Eaton PFC Guide Plant Engineer SA02607001E
Eaton PFC Guide Plant Engineer SA02607001E
Contents
Description Page Description Page
Part one: Power factor
Part two: Harmonics
What is power factor?...............................2
Introduction.................................................17
Should I be concerned about
low power factor?.....................................3 What are harmonics?..................................17
What can I do to improve power factor?......3 What are the consequences of high
harmonic distortion levels?.........................18
How much can I save by installing
power capacitors?........................................4 IEEE 519......................................................18
How can I select the right capacitors How are harmonics generated?..................19
for my specific application needs?...............8 What is the relationship between power
How much kVAR do I need?..........................8 factor correction capacitors and harmonics?
....................................................................
Where should I install capacitors 19
in my plant distribution system?................14
How do I diagnose a potential
Can you use capacitors in nonlinear, harmonics-related problem?.......................20
nonsinusoidal environments?.....................16
What is an active harmonic filter?..............20
What about maintenance?.........................16
How can you eliminate harmonic problems? 20
What is a passive harmonic filter?..............20
Do I need to perform a system analysis
to correctly apply harmonic filters?............21
What is Eaton’s experience in
harmonic filtering?......................................21
Useful capacitor formulas...........................22
Power factor correction capacitor bank
survey sheet............................................23
Technical Data Power factor
SA02607001E correction: A guide for
Working power consumes watts and can be read on a PF= Working Power (WP) / Apparent Power (AP) = kW/kVA = cosine θ
wattmeter. It is measured in kilowatts (kW). Reactive
power doesn’t perform useful “work,” but circulates
between the generator and the load. It places a heavier
drain on the power source, as well as on the power For example, if you had a boring mill that was operating at
source’s distribution system. Reactive power is measured 100 kW and the apparent power consumed was 125 kVA,
in kilovolt-amperes-reactive (kVAR). you would divide 100 by 125 and come up with a power
factor of 0.80.
Working power and reactive power together make up
apparent power. Apparent power is measured in
kilovolt-amperes (kVA). WP/AP = (kW) 100 / (kVA) 125 = (PF) 0.80
Note: For a discussion on power factor in nonlinear, nonsinusoidal
systems, turn to Page 16.
Heat component = work done
Figure 1. kW power
kW
Motor field
G M
Figure 4. Power
triangle
Figure 2. kVAR
power
2 EATON
Power factor correction: Technical Data
A guide for the plant SA02607001E
18 A M
100 kW
WP/AP = PF = 100 kW / 142 kVA = 70% 10 hp, 480 V motor at 84% power factor
105
kVA
33 kVAR 16 A M
3.6 A
100 kW
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3
33 kVAR
1 95% PF
after
after
Technical Data 2 Power factor
SA02607001E correction: A guide for
Figure 7. Required apparent power before
and after adding capacitors
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Power factor correction: Technical Data
A guide for the plant SA02607001E
$2631.
20
+$
495.72
kW = kVA $3126.92 uncorrected energy charge
PF
Corrected energy:
400 kW = 412 kVA corrected billing demand kWh = 112,400
0.97 412 kVA × 200 =
From kW multipliers, to raise the power factor from 82,400 kWh @ 0.0286
0.87 to 0.97 requires capacitor: = $2356.64
Multiplier of 0.316 x kW
0.316 x 400 kW = 126 kVAR (use 140 kVAR) 412 kVA × 300 = 123,600
Uncorrected original billing: but balance only =
30,000 @ $0.0243
460 kVA × $4.75 = $2185 / month
= $729.00
–$1957
$ 228 / month savings × 12 $2356.
$2736 annual savings 64
+$
729.00
$3085.64 corrected energy charge
Corrected new billing:
412 kVA × $4.75 = $1957/month $3126.92
–$3085.64
140 kVAR, 480 V capacitor cost: $1600 (installation extra). This capacitor pays for itself in less than eight months.
$ 41.28 savings in energy charge due to rate charge
(9600 kWh in first step reduced by $0.0043)
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Technical Data Power factor
SA02607001E correction: A guide for
New billing:
First 40 kW @ $10.00 = $ 400.00 Next 160 kW @ $ 9.50 = $1520.00 Bal. 175 kW @ $ 9.00 = $1575.00
$3495.00 power factor adjusted billing
6 EATON
Power factor correction: Technical Data
A guide for the plant SA02607001E
Case 1
Assume a 400 kW load demand at 81% power factor.
