401, Madhav Apts., Jawahar Road, Opp. Rly.

Stn,
Ghatkopar (E), Mumbai 400 077. Maharashtra.
Tel: 2501 3661 / 2 / 3. 6575 4002 / 03.
Malde Capacitors Mfg. Co. Fax: (022) 2501 0758 / 3660
maldecapacitor@gmail.com

How to Save Money In Electricity Bill?

- By Proper Distribution of Power Capacitors.

By proper Distribution of Power Capacitors you can avail the following Financial
Savings:
1. If S.E.B has rebate system for improved PF than one can avail upto 7 % Rebate in
Electricity Bills for improved PF. States like Maharashtra, M.P, Chattisgarh,
Rajasthan, Gujarat, Goa, Haryana, etc have started giving rebate for improved PF.
2. As we know
PF = KW
KVA

By Improving PF, KVA goes down, i.e. reduction in MD (KVA Demand) charges.
3. By proper distribution of capacitors (near to load point) we are eliminating
Magnetizing current near to the load points hence there is a reduction in System
Current, due to which there is a reduction in System Losses (I2R losses) i.e.
Reduction in KWh consumption by about 2.5% to 4% (varies from system to
system)
4. As there is reduction in KWh consumption due to reduction in I2R losses, there will
further reduction in KVAh. The reduction in KVA will be proportional to the %
reduction in KW.

Hence about 5% to 8 % savings in your electricity Bill

Quite often, one needs to operate his factory on DG set. Hence, Diesel becomes an
important but costly fuel for production of electricity. We can bring this cost down by
the following ways:
1. By reduction in System Losses
2. By reduction in Alternator Losses.
All the above benefits can be obtained only by one option. i.e.
TO SELECT CAPACITORS AS PER INDIVIDUAL LOAD AND TO CONNECT THEM
TO THE OUT GOING / SECONDARY OF MOTOR STARTER.

Advantages:
1. LEADING CURRENT WILL NEVER GO INTO THE ALTERNATOR WINDING.
HENCE NO VOLTAGE BUILT UP, SO NO FEAR OF TRIPPING OF DG SET
OR BURNING OF AUTOMATIC VOLTAGE REGULATOR (AVR)
2. EVEN AFTER POWER TO TRANSFORMER RESUMES A SEPARATE
CAPACITOR FOR THE TRANSFORMER WILL COMPENSATE FOR THE
MAGNETIZING CURRENT OF TRANSFORMER, WHILE WE ARE YET
RUNNING ON DG SET.
 2

Transformer: (e.g. 1000 KVA)

As metering system is connected at primary side (i.e. H.T. side) of transformer, it will
register transformer losses and the magnetizing current of Transformer. Magnetizing
current of transformer spoils power factor.
Ix Real / Loss Component
Current V
1
P.F = COS1 = BAD

Iy Magnetizing Current
Ix + Iy
Iy Ix

Ix + Iy Iy Ix
I TRANS

Theoretical Circuit representation of a Transformer Power factor of Transformer

without capacitor

To LIGHTING
TRIVECTOMETER ACB/OCB/MCCB DG Set Supply
Main Switch
CT PT
NO LOAD
CONDITION

HT SIDE CHANGE
SFU SFU SFU OVER
TRANSFORMER
1000 KVA SWITCH

CAPACITOR CAPACITOR CAPACITOR

Cx1 Cx2 Cx3
30 KVAr 15 KVAr 5 KVAr

Capacitor Connection For Transformer

Hence, in our example for 1000 KVA transformer, one must connect separate capacitor
of 100 KVAr Cx bank to overcome the magnetizing KVAr (Reactive Power) of the
Transformer.
We recommend breaking these Cx Capacitors in three parts viz Cx160%, Cx225%
and Cx315%. All these capacitors should be connected through separate switch fuse
unit (SFU) as shown in the diagram above. With these you will get seven steps (ie Cx1,
Cx2, Cx3, Cx1+Cx2, Cx1+Cx3, Cx2+Cx3 and Cx1+Cx2+Cx3). See Table on Right Hand Side.
Select this suitable step of capacitor to compensate the No Load Magnetizing Current,
due to leakage flux in air gap in transformer core, by seeing slower counts of RKVAh
units or nearly equal counts of KWh or KVAh units (means good PF). Keep this
capacitor ON for 24 Hrs x 7Days.
 3

Ix Ix + Iy 2
Ix
V
Ic Iy IY Iy Ix I TRANS
1

Iy Ic = Capacitor current
Required Capacitor to
Ix improve P.F

P.F = COS1 = Bad

Ix Ix + Iy Transformer P.F.=COS 2 = Good
Iy
Circuit diagram with attached capacitor. Capacitor Reduction in current
current Ic=Iy i.e. magnetizing current of Transformer Improved Power factor after connecting capacitor
winding. Hence they form a localized circuit.

