Power Factor Correction Capacitors

Selection & Applications

Of
Power Factor Correction Capacitor
For
Industrial and Large Commercial Users

Ben Banerjee
Power Quality Solution Group
1
 Agenda

• Power Factor Fundamental

• The Need for Power Factor Correction
• Effects of Harmonics: TPF & DPF
• Correction Alternatives & Capacitor Locations
• PF Rate, Capacitor Sizing, & ROI
• Capacitor Applications To Motors
• Capacitor Switching Equipment
• Other Application Issues
* Steady State VAR Correction
* Dynamic VAR Correction
• Standards & Codes
2
 Power Quality Correction

Power Factor
Fundamentals

11/19/21
 Power Quality Correction

ACTIVE & REACTIVE POWERS

 Most plant loads are Inductive and require a magnetic field to

operate:
 Motors
 Transformers
 Florescent lighting
 The magnetic field is necessary, but produces no useful work
 The utility must supply the power to produce the magnetic field
and the power to produce the useful work: You pay for all of it!
 These two types of current are the ACTIVE and REACTIVE
components

11/19/21
 Power Factor Fundamental
• Definitions:
– Working /Active Power: Normally measured in
kilowatts (kW). It does the "work" for the
system--providing the motion, torque, heat, or
whatever else is required.
– Reactive Power: Normally measured in kilovolt-
amperes-reactive (kVAR), doesn't do useful
"work." It simply sustains the electromagnetic
field.
– Apparent Power: Normally measured in kilovolt-
amperes (kVA). Working Power and Reactive
Power together make up apparent power.

5
Power Factor:The Beer Analogy

kVAR Mug Capacity = Apparent Power (KVA)

Reactive
Power Foam = Reactive Power (KVAR)
Beer = Real Power (kW)

kVA
Apparent Beer (kW)
Power
Power Factor =
Mug Capacity (KVA)
kW
Active
Power
Capacitors provide the Foam (KVAR),
freeing up Mug Capacity so you don’t have
to buy a bigger mug and/or so you can pay
less for your beer !

6
 Power Factor Fundamental
Power Factor : A measure of efficiency. The ratio of Active Power (output) to Total Power (input)

A power factor reading close to 1.0 means that electrical power is being utilized effectively, while a low power factor indicates poor utilization of electrical power.

Active Power (kW) Power Factor

Active (Real) Power =
 Total Power
Reactive
Power = kW
Total Power (kVA) (KVAR)
kVA
= Cosine (θ)
= DISPLACEMENT POWER FACTOR

7
 LEADING AND LAGGING
IR
IC

IR V
ILOAD
IL
G IC L
KVARC

KW

KVARL

Division - Name - Date - Language 8

LEADING AND LAGGING
G G

KW KVAR (LAG) KW KVAR (LEAD)

KW KVAR (LAG) KW KVAR (LEAD)

L L

INDUCTION OVER-EXCITED
MOTOR
SYN. MOTOR

9
 Typical Uncorrected Power Factor
(Use only as a Guide)
By Industry Power By Operation Power
Factor Factor
Auto parts 75-80 Air compressor:
Brewery 76-80 External motors 75-80
Cement 80-85 Hermetic motors 50-80
Chemical 65-75 Metal working:
Coal mine 65-80 Arc welding 35-60
Clothing 35-60 Arc welding with 40-60
standard capacitors
Electroplating 65-70 Resistance welding 40-60
Foundry 75-80 Machining 40-65
Forge 70-80 Melting:
Hospital 75-80 Arc furnace 75-90
Machine 60-65 Inductance furnace 100
manufacturing 60Hz
Metalworking 65-70 Stamping:
Office building 80-90 Standard speed 60-70
Oil-field pumping 40-60 High speed 45-60
Paint 55-65 Spraying 60-65
manufacturing
Plastic 75-80 Weaving:
Stamping 60-70 Individual drive 60
Steelworks 65-80 Multiple drive 70
Textile 65-75 Brind 70-75
Tool, die, jig 60-65