Tariff structure
Demand charge is:
$635.00 for the first 200 kW demand
$ 2.80 per kW for all addition 480 kVA
317 kVAR
Reactive demand charge is: 578 A
$ 0.60 per kVAR in excess of 50% of kW demand In this example, kW demand = 400 kW,
therefore 50% = 200 kVAR that will be furnished at no cost.
75% PF
original condition
360 kW
474 kVA
Cos θ = PF = kW or Adj 570 A
kVAHyp 95% PF148
correctedkVAR
Tan θ = kVAR or Opp
kWAdj
It is desired to increase production by 25%, which means that about 450 kW out
More likely, the next size standard rating would be needed (750 kVA).
Perhaps a better solution would be to improve the power factor and release eno
To correct 450 kW from 75% to 95%, power factor requires 450 x 0.553 (from =
289.6 kVAR
200 kVAR
2
1
400 kW
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Technical Data Power factor
SA02607001E correction: A guide for
2
original power factor
% reduction losses = 100 – 100 ×
( new power factor
1.00 1.00
0.80 0.80
0.70 0.70
0.60 0.60
0.50 0.50
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
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Power factor correction: Technical Data
A guide for the plant SA02607001E
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Power factor correction: Technical Data
A guide for the plant SA02607001E
A For use with three-phase, 60 Hz NEMA Classification B Motors to raise full load power factor to approximately 95%.
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Technical Data Power factor
SA02607001E correction: A guide for
Table 4. Suggested capacitor ratings, in kVARs, for NEMA design C and D, and wound-rotor motors
Induction Design C motor Design D motor
motor
hp rating 1800 and 1200 r/minimum 900 r/minimum 1200 r/minimum Wound-rotor motor
15 5 5 5 5.5
20 5 6 6 7
25 6 6 6 7
30 7.5 9 10 11
40 10 12 12 13
50 12 15 15 17.5
60 17.5 18 18 20
75 19 22.5 22.5 25
100 27 27 30 33
125 35 37.5 37.5 40
150 37.5 45 45 50
200 45 60 60 65
250 54 70 70 75
300 65 90 75 85
Note: Applies to three-phase, 60 Hz motors when switched with capacitors as single unit.
Note: Use motor manufacturer’s recommended kVAR as published in the performance data sheets for specific motor types: drip-proof,
TEFC, severe duty, high efficiency and NEMA design.
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Power factor correction: Technical Data
A guide for the plant SA02607001E
Above sizes are intended to provide a corrected power factor of approximately 95% at full load. Because of the limited
number of capacitor ratings available, it is not possible to raise every motor PF to 95%.
Example:
If your plant consumes 410 kW, is currently operating at 73% power factor, and you want to correct power factor to 95%, you
would:
If you don’t know the existing power factor level of your plant, you will have to calculate it before using Table 6 on
the following page. To calculate existing power factor: kW divided by kVA = power factor.
