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Application ProjectÊ
Power Factor ImprovementÊ
Based on a study done for an industrial pla
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Presented to:Ê
Dr. Mahmoud GilanyÊ
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Presented by:Ê
Moataz Mohammad AttallahÊ
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I-Abstract:ÊÊ

The aim of this technical report is to introduce a summary for a study done by a public
sector company for power factor improvement. This report includes an electrical
engineering background about the problem of power factor, including: the causes, the
consequences, the economical importance for the company and for the country as well, and
the theoretical solution for solving that problem.ÊÊ
The report links the theoretical solution with the real applicable solution through the
study done by the organization for energy planning. This study includes a nine months
research done by the researchers and the electrical engineers, that represents an ideal
methodology for solving this problem starting from defining the magnitude of the power
factor problem until designing the equipment that can solve that problem.ÊÊ
The report represents all the previous points in simple terminology, according to the
objectives of the course ENGR 318 (general electrical engineering).ÊÊ

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II-Table of Contents:ÊÊ

Topic PageÊÊ
Introduction 3ÊÊ
Objectives 5ÊÊ
Theory 5ÊÊ
Description of Experiments and Apparatus 6ÊÊ
Procedure (work plan) 7ÊÊ
Results 9ÊÊ
Discussion 10ÊÊ
Recommendations 10ÊÊ
References 10ÊÊ
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III-Nomenclature:ÊÊ

Symbol Meaning UnitÊÊ

S Apparent (total) Power kVA (VA = Volt Ampere)ÊÊ
P Active (real) power kWattÊÊ
Q Reactive power kVARÊÊ
Vline Line Voltage kVoltÊÊ
Vphase Phase Voltage kVoltÊÊ
Iphase Phase Current A (A= Amperes)ÊÊ
cos f Power Factor determines the amount utilized of SÊÊ
f Phase Angle angle between the current and the voltage RadiansÊÊ
w Angular frequency (w=2pf) rad/secÊÊ
C Capacitance FaradÊÊ
Xc Capacitive reactance OhmsÊÊ
Vrated Rated voltage for a device kVoltÊÊ

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IV-Introduction:ÊÊ

Industrial plants usually pay large fines because of any large inductive loads in their
factories. Inductive loads result from the storage of energy in magnetic fields, which occurs
in coils of wire, such as in motor windings and transformers. To decrease high electricity
bills resulting from these large inductive loads, capacitors may be installed at the facility to
increase the power factor.ÊÊ
Power factor is the ratio of active (real) power to apparent (total) power.ÊÊ

(1) P.F.=cos Ë P/SÊÊ

Apparent power is made up of two components, called active power and reactive power.
Reactive power, whether inductive or Capacitive, always acts at right angles to active
power. Reactive power is not useful in an industrial setting, as it does no real work when
supplied to motors or other electrical devices. Power distribution company in Egypt bill
customers for how much reactive power they use, and since reactive power supplies no
benefit to the manufacturer, it is desirable to reduce or eliminate the reactive component of
power that the manufacturer uses.ÊÊ
For any three phase factory, the amount of the active power required from the source to
run its machines is:ÊÊ

(2)ÊÊ
Assuming that the amount of apparent power supplied to the factory constant, and that the
load consumption of reactive power becomes less, then the current becomes smaller. Hence,
voltage drop, power, and energy losses decrease. This enables the factory to add more loads
using the same power stations.ÊÊ
The problem with low power factor exceeds the commonly known consequences, such as:
power, energy, and voltage losses. Along with these consequences, the active power
produced will decrease. This mainly affects power stations, either the main stations or sub-
stations installed in the plant. They have to work faster, and large amounts of fuel will be
consumed to make up for the reactive losses.ÊÊ
Since the current is inversely proportional to the power factor, it can be proved that
power losses are inversely proportional to the square of the power factor.ÊÊ
P loss = I^2 R (3)ÊÊ
Thus power factor improvement is a method to reduce network losses, either active power
of reactive power.ÊÊ
Both Power consumers and suppliers are interested in power factor improvement. For
consumers, they have to decrease the economical losses because of the high fine assigned by
the power supplier because of the low power factor. In Egypt, some companies pay large
fines because of the low power factors in case the power factor is below 0.9 along with the
power bill due to the normal consumption. For the suppliers, the request for power will
decrease resulting in a decrease in the amount of fuel used in the power stations.ÊÊ
It is known that the power factor for a fully loaded induction motor ranges between 0.75
to 0.85. When the motor load is below rated, the power factor drops since the motor draws
less active power and about the same reactive power.ÊÊ
In conclusion, low power factor results in:ÊÊ
1- Large power losses in the lines, transformers and generators.ÊÊ
2- Extra copper and aluminum good conductors have to be used to minimizeÊÊ
losses.ÊÊ
3- Smaller capacities of transformers and lines must be used to avoid power losses due to
the large current flowing out.ÊÊ
4- Lower network voltage due to the large current.ÊÊ

