Published by : International Journal of Engineering Research & Technology (IJERT)

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Vol. 9 Issue 05, May-2020

Design of APFC Panel for Industrial Application

1
Deep Patel, 3Henil Patel, 4Krina Suhagiya 2
Dr. Sweta Shah
5 2
Rutvik Rohit, Assistant Professor,
1,3,4,5
B.Tech Student, Electrical Engineering, Dept. of Electrical Engineering,
Indus University, Indus University,
Ahmedabad, Gujarat, India. Ahmedabad, Gujarat, India

Abstract---In modern days the power demand is increasing as

the industrial load is increasing. There are various types of III.PENALTY REDUCTION METHODS
electrical and power electronic loads. These loads are EXISTING METHODS
fluctuating without manual interventions. These fluctuating
1. Static Capacitors
loads can be stable with the use of a suitable capacitor.
Majority of load are inductive in nature in industries. This In the passage of time many methods have been used for
inductive load consumes reactive power which affect the power factor correction, one mainly prevalent method is that
generation of the plant. Basically inductive load means lagging of a static capacitor bank. In this method, capacitors are
of power factor. To increase power factor there is a need of normally known as a static capacitor induces a leading
APFC Panel. Many industries use a lot of power from the grid current and partly or completely neutralizes the lagging
but failed to utilize in an effective way. In many cases, reactive component of load current. This raises the power
consumer draws access to power than their sanctioned load. factor of the load. For these loads the power factor capacitors
Therefore, the consumer has to pay a penalty. So, this penalty can be connected in delta or star. Static capacitors are
can be reduced by APFC Panel.
invariably used for power factor improvement in factories
Keywords--- Power Factor, APFC Panel, Power factor and industries.
correction, Inductive, Fixed capacitors, Penalty.
2. SYNCHRONOUS CONDENSER
I.INTRODUCTION Asynchronous motor takes a leading current when over-
excited and therefore behaves as a capacitor. When that
In a current scenario, it has been observed that power is very category of a machine is coupled in parallel with the supply
prized for all and also demand of power is always high. The it takes a leading current which partly neutralizes the lagging
electric power system has grown in size and complexity with reactive component of the load. Therefore the power factor
a huge number of interconnections to meet the increase in is significantly improved. In power factor improvement by a
electric power demand. Most of the industrial plants are synchronous condenser, the three-phase load takes current
using the induction loads in infrastructure such as IL at low lagging power factor cosфL. The synchronous
transformers and motors. Hence the use of more inductive condenser takes a current Im which the voltage by a by an
load results in a lagging power factor i.e. the system power angle фm. The resultant current I is the phasor sum of Im
factor gets poor, due to access of reactive power consumed and IL and lags behind the voltage by an angle ф. It is clear
by inductive load such as induction motors which increases that ф is less than фL so that cos ф is greater than cosфL.
the reactive losses. Also, the reactive power consumption Thus the power factor is increased from cosфL to cosф.
causes the reduction of voltage and power factor in Synchronous condensers are generally used at large scale
networks. Power factor correction is the process of supply substations for power factor improvement.
compensating a lagging current by a leading current through
connecting capacitor to the supply. Practically, correcting 3. PHASE ADVANCERS
power factor much nearer to the one may result in harmonic They are used to improve the power factor of induction
distortion. APFC or Automatic Power Factor control panels motors. Due to the fact that the stator winding draws exciting
are mostly used in the improvement of power factor. current which lags behind the supply voltage by 90°,
induction motors have a low power factor. If the exciting
II.NEED FOR POWER FACTOR CORRECTION ampere turns can be managed from some other A.C source
• Varying power demand on the supply system. then the stator winding will be relieved of exciting current
• Power factor (cosφ) also varies as a function of the and the power factor of the motor can be improved. This job
load requirements. is skilled by the phase advancer which is simply an AC
• Difficult to maintain a consistent power factor (cosφ) exciter. The induction motor can be manufactured to operate
by use of fixed compensation. on leading power factor like an over-excited synchronous
motor. Phase advancers have an advantage because the
• Leading power factor under light load condition.
exciting ampere-turns are supplied at slip frequency
• Automatically variation without manual intervention,
.therefore lag not KVAR drawn by the motor are
the compensation to suit the load requirement.
considerably reduced. Phase advancers can be conveniently
• Increase available power used where the use of synchronous motors is inadmissible.
• Reducing the installation size
• Reducing the voltage drops on installation