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Technical Data Power factor
SA02607001E correction: A guide for
Table 6. Multipliers to determine capacitor kilovars required for power factor correction
Original Corrected power factor
power
factor 0.8 0.81 0.82 0.83 0.84 0.85 0.86 0.87 0.88 0.89 0.9 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99 1.0
0.50 0.98 1.00 1.03 1.060 1.08 1.112 1.139 1.16 1.19 1.22 1.248 1.27 1.30 1.33 1.36 1.40 1.44 1.48 1.52 1.58 1.73
2 8 4 6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.51 0.93 0.96 0.98 1.015 1.04 1.067 1.094 1.12 1.14 1.17 1.203 1.23 1.26 1.29 1.32 1.35 1.39 1.43 1.48 1.54 1.68
7 2 9 1 0 7 5 1 1 2 4 8 5 6 4 4 7
0.52 0.89 0.91 0.94 0.971 0.99 1.023 1.050 1.07 1.10 1.13 1.159 1.18 1.21 1.24 1.28 1.31 1.35 1.39 1.44 1.50 1.64
3 9 5 7 6 3 1 7 7 8 0 4 1 2 0 0 3
0.53 0.85 0.87 0.90 0.928 0.95 0.980 1.007 1.03 1.06 1.08 1.116 1.14 1.17 1.20 1.23 1.27 1.30 1.34 1.39 1.45 1.60
0 6 2 4 3 0 8 4 4 5 7 1 8 9 7 7 0
0.54 0.80 0.83 0.86 0.887 0.91 0.939 0.966 0.99 1.01 1.04 1.075 1.10 1.13 1.16 1.19 1.23 1.26 1.30 1.35 1.41 1.55
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.55 0.76 0.79 0.82 0.847 0.87 0.899 0.926 0.95 0.97 1.00 1.035 1.06 1.09 1.12 1.15 1.19 1.22 1.26 1.31 1.37 1.51
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.56 0.73 0.75 0.78 0.808 0.83 0.860 0.887 0.91 0.94 0.96 0.996 1.02 1.05 1.08 1.11 1.15 1.18 1.22 1.27 1.33 1.48
0 6 2 4 3 0 8 4 4 5 7 1 8 9 7 7 0
0.57 0.69 0.71 0.74 0.770 0.79 0.822 0.849 0.87 0.90 0.93 0.958 0.98 1.01 1.04 1.07 1.11 1.15 1.19 1.23 1.29 1.44
2 8 4 6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.58 0.65 0.68 0.70 0.733 0.75 0.785 0.812 0.83 0.86 0.89 0.921 0.94 0.97 1.01 1.04 1.07 1.11 1.15 1.20 1.26 1.40
5 1 7 9 8 5 3 9 9 0 2 6 3 4 2 2 5
0.59 0.61 0.64 0.67 0.697 0.72 0.749 0.776 0.80 0.82 0.85 0.885 0.91 0.94 0.97 1.00 1.04 1.07 1.11 1.16 1.22 1.36
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.60 0.58 0.60 0.63 0.661 0.68 0.713 0.740 0.76 0.79 0.82 0.849 0.87 0.90 0.93 0.97 1.00 1.04 1.08 1.13 1.19 1.33
3 9 5 7 6 3 1 7 7 8 0 4 1 2 0 0 3
0.61 0.54 0.57 0.60 0.627 0.65 0.679 0.706 0.73 0.75 0.78 0.815 0.84 0.87 0.90 0.93 0.97 1.00 1.04 1.09 1.15 1.29
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.62 0.51 0.54 0.56 0.594 0.62 0.646 0.673 0.69 0.72 0.75 0.782 0.81 0.84 0.87 0.90 0.93 0.97 1.01 1.06 1.12 1.26
6 2 8 0 9 6 4 0 0 1 3 7 4 5 3 3 6
0.63 0.48 0.50 0.53 0.561 0.58 0.613 0.640 0.66 0.69 0.72 0.749 0.77 0.80 0.83 0.87 0.90 0.94 0.98 1.03 1.09 1.23
3 9 5 7 6 3 1 7 7 8 0 4 1 2 0 0 3
0.64 0.45 0.47 0.50 0.529 0.55 0.581 0.608 0.63 0.66 0.68 0.717 0.74 0.77 0.80 0.83 0.87 0.90 0.95 0.99 1.06 1.20
1 4 3 5 4 1 9 5 5 6 8 2 9 0 8 8 1
0.65 0.41 0.44 0.47 0.497 0.52 0.549 0.576 0.60 0.62 0.65 0.685 0.71 0.74 0.77 0.80 0.84 0.87 0.91 0.96 1.02 1.16
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.66 0.38 0.41 0.44 0.466 0.49 0.518 0.545 0.57 0.59 0.62 0.654 0.68 0.71 0.74 0.77 0.80 0.84 0.88 0.93 0.99 1.13