From IEEE Std 141-1993

10
WHY DO WE CARE ABOUT POWER FACTOR

11
 MOTOR LOAD CHARACTERISTICS

NAOD – PQCG US – May 16, 2007 - English 1

2
 Why do we care about Power Factor?
• In Industrial Facilities, Mostly Induction Motor
loads
• Energy Efficient Motors not optimized for PF
• Low power factor is caused by oversized or lightly
loaded induction motors
• Low power factor results in:
– Poor electrical efficiency!
– Higher utility bills **
– Lower system capacity
– On the Supply Side, Generation Capacity & Line Losses
• Power Factor Correction Capacitors (PFCC)
provide an economical means for improving
Energy utilization

13
 Power Quality Correction

Why do we install Capacitors?

Before After  In this example, demand
was reduced to 8250 kVA
from 10000 kVA.

 1750KVA Transformer
Capacity Release.

 The power factor was

improved from 80% to
97%

14

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Harmonics
• Displacement Power Factor
• Total Power Factor
• Effects of Harmonics on Capacitors
15
 Power Quality Correction

Linear vs Non-Linear

 Until recently, most electrical equipment

drew current in a “linear” fashion:

v i • Current (i) & Voltage (v) are both “Sinusoidal”

 Today, many electrical loads draw

current in a
“non-linear” fashion:
• Current (i) is periodic, but not “sinusoidal”
v
i

16

11/19/21
What produces “Non-linear” Current?

• Computers • Variable
M
Frequency
Drives
• Fax Machines • Electronic
Ballasts

• Almost
• Copiers anything
electronic

17
 Power Quality Correction

Time vs Frequency
Time Domain Frequency Domain
1
f1 = 6 0 Hz
0.5

60 Hz f1 0
1 3 5 7 9 1 1

f3 = 3 x 6 0 hz =

+
1
18 0 hz
0.5
180 Hz f3 0
1 3 5 7 9 1 1

+
f5 = 5 x 6 0 hz = 1
3 0 0 hz

f5
0.5
300 Hz 0
1 3 5 7 9 1 1

f7 = 7 x 6 0 hz = 1

+ 4 2 0 hz
0.5

420 Hz f7 0
1 3 5 7 9 1 1

D is to rte d Wa v e =
f1 + f3 + f5 + f7 1

0.5

= 0
1 3 5 7 9 1 1

18

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 Power Quality Correction

Total Harmonic Current Distortion

Is Same As
Total Demand Distortion (TDD)

 Ih 2

I
2
 I 2  I 2
  2
I  2
3
4  100 %  h
 100 %
TDD
I 1
I 1

19

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 Power Quality Correction

Total or True Power Factor (TPF)

TPF = (DPF) x (Harm Coefficient)

KW
DPF = = Cos 
KVA

Harm Coefficient = 1
1 + TDD2

TPF = Total or true power factor

DPF = Displacement power factor
Harm coefficient = Harmonic power factor = Cos 
20

11/19/21
 Total Power Factor Example

• VFD ( Six Pulse )

• DPF = .95
• TDD = 90% ( No Line Reactor)

Harm coefficient =
1 = .7433
1 + .92

• TPF = .95 x .7433 = .7061

 Power Quality Correction

Applying Capacitors:
 Caps at Motors or at SWBD / MCC:
Disadvantage:
 If Drives are present anywhere, the harmonic currents

they produce can flow back to the point of lowest

impedance: the capacitor!
 This will cause premature failure of the capacitor.

