Capacitor banks protection, cautions and maintenance

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electrical-engineering-portal.com/capacitor-banks-protection-cautions-maintenance-tips

By Rahmatullah Alam April 4, 2022

Power Quality and Cost Savings

It would not be wrong to say that humanity has never consumed so much electricity, and to
make the paradox bigger, there is still a lack of energy. The sharp increase in consumption in
the last couple of decades has created a lot of problems in electrical networks around the
world. The optimization of costs and reducing transmission and distribution losses are
urgently needed. Here we come to the main topic of this article, how to handle all these
problems using capacitor banks.

Capacitor banks protection, cautions and maintenance

Requests for reactive power compensation, voltage stability, and harmonic filter mitigation
have increased as a result of the integration of renewable energies many other technologies
into the electrical system. Capacitor banks are abundantly utilized in substations for

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improving overall power quality.

Due to the neck-to-neck competition, every industry aims to reduce production expenses and
better control and optimize electrical energy by employing power quality improvement.

Nowadays, in the light of the coming global crisis, this is important more than ever.
Let’s talk about capacitor banks.

Table of Contents:

1. Capacitor Bank Purpose

Let’s start with some basics. In a few words, capacitor banks provide stable voltage level,
reactive power support, and increasing power transfer capability in the power system. They
are also used to compensate for the losses in transmission systems. Capacitor banks reduce
the phase difference between the voltage and current.

A capacitor bank is used for reactive power compensation and power factor correction in the
power substations. Capacitor banks are mainly used to enhance the electrical supply quality
and enhance the power systems efficiency.

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2. Capacitor Banks Connections

The capacitor bank is connected in two ways – star and delta, but most of the time, delta
connection is used. Both of these two connections have their benefits and drawbacks. The
main application is power factor correction because, in a 3-phase system, a 3-phase
capacitor bank is used for the power factor correction which may be connected in star or
delta.

Figure 1 – Delta-Connected Capacitor Bank

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 Figure 1 – Delta-Connected Capacitor Bank

The star-connected capacitor bank is used for medium to high voltage applications. In star
connection, the voltage across each capacitor is root 3 times lesser than the phase voltage,
so the voltage stress across the capacitors is low even in high voltage applications.

There are two types of star connections in the capacitor bank:

1. Grounded star connection

2. Ungrounded star connection

Grounded star connection: The neutral point is grounded. In this type of connection, the
unbiased point of the bank is stably earthed, which means the neutral should not be
insulated toward the BIL level of the complete system.

An error on the 1-phase of the bank will not affect the rise of voltage within the remaining
legs of the bank. So, a fault on one phase of the capacitor will not affect other phases.

Figure 2 – Grounded star connection of capacitor bank

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 Figure 2 – Grounded star connection of capacitor bank

Ungrounded Star Connection: The neutral point is isolated from the earth or ground. In this
kind of connection, the capacitor bank’s neutral point is not connected toward earthing. So,
this type of connection does not allow the supply of GND currents & zero series harmonic
currents

Figure 3 – Ungrounded star connection of capacitor bank

Figure 3 – Ungrounded star connection of capacitor bank

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Go back to the Contents Table ↑

3. Failure of Capacitor Banks

Nowadays, modern capacitors use a “self-healing, safety disconnect” technology, in
which the integrity of the capacitor dielectric is maintained very effectively. Under minor fault
conditions, gases are released within the capacitor element to effectively weld and close any
hole caused by the dielectric fault.

Under major fault conditions, the gas is released with such force that the capacitor
disconnects itself from the supply before further damage is caused by raising the top of the
preformed canister and mechanically breaking the internal fuses. In some oil-filled
capacitors, the oil can be seen to leak out of the top of the capacitor.
Typical failures of power factor correction capacitors can be attributed to several reasons as
detailed below:

3.1 Harmonics and Detuned Capacitors

Harmonics are currents or voltages that are a multiple of the fundamental power frequency,
harmonics are generated by some non-linear loads like variable speed drives, capacitors are
particularly sensitive to harmonic currents since their impedance decreases proportionally to
the order of the harmonics present.

This can result in a capacitor overload, shortening steadily its operating life.

Suggested Video – Using Harmonic Analysis Software

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3.2 Resonance

Resonance is a situation where the capacitors and supply transformer creates a low
impedance path for the circulating harmonic currents, when this happens, the electrical
system could tune to the most dominant specific harmonic frequency thus increasing current
flow through the electrical system.

Amplification of harmonic currents is very high when the natural resonance frequency of the
capacitor and the network combined happens to be close to any of the harmonic
frequencies present.
There is no safe rule to avoid such resonant currents, but resonances above 1000 Hz will
probably not cause problems except interference with telephone circuits.