8 4 0 2 1 8 6 2 2 3 5 9 6 7 5 5 8
0.67 0.35 0.38 0.41 0.436 0.46 0.488 0.515 0.54 0.56 0.59 0.624 0.65 0.68 0.71 0.74 0.77 0.81 0.85 0.90 0.96 1.10
8 4 0 2 1 8 6 2 2 3 5 9 6 7 5 5 8
0.68 0.32 0.35 0.38 0.406 0.43 0.458 0.485 0.51 0.53 0.56 0.594 0.62 0.65 0.68 0.71 0.74 0.78 0.82 0.87 0.93 1.07
8 4 0 2 1 8 6 2 2 3 5 9 6 7 5 5 8
0.69 0.29 0.32 0.35 0.377 0.40 0.429 0.456 0.48 0.50 0.53 0.565 0.59 0.62 0.65 0.68 0.72 0.75 0.79 0.84 0.90 1.04
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.70 0.27 0.29 0.32 0.348 0.37 0.400 0.427 0.45 0.48 0.50 0.536 0.56 0.59 0.62 0.65 0.69 0.72 0.76 0.81 0.87 1.02
0 6 2 4 3 0 8 4 4 5 7 1 8 9 7 7 0
0.71 0.24 0.26 0.29 0.320 0.34 0.372 0.399 0.42 0.45 0.48 0.508 0.53 0.56 0.59 0.62 0.66 0.70 0.74 0.78 0.84 0.99
2 8 4 6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.72 0.21 0.24. 0.26 0.292 0.31 0.344 0.371 0.39 0.42 0.45 0.480 0.50 0.53 0.56 0.60 0.63 0.67 0.71 0.76 0.82 0.96
4 0 6 8 7 4 2 8 8 9 1 5 2 3 1 1 4
0.73 0.18 0.21 0.23 0.264 0.29 0.316 0.343 0.36 0.39 0.42 0.452 0.48 0.51 0.54 0.57 0.60 0.64 0.68 0.73 0.79 0.93
6 2 8 0 9 6 4 0 0 1 3 7 4 5 3 3 6
0.74 0.15 0.18 0.21 0.237 0.26 0.289 0.316 0.34 0.36 0.39 0.425 0.45 0.48 0.51 0.54 0.58 0.61 0.65 0.70 0.76 0.90
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 6 9
0.75 0.13 0.15 0.18 0.210 0.23 0.262 0.289 0.31 0.34 0.37 0.398 0.42 0.45 0.48 0.51 0.55 0.59 0.63 0.67 0.73 0.88
2 8 4 6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.76 0.10 0.13 0.15 0.183 0.20 0.235 0.262 0.28 0.31 0.34 0.371 0.39 0.42 0.46 0.49 0.52 0.56 0.60 0.65 0.71 0.85
5 1 7 9 8 5 3 9 9 0 2 6 3 4 2 2 5
0.77 0.07 0.10 0.13 0.157 0.18 0.209 0.236 0.26 0.28 0.31 0.345 0.37 0.40 0.43 0.46 0.50 0.53 0.57 0.62 0.68 0.82
9 5 1 3 2 9 7 3 3 4 6 0 7 8 6 5 9
0.78 0.05 0.07 0.10 0.130 0.15 0.182 0.209 0.23 0.26 0.29 0.318 0.34 0.37 0.40 0.43 0.47 0.51 0.55 0.59 0.65 0.80
2 8 4 6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.79 0.02 0.05 0.07 0.104 0.13 0.156 0.183 0.20 0.23 0.26 0.292 0.32 0.35 0.38 0.41 0.44 0.48 0.52 0.57 0.63 0.77
6 2 8 0 9 6 4 0 0 1 3 7 4 5 3 3 6
0.80 0.00 0.02 0.05 0.078 0.10 0.130 0.157 0.18 0.21 0.23 0.266 0.29 0.32 0.35 0.38 0.42 0.45 0.49 0.54 0.60 0.75
0 6 2 4 3 0 8 4 4 5 7 1 8 9 7 9 0
0.81 0.00 0.02 0.052 0.07 0.104 0.131 0.15 0.18 0.21 0.240 0.26 0.29 0.32 0.36 0.39 0.43 0.47 0.52 0.58 0.72
0 6 8 7 4 2 8 8 9 1 5 2 3 1 1 4
0.82 0.00 0.026 0.05 0.078 0.105 0.13 0.15 0.18 0.214 0.24 0.27 0.30 0.33 0.36 0.40 0.44 0.49 0.55 0.69
0 2 1 8 6 2 2 3 5 9 6 7 5 5 8
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Power factor correction: Technical Data
A guide for the plant SA02607001E
0.83 0.000 0.02 0.052 0.079 0.10 0.13 0.16 0.188 0.21 0.24 0.27 0.30 0.34 0.38 0.42 0.46 0.52 0.67
6 5 2 0 6 6 7 9 3 0 1 9 9 2
0.84 0.00 0.026 0.053 0.07 0.10 0.13 0.162 0.19 0.22 0.25 0.28 0.31 0.35 0.39 0.44 0.50 0.64
0 9 6 4 0 0 1 3 7 4 5 3 3 6
0.85 0.000 0.027 0.05 0.08 0.10 0.136 0.16 0.19 0.22 0.25 0.29 0.32 0.36 0.41 0.47 0.62