The balance capacitor step to be switched ON when your factory load is ON. The
leading current of these capacitors will compensate the inductive current used to
produce magnetic flux which is used in the secondary winding of the transformer to
induce the voltage.
Connecting a separate capacitor for Transformer, as shown above plays a very
important role during the following events:
1. Newly started project, where the transformer is energized and is only loaded with
Lighting load, i.e. production is yet to start.
2. Company having labour unrest / strike.
3. Maintenance/Breakdown Period.
4. Staggering Holiday or Public holidays.
5. When company is running on DG set, but supply to Transformer has resumed.
For all the above events if a separate capacitor for the transformer is not connected
then the company may have to pay for low P.F. penalties, which is registered by the
H.T. meter due to magnetizing current of transformer and lighting loads.
Also, APFC panels cannot sense the low P.F of transformer as the CT of APFC Panel
senses the current signal after the secondary (LT Side) of transformer. So one needs
to connect separate capacitors for transformer.
Table 1: Capacitors required for the following Transformer KVA
KVA of Size of Capacitor Cx1, Cx2 and Cx3 in KVAr Remark
Transformer Cx Cx1 SFU HRC Cx2 SFU HRC Cx3 SFU HRC
KVAr 60% Fuse 25% Fuse 15% Fuse
150 5 3 16A 10A 1 16A 4A 1 16A 4A Connect
200 7.5 4 16A 10A 3 16A 10A 2 16A 6A capacitor
250 10 6 32A 16A 3 16A 10A 1 16A 4A with the
315 12.5 7.5 32A 20A 3 16A 10A 2 16A 6A help of
500 25 15 50A 32A 6 32A 16A 4 16A 10A SFU &
750 35 20 63A 50A 10 32A 25A 5 16A 16A HRC fuse
1000 50 30 100A 80A 15 50A 32A 5 16A 16A at the
1250 75 45 125A 125A 17.5 50A 50A 12.5 32A 32A secondary
1500 100 60 200A 160A 25 63A 63A 15 50A 32A
of
2000 125 75 250A 200A 35 100A 100A 15 50A 32A
ACB/OCB
2500 150 90 250A 250A 40 125A 100A 20 63A 50A
 4

AC Motors: (e.g. 100 HP / 1440 RPM)

The equivalent circuit of motor in a simplified manner can be shown as below:

Ix
V
1
Ix + Iy P.F = COS1 = Bad
Iy Ix

Iy Ix
Ix + Iy

Theoretical Circuit representation of a Motor.

Iy I MOTOR
Power factor of Motor without capacitor

From above diagram, we can conclude that for a motor, requirement of capacitor is
fixed as magnetizing current, which spoils the power factor, is fixed. Hence for the 100
HP/1440 RPM motor connect 40 KVAr capacitor.

Ix Ix + Iy

2 Ix
Ic Iy IY Iy Ix V
1 I MOTOR

Iy
Ix
Ic = Capacitor current
Required Capacitor to
Ix Ix + Iy Motor Improve P.F

Circuit diagram with attached capacitor. Capacitor

P.F = COS1 = Bad
current Ic=Iy i.e. magnetizing current of motor Iy P.F.=COS 2 =Good
winding. Hence they form a localized circuit.
Reduction in current, i.e. Reduction in I2R Losses
Improved P.F. after connecting capacitor
 5

As you may be having a Star Delta starter for the 100 HP motor, connect capacitor as
shown below:

Main / Line/ Hold On

K1 =
Contactor
K2 = Delta Contactor
K3 = Star Contactor MAIN / LINE
MAIN / LINE
HOLD ON
HOLD ON
Contactor IX
Contactor

