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    Power Factor Corretor - A Guide For The Plant Engineer

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    Rafa Carmona
    guide for the selection capacitor industrial

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    Power Factor Corretor - A Guide For The Plant Engineer

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    Rafa Carmona
    11 views18 pages
    guide for the selection capacitor industrial

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    Power Factor Corretor - A Guide for the Plant Engineer

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    guide for the selection capacitor industrial

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    11 views18 pages

    Power Factor Corretor - A Guide For The Plant Engineer

    Uploaded by

    Rafa Carmona
    guide for the selection capacitor industrial

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 18
    What is power factor? Special electrical requirements of inductive loads Most loads in modern electrical distribution systems are inductive, Examples include motors, transformers, gaseous tube lighting ballasts and induction furnaces. Inductive Toads need an electromagnetic field to operate. Tnductive loads require two kinds of current: = working power (KW) to perform the actual work of creating heat, light, motion, machine output, ec. - reactive power (KVAR) to sustain te electromagnetic field Working power consumes watts and can be read on a ‘wattmeter. It is measured in kilowatts (KW). Reactive power doesn’t do 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 source's distribution system, Reactive ower is measured in kilovolt-amperes reactive (KVAR). ‘Working power and reactive power together make up apparent power. Apparent power is measured in kilovolt- amperes (KVA). uy WN Resistive a HotPlae Light Figure 1 KW Power Motor Field Figure 2 _ VAR Power Heat Component > = Wor Done: Component No Work Figure 3 VA Power A tight “power” tangle is often used to illustrate the relationship between KW, KVAR, KVA. KW . KVAR coso= KY = pp KVA Figure 4 Right Power Triangle Note: Fora discussion on power factor in non-linear, non-sinusoidal systems, turn to page 15. Fundamentals of power factor Power factor is the ratio of working power to apparent power. It measures how effectively electrical power is being used. A high power factor signals efficient uilizaton of electtical power, while a low power factor indicates poor utilization of electrical power. To determine power factor (PF), divide working power (KW) by apparent power (KVA). In a linear or sinusoidal system, the result is also referred to as the cosine @. KW va For example, if you had.a boring mill that was operating at 100 KW and the apparent power consumed was 125 KVA, you would divide 100 by 125 and come up with a power factor of 0.80. caw) 100 aevajias Note: Power factor in a non-linear environment will not hold to the presented formulas or tables without filters or chokes installed on the harmonic generators. PF) 0.80 Why should I be concerned about low power factor? Low power factor means you're not fully utilizing the lecrical power you're paying for. In the example above, with a power factor of 80%, your boring mill would be wilizing only 80% of the energy supplied by the utility. That means only 80% of the incoming current is being used to produce useful work, ‘As the triangle relationships in Figure 5 demonstrate, KVA decreases as power factor increases. At 70% power factor, it requires 142 KVA to produce 100 KW. At 95% power factor, it requires only 105 KVA to produce 100 KW. Another way (0 look at itis that at 70% power factor, it takes 35% more current to do the same work. ‘Figure 6 illustrates the effects of various power factors on