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There are some factors that motivate the companies to improve their power factors, these
are:ÊÊ
1 - The economical importance (elimination of the power factor penalty):ÊÊ

Some factories pay large fines because of their low power factor, sometimes larger than
the normal power consumption bill. In Egypt, the power distribution companies give
bonuses for the companies of high P.F. (more than 0.9)ÊÊ
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2 - Reduction of internal power losses:ÊÊ

These losses may take the shape of reactive power, or power, energy, and voltage losses.ÊÊ

3 - Payback period:ÊÊ
 After installing the equipment needed to correct the power factor, there will be a very
short payback period. This means that the cost of the equipment needed to improve the
power factor will be recovered in a very short period. On the other sides, the costs of the
equipment are by far less than the fine required from the company due its low P.F. Based
on the study, the payback period is 6 months.ÊÊ
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V-Objectives:ÊÊ

The aim of this report is to introduce an ideal methodology for power factor improvement
of an industrial plant.ÊÊ
The shape of the study was as follows:ÊÊ
1-Introduction:ÊÊ
a - Description of the low power factor problem.ÊÊ
b - Description of the industrial plant, and its activities.ÊÊ
c - Power consumption data.ÊÊ
2-Work plan:ÊÊ
Phase A includes:ÊÊ
a - Measurements.ÊÊ
b - Data analysis.ÊÊ
c - Recommendations.ÊÊ
d - Equipment design, sizing, and location.ÊÊ
Phase B includes:ÊÊ
a - Detailed design.ÊÊ
b - Installation.ÊÊ
c - Evaluation and supervision.ÊÊ

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VI-Theory:ÊÊ

A simple idea for the power factor improvement is the use of a capacitor in parallel to the
factory to decrease the reactive power losses.ÊÊ
It is known that in the capacitor the current leads the voltage by a 90° angle. Given that
the active and reactive powers are given as:ÊÊ

(4,5)ÊÊ
Therefore, for the capacitor P = 0, while Q = -S (because it is the current that leads the
voltage).ÊÊ
The meaning of the negative reactive power is that the capacitor can be used as a source
of negative reactive power.(i.e., it reduces the reactive power)ÊÊ

(6)ÊÊ

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For the capacitor,ÊÊ

(7)ÊÊ
equating (1) and (2) together gives the value of the capacitance of the capacitor to be
installed in parallel to the factory.ÊÊ

(8)ÊÊ
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VII-Description of the used devices:ÊÊ

Conducting such a study requires collecting of essential data, because dependence on the
bills of the distribution company might lead to false design.ÊÊ
The used device is called:ÊÊ
BMI 3030 A Power ProfilerÊÊ
(Energy and harmonic analyzer)ÊÊ
This device is a basic measuring device that measures:ÊÊ
· True RMS of voltage and current.ÊÊ
· Active power (kW)ÊÊ
· Reactive power (kVAR)ÊÊ
· Apparent power (kVA)ÊÊ
· True power factor (PF)ÊÊ
· Harmonic content of the current and voltageÊÊ
The device records the data on 3.5² floppy disks.ÊÊ

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VIII-Procedures (work plan):ÊÊ

PHASE AÊÊ
1-Measurements:ÊÊ
refer to the section of the used devicesÊÊ

2-Data analysis:ÊÊ

The data retrieved from the measuring device calculates the above mentioned quantities.
By analyzing these data, some important facts are highlighted, such as:ÊÊ
· The power factor calculated by the distribution company was less than the actual power
factor. This means that the distribution company measuring devices are not working
efficiently and they need to be replaced.ÊÊ
· Some parts of the plan have high P.F. because they are pure resistive loads.ÊÊ
· Some motors and transformers are partially loaded.ÊÊ

3-Recommendations:ÊÊ

The P.F. problem can be improved basically without the need to install any capacitors by
reducing the amount of reactive power consumed in motors and transformers. This may be
achieved by:ÊÊ
· Installing motors of proper rating, speed, type and size according to the load and the
operating of the machine.ÊÊ
· Replacing large induction motors with synchronous motors.ÊÊ
· Replacing lightly loaded motors or transformers with others of smaller ratings.ÊÊ
· Cutting down no load operations of motors through limiters and electrical interlock that
disconnect the motor when the operation is terminated. For slightly loaded motors, the
electric interlocks might be used to shift the windings from delta to star.(In star Vline =Ö3
Vphase)ÊÊ
· Produce additional load on the lightly loaded motors through electrical process.ÊÊ