IM
Over Load Trip Relay
Iy
Iy IC

Starter Current Reduced

40 KVAr 100 HP
Motor Overload Setting Unchanged
Capacitor
Capacitor Connection Diagram With Star Delta Starter Capacitor Connection
with DOL Starter

Table 2: Capacitor Rating in KVAr to improve PF of Motors to about 0.99:

Capacitor rating in KVAr for improving PF to
Motor Rating Motor Rating about 0.99 or better when motor speed (Rev/Min)
in HP in KW is:
3000 1500 1000 750
5 4 2 3 3 3.5
7.5 5.5 3 4 4 5
10 7.5 4 5 5 6
15 11 5 7 7.5 9
20 15 6.5 8 9 10
25 18.5 8 10 11 12.5
30 22 10 12.5 14 15
40 30 14 15 18 20
50 37 15 20 20 23
60 45 20 25 25 25
75 55 23 30 30 35
100 75 35 40 40 45
120 90 40 45 45 50
150 110 45 60 60 70
180 132 50 70 70 80
215 160 60 75 80 100
270 200 75 100 100 125
335 250 90 125 130 150
425 315 110 150 160 200
 Voltage Direction
IX = Real /Resistive Current

Current in Phase with Voltage
100 KVAr Bank KWh = Volt X Ix

100 KVAr Bank

Resultant System Current with

50 KVAr Bank
Individual Power Capacitors.

25 KVAr

12.5 KVAr
10 KVAr
Example: High Consistency Pulping Section in a Kraft Paper Mill

Current of Poir Motor 120 HP, 1500 RPM

Current of 1500 KVA Transformer

Poir Pump 60 HP, 1500 RPM

Description KVA or HP/RPM KVAr Required
Current of Main Motor = 250 HP, 1500 RPM

Dump Pump 30 HP, 1500 RPM

Dump Agitator 20 HP, 1500 RPM
Transformer 1500 KVA 100 KVAr Bank

Conveyor 7.5 HP, 1500 RPM

High Consistency Pulping Section
1. Main Drive 250/1500 100 KVAr Bank
2. Poir Motor 120/1500 50 KVAr
3. Poir Pump 60/1500 25 KVAr
4. Dump Pump 30/1500 12.5 KVAr
5. Dump Agitator 20/950 10 KVAr

6
6. Conveyor 7.5/1500 NIL
Total Capacitor Required for Individual 197.5 KVAr
Connection
For Transformer 100 KVAr
Total Capacitors Required 297.5 KVAr

SYSTEM VECTOR DIAGRAM

Reduction in system Current.
i.e. Reduction in I2R Losses
i.e. Reduction in System Losses.
Current Lags Voltage by 90
IY = Magnetizing Current

i.e. Savings in KWh.