an electrical system of 100 KW demand at 480 volts, As the chart shows, the wire size requirement on the system with 100% power factor is no. 1/0. The same system with a 60% power factor cequires a no, 4/0 conductor. Actual wire diameters are shown, 100 KW e 100 2 KVAR KVA 100 re 100 KW 33 KVAR 105 KVA 100 PR= 12 = 959% 7% Figure 5 ‘Typical Power Triangles Teadtinoare) [00 | war | wos [To | 20 Tinslormar | TOOKWA | T25KWA | TZ5RVA | TEOKVA Tecwiesee | vo | wo | wo | 2m. | 40 ‘wieDanaer [oars | oavs | oats | 0ai9 (THN Cope 180] vas HVA Kw POWER FACTOR Figure 6 Characteristics of Power Factor on 100 KW Loads What can I do to improve power factor? You can improve power factor by adding power factor correction capacitors to your plane distribution system. ‘When apparent power (KVA) is greater dan working power (KW), the utlcy must supply the excess reactive courtent plus the working current. Power capacitors act as reactive current generators. By providing the reactive current, they reduce the total anount of current your system rust draw from the utility. 18 Amperes 10 HP, 480 V Motor At 84% Power Factor 16 Amperes 3.6 Amperes 3KVAR Capacitor Power Factor Improved 10.95% Line Current Reduced 11% Figure? Capacitors as KVAR Generators 95% power factor provides maximum benefit ‘Theoretically, capacitors could provide 100% of needed reactive power. In practical usage, however, power factor correction to approximately 95% provides maximum benefit. ‘The power triangle in Figure 8 shows apparent power demands on a system before and after adding capacitors. By installing power capacitors and increasing power factor (o 95%, apparent power is reduced from 142 KVA to 105 KVA - a reduction of 35%. + KAR tr roo KyaR Bele + rena Capac ‘Reed cos 01 = 22 i = rowr oa = 1005 costes = 1 = osm Figure 8 Required Apparent Power Before and After Adding Capacitors How much can I save by installing power capacitors? Power capacitors provide many benefits: ~ Reduced electric utility bills « Increased system capacity ~ Improved voltage duced losses Reduced utility bills ‘Your electric utility provides working (KW) and reactive power (KVAR) to your plant in che form of apparent power (KVA). While reactive power (KVAR) doesn’t register on KW demand or KW hour meters, the utility's transmission and distribution system must be large enough to provide it. Uilities have various ways of passing along the expense of larger generators, transformers, cables, switches, etc. to you. ‘As shown in te following case histories, capacitors can save you money no matter how your utility bills you for power. KVA billing ‘The utility measures and bills every amp of current, including reactive current. CASEL Assiime an uncorrected 460 KVA demand, 480 volt, power factor (normally good.) BILLING: ‘S4.7S/KVA demand Correct to 97% Power Factor. SOLUTION: KVA x Power Factor = KW 460 x 0.87 = 400 KW Actual Demand Maeva M0 FF 397 From Table 3 KW Multipliers, to raise the Power Factor fom 0.87 10 0.97 requires capacitor: ruliplier 0216.x KW 0.316 x 400 = 126 KVAR (Use 130 KVAR) Uncorrecied oviinal billing: 460 KVA x $4.75 = s2185/mo, + S987 $ 228/mo, saving x 12 = $2736 annual saving ‘Corrected new billing: 412 KVA x $4.75 = $195TImo. 130 KVAR, 480 volt capacitor cost in 1988, $1750.00 (installation extra), This capacitor pays for itself in less than eight montis. CASE2 ‘Assume the same conditions except that 400 KW.