Suggested Reading – Six network operating conditions under which ferroresonance can
occur

3.3 Relevant Load Changes

Capacitor banks are designed for an original load. Over time, this changes. This can lead
to the original capacitor bank being insufficient or unsuitable for the new situation. It can also
be the case that the bank enters in resonance with the installation and becomes a harmonic

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generator, worsening the efficiency level of the installation.

3.4 Capacitors in Poor Condition

Poor maintenance of the capacitor bank may cause it to fail as expected. Capacitors lose
their capacitance over time. If they are not replaced in time, the performance of the set is
no longer effective: it does not perform its function correctly

3.5 Equipment damage

In the face of a power failure, the non-disconnection of the capacitor bank can cause a
sudden surge of tension. This may damage sensitive equipment in the installation.

Go back to the Contents Table ↑

4. Protection of Capacitor Banks

According to a large capacitor manufacturer, approximately half of all large industrial plants
operate at a power factor of less than 0.85! At the same time it is commonly known that
lower power factor results in higher utility cost.

It is worth mentioning that:

1. Raising power factor will also reduce peak charges.

2. System capacity will increase with a higher power factor.
3. Lighting and motor performance will benefit from improved power factor.
4. Since capacitor banks are prone to severe damages due to varied equipment
connected to them, it is of utmost importance to ensure proper protection of same.

Suggested Reading – Unbalance protection of grounded & ungrounded wye shunt capacitor
banks

4.1 Internal Resistors

Internal resistors are specifically designed as individual capacitors to ensure the discharge
of individual capacitor separately and hence the complete capacitor bank ultimately. With
capacitor banks having multiple sections of capacitors in series, the residual voltage section
in each section exactly equal to the residual voltage on the bank terminal.

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4.2 External Discharge Devices
Every project site has different schemes and protection systems. Insulation level and strike
distance shall be suitable to the structure and designing of each device. If the capacitors
have no internal discharge resistors, there should be no isolating device between the
capacitor bank and the discharge device.

4.3 Internal Fault Protection

The idea behind providing internal capacitor protection is to proactively safeguard our
costly capacitors banks and prevent any outage or halting of processes. Capacitor banks
are bunch of individual capacitor units with different ratings rather than capacitance values.

During manufacturing stage, errors due to machinery or human intervention causes a

certain amount of potential unbalance which ultimately affects the current balance existing
between the strings and phases of bank. An internal fault protection system prevents the
whole capacitor from being damaged due to the damaging of any single capacitor.
Also, it prevents the capacitor bank from internal short circuits, capacitor failure, internal
unbalance.

Figure 4 – Group of elements in capacitor bank

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 Figure 4 – Group of elements in capacitor bank

During occurrence of any fault, the internal protection system of capacitor banks is such as
to disconnect an individual or multiple capacitors from the main circuit. Every single capacitor
in a capacitor bank is called an element and the multiple capacitors connected in the same
way either series or parallel is called the group of elements.

So, elements and groups of elements both need to be protected.

4.4 Element Protection

A fuse in series is connected with each individual capacitor. In the event capacitors drawing
more current which happens during occurrence of fault, the fuse protects the capacitors
by disconnecting that single capacitor from circuit. And in this way the other capacitors are
safeguarded and continue their normal operations.

4.5 Group of Element Protection

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As discussed under element protection, a fuse in series protects individual capacitors. At
times, it happens that the element protection fails hence, group element protection is
designed. A group of element protection protects against the short-circuit or any fault in the
connection of the capacitor rather than the fault in individual capacitor.

Figure 5 – Internal protection system for star-connected 3-phase capacitor bank

Figure 5 – Internal protection system for star-connected a 3-phase capacitor bank

4.6 Different Types of External Fault Protection

An external fault protection system prevents the whole capacitor bank from any fault in the
electrical power system where the capacitor bank is connected. It also prevents the electrical
system from any internal fault of the capacitor bank.

Different types of external fault protection are:

1. Overvoltage Protection
2. Undervoltage and Under Current Protection
3. Overload Protection

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 4. Unbalanced Protection
5. Power Fluctuation Protection

4.6.1 Overvoltage Protection

It is always advised to disconnect the capacitor banks during overvoltage in system. A

voltage detector is employed for protection of capacitor banks from overvoltage. A time delay
protection aids in disconnecting the capacitor banks for vey minute duration.

Without surge arresters, probable restrike leads to switching voltage being exceeded on the
capacitors for both standard and detuned capacitor bank designs. Such overvoltages could
lead to capacitor breakdown.