3 0 8 4 4 5 7 1 8 9 7 7 0
0.86 0.000 0.02 0.05 0.08 0.109 0.13 0.16 0.19 0.23 0.26 0.30 0.34 0.39 0.45 0.59
6 3 1 7 7 8 0 4 1 2 0 0 3
0.87 0.00 0.02 0.05 0.083 0.11 0.14 0.17 0.20 0.23 0.27 0.31 0.36 0.42 0.56
0 7 5 1 1 2 4 8 5 6 4 4 7
0.88 0.00 0.02 0.056 0.08 0.11 0.14 0.17 0.21 0.24 0.28 0.33 0.39 0.54
0 8 4 4 5 7 1 8 9 7 7 0
0.89 0.00 0.028 0.05 0.08 0.11 0.14 0.18 0.22 0.26 0.30 0.36 0.51
0 6 6 7 9 3 0 1 9 9 2
0.90 0.000 0.02 0.05 0.08 0.12 0.15 0.19 0.23 0.28 0.34 0.48
8 8 9 1 5 2 3 1 1 4
0.91 0.00 0.03 0.06 0.09 0.12 0.16 0.20 0.25 0.31 0.45
0 0 1 3 7 4 5 3 3 6
0.92 0.00 0.03 0.06 0.09 0.13 0.17 0.22 0.28 0.42
0 1 3 7 4 5 3 3 6
0.93 0.00 0.03 0.06 0.10 0.14 0.19 0.25 0.39
0 2 6 3 4 2 2 5
0.94 0.00 0.03 0.07 0.11 0.16 0.22 0.36
0 4 1 2 0 0 3
0.95 0.00 0.03 0.07 0.12 0.18 0.32
0 7 9 6 6 9
0.96 0.00 0.04 0.08 0.14 0.29
0 1 9 9 2
0.97 0.00 0.04 0.10 0.25
0 8 8 1
0.98 0.00 0.06 0.20
0 0 3
0.99 0.00 0.14
0 3
0.00
0
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Technical Data Power factor
SA02607001E correction: A guide for
Table 7. Recommended wire sizes, switches and fuses for three-phase, 60 Hz capacitors
These wire sizes are based on 135% of rated current in accordance with the National Electrical CodeT, Article 460.
240 V 480 V 600 V
Fused Fused Fused
disconnect disconnect disconnect
(amperes) (amperes) (amperes)
Current Wire Current Wire Current Wire
kVAR (amperes) size A Breaker Fuse Switch (amperes) size A Breaker Fuse Switch (amperes) size A Breaker Fuse Switch
0.5 1.2 14 10 3 30 — — — — — — — — — —
1 2.4 14 10 6 30 1.2 14 10 3 30 1 14 10 3 30
1.5 3.6 14 10 6 30 1.8 14 10 3 30 1.4 14 10 3 30
2 4.8 14 10 10 30 2.4 14 10 6 30 1.9 14 10 6 30
2.5 6 14 10 10 30 3 14 10 6 30 2.4 14 10 6 30
6 7.2 14 15 15 30 3.6 14 10 6 30 2.9 14 10 6 30
4 9.6 14 25 20 30 4.8 14 10 10 30 3.8 14 10 10 30
5 12 14 25 20 30 6 14 10 10 30 4.8 14 10 10 30
6 14 14 25 25 30 7.2 14 15 15 30 5.8 14 10 10 30
7.5 18 12 30 30 30 9 14 15 15 30 7.2 14 15 15 30
8 19 10 35 35 60 9.6 14 20 20 30 7.7 14 15 15 30
10 24 10 40 40 60 12 14 20 20 30 9.6 14 20 20 30
12.5 30 8 50 50 60 15 14 25 25 30 12 14 20 20 30
15 36 8 60 60 60 18 12 30 30 30 14 14 25 25 30
17.5 42 6 80 80 100 21 10 40 40 60 17 12 30 30 30
20 48 6 90 80 100 24 10 40 40 60 19 10 40 35 60
22.5 54 4 100 100 100 27 10 50 50 60 22 10 40 40 60
25 60 4 100 100 100 30 8 50 50 60 24 10 40 40 60
30 72 3 125 125 200 36 8 60 60 60 26 8 50 50 60
35 84 2 150 150 200 42 6 80 80 100 34 8 60 60 60
40 96 1 175 175 200 48 6 80 80 100 38 6 80 80 100
45 108 1/0 200 200 200 54 4 100 100 100 43 6 100 90 100
50 120 2/0 200 200 200 60 4 100 100 100 48 6 100 100 100
60 144 3/0 250 250 400 72 2 125 125 200 58 4 100 100 100
75 180 250M 300 300 400 90 1/0 150 150 200 72 3 125 125 200
80 192 300M 400 350 400 96 1/0 175 175 200 77 3 150 150 200
90 216 350M 400 400 400 108 1/0 200 200 200 86 1 150 150 200
100 241 400M 400 400 400 120 2/0 200 200 200 96 1 175 175 200
120 289 (2)3/0 400 500 600 144 3/0 200 200 200 115 2/0 200 200 200