@ 87% = 460 KVA 400 KW @ 97% = 412 KVA Corrcted Bling KVA Demand Charge: $1.91/KVA/month (112,400 Kwitimonth energy consumed.) Energy Charge S0.0286/KWH (first 200 KWHVKVA of demand), '$0.0243/K WH (next 300 KWHIKVA of demand) '50.021/K WH (ll over SOOKWH/KVA of demand). ‘Uncorrected: Corrected Demand: 460KVA x $1.91 412 KVAxS1.91 = 587 = $786.92 - S76.92 ‘591.68 Savings in demand charge Energy’ KWH = 112,400 KOWH= 112,400 460x200 = 92,000K WH 4123200 = 82.400KWHH @ S0.0286 = $2531.20 @ 80.0286 = $2356.66 460 x30 = 138,000, but balance only = 20,400 @ 80.0243 = § 495.72 412 x 300 = 123,600 but balance only = 30,000 @ $0.0243 = $729.00 $2531.20 $2356.64 +5.495.72 +$729.00 {$3126.92 Unerceed Bry Chege $3085.64 Care Earey hips $3085.64 5 41.28 saving in energy charge due to rate change, (9600 KWH in first step reduced by $0.0043) NOTE: This is nots eat in energy consumed, but in bling ony. Saving: 541.28 Bnorgy +$.91.68 Demand $132.96 Monthly toa saving 22 1395.52 ‘A.130 KVAR capacitor can be paid for in less than 14 mionths, KW demand billing with power factor adjustment ‘The utility bills according to KW demand and adds'a surcharge or adjustment for power factor, The adjustment may be a mulipier applied to KW demand. ‘The following formula shows a billing based on 90% power factor: HOW demand x 0,90 actual power factor If power factor was 0.84, the utility would require 7% increase in billing, as shown in this formula: 3% 0.90 07 mutipticr 0.84 Some utilities charge for low power factor but give a credit or ‘bonus for power factor above a certain level CASE ‘Assume a 400 KW Load, 87% power factor wit the following Us wit: ‘A. Demand Charges: Fit 40 KW @ 310.00/KW monthly bing demand New 60KW —@S9.30/KW New KW @ $8.00KW Allover 1000KW @ $8.50KW B. Power Facior Clauss Rates based on power factor of 90% o beh, When power flor ese than 85% the demand will be inrensed 1% for es 1% tha the powe ter Isbelow 90%. Ifthe power factor is higher than 98%, the demsnd il be eceased 1% foreach 1% that the peter Iator is above 90%. (ote that ‘here would be no penalty for 87% power factor. However, a bons could be credited the power factor were rated 10 96%) ‘Tomise an €7% power ctr to 96% refer to Table3. Find 275 x 400 KW -IIOKVAR (Selec 120 KVAR to assure the msitenance ofthe 96% seve. ‘To Caloite savings Nommat 400KW biling demand Fit 4oKw @$10.00= $400.00 Nox 160KW @$9.50= $1520.00 Bal, 200KW @ $9.00 = © $1800.00 "Toa 400K $5720.00 Normal Monthly Bing New Biling: ‘vho.s0 = New Power Factor 400x090, a Fics 40KW @ $10.00 SSW demand 400.00 Next 160KW @ $ 9.50 $1320.00 Bal 17SKW @ $9.00 "= $1575.00 $3495.00 Power Faior Adjusted Ding CASE 2 Wit the stn 400KW lad the power ficor sony 81% In this namie, the ‘exslomer wil pay an ajrtment based on; (From Cass 1, When the Power Factor = 96%, the Ding demsnd is 375 KW $2495.00 per month) irs 40K @si0.0 = $400.00 New 10KW —@ $9.50 1520.00 Nex 2eKW — @ $9.00 2196.00 Tol 444KW $4116.00 - $3495.00 $5621.00 12 = $7452.00 _eary savings if erro 0 96%, $4116.00 Charge at sis “$8720.00 Normal OW Demand Charge $396.00 Power Factor Adjustment for 81% Power Factor* ‘To mise 81% power factor to 96%, slat te nip from Table 3 0.432. x 400KW m ITIKVAR. Use 1HOKVAR to assure a 96% power con “The ost ofa 180 KVAR capacitor i $2070.00 and te payosTis es than four mont “SSKVAR would eliminate the penalty by eoreting power fer fo 85%, KVAR reactive demand charge The utility imposes a direct charge forthe use of aaghetizing power, usually a waiver of some percentage of KW demand. For example, if this charge was 60 cents per KVAR for everything over 50% of KW, and a 400 KW load existed atthe time, the utility would provide 200 KVAR free. case ‘Assumes AOOKW lad demand 81% pos ar. Tai siete Deniad Cages 5635.00 0 Weft 200 KW dead $2.40 pe KW fora aon Reslve dan cares $0.60 por VAR in xe: of 50% of KW dena Inis ample, KW demand = AOOKW, therfore 50% = 200 KVAR which wil be isa tn cose Wg, ADI, corre= KM gy kva “We KVAR _ oP? KW” ADI isthe basi of thes “Thiet eof Mule: (Table3), 00 SH ‘Wit 200 KVAR allowed at no eos, then 0, = 200/400 =0.5 or 50% of KW. From 1.0 or uly power factor coum, ‘Table 3, noe that 0.500 fats between 89% and 90% power fair. Te bling for excess VAR is