Figure 6 – General arrangement for protection of a high-voltage capacitor bank against

overvoltages

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 Figure 6 – General arrangement for protection of a high-voltage
capacitor bank against overvoltages

4.6.2 Undervoltage and Undercurrent Protection

Circuit breakers are damaged basically due to undercurrent situation arising in power. An
undervoltage situation drops down the system voltage lower than the capacitor voltage
thereby resulting in reverse current flow.

4.6.3 Overload Protection

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An event where the excessive current than normal is drawn by the capacitor bank is called
an overload fault. Causes of excessive current are mainly due to insulation failures or
internal shorts. As discussed under protections, the capacitor banks shall be immediately
disconnected if found drawing additional current from the power system.

Circuit breaker, current transformers and current sensing protection relay are usually
engaged for overload protection.

4.6.4 Unbalanced Protection

As discussed at the beginning of this article, any unbalance fault in capacitor bank will
ultimately make our power system also unbalanced. An unbalanced fault occurs due to
capacitor failure per phase, loose connection etc.

4.6.5 Power Fluctuation Protection for Capacitor Bank

During working life of capacitor banks, trapped charges are stored. When the capacitor bank
does not draw any current from the power system, they should be immediately disconnected.
Before connecting, capacitors should be discharged with an internal resistor.

Suggested Reading – Inspection and maintenance of capacitor banks (recommended

practices)

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5. Maintenance of Capacitor Banks

No. Observations Root Cause Corrective Measures

1 Overheating Poor Ensure the ventilation for the

of capacitor ventilation installation area
unit Drawing Check for the harmonic presence
excessive Check the system voltage and
current capacitor rated voltage.
Over voltage If required replace with capacitor of
proper rated voltage

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 2 Capacitor Low voltage Voltage to be maintained
drawing less Failure of In case of elements failure due to
current capacitor excessive harmonic currents, capacitor
elements should be replaced with reactor and
higher rated capacitor.

3 Power factor Installed Transformer should be provided with

is not capacitor is fixed compensation
improved not operated. Do the proper selection of capacitor as
Supply per the requirement.
transformer
fixed
compensation
is not
provided.

4 Short circuit Short circuit Use special capacitor duty contactors

device rating/setting for inrush current limiting in case of
operating is improper parallel switching
frequently Harmonic
overloading

5 Capacitor Proper size Check the size of lugs used and

terminal over for lug is not replace with suitable size
heating used Check the cable current carrying
Loose capacity
connection Check the harmonics in Supply voltage
Inadequate
rating of
cable
Capacitor
drawing over
current

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6. Cautions to be Taken Care With Capacitor Banks

Caution #1

kVAR units subject to frequent starts, plugging or reversing should never be connected on
load side of starter or contactor. In crane, or any motor where the load may drive the motor
(or multispeed motors, or motors involving open transition reduced voltage starting), the

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KVAR units should be installed on the distribution system ahead of the motor controller
and must not be switched with the load motor.

Caution #2

During any CB tripping the capacitor should be discharged immediately and completely. If
there is no abnormality in the inspection, it may be caused by the fluctuation of the grid
voltage. If the operation is abnormal, it may be caused by the internal fault of the capacitor.

Check and test each capacitor until the relevant cause of the fault is found.

Figure 7 – Discharging capacitor banks

Figure 7 – Discharging capacitor banks

Caution #3

Utmost care to be taken with the working temperature. No work shall be continued in as
climatic condition where temperature is more than 140 °F. During abrupt rise in temperature,
the blockage of ventilation is the main culprit. If it is not caused by ventilation problems,
quickly find out the causes and deal with the abnormalities.

Caution #4

Many a times there are cases of explosion or fire. In such case , powers supply must be
immediately cut off and then put out the fire. Individual capacitor units or banks shall b
equipped with means of discharging and disconnecting from the network.

Caution #5

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Discharge circuits must have the adequate current-carrying capacity to discharge the
capacitor from the peak of the 1.3×Un overvoltage.

Suggested Reading – 15 bad situations that may lead to catastrophic explosion of a

capacitor bank

15 bad situations that may lead to catastrophic explosion of a capacitor bank

Caution #6

The rated voltage of the capacitor should be at least equal to the service voltage of the
network to which the capacitor is to be connected, account being taken of the influence of
the presence of the capacitor itself.

Caution #7

Applying large fixed KVAR units on the main service can cause a leading power factor when
plant loads vary widely. The capacitors should only be online when the load requires KVAR
and disconnected when the load is reduced.