125 300 (2)3/0 600 500 600 150 3/0 250 250 400 120 2/0 200 200 200
150 361 (2)250 600 600 600 180 250M 300 300 400 144 3/0 250 250 400
M
180 432 (2)350 800 750 800 216 350M 400 400 400 173 250M 300 300 400
M
200 481 (2)400 800 800 800 241 400M 400 400 400 192 300M 350 350 400
M
240 — — — — — 289 (2)3/0 500 500 600 231 400M 400 400 400
250 — — — — — 300 (2)4/0 500 500 600 241 400M 400 400 400
300 — — — — — 361 (2)250 600 600 600 289 (2)3/0 500 500 600
M
360 — — — — — 432 (2)350 800 750 800 346 (2)250 600 600 600
M M
400 — — — — — 480 (2)400 800 800 800 384 (2)300 800 650 800
M M
A 90 °C Copper Type THHN, XHHW, or equivalent, applied at 75 °C ampacity. Rate current based on operation at rated voltage, frequency and kVAR. Consult National Electrical Code for
other wire types. Above size based on 30 °C ambient operation. (Refer to NEC Table 310.16.)
Note: Fuses furnished within capacitor assembly may be rated at higher value than shown in this table. The table is correct for field
installations and reflects the manufacturer’s suggested rating for overcurrent protection and disconnect means in compliance with the
National Electrical Code.
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Power factor correction: Technical Data
A guide for the plant SA02607001E
Motor
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Technical Data Power factor
SA02607001E correction: A guide for
5
Start: 4A
Close 6-7-2-3-4
Transfer:
Open 6-7 Run:Line
Close 1-5 7 Motor stator
3 B
6
2 C
1
4
1
2AB
Wye start: Close 1-2-3-7-8
5
Delta run:
Close 1-2-3-4-5-6 Motor stator
7
Line
6
3
C
69 Start:
Start: 6
Close 1-2-3 Run:
Close 1-2-3 Second3step:
A Close 4-5-6
Open 4-5-6 Line Third step: 3 A
5 8 Line
Close 7-8-9 Motor stator 5
Motor stator
2 B
4 7 2 B
4
1 C
1 C
A
Line3 B
2 C
1
Start: Close 1-2-3 Motor stator
Run: Close 4-5-6
6
5
4
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Power factor correction: Technical Data
A guide for the plant SA02607001E
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Technical Data Power factor
SA02607001E correction: A guide for
Introduction
There has been much discussion and interest in Volts
recent years on the subject of power quality.
Whereas in the past, power
received from the electric utility and used by an industrial Fundamental
plant was generally a pure sinusoidal waveform—for
example, clean power— more frequently today, industrial
plants are finding that they have 5th Harmonic
to deal with the problem of “dirty” power. Dirty power is
a slang expression used to describe a variety of voltage
and current contaminations on the pure sinusoidal
waveform. Dirty power can come in the form of short-
term transients or steady-state,
continuous distortions. In addition, the sources of dirty
power can be external to a plant (as might be the case if a
neighboring plant is contaminating the utility’s distribution
system), or the source can reside within the plant itself.