RKVAh = Iy X Volt

KVAh = Resultant System Current x Volt

High Consistency Pulping Section Resultant System Current with out

Individual Power Capacitors.
 7

Distribution of capacitors has the following advantages

1. Distribution of capacitors results in a self-automatic system as capacitor is energized

only when motor is running. I.e. eliminates human importance in maintaining P.F.
2. Cost of installation is reduced, as there is no need for separate switching devices, fuses,
etc.
3. Since capacitors are connected in parallel to the motor, the magnetizing current of the
motor and capacitive current make a localized circuit, hence there is substantial
reduction of current in the motor starter, fuses, cables* and further switchgear.
4. Losses I2R. Now as line currents are reduced there will be reduction in system losses
which will result in proportional reduction in Unit consumption i.e. KWh.
5. We can reduce MD (KVA Demand) by improving P.F. But, by proper distribution of
power capacitors we can further reduce system losses i.e. reduction in KW. Due to this
reduction in KW there will be further reduction in KVA. Hence we can load the system
further without crossing the Contracted Demand.
6. HRC fuses for motor protection can be derated by about 25%.
7. Due to reduction in line current, sparking at the contacts of switchgear will reduce as
Sparking I2. Hence life of switchgear increases.
8. Now as losses are reducing, i.e. heat generated at the point where lugs are crimpled
with the cable or where cable joints are present will reduce, by which there will be
reduced heating and aging of phase insulation. Hence, lesser chances of Short Circuits
and related maintenance.
9. Due to reduction in System current, the voltage drop across cables will reduce. This will
result in more voltage at the motor terminal.
10. Motor output (P) = Voltage x Current. Now as more voltage will be available at motor
terminals, Motor will draw lesser current for same output, resulting in reduced losses and
lower operating temperatures of motor.
11. Torque V2. With more voltage available, motor will deliver better torque.
12. One can also operate the above system on a D.G. set, without fear of D.G. set tripping
or burning of the Automatic Voltage regulator (AVR), as capacitors come into circuit only
when corresponding Inductive load is switched ON. Thus there is no fear of leading
current going into the alternator of D.G set, hence no fear of voltage built up.
13. Due to reduction in system losses and Alternator losses, there can be proportional
savings in diesel consumption.
14. The problem of parallel switching in APFC Panels can be eliminated by distribution of
capacitors. In APFC panels, when a capacitor is switched on, all charged capacitors on
the same busbar discharge instantaneously to the switching capacitor, increasing the
periodic maintenance and leading to manual operation
15. APFC panels cannot sense the low P.F of transformer as it senses the current signal
after the secondary of transformer. So one needs to connect a separate capacitor for
transformer
16. Huge capital investments in full size APFC panels can be saved.
17. As explained above, by distributing capacitors one can improve the low P.F of non-linear
loads i.e. thyristor drives and also avoid Harmonic currents from flowing through the rest
of the system.
18. Due to individual P.F Correction of all kinds of loads, we are achieving a good voltage
regulation as we are feeding the Transformer with a improved Power Factor Current.
 8
Savings in DG Set:
(Calculation shown is a presumption and is only for demonstration purpose)
Consider a 1000 KVA DG Set designed at 0.8 PF
Hence max KW, which can be operated on the DG set, is 800 KW
Full load alternator losses can be considered to be 3.5 % of Full Load KW
I2 R Losses = 3.5 % of 800 KW
= 28,000 watts.
Hence, Alternator Resistance is:
R = 28,000 = 28,000
I2 1391.202
R = 0.014467
Max current, which can flow through the alternator winding is
Imax = KVA x 1000 = 1000 x 1000
3 x 415 V 3 x 415 V
= 1391.20 Amps
Now by proper distribution of capacitors we improve PF from 0.8 to 0.95 for that capacitor required
will be approx 340 KVAr (MF = 0.421. KVAr = KW x 0.421 = 800 x 0.421 =336.8 KVAr 340 KVAr)
Hence reduction in current will be
KVA RED = KW = 800 = 842.10
PFNEW 0.95
IRED = KVA x 1000 = 1171.54 Amps
3 x 415 V
I2R = 1171.522 x 0.014467 = 19855 watts
Hence Reduced Losses is 19855 watts
Thus reduction in losses will be = (Full load alternator losses - Losses after PF correction )
= (28000 19855 )
= 8145 watts approx
Assuming that the DG set is run for approx 15 hours daily for 25 days a month.
Hence reduction is alternator losses is 3054375 watt hours i.e. approx 3054 KWh
From 1 Litre HSD (High Speed Diesel) we can produce 3.5 KWh
Hence saving in HSD per month will be (3054 KWh / 3.5KWh per Litre) = 873 litres
1 Litre of HSD cost approx Rs 60/-
Hence monthly savings in Rupees (873 Lt x Rs 60 ) = 52,380/-
Yearly savings = 6,28,560/-
The above savings are just from alternator losses. By proper distribution of
capacitors further saving can be seen due to reduction in I2R (System) losses.
Distribution of capacitors, NEVER ALLOWS LEADING CURRENT TO GO TO
THE ALTERNATOR. HENCE NO FEAR OF DG SET TRIPPING OR BURNING OF
AUTOMATIC VOLTAGE REGULATOR (AVR)
As currents in the system have reduced, sparking at the contacts and wearing of
the carbon brushes also reduce.
You can try out distribution by using all your healthy capacitors at appropriate places and observe the results.

Note: Incase you need our suggestion for your unit please send us the following:
Transformer KVA with % Impedance.
All your Motor details like HP, RPM, application, etc.
One line diagram of your factory (if available.)
Photocopy of your past two months electricity bills,

The above information is given upto the best of our knowledge without any guarantee as regards to either mistake or omissions