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Fundamental Theories
Power Factor
Harmonics
Design inputs
Design Inputs Based on Existing PF Installation
Designing PF Panel with Limited Information
Dimensionless
Range between -1 to 1
Non-linear load
Active filter
1.5% surcharge of the current bill for every 0.01 less than 0.85 power factor.
3% surcharge of the current bill for every 0.01 less than 0.75 power factor.
For all Tariffs, except Tariffs A and G, the consumer should strive to obtain the highest
Power Factor possible in the operation of any of his electrical installations.
Below 0.85 and up to 0.75 lagging, a supplementary charge of one and one-half
per cent (1%) of the bill for that month for each one-hundredth part (0.01)
below 0.85 and up to 0.75 lagging Power Factor will be added to the bill for that
month, and
Below 0.75 lagging, in addition to the charge payable under subparagraph (A)
above, a supplementary charge of three per cent (3%) of the bill for that month
for each one-hundredth (0.01) part below 0.75 lagging Power Factor will be
added to the bill for that month.
Required information:
Utility bill
Total reactive load
Transformer size
Power meter reading
Q = P x (Tan 1 Tan 2)
Power Factor - Displacement Power Factor (DPF) vs. Power Factor (PF)
Power Factor
Power factor is the ratio of total
active power [W] over total
apparent power [VA]
PF = P / |Vrms| x |I rms|
PF DPF
What is Harmonics
Arc discharge
Rotating devices
Static Power Converters are the largest none linear load that are used in the
industry
UPS
Inverter systems
Adjustable speed drives
Switch mode power supply (SMPS)
h = kq 1
k = any integer
q = pulse number of converter
IEEE Recommended Practices and Requirements for Harmonic Control in Electric Power System
IEC 61000-3-6
Part 3: Limits. Section 6: Assessment of Emission Limits for Distorting Loads in MV and HV
Power Systems
IEC 61000-3-2
Part 3-2: Limits - Limits for harmonic current emissions (equipment input current 16 A per
phase)
There is a possibility where the neutral current will be 300% of the phase
current due to the triplen harmonics
User can utilize solution such as 6-pulse inverter to cancel off harmonics
Expensive equipment
Creating a trap filter using a reactor in series with the power factor
correction capacitor
12
10
Amp
6
Filter Attenuation
4
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Order
150Hz
50Hz
150Hz
100Hz 200Hz
Non-linear
Utility load
Non-linear
load
50Hz
150Hz
150Hz
150Hz
100Hz 200Hz
200Hz
Non-linear
Utility load
Non-linear
load
50Hz
189Hz
150Hz
189Hz
200Hz
Design Input
Data required
New Design
Output
Type of panel
Type of compensation
Capacitor voltage
Data required
Effective kVAR requirement
Resonance
THD-I
THD-V
Equipment required
Hioki PW3198
Yokogawa CW120
Yokogawa CW10
Check on TNB meter if PF > 0.85 and still have available capacitor banks yet
to turned on?
OR
Turn on all capacitor banks manually and check if the TNB meter displays
leading/capacitive power factor?
If not, . Continue
6. Sub divide the kVAR to 15 25 % of the total capacitor bank kVAR for a
good average power factor compensation
www.itmikro.com Copyright Mikro Sdn Bhd Tay Siang Hui
Mikro Electrical Distribution Solution 2014
3. Turn on 1 by 1 capacitor banks and record the THD-I and THD-V value
N
Is THDV > 7%? Use p=7%
type reactor
N
N Use p=5.67%
Is THDV > 10%?
type reactor
Y
Customize
type reactor
Y
Does your utility company penalize you for low power factor?
If your answer is yes for either one of the questions above, your factory
requires a power factor panel for power factor compensation.
What is your minimum power factor requirement imposed by the utility company
without penalty?
What is your monthly calculated cos phi (also known as displacement power factor),
or X/R ratio and total active power at your point of common coupling (PCC)?
What is your calculated total reactive power (kVAR) per month at your PCC?
Does your utility company calculate power factor penalty by averaging or demand
method?
If all of the above is not available, size power factor panel 30% or up to 40%
of transformers kVA rating for kVAR compensation
Automated compensation
Rated Frequency
Power kVAR
Temperature
Indoor or outdoor
PFC System and Components Selection - Oil Type vs. Dry Type Capacitor
Safety (fire Capacitor Oil will not catch fire, but it N/A
hazard) have a flash point at 230oC
Losses of the It is same, because it used metalized PP film with low loss factor
capacitor
Other
Need more space for installation More convenience, no
- Installation need more space
- Leakage After using for long time oil may leak and No liquid impregnate
dirty.
U1Rated Voltage 1
U2Rated Voltage 2
kVAR1 Rated Reactive Power at U1
kVAR2 Rated Reactive Power at U2
Example :
What is the effective reactive power of a capacitor rated at 75kVAR, 525V AC
used at system voltage 400V AC?