Caution #8

Shunt-connected capacitors may cause a voltage rise from the source to the point where
they are located; this voltage rise may be greater due to the presence of harmonics.
Capacitors are therefore liable to operate at a higher voltage than that measured before
connecting the capacitors.

Caution #9

The voltage on the capacitor terminals may be particularly high at times of light load
conditions in such cases, some or all the capacitors should be switched out of the circuit to
prevent overstressing of the capacitors and undue voltage increase in the network.

Suggested Video – Explosion of 22kV Capacitor Bank

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Caution #10

Only in case of emergency should capacitors be operated at a maximum permissible voltage

and maximum ambient temperature simultaneously. It should be only for short periods.

Caution #11

The switching and protective devices and the connections must also be capable of
withstanding the electrodynamic and thermal stresses caused by the transient
overcurrent of high amplitude and frequency that may occur when switching on.

Caution #12

Devices for switching parallel steps and their associated protective equipment should be able
to withstand the inrush current (amplitude and frequency) resulting when one bank
connected to a bus bar to which other banks (s) are already connected.

Suggested Paper – Analysis of the effect of capacitor switching transient on a grid substation
(case study)

Caution #13

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Since the residual voltage at energization must not exceed 10% of the rated voltage,
discharge resistors with lower resistance or additional switched discharge device are
needed, for the automatically controlled capacitors.

Caution #14

Before touching any live parts, allow at least 5 min for the bank to self-discharge and then
short-circuit each capacitor terminal together and ground.

Suggested Video – Capacitance Measurements

Caution #15

Applying large fixed KVAR units on the main service can cause a leading power factor when
plant loads vary widely. The capacitors should only be online when the load requires KVAR
and disconnected when the load is reduced

Caution #16

Certain motor applications are not suitable for connecting the capacitor to the load side of the
motor starter. Applications involving:

Reversing, plugging, or frequent starts;

Crane or elevator motors, or
Any motor where the load may drive the motor,
Multispeed motors, or
Motors using open transition reduced voltage starting,

must be corrected on the distribution panel or main service panel.

Caution #17

Oil leakage from the capacitor: There was evidence of oil leakage (arrow) from the
capacitor, allowing air to fill the void inside. As the capacitor plates become exposed to the
air, the dielectric strength of the plate gap decreases, causing a sudden high energy
electrical discharge between plates.

This discharge has sufficient energy to ignite oil vapor and cause an explosion, albeit a small
one.

Suggested Video – Leakage oil from Capacitor bank 22kV

Caution #19

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Improper installation: Example of improper installation is an excessive strain on the
capacitor housing from mounting or deforming the unit during installation. Damage to the
capacitor case can result in plate gap reduction that can cause a discharge and capacitor
failure.

Finally, an intervening cause such as a rodent (biologic) contacting the two electrodes
simultaneously will likely cause a capacitor failure.

Go back to the Contents Table ↑

7. Case Study
Subject: A strange noise heard from the motor control center (MCC). An explosion occurred,
causing arc inside panel room.

Initial investigation: It was found that 4,160V, 200kVA capacitor exploded. Because the
capacitor was oil-filled, it produced a fireball upon explosion. The capacitor bank was located
in an enclosed shelf unit with heavy-gauge steel perforated exterior walls. One area of the
wall had been exploded outward at the capacitor location (Figure 8).

Figure 8 – Component where the failed capacitor exploded

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 Figure 8 – Component where the failed capacitor exploded

Root Cause: The salt atmosphere could have contributed to the failure. Also, there were
adjacent capacitors also which suffered from the explosion (Figure 9). Some blame can also
be assigned to the porous cabinet. The cabinet was arc flash rated but not fault current
rated.

Figure 9 – Rupture the adjacent capacitor

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 Figure 9 – Rupture the adjacent capacitor

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8. Conclusion
Loads are being switched so fast that the traditional capacitor bank systems struggle to
maintain an effective compensation set point. Therefore, they are perpetually ‘chasing’ the
load, either under or over-compensating but rarely providing effective compensation.

The biggest practical lesson for everyone working in the electrical field is to show a great
deal of caution and respect for power factor capacitors, even if fused. Do not assume
because the fuse exists that you’re dealing with the correct type or size. Capacitor failure is a
unique fault condition that requires special protection.

Therefore, it’s critical to make sure the fuses are de-energized upstream before
approaching. Another word to the wise is don’t rely on PPE to afford sufficient protection
from an explosion either. Finally, remember that decoupling the capacitor bank from the load
will not affect the operation of the load, which can still perform any critical mission.
Recent improvements such as controlled switching technologies have allowed minimizing
inrush currents during energization and also fast switching of capacitor banks.

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Go back to the Contents Table ↑

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