M VFD M M M M

22

11/19/21
 How Harmonics Affect Capacitors

• Capacitors are naturally a low impedance to

high frequencies:
– Caps absorb harmonics
– Caps do not generate harmonics
• As capacitor absorbs harmonics, the capacitor
heats up
– Reduced life expectancy
• Voltage harmonics stress the capacitor dielectric
– Reduced life expectancy
• Parallel combination of capacitors with motor or
transformer can cause resonance condition

23
 Resonance

The installation of standard capacitors can

magnify harmonic currents on the network

24
 How Harmonics Affect Capacitors:

• Resonance:

XL Resonance
fr  f 1
XC
X L  2 fl Z XL

( XL-Xc )
1 fr XC
XC 
2 fc

25
 Capacitor Resonance
Resonant Point likely to amplify dominant
harmonic (typically 5th)

Magnification of Harmonic Current when Standard

Capacitor are Added to the Network

26
 Power Factor Correction With Harmonics:

• De-tuning a network:
– “Force” the resonant point away from naturally occurring
harmonics

4.2 Harmonic (252 Hz)

I<h5>

Ih5
f

f1 f3 f5 f7 f9 We control the impedance

of these two elements
27
UTILITY RATE & PFCC

28
 Most utilities penalize for bad Power
Factor...
 If the consumer does not correct the power factor, the
utility may have to
 Build more power plants
 Install New/ Large transformers
 Use larger utility cables/ Wires, Switchgear,etc.
 Many different rate structures across the country.
Typically, penalties are imposed for PF < 95%.
 Thousands of Customers across the country are
currently unaware that they are being penalized for
low power factor!!!

29
 How do utilities charge for Power
Factor?
• Utilities recoup the cost of providing reactive power
in different ways…..
– kVA billing: utility measures and bills every ampere of
current including reactive current.
– kW demand billing with Power factor adjustment: utility
charges according to kW demand and adds a surcharge for
power factor, typically in the form of a multiplier applied
to kW demand.
– kVAR Reactive Demand charge: A direct charge for use
of magnetizing power. (example:$ 4.50/kVAR)
 Two utilities recently introduced substantial Power Factor
Penalties
 TXU (Texas) $3.50 - $5.50 per kW Demand to 95% pf
 TVA (Tennessee) $1.46 per kVAR lagging, $1.14 per
kVAR leading (April 1, 2004)
30
 MOST COMMON POWER
FACTOR RATE CLAUSE

BILLING KW DEMAND =

ACTUAL KW DEMAND X BASE PF/ ACTUAL PF

 Penalty Calculation From Utility Bills In TX
BILLING DEMAND (apfa) = KW2 & ACTUAL DEMAND = KW1

Due to PF Adjustment, KW2 > KW1

*Distribution System Charge = (KW2-KW1) x $3.55 / apfa = M1

*Nuclear Decommission Charge = ( KW2-KW1) x $0.044/apfa = M2
*Transition Charge-1 = (KW2-KW1) x $0.177/ apfa = M3
*Transition Charge-2 = (KW2-KW1) x $0.272 / apfa = M4
*Transmission Service Charge = (KW2-KW1) x $1.19 / apfa = M5
*Transmission Cost Recov Factor = (KW2-KW1) x $0.27103 /apfa
=M6

Total / Month = M1+M2+M3+M4+M5+M6 = $ / Month

CAPACITOR LOCATION & TYPE

33
 Power Quality Correction

Capacitor Locations
 Three Options for Applying Power Factor
Capacitors:
A) Fixed capacitors @ individual motors or @ MCC
B) Automatic Banks at Main Switch Board
C) De-tuned Automatic Capacitor Bank at Main Switch Board

Harmonic
Source
e.g. Variable
M M M M M Speed Drive
A B C A

34

11/19/21
Fixed Capacitors - Low Voltage
• Main Benefit
– pf correction
• Side Benefit
– voltage support
– Small I2R reduction
• Usage
– Correcting pf on individual loads such as motors
• Disadvantages
– Overcompensation (correct past unity)
– Not to be used on non-linear loads
– Unable to track minute by minute load changes
occurring on non-compensated feeders

35
Standard Automatic Capacitor Systems

• Main Benefit
– pf correction
• Side Benefit
– voltage support
– Small I2R reduction
• Usage
– Correcting pf on entire
MCC’s or substations
• Application alert
– Not to be used on non-
linear loads

36
Anti-Resonant Automatic Cap. Bank

 Automatic Cap. Bank

with a reactors in series
 Reactors tuned to 4.2 or
4.4
 Use where Non-Linear
Loads less than 50% of
total loads.