Harmonic distortion is a specific type of dirty power that is
usually associated with an industrial plant’s increased use
of adjustable speed drives, power supplies and other
devices that use solid-state switching. However, harmonic
Time
distortion can be generated by
any of a variety of nonlinear electrical devices existing Figure 17. Fundamental and 5th harmonic
within a manufacturing plant or within nearby plants.
Because harmonic distortion can cause serious operating
problems in certain plant environments, it is important
that the plant engineer or facilities personnel understand Volts
the fundamentals of harmonic distortion, know how to
recognize the symptoms of this problem, and know what
can be done to solve the problems once they are
identified.
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Power factor correction: Technical Data
A guide for the plant SA02607001E
Two very important points must be made in reference to the above limitations:
1. The customer is responsible for maintaining a current distortion to within acceptable levels, while the utility is
responsible for limiting voltage distortion.
2. The limits are only applicable at the point of common coupling (PCC) between the utility and the customer. The PCC,
while not explicitly defined, is usually regarded as the point at which the utility equipment ownership meets the
customer’s, or the metering point. Therefore, the above limits cannot be meaningfully applied to, say, distribution
panels or individual equipment within a plant—the entire plant must be considered when complying with these limits.
Electric utilities are currently considering financial penalties and/or service interruption for customers injecting excessive
harmonics into the utility system. Therefore, while a customer may not be currently penalized for low power factor, a
harmonic distortion–based penalty structure, in the manner of IEEE 519, may be forthcoming.
EATON
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Technical Data Power factor
SA02607001E correction: A guide for
How are harmonics generated? Common names given to electronic power converters
Harmonics are generated by nonlinear loads. A nonlinear •
Adjustable speed drives
load is a circuit element that draws current in a
nonsinusoidal manner. Until recently, most factory loads
•
Variable frequency drives
were primarily linear, with current waveform closely •
SCR drives
matching the sinusoidal voltage waveform and changing in
proportion to the load. More recently, however, factory
•
AC motor drives (AC/DC/AC)
loads with major nonlinear components have increased •
DC motor drives (AC/DC)
dramatically. Table 11 gives typical examples of linear and •
Three-phase full wave rectifiers
nonlinear devices.
•
Three-phase full wave converters
Primarily
Table 11. linear devicesDevices
Examples with major
of linear and nonlinear
nonlinearcomponents
devices •
Six-pulse converters
Some motors
Incandescent DC drives
Variable frequency
As most plant engineers appreciate, there is an increased
lighting Heating use of electronic drives due to their ability to more
loads drives Programmable
controllers Induction efficiently or precisely drive a motor or process.
furnaces
Solid-state uninterruptible power supplies Arcing devices
(UPSs) Arc furnaces
Arc welders
Arc furnaces and welders are the two types of arcing
devices that cause the most harmonic distortion,
although arc lighting (fluorescent, mercury vapor) will
also cause small degrees of harmonic distortion.
Six-pulse Harmonic power converter Other equipment
Motors, generators, transformers and arc lighting also
30.0%
have small nonlinear components, although the
contribution of these devices to total harmonic distortion
5 in a plant tends to be relatively small.
17.5%
2 EATON
Power factor correction: Technical Data
A guide for the plant SA02607001E
EATON
2
Technical Data Power factor
SA02607001E correction: A guide for
How can you eliminate harmonic problems?
When power factor correction is required in
the presence of nonlinear loads, or the
amount of harmonic distortion must be
reduced to solve power quality problems or
avoid penalties, the most reliable, lowest
cost solution is often realized with the use of
harmonic filters.