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However, the primary disadvantage of phase advancers is

that they are not economical for motors below 200HP.

IV.PROPOSED METHOD V.DESIGN METHODOLOGY

For industrial purpose to improve the power factor, aPFC
panel is used which includes capacitor with the detuned Panel design comprising following steps:
reactor. It will maintain the power factor and maximize the 1. GA Drawing
receving power. It contains APFCR relay as shown in figure 2. SLD Drawing
1. It is a microcontroller device which includes current 3. Schematic Wiring Diagram
control, voltage control senser and many more. And with the 4. Power and Control wiring Diagram
help of that, selection of capacitor will be done smoothly.
1. GA (General Arrangement)
GA requires following details to accomplish the panel
design.
➢ Details of transmitted data.
➢SLD with incoming and outgoing lines details.
➢The formation list for the components to be used.
➢The rating of the input lines for specific applications.
During this project, we measure the varied parameters
(length, width, height) of panel and pieces of equipment. By
using these parameters, we made a GA diagram of the APFC
panel. It refers to the location of varied equipment and
assemblies within the aggregated design of the electrical
panel. It is a schematic representation of a corporal electrical
panel design. Figure as

Figure 1:- SIEMENS APFCR Relay FIGURE V.I – GA (General Arrangement)

Top view

Side view

Front view

Bottom view

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FIGURE V.II – TOP VIEW OF GA

FIGURE V.III – SIDE VIEW OF GA

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FIGURE V.IV – FRONT VIEW OF GA

FIGURE V.V – BOTTOM VIEW OF GA

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2. SLD (SINGLE LINE DIAGRAM )

From the fig. shown the system is 3 phase 3 wire system. button is provided. An APFC relay is provided and it shows
Three indication Lamp is connected to the supply and there balanced usage of capacitors based on the number of
is one 6A TP MCB is connected to the indicating lamps. This switching operations and connection time of each step.
is because for the protection of indicating lamps. There is an There are three switch fuse units are connected to the supply.
air circuit breaker is used, which is mainly used to provide The purpose of the SFU is to provide protection to the
for over current and short circuit protection. In this ACB capacitor banks from fluctuating conditions. There are three
there is on, off and trip indication lamps and off/stop push power contactors are provided. During overload condition
when excessive current is passing through the circuit
normally closed contactor will be opened and protect the
capacitor banks. Here the detuned reactor is coupled with the
capacitor as shown in the figure. Detuned reactor is used
when a high amount of harmonic current passed through the
capacitor, it will directly connect it
to the mains.

FIGURE V.VI – SLD (SINGLE LINE DIAGRAM

)

3. SCHEMATIC WIRING DESIGN blew it out. They are connected with 6A

Figure shows, wiring connection of 3 single phase MCB for phase wire and with
phase system. As this is a three-phase 4 the neutral link for the neutral wire. In
wire system the neutral link is connected addition to all this another 3 indication
to the 4th wire and is further connected to lamp for ON, OFF, TRIP condition is
the 3 indicating lamps in series. Now in provided. This 3 lamp is connected in
between the 3 phases and indicating lamp, parallel with the auxiliary contactor for
there is three pole MCB is connected for tripping purpose. Along with that, a
each. It should be provided for the neutral link is connected with the neutral
protection of the lamp mainly. Further 3 wire. Now as the supply is ON, the ON
exhaust fans is provided. They are mainly indication lamp will be ON and the other
provided for maintaining the temperature 2 lamp will be OFF at the same time.
inside the panel. As the panel contains Similarly, during the OFF condition, the
reactors and capacitors, so it will absorb
the heat generated inside the panel and

