERS, CHIPPERS, SHREDDERS) ARC FURNACES

SOLUTIONS
APPLICATION OF:
HYBRID VAR COMPENSATION (HVC)

RESULTING IN
VOLTAGE FLICKER VOLTAGE SAGS POOR POWER FACTOR INABILITY TO START MOTORS

DYNAMIC VAR INJECTION ON PER CYCLE BASIS PASSIVE/ACTIVE SYSTEM ARRANGEMENT WITH INRUSH OR DE-TUNED REACTORS CUSTOM-ENGINREERED FOR SPECIFIC SITE, NETWORK, LOAD CHARACTERISTIC NEEDS

Division - Name - Date - Language

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CAPACITOR APPLICATIONS AT MOTOR TERMINAL

> Motor Overload Protection > Re-closure Issue Jogging , Reversing, Inching , Plugging Applications

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Capacitor At Motor Terminal Motor Over Load Protection Issue

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Motor Self-Excitation Voltage Influenced By Capacitor Ratings

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Reclosed Breaker & Net Voltage

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CAPACITOR APPLICATION ISSUES

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Power Quality Correction

Multi-Energy Power System of the Future ?

Hospital with cogeneration (1.5 MW) Residential photovoltaic system (6 kW) Residential Fuel cell (7 kW)

Utility-owned wind turbine site (1 MW)

Substation

Small wind turbine (10 kW)

Utility-owned Photovoltaic site (500 kW)

Factory with natural gas fuel cell (100 kW to 5 MW)

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Power Quality Correction

Utility & Customer Owned

Solar Power System Working In Parallel
1000 KW 3000 KW

Cos 2= 0.55

Cos 1= 0.89

1818 KVA

1537 KVA

1537 KVAR 1537 KVAR

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Key Questions to ask Customer For Capacitor Applications

Are you being charged for poor power factor by your utility (ask for a copy of their electric bill - kW, kVA, Power Factor)? Do you have a large number of drives, rectifiers or other harmonic generating equipment? Do you have nuisance tripping of overloads ? Do you have welders, chippers, or other large cyclical loads? Do you have problems with voltage sags or flicker? How sensitive is your equipment to these power issues? Do you have capacity issues on any of your substations? Do you have HID lighting or critical processes with low tolerance to brownouts? Have you been experiencing poor weld quality? Do you have Soft Starters in the System? Do you have Motors subject to reversing, jogging, inching, or plugging?
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Capacitor Standards
NEMA CP-1 for Shunt Capacitors UL 810 Standard for Capacitors NFPA 70, National Electrical Code IEEE Standard 399, Power System Analysis ANSI / IEEE Standard 18, Shunt Power Capacitors IEEE Standard 141, Recommended Practice for Electrical Power Distribution for Industrial Plants

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Other Capacitor Application Issues

NEC & NEMA : * The Ampacity of Capacitor Circuit Conductors shall not be less than 135% of rated Capacitor Current * Breaker Rating based on 135% Rated Capacitor Current * Fuse Rating based on 165% Rated Capacitor Current for Class R Time Delay * Fusible Switch Rating based on 165% Rated Capacitor Current

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Capacitor Operating Environment Issues

Capacitor When Properly Applied Will Have Long Life. Conditions that affect the Life of Capacitor: * Ambient Temp. < 46Deg C or 115Deg F
* Case Temp. of Capacitor < 55Deg C or 131 Deg F * Shunt Capacitor designed to operate at 110% Rated Voltage. * Avoid sustained Over Voltage * High System Harmonics

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Power Quality Correction

Summary of Benefits:

Reduced Power Costs:

Since Capacitors supply reactive power, you dont pay the utility for it Depending up on location of Cap. Bank, Line Loss can be reduced. You can calculate the savings

Off-load transformers

Defer buying a larger transformer when adding loads

Reduce voltage drop at loads

Only if capacitors are applied at loads (minimal benefit at best)

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Power Quality Correction

Thank You ! Questions?

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