Phase A
B
C
Reactor
2 EATON
Capacitor bank
Power factor correction: Technical Data
A guide for the plant SA02607001E
EATON
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Technical Data Power factor
SA02607001E correction: A guide for
Nomenclature
Miscellaneous
C = Capacitance in kW
Q = Reactive Power Power factor = Cos P/S
μF kilo = 1000 θ =kVA =
(kVAR) V = Volts
E = Voltage A = Amperes
(Amps) Tan (See Table 6.) = Q/P
(V) I = θ
kVA = kilovolt- kV
Current (A) AR
S = Apparent Power amperes kW = kW
(kVA)
kilowatts
P = Real Power Single-phase E×I×
kVAR = kilovolt-amps- PF
(kW) reactive kW = 10
3
√ 3 × E × I × PF
Three-phase kW =
Additional data 103
√ 3×E
frequency:
Note: Use of voltages and frequencies above the rated
values can be dangerous. Consult the factory for any unusual Capacitor current (A) = (2πf) CE ×10–6
operating conditions. Q (kVAR) × 103
Single-phase capacitor current =
E
Reduced voltage Q (kVAR) × 103
( )
actual voltage 2
Actual kVAR (output) = Rated kVAR
rated
voltage Three-phase capacitor
current = √3×E
Reduced
frequency
(
kVAR (208) = kVAR (240) 2
208 =
0.75
240
(10 kVAR @ 240 V = 7.5 kVAR @ 208 V)
Frequency reduction
2
120 50
( (
kVAR (120) = kVAR (240) = 0.25 kVAR (50 Hz) = kVAR (60 Hz) = 0.83
24 60
0
(60 kVAR @ 480 V, 60 Hz = 50 kVAR, 480 V, 50 Hz)
(10 kVAR @ 240 V = 2.5 kVAR @ 120 V)
2 EATON
Voltage μF / kVAR total Single-phase Three-phase
208 61.2 4.81 2.78
240 46.0 4.17 2.41
Power factor correction: 480 11.5 Technical Data
2.08 1.20
A guide for the plant 600 7.37 SA02607001E
1.67 0.96
2400 0.46 — 0.24
4160 0.153 — 0.139
Note: Above is at nominal voltage @ 60 Hz = nominal kVAR μF and current.
EATON
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Technical Data Power factor
SA02607001E correction: A guide for
Intent:
(Reduce or eliminate PF penalty, release
plant/transformer/cable capacity, assist in voltage
regulation, filter or correct harmonics, fault ride-
through, bus voltage support, or other).
h Plant one-line drawing attached (if not available, a hand
sketch of the distribution system) showing major
distribution levels (HV, MV, LV and distribution panels and
PF expected/observed at each distribution level)
Distribution and utilization voltage (HV/MV/LV)
Additional source of generation
(co-gen, diesel generators, etc.)
Total connected load (kVA/kW/hp)
Total demand load (kVA/kW/hp)
Largest motor size (kW/hp)
General Largest non-motive load
(kVA/kW/hp)
Customer:
hType of nonlinear
Adjustable speedload
drives type
Customer (DC drives, 6 pulse, 12 pulse, 18 pulse)
contact: h Soft
Address:
starters h
Email: Arc furnaces
Phone: h Welders
Eaton contact: h UPS
Preliminary information for budgetary h UV equipment
estimate h DC–DC, AC–DC converters (electrolysis cells, etc.)
h Others (please describe)
Name of utility*
Current billed demand* (kW/kVA) Type of production facility: (cement, chemical,
sawmill, underground mine, etc.)
Present power factor
(known/calculated)* (lagging) Type of environment: (dusty,
conductive metallic dust, hazardous,
Desired power factor* (lagging) very hot, marine,
kVA of service transformer (kVA) chemically reactive, etc.)
Short-circuit capacity of the system on
Transformer primary and
the primary side (MVA)
secondary voltages (V)
Are there PF capacitors currently
Impedance of transformer present? (Y/N)
(if known) (%Z)
Nonlinear loads present (Y/N) (Preferably collect information on utility bulk correction
Approximate ratio of nonlinear capacitors for the line) If yes, kVAR capacity and voltage
load to total load (%) (kVAR)
*If information is unknown, please provide the following: (volts)
h Rate sheet attached/rate structure
h Past 12 months of billing information attached (if not
available, at least 3 months summer and 3 months
winter bills)
For product support,
please contact Eaton’s
power factor
application engineers
2 EATON at
Power factor correction: Technical Data
A guide for the plant SA02607001E
Eaton
1000 Eaton Boulevard
Cleveland, OH
44122 United
States Eaton.com
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Reserved
Printed in USA All other trademarks are
Publication No. SA02607001E / property of their respective
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