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4. POWER AND CONTROL WIRING

connected with 6A single phase MCB for phase wire and DIAGRAM
with the neutral link for the neutral wire. In addition to all In this figure, we can see that there are
this another 3 indication lamp for ON, OFF, TRIP condition capacitor bank, inductor, power contactor,
is provided. This 3 lamp is connected in parallel with the and fuse. This all are connected in series.
auxiliary contactor for tripping purpose. Along with that, a In the normal condition, the power
neutral link is connected with the neutral wire. Now as the contactor is open. When power is ON, the
supply is ON, the ON indication lamp will be ON and the circuit becomes closed. There are two
other 2 lamp will be OFF at the same time. Similarly, during
ways to control the circuit manual mode
the OFF condition, the OFF indication lamp will be ON and
the other will be OFF. Whenever during a short circuit or and auto mode. In the manual mode, it is
overcurrent or any other condition the TRIP indication lamp operating manually and in auto mode it
will get ON and the other 2 will be OFF. will be controlled by APFCR relay. There
are manually start and stop push button. In
FIGURE V.VII – SCHEMATIC WIRING

4. POWER AND CONTROL WIRING DIAGRAM

In this figure, we can see that there are capacitor bank, the intial condition stop push button is in
inductor, power contactor, and fuse. This all are connected the close condition, whereas start push
in series. In the normal condition, the power contactor is button is in the open condition. When the
open. When power is ON, the circuit becomes closed. There power is ON in the circuit that time lamp
are two ways to control the circuit manual mode and auto
blows ON. There is MCB to protect the
mode. In the manual mode, it is operating manually and in
control circuit from the short circuit and
auto mode it will be controlled by APFCR relay. There are
manually start and stop push button. In the intial condition over-voltage condition. Figure as shown
stop push button is in the close condition, whereas start push V.VIII
button is in the open condition. When the power is ON in the
circuit that time lamp blows ON. There is MCB to protect
the control circuit from the short circuit and over-voltage
condition. Figure as shown V.VIII

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FIGURE V.VIII – POWER AND CONTROL

WIRING DIAGRAM

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VI.CONCLUSION
It can be concluded that power factor correction techniques
can be applied to the power system and due to that the
system becomes stable and reliability of the system. In this
research, capacity of shunt capacitor bank installed at 230kV
line. Capacitor banks have generated reactive power and
requirement of reactive power drawl from the system
reduces it further reduces the corresponding amount of
current in the line. Therefore applications of capacitor banks
on substation, reduces the reactive power flow and reduce
the losses in square proportion. In result, improvement in
power factor from 0.5to 0.94 in stage – 9.The APFC device
helps to pull in high current drawn from the system and
reduce charges on utility bills. A reduced power
consumption results in lower greenhouse gas emissions and
fossil fuel depletion by power stations and would benefit the
environment.

VII.REFERENCES

1. International Journal OF Recent Technology and Engineering

(IJRTE) ISSN: 2277-3878, Volume-2, Issue-4, September 2013.
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controls/7ug-monitoring-relays.html
4. http://www.electrosome .com
5. http://www.metroelectrician.com/uploads/1/1/0/9/110950405/control
_panel_technical_guide.pdf
6. Asst. Prof. Smitha Paulose1, Ann Mary George2, Linu Jose3, Sruthi
Harikumar4, “Reactive Power Compensation Using SVC”
International Research Journal of Engineering and Technology
(IRJET) Volume: 03 Issue: 06 | June-2016.
7. Alexander, C. K., & Sadiku, M. N. (2007). Fundamentals of electric
circuits. Boston: McGraw-Hill Higher Education.
8. "POWER FACTOR CORRECTION." www.nhp.com.au. NHP
Catalogue- PFC

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