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A review of the different aspects of power factor; how low power factors can cost you money. How to define it in SCR power control.

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Arthur Holland, Holland Technical Skills

When you are buying electrical energy (kilowatt-hours) why should your supplier care

about your power factor (PF) and why should he give you a better deal for having a high

power factor?

The answer: At PFs less than 1, your supplier’s generators, transmission cables and

transformers hit their kVA output limit before his generators have reached their full rated

kW output.

This denies him the extra revenue that delivering full rated kW output to his consumer

base would give him.

motor.

Fig 2. Voltage and current waveforms of the inductive load and their vector

representation. The current is shown lagging the voltage by φ º

The motor represented by Fig 1 does not get the benefit of all the current ( I )shown here.

It can only use the component that is in phase with the voltage, i.e. Icosφ.

VIcosφ is the effective motor input in watts and cosφ is called the power factor.

1

The other component of current Isinφ lags V by 90 º and makes no contribution to motor

power. It is sometimes called quadrature or wattless current. It does however make an

unwanted and costly contribution to the resistance losses and consequent capacity

limitation all the way from the generator to the motor terminals.

Another way to define load PF is Watts/Volt-Amps.

Power Factor Correction

You can eliminate that 90 º lagging component by connecting capacitors in parallel with

your load. Capacitors take a 90 º leading current that can reduce or totally cancel out the

90 º lagging (quadrature) component thereby minimizing your total current and

increasing the PF. You do not need to connect enough capacitors to reach a PF of 1

because at some point you will spend more on adding capacitors than you save on your

electric bill.

A typical bulk tariff bill would have two parts:

1. A monthly demand charge based on the largest kVA recorded, averaged over any

15min period in the month. This penalises a consumer for excessive demands on

the capacity of the system.

2. An energy charge based on total consumption. The meter is calibrated to record

kVA multiplied by 0.8 instead of recording kWh. This is an incentive for a

consumer to maintain a high PF.

Consider a resistive heater R (negligible inductance) controlled by a silicon controlled

rectifier (SCR).

Myth 1. : “ With a resistive load (no inductance) there is no lagging current therefore PF

must equal 1”. Look closer. First at phase angle control.

Fig 3. Phase angle control showing full power at 200A and half power 141.4A

At full power the rms line voltage is constant at 500V. The current is 200A rms, it is

sinusoidal and in phase with the voltage so kW = kVA = 500V x 200A = 100kW.

Power factor = kW/kVA = 1.

At half power the current does not appear until the voltage wave is at 90 º. The current

looks like it is lagging and somewhat out of shape. It cannot be represented by a vector

and definitions based on cosφ do not apply. So let’s calculate the VA and the power

factor at half power (50kW).

2

By removing a symmetrical half of each half cycle of the current wave the power has

been halved to 50kW.

So heater power I2R has been halved so I2 has been halved (multiplied by 0.5). Therefore

the rms value (not the average value) of current I has come down by a factor √0.5 =

0.707 and the reduced current is 141.4A rms.

The kVA comes to 500 times 141.4 = 70.7kVA and the PF (kW/kVA) = 0.707.

Fig 4. The waveforms representing an SCR controlled resistive load in fast cycle

(time-proportioning) mode.

The fast cycling waveform shows the current to be present for half the time, resulting in

half power (50kW) into the same load as in the phase-angle case. A damped rms ammeter

would show 141.4A as before. Multiply this by the line voltage (500) and you get 70.7

kVA as before and a PF of 0.707.

You can now dismiss Myth 2. “ With sine waves and resistive loads PF must be 1”. This

myth is still circulated even by some manufacturers of SCR controls.

In both SCR firing modes above, let’s say you turn down the power by a factor “a” – call

it the per unit power instead of percentage of full power. The PF turns out to be √a (the

square root of a).

It is only when you turn power down that you see a decrease in PF. Your threat to the

energy supplier’s capacity is thereby mitigated.

Don’t even try using capacitors for PF correction they are largely ineffective.

As little as one additional comparably sized sinusoidal resistive load such as building

lighting and space heating can easily take your overall plant PF up out of the penalty

zone.

Power Factor.doc 2002/Feb/25 Arthur Holland. Holland Technical Skills. Ph: 905 827 5650 email: aholland51@cogeco.ca

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