Issue no 4

K – Factor monitoring through Multifunction meter

Introduction
The use of VFD’s in industries were limited until two decades ago. Simple AC Induction motors were
more in prominence during that era i.e. the loads were linear in nature. However, due to continuous
modernization efforts and energy saving initiatives many applications now operate with VFD driven
motors instead of old technology. Due to this, various feeders now handle a higher percentage of non-
linear loads and this results in harmonic currents getting injected into the supply system.
The transformers that feed the present-day power electronic devices exhibit additional losses due to
high level of harmonic currents manifested as distorted current and voltage waveforms. The transformer
manufacturer used to test their product only under ideal conditions i.e with linear load and therefore a
substantial gap exists between published loss data and actual losses incurred after installation.

Genesis of K Factor concept

Losses in transformers are primarily due to eddy current losses and stray magnetic losses in the core and
resistive losses in the windings. Of these, eddy current loss would play a major role because of the
presence of harmonics. This loss is directly proportional to the square of the frequency. Higher harmonic
content (in buildings, industries with more non-linear loads and so on) would lead to higher eddy current
loss. This in turn would rise the operating temperature of transformer and would result in premature
failure of transformer.
Underwriter’s Laboratory had brought out the standards for the transformers handling higher frequency
harmonic currents. This is described under UL1561 based on K factor concept derived from ANSI/IEEE
C57.110 standard – Recommended practices for establishing Transformer capability when supplying non sinusoidal
load currents.

Need for K-Factor rated Transformers

K-Factor is the weighting of the harmonic load currents according to their effects on transformer heating.
K-Factor of 1.0 indicates a linear load (no harmonics). The higher the K-Factor, greater is the harmonic
heating effects.
The K-Factor transformers have additional thermal capacity to tolerate the heating effects of the
harmonic currents. K-factor indicates the multiples of 50 Hz winding eddy current losses that the
transformer can safely dissipate, without requirement of de-rating.
Transformer load losses consist of winding I2R losses plus eddy current and stray losses. For example, a
transformer with K-4 rating that has winding I2R loss of 2000W and 50 Hz eddy current and stray losses

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 of 100W will be required to dissipate the 2000 watts of I2R losses plus 4 times the 50 Hz value of 100
watts i.e a total load loss of 2400 watts without exceeding the maximum winding temperature rise.
UL has chosen standard K factors of K-4, K-9, K-13, K-20 etc. K factors greater than 9 are infrequent. K
factors above 4 normally find use with single phase transformer supplies used to feed computer loads in
office, etc.

Name plate of K factor Transformer

Image only for representational purposes

K factor calculation

𝑃
𝐾= = 𝐼 ℎ
𝑃

Where, Pf is the eddy current loss at the fundamental frequency, f

Pt is the eddy current loss at hth harmonic
Ih is the hth harmonic current in %
h = Harmonic order i.e 3rd, 5th, 7th, etc (this is generally limited to 25th harmonic)

Based on these assumptions, sample calculations are shown in table below for the given individual
harmonic current percentages.
K-factor calculation for a single-phase transformer feeding typical non-linear load
h (harmonic number) Ih (non-linear load (Ih)2 Ih = I / [∑ (Ih)2 ]1/2 (Ih)2 (Ih)2* h2
current) %
1 100 1.000 0.792 0.626 0.626
3 65.7 0.432 0.520 0.270 2.434
5 37.7 0.142 0.298 0.089 2.226
7 12.7 0.016 0.101 0.010 0.495
9 4.4 0.002 0.035 0.001 0.098
11 5.3 0.003 0.042 0.002 0.213
13 2.5 0.001 0.020 0.000 0.066
15 1.9 0.000 0.015 0.000 0.051

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 17 1.8 0.000 0.014 0.000 0.059
19 1.1 0.000 0.009 0.000 0.027
21 0.6 0.000 0.005 0.000 0.010
23 0.8 0.000 0.006 0.000 0.021
25 0.4 0.000 0.003 0.000 0.006
Total 1.596 1.00 6.33

Here the calculated K factor of the load is 6.33. If a transformer with K factor of 4 is selected, then
derating is required. However, a transformer with K factor of 9 will meet the load without any derating.
3 phase transformers supplying balanced loads won’t have 3rd harmonic component and hence the K
factor for 3 phase transformers are normally less.
Following are the typical K-factor considered for non-linear loads connected.
% non-linear load K-factor
<5% K-1
<35% K-4
<50% K-7
<75% K-13
<100% K-20

The critical component to first get affected by higher % of non-linear loads are Transformers. K factor
ratings are based on the heating effects of harmonics and are not necessarily applicable to other power
system components. If harmonic rating systems for other components are needed, they must be
developed by other methods, e.g. THD, crest factor or some new and component specific weighting of
harmonic currents. The non-linear transformer does not generate, nor does it eliminate harmonics infact
the transformer tolerates the nonlinear load conditions.

Monitoring through MFM

L&T Multifunction meter from 4410 series onwards have the provision to display K-factor phase wise for
both voltage and current. The meter will help to continuously monitor the K factor levels in the plant
with increasing addition of non-linear loads.

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 Monitoring through EMS

SmartComm EMS offers the flexibility of monitoring energy from all electrical feeders at the
convenience of desktop. However, the Energy manager or Maintenance manager is empowered when
he gets critical feedback of energy performance parameters of the plant.

SmartComm EMS along with 44XX / 50XX series of meters can help in continuous monitoring of K-
Factor levels at Incomer levels along with other critical power quality parameters like THD% and
Individual harmonics.

Way ahead

User can continuously monitor K-factor levels based on the addition of non-linear loads. This
information can be used during Transformer upgradation/retrofit or plant expansion. The user can
select the K rating of new transformer required based on the previous information available.

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SmartComm EMS benefits

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