These points can be explained as follows. The voltage of the motor determines the self-
induced e.m.f of the motor windings. Thus, the higher the voltage and the lower the load
on the motor, the higher the induced e.m.f. and the lower the P.F.ÊÊ
The second problem is the transformers; transformers consume about 30% of the reactive
power of the system. Transformers carrying less than 30% of their rating cause enormous
losses in the P.F. Thus they should be loaded within a limit of 30è 70% of their ratings.ÊÊ
 Mostly the power factor improvement equipment is capacitors. Their advantage is that
they have very small active power losses (0.0025è0.005kW per kVAR). They are simple and
easy devices and they do not have rotating parts that may produce inductive reactance.
Their shortcomings are their relatively small life (8à10 years), the potential danger of
short-circuit (wiring) of the capacitor in case the voltage exceeds their rated voltage by
1.1Vrated, and that they are unrepairable.ÊÊ
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4-Equipment design, sizing and location:ÊÊ

The design of the capacitors depends on the P.F. as above mentioned in the theory section.
The difficulty usually lies in the locating the capacitors.ÊÊ
For any plant, the overall average P.F. is different from the P.F. for every sub-station or
even each load section of the factory. Thus there is a very important factor that should be
considered, which is:ÊÊ

The position of the installed capacitor:ÊÊ

1-Input side of the main power feeder switch gear: This method is less costly for the user
than the capacitor used for low voltages. However, it does not eliminate the problem; in a
way it increases the overall power factor of the whole plant, but all the inductive reactive
currents are still circulating between the factory loads, sub-stations, and the capacitors.
Despite improving the power factor, power losses are not reduced to a satisfactory range.
Moreover, the cost of switch gears is much expensive when the capacitor is connected to the
main power feeder.ÊÊ
2-Input side of each load center: This method is usually used with the third one. The
capacitor is installed at the input side of each load center. The total capacitance is divided
on all the load centers. Regardless of the fact that the inductive reactive currents will still
be flowing between the machines, load center, and the capacitor but they will never reach
the main power feeder.ÊÊ
3-Low voltage side of each load center: This method is efficient in both eliminating the low
P.F., because the inductive reactive current will be flowing between the motor and the
capacitor. However, the price of the capacitors in this case is relatively high because of its
small capacitance, thus increasing the payback period.ÊÊ
PHASE BÊÊ

1-Detailed design:ÊÊ
2-Installation:ÊÊ
It is not intended to go through the technical details of the design and installation, however
some points must be mentioned that suit the objectives of the course.ÊÊ
The equipment needed for the P.F. improvement is:ÊÊ
· Switchboard panel of enameled steel (enclosure IP 30) .ÊÊ
· Three phase Circuit breakers (air type).ÊÊ
· Copper bus bars.ÊÊ
· Capacitors according to the value required (capacitance is measured here in kVAR).ÊÊ
 · Power factor meter and controller.ÊÊ
· VAR metersÊÊ

3-Evaluation and supervision:ÊÊ

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The capacitors should have the following specifications:ÊÊ
· There is a need for substitute capacitors to be used in case of maintenance.ÊÊ
· Each unit should contain discharge resistors to bleed off residual voltages after the
disconnection of the power. The discharge time should be around 5 minutes.ÊÊ
· Vrated should be 1.1 Vrequired-ÊÊ
· Capacitance variation with temperature should be minimized, either by cooling the
capacitor or selecting a capacitor of good temperature-capacitance properties.ÊÊ
· They should be adapted to automatic step systems controlled by the power factor meters.ÊÊ
· IP 45ÊÊ
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IX-Results:ÊÊ

Quality Before P.F. improvement After P.F. improvementÊÊ

Average annual P.F. 0.77 0.95ÊÊ
Active power (P) 2280 kW 2280 kWÊÊ
Apparent power (S) 3800 kVA 2400 kVAÊÊ
Annual consumption 5274 MWh 5116 MWhÊÊ

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X-Discussion:ÊÊ

Since the reactive power in factories is due to inductive loads, then they might be
compensated by Capacitive reactive loads because they cancel each other. Thus the solution
to decrease the inductive reactive power is to increase the Capacitive power because they
cancel each other, and hence decreasing the overall reactive power, which is considered as
a kind of losses of the total supplied power.ÊÊ

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XI-Recommendations:ÊÊ

The problem of power factor is not a smoldering problem that arises all of a sudden.
Undoubtedly, this problem is a result of poor electrical engineering design. The problem
might be avoided from the start by considering the following facts:ÊÊ
1-Once the motor is loaded less than its rating, the used active power is less. Thus the
reactive power takes a large share of the apparent power. Therefore, motors of adequate
rate, speed, type, and size should be installed according to theÊÊ
load and the operating of the machine.ÊÊ
2- As previously mentioned, transformers consume about 30% of the reactive power of the
system. Transformers carrying less than 30% of their rating cause enormous losses in the
P.F. Thus they should be loaded within a limit of 30è 70% of their ratings.ÊÊ

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XII-References:ÊÊ
ÊÊ

Abdel-Aziz, Abdel-Aziz M. Power Factor Improvement Project. Organization for

Energy Planning, Cairo. 1993ÊÊ

Lipkin, B.Y. Electrical Equipment for Industry. Higher School Publishing House,
Moscow. 1967.ÊÊ
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