37
Transient Free De-Tuned Automatic Cap. Banks


For sensitive
networks

Similar to Anti-
resonant Automatic
Capacitor System
except solid state
switching

Reactor tuned to 4.2
or 4.4

Response time < 5
sec

Use where Non-
Linear Loads < 50%
of Total Loads.
38
 Electronic Switch –Transient Free
L1 L2 L3

Fuses

SCR-Diode
De-tuned
Inductor

39
 Power Quality Correction

Rule Of Thumb For PFCC Applications

* When Non-Linear Loads < 15% Of Total Loads

Select Standard Automatic Cap. Bank

* When Non-linear Loads >15% But < 50% Of Total Loads

Select Anti-Resonant (Detuned) Auto. Cap. Bank

* When Non-Linear Loads > 50% Of Total Loads

Select Active Harmonics Filter For VAR Correction

* When Transformer KVA To Cap. KVAR Ratio < 3

Select Anti-Resonant ( Detuned) Auto. Cap. Bank

* When Soft-Starters are present, select Detuned Auto. Cap. Bank

40

11/19/21
ACTIVE FILTER in VAR Correction Mode

41
 Cyclical Loads & Loads With Dynamic VAR Movements

CAUSES
 WELDING OPERATIONS
 LARGE HP MOTOR STARTING
 PROCESS LOADS (i.e. MIXERS,
CRUSHERS, CHIPPERS,
SHREDDERS)
 ARC FURNACES

RESULTING IN
 VOLTAGE FLICKER
 VOLTAGE SAGS
 POOR POWER FACTOR
 INABILITY TO START MOTORS

Division - Name - Date - Language 4

2
 Active Filter (AHF)

• For Power Factor Correction For System where

Non-Linear Loads > than 50% of Total Loads.
• When Fast VAR Movements Necessary
• AHF-New breed of power quality product
– Harmonics cancellation
– Power factor correction
– VAR compensation
– Resonance elimination
• Independent or simultaneous modes of operation

43
 Active Harmonics Filter

• Electronic filtering up to the 50th harmonic

I source I load
Power Non-linear
source load
I conditioner
Active
Harmonic
Conditioner

44
 Hybrid Filters

• Combination of passive & active technologies

45
 MV HVC Banks – General Layout
MAIN INCOMING INTERFACE
WITH CUSTOMER'S NETWORK

15kV HVL LINEUP

NEMA 3R

4000kVA, 13.8kV/480V
NEMA 3R

5000A, 480V MAINS

NEMA 1

2000A, 480V
NEMA 1

4x300A 4x300A 4x300A 4x300A 4x300A 4x300A

ACCUSINE ACCUSINE ACCUSINE ACCUSINE ACCUSINE ACCUSINE
6000kVAR, 13.8kV, 60Hz
POWER ZONE HOUSE 1 POWER ZONE HOUSE 2
FIXED, DE-TUNED
NEMA 3R
24X300A ACCUSINE -> 6000kVAR

PASSIVE ACTIVE

Division - Name - Date - Language 4

6
 HVC Banks – General
 Marriage of two technologies
 Fixed capacitor banks and AHF
 Auxiliaries: MV/LV SWGR

HVC

15000
Vars Leading/Lagging

10000
Fixed Kvar
5000
Load
0 Accusine
Result Kvar
0 2 4 6 8 10 12 14 16 18
-5000

-10000
Time in cycles

Division - Name - Date - Language 4

7
 Cyclical Loads & Loads With Dynamic VAR Movements

CAUSES SOLUTIONS
 WELDING OPERATIONS APPLICATION OF:
 LARGE HP MOTOR STARTING  HYBRID VAR COMPENSATION
 PROCESS LOADS (i.e. MIXERS, (HVC)
CRUSHERS, CHIPPERS,  DYNAMIC VAR INJECTION ON PER
SHREDDERS) CYCLE BASIS
 PASSIVE/ACTIVE SYSTEM
 ARC FURNACES ARRANGEMENT
 WITH INRUSH OR DE-TUNED
REACTORS
RESULTING IN  CUSTOM-ENGINREERED FOR
SPECIFIC SITE, NETWORK, LOAD
 VOLTAGE FLICKER CHARACTERISTIC NEEDS
 VOLTAGE SAGS
 POOR POWER FACTOR
 INABILITY TO START MOTORS

