09 ELECTRICAL 0947 Power factor correction

0947 POWER FACTOR CORRECTION

1 GENERAL

.1.1 RESPONSIBILITIES
General
Requirement: Provide power factor correction as documented.
Type: Microprocessor controlled.
Function: To maintain the system power factor in the documented range and to provide harmonic
filtering under all load conditions.
Components: Size and select as follows:
- Limit the increase in incoming supply voltage total harmonic distortion to less than 2.5%.
- Limit the total harmonic distortion to less than 4%.
- Prevent interference with Supply Authority frequency injection systems
Harmonics: Reduce parallel supply impedance resonance using a series connected reactors tuned to
limit the total harmonic current within the capacitors to less than 5% of their nominal rating.
Service life of all components: > 10 years.
Standards
Electronic compatibility (EMC) requirements: To AS/NZS 61000.
.1.2 CROSS REFERENCES
General
Requirement: Conform to the following worksection(s):
- General requirements.
- Low voltage power systems.
- Switchboards – custom-built.
- Switchboard components.
.1.3 INTERPRETATION
Abbreviations
General: For the purposes of this worksection the following abbreviations apply:
- PFC: Power factor correction equipment.
.1.4 INSPECTION
Notice
Inspection: Give notice so that inspection may be made of the following:
- Equipment is ready for inspection before despatch from factory.
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.1.5 SUBMISSIONS
Shop drawings
Shop drawings: Provide the following:
- The system general arrangement and layout with details of connections, circuit breakers, cable
sizes, overall dimensions, weight, location of access doors, cable terminating locations and
necessary clearances.
- Control schematics. A description of operation with all control schematics.
- Functional block diagram.
- Heat generated by the PFC.
- Type and rating of all equipment items.
Technical data
General: Submit the following:

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- EMC technical data to AS/NZS 61000.

- Design calculations for the sizing of all capacitors and reactors.
.1.6 PRE-COMPLETION TESTS
Capacitors
General: Carry out capacitance and d.c. dielectric tests. Submit the capacitor unit test report before
factory inspection.

2 PRODUCTS

.2.1 CAPACITORS
General
Standard: To IEC 60831-1 and IEC 60831-2.
Type: Vacuum oil impregnated metallised polypropylene (MPP).
Automatic overpressure disconnection: Required.
Capacitance tolerance: -5% to +10%.
Construction: Cylindrical with single capacitor unit per can.
Dielectric rating: ≥ 500 V r.m.s. at 50 Hz selected to accommodate the series reactor voltage.
Discharge resistance: Required.
Loss: < 0.5W/kVAR (low loss type).
Removal: Arranged to permit removal of faulty module while the remaining capacitors continue to
function normally.
Surface temperature: Rated to achieve < 60°C.
Terminals: Tunnel or post type.
.2.2 CONTACTORS
General
Standard: To AS 60947.4.1.
Type: Step-switching.
Utilisation category: for capacitor switching AC-6b.
Rating: For capacitor switching duty at ≥ 1.5 times the capacitor step full load current.
.2.3 CONTROLLER
General
General: Provide a site-programmable, microprocessor, step controller, incorporating non-volatile
programme and data memory. Include the following:
- Automatic cycling of use of capacitor steps: Required.
- Automatic isolation in the event of capacitor over temperature or over current: Required.
- Data interface for remote monitoring and data download: RS232.
- Local alarms for:
. Over temperature.
. Over voltage.
. Reactive power exceeding adjustable programmed levels.
- Local digital display and remote monitoring of:
. Power factor.
. Incoming supply load (amps, kW and kVAR).
. Number of steps in use.
. Percent harmonic current.
. Harmonic currents.
. Stored data for greater than or equal to 1 week in date/time format.
- Manual-off-auto selection: Required.
- Remote alarm output contact for remote group alarm facility: Required.
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- Supply from an alternative source: Provide terminals and logic to disable all capacitor steps.
- Time delay after restoration of power supply: ≥ 60 s before switching in the first stage.
- Time delay between stages: Switching adjustable to be from 1 to 300 s.
Software: Provide 3 copies of proprietary software for remote monitoring and alarms.
.2.4 CURRENT TRANSFORMER INTERFACE
General
General: Provide interface to a 5 A secondary, 10 V.A, class 1, PFC current sensing transformer
installed in the relevant switchboard.
.2.5 INDUCTORS
General
Carrying capacity: ≥ 1.5 times the rated capacitor current at 50 Hz without saturating at 40°C ambient.
Cores: Insulated, laminated, high permeability silicon iron.
Flux density at rated current: < 0.85 tesla.
Inductance tolerance: ± 5% at rated current.
Losses: Very low loss design.
Mounting hardware: Non-ferrous.
Q factor: > 10.
Separate inductors for each capacitor step: Required.
Windings: High purity copper with Class F temperature rated insulation.

3 EXECUTION

.3.1 INSTALLATION
General
General: Connect the PFC to the power system as documented.
Power system
Protection: Provide protective devices to grade and discriminate with upstream devices. Individually
protect each kVAR step.
Capacitors
Insulation: Insulate all live parts.
Layout: Arrange capacitors for easy removal and replacement.
Mount capacitors in separate cubicle compartment, segregated from inductors, fuses and switchgear.
Ventilation: Separate capacitors by at least 25 mm of air space.
Inductors
General: Mount inductors in separate cubicle compartment, segregated from capacitors, fuses and
switchgear.
Harmonic Resonance
General: Vary the kVAR output and capacitor switching combinations to avoid resonant frequency
generation in the system.
Cubicle
Construction: To Switchboards – custom-built.
Colour: Match main switchboard.
Cooling fans: Muffin type axial fans.
Temperature rise: Ventilate the PFC cabinet so internal temperature rise is less than 5°C above
ambient in each cabinet compartment.
.3.2 COMPLETION
Warranties
Warranty: Provide 24 month warranty with six monthly service.

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.3.3 OPERATION AND MAINTENANCE

General
Standard: To AS 2467.
Operational and maintenance manuals
Requirement: Provide all operational and maintenance documentation necessary to operate and
maintain the equipment and systems installed.

4 SELECTIONS

.4.1 PERFORMANCE
Performance schedule
Property A B C
Power factor range: 0.95
Minimum
Power factor range: 1.0
Maximum
KVAR steps: Step size < 50
(kVAR)
KVAR steps: Number ≥5
Maximum design load
(kW)
Uncorrected power factor
(PF)
Expected harmonic: First
(amps)
Expected harmonic: Third
(amps)
Expected harmonic: Fifth
(amps)
Expected
harmonic: Seventh
(amps)
Expected harmonic: Ninth
(amps)
Acoustic noise limits

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