X kVAR Capacitor at 525V AC using at 400V AC will yield a smaller kVAR then
X
The kVAR of 440V AC rated power factor capacitor is about 89% at 415V AC
%p Detuning factor
Rated Frequency
System voltage
Linearity
Core type
%p = XL / XC
6% 233 Hz
7% 189 Hz
14% 134 Hz 6
5.67% 210 Hz 5
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Frequency
On top of that, the capacitor will have an additional voltage increase due to
harmonics current flowing in the detuning circuit
Example
System voltage 400V AC, using p = 7% reactor, what is the voltage increase due
to the induced voltage of the reactor?
Uc = 400 / (1 - 0.07)
= 430V AC
Example
System voltage 380V AC, using p = 7% reactor matching with 50kVAR 525V AC
power factor capacitor, what is the effective kVAR?
Current per phase = 2
3
PFC System and Components Selection - Cable Selection Table for Capacitor
With the installation of reactor, possible to use AC-6 type contactor as the
reactor would limit the inrush current
We need to set C/K value and rated step size (or let the regulator auto-
detect) for the regulator to know
Load
PF Panel
PFR
? kVAR ? kVAR ? kVAR ? kVAR
Setting the C/K value tells the regulator what the smallest capacitor size
is in the PF panel
Setting the rated step size tells the regulator what other capacitor sizes
are in the PF panel
Load
PF Panel
PFR
5 kVAR 10 kVAR 15 kVAR 25 kVAR
PFR60
5 kVAR 10 kVAR 15 kVAR 25 kVAR
415V 415V 415V 415V
Note:
Need to use effective kVAR, e.g. 100kVAR 525V used at 415V, effective kVAR is 62kVAR
Demand = 7kVAR
Smallest step size = 5kVAR
PF Panel
Demand = 7kVAR
Step 1 Step 2 Step 3 Step 4
PF Panel
Demand = 2kVAR
Step 1 Step 2 Step 3 Step 4
PF Panel
Minimum Current
PFRLCD
Lowest current detection capability : 0.01A
The latest improvement of Mikros power factor regulator series expands the
dynamic range of current detection to better detect low load condition
Minimum Current
100A ON Big
Load
1000/5
0.5A PF Panel
ON Small
PFR
5 kVAR
Load
2.5 kVAR 10 kVAR 10 kVAR
Minimum Current
ON Small
PFR
2.5 kVAR 5 kVAR 10 kVAR 10 kVAR Load
PF Panel
Step 1 turn ON
Net Demand = 12kVAR
PF Panel
Step 2 turn ON
Net Demand = 7kVAR
PF Panel
Step 3 turn ON
Net demand = 2kVAR
Regulator will stop switching in more capacitor banks because
net demand (2kVAR) < smallest step size (5kVAR) of the PF panel
PF Panel
PF Panel Capacitive!
PF Panel
PF Panel
Step 4 turn ON
Net Demand = 2kVAR
PF Panel
PF Panel Capacitive!
PF Panel
PF Panel
Step 2 turn ON
Net Demand = 7kVAR
PF Panel
Step 1 turn ON
Net Demand = 2kVAR
Regulator will stop switching in more capacitor banks because the
net demand (2kVAR) < smallest step size of the PF panel
PF Panel
PF Panel Capacitive!
PF Panel
PF Panel
Step 3 turn ON
Net Demand = 1kVAR
Regulator will stop switching in more capacitor banks because the
net demand < smallest step size of the PF panel
PF Panel
FIFO typically have the same step size per step e.g. 25kVAR for all 12 steps
Disadvantage of using same step size is target power factor might not be
achieved (i.e. oscillation issue, longer time, need a lot of steps)
Example 1:
Smallest step: 10kVAR
Required kVAR: 20kVAR
Demand vs. C/K*
DPF < Target PF Turn on capacitor
Oscillation Issue
Most regulator will have hysteresis threshold and time delay to avoid
oscillation (i.e. switching on and off capacitor frequently)
No. of Capacitor
Switching Lifespan
Case 1:
If your systems worst case of load fluctuation causes you to incur power
factor penalty, increase the response time of switching (i.e. reducing the
sensitivity time setting) to track the load fluctuation so that your system
will not incur power factor penalty
Condition
Penalty threshold : 0.85
Fluctuation demand > Smallest step size
Fluctuation power factor : 0.95 -> 0.98 (Does not incur penalty)
Fluctuation time = 10s (Oscillate from 0.95)
Solution
Priority to prevent capacitor from switching in and out frequently
Setting of sensitivity/time delay > fluctuation time (10s)
Case 2:
If your systems load fluctuation does not cause you to incur power factor
penalty, decrease the response time of switching (i.e. increasing the
sensitivity or time delaysetting) to avoid reducing the lifespan of capacitor
banks
Condition
Penalty threshold : 0.85
Fluctuation demand > Smallest step size
Fluctuation power factor : 0.80 -> 0.98 (Incur penalty)
Fluctuation time = 10s (Oscillate from 0.95)
Solution
Priority to avoid penalty in the expense of frequent switching of capacitor
Setting of sensitivity/time delay = Fluctuation time (10s)
As the kVAR demand drops close to the smallest step size of the PF panel,
response time to switch in/out capacitor banks will be slow
At a small demand requirement on the other hand, Mikros PFR will have
a same response time as regulators using time delay method (if time
delay setting is set to be same as Mikros sensitivity time setting)
10s 10s
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