Division - Name - Date - Language 4

8
 CAPACITOR APPLICATIONS
AT
MOTOR TERMINAL

> Motor Overload Protection

> Re-closure Issue – Jogging , Reversing, Inching , Plugging Applications

49
 Capacitor At Motor Terminal
Motor Over Load Protection Issue

50
 Motor Self-Excitation Voltage
Influenced By Capacitor Ratings

51
Reclosed Breaker & Net Voltage

52
CAPACITOR APPLICATION ISSUES

53
 Power Quality Correction

Multi-Energy Power System

of the Future ?
Residential
Hospital with photovoltaic system
cogeneration (1.5 MW) (6 kW)
Residential
Fuel cell (7
kW)
Utility-owned wind
turbine site (1 MW)

Substation Feeder

Small wind turbine

Utility-owned
(10 kW)
Photovoltaic site
(500 kW)
Factory with natural gas
fuel cell (100 kW to 5 MW)
54

11/19/21
 Power Quality Correction

Utility & Customer Owned

Solar Power System Working
In Parallel

1000 KW 3000 KW

Cos Ø1= 0.89

Cos Ø2= 0.55

1537 KVA
1818 KVA

1537 KVAR
1537 KVAR

55

11/19/21
 Key Questions to ask Customer
For Capacitor Applications
• Are you being charged for poor power factor by your utility (ask
for a copy of their electric bill - kW, kVA, Power Factor)?
• Do you have a large number of drives, rectifiers or other
harmonic generating equipment? Do you have nuisance tripping
of overloads ?
• Do you have welders, chippers, or other large cyclical loads?
• Do you have problems with voltage sags or “flicker”? How
sensitive is your equipment to these power issues?
• Do you have capacity issues on any of your substations?
• Do you have HID lighting or critical processes with low tolerance
to “brownouts”?
• Have you been experiencing poor weld quality?
• Do you have Soft Starters in the System?
• Do you have Motors subject to reversing, jogging, inching, or
plugging?

56
 Capacitor Standards

• NEMA CP-1 for Shunt Capacitors

• UL 810 Standard for Capacitors
• NFPA 70, National Electrical Code
• IEEE Standard 399, Power System Analysis
• ANSI / IEEE Standard 18, Shunt Power
Capacitors
• IEEE Standard 141, Recommended Practice for
Electrical Power Distribution for Industrial
Plants

57
 Other Capacitor Application Issues

NEC & NEMA :

* The Ampacity of Capacitor Circuit Conductors
shall not be less than 135% of rated Capacitor
Current
* Breaker Rating based on 135% Rated Capacitor
Current
* Fuse Rating based on 165% Rated Capacitor Current
for Class R Time Delay
* Fusible Switch Rating based on 165% Rated
Capacitor Current

58
 Capacitor Operating Environment Issues

Capacitor When Properly Applied Will Have

Long Life.
Conditions that affect the Life of Capacitor:
* Ambient Temp. < 46Deg C or 115Deg F
* Case Temp. of Capacitor < 55Deg C or 131 Deg F
* Shunt Capacitor designed to operate at 110%
Rated Voltage.
* Avoid sustained Over Voltage
* High System Harmonics

59
 Power Quality Correction

Summary of Benefits:
 Reduced Power Costs:
 Since Capacitors supply reactive power, you don’t pay the utility
for it
 Depending up on location of Cap. Bank, Line Loss can be reduced.
 You can calculate the savings
 Off-load transformers
 Defer buying a larger transformer when adding loads
 Reduce voltage drop at loads
 Only if capacitors are applied at loads
 (minimal benefit at best)

60
A2
11/19/21
 Power Quality Correction

Thank You !
Questions?

61

11/19/21