sbore lat evel, 81% power fear Tan, = 0.724 RVAR = KW xTan Oy = 400 EOT24 ~ 289.6 KAR, Since 200 KVAR i afowe the excess KVAR is 89.6 (ound 0 90) x $0.60 = $54.00 pee mont ing for reactive demand SOLUTION: "To correct 400 KW from 81% to 90% equces 400 x 0.240 (From Table 3) 96 KVAR, (Use 100 KVAR), ‘he 1985 ens (0 his capacior i $1250,0, ‘The ayo about 23 months. NOTE: KWAR charges vary from about 15 ces toa dalle and free KVAR enges from 25% (97% power factor) 10 15% (8% power feoe) of KW demand Increased system capacity over capacitors inzease system current-carrying capacity. Raising the power factor on a KW load reduces VA. Therefore, by adding capacitors, you can add additional KW load to your system without altering the KVA, [A plant hs 9 SOOKWA transformer operating near capacity. I draws “ABOKYVA of $78 amperes 2480 vols. "The present power for is 75%, tothe actual working power svallble is 360KW. Wis desired to increase production by 25%, which means tbat about “450KW ouput mut be obtained. How is this accomplished? A new transformer wold extinly be one soon. For 4S0KW ouput the transformer would be raed at GOOKVA to Inne 75% power fair loa. ‘More likely, the next size sana raling would Ye neaded. ISOKVA). Perhap Betis soltion would be to improve the power factor and release enough capacity to scommodats the increased loa. “To correct 4SOKW from 75% to 98% power facior rues 450 x 0.553 (fom Table 3) 248.SKVAR use 250K VAR at about $3400. soos Condition: a on ue aan ot ‘STO Anges 4 Figure 9 Correcting Power Factor Increases Transformer Output ‘The same principle holds true for reducing current on overloaded facilites. Increasing power factor from 75% to 95% on the same KW load results in 21% lower current flow. Put another way, it takes 26.7% more current for load to operate at 75%, and 46.2% more current to operate at 65%. Industries with low power factors benefit most from capacitors . Low power factor results when motors are operated at less than full oad. This often occurs in eycle processes such as those using circular saws, ball mills, conveyors, compressors, grinders, punch presses, etc.- where motors are sized for the heaviest load. Examples of situations where low power factors (from 30% to 50%) occur include a surface ‘grinder performing a light cut, an unloaded air compressor and a circular saw spinning without cutting. “The following industries typically exhibit low power factors: Uncorrected Industry power factor saw mills 45-60% plastics (esp. extruders) 55%-10% machine tls, stamping 60%-70% plating, textiles, chemicals, breweries 65-75% hospitals, granares, foundries 10%-80% Include power capacitors in new construction! expansion plans Including power capacitors in your new construction and expansion plans can reduce the size of transformers, busses, switches, etc. and bring your project in at lower eost. Figure 10 shows how much system KVA can be release by improving power factor. Raising the power factor from 70% to 90% releases 0.32 KVA per KW. Ona 400 KW load, * 128 KVA are released. Improved voltage conditions Low voltage, resulting from excessive current draw, causes motors to be sluggish and overheated, As power factor decreases, (ota line current increases, causing further voltage drop. By adding capacitors to your system and improving voltage, you get more efficient motor performance and longer motor life. Reduced losses Losses caused by poor power factor are duc to reactive current flowing in the system. ‘These are watt-related charges and can be eliminated through pwer factor correction. Power loss (watts) ina distribution system is calculated by squaring the current and multiplying it by the circuit resistance (FR). To calculate loss reduction: Orie % reduction tosses =100-100 x

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