A Simplistic Technique for Power Factor Compensation Capacity Calculation in Medium Size Industry

There are a variety of techniques developed in order to improve the efficiency of electrical systems and reduce cost of providing electricity to the consumer. In this paper, a simplistic technique for power factor capacity calculation in medium-sized industrial/commercial setups is presented. Various loads of similar nominal power factor are categorized and demand factor of loads is so selected that it has engineering justifications. The proposed system works on principle of low voltage power factor correction, which substantially reduces electricity bill and increases electrical system loading capacity. It allows commercial and industrial consumers to save on their power cost appreciably. This work is augmented by application software, which takes a few inputs and produces numerous useful results. Adoption of this system helps user in computing compensation capacity, system KVA (size of transformer) and cost of compensation. A feature of this system is prediction of low PF penalty. Moreover, it also suggests the tentative payback period.Choudhry, M.A.; Zada, W.Power Engineering Conference, 2005. IPEC 2005. The 7th International1-629-02 Nov. 2005

scholar search
www.libsou.com

A Simplistic Technique for Power Factor Compensation Capacity Calculation in Medium Size Industry
M. A. Choudhry, Member, IEEE, and Wazir Zada

Abstract--There are a variety of techniques developed in order to improve the efficiency of electrical systems and reduce cost of providing electricity to the consumer. In this paper, a simplistic technique for power factor capacity calculation in medium-sized industrial/commercial setups is presented. Various loads of similar nominal power factor are categorized and demand factor of loads is so selected that it has engineering justifications. The proposed system works on principle of low voltage power factor correction, which substantially reduces electricity bill and increases electrical system loading capacity. It allows commercial and industrial consumers to save on their power cost appreciably. This work is augmented by application software, which takes a few inputs and produces numerous useful results. Adoption of this system helps user in computing compensation capacity, system KVA (size of transformer) and cost of compensation. A feature of this system is prediction of low PF penalty. Moreover, it also suggests the tentative payback period.

Index Terms-- Compensation, Load modeling, Reactive power, Reactive power control, Power quality.

scholar search
www.libsou.com
II.

capacitor literally recycles this non-consumed element of electricity and supplies it back to the load. A conventional method used for PF compensation depends upon approximate calculation is carried out based on the assumption of a power factor (PF) lagging value before, compensation and a multiplying factor is selected for a target PF at intersection point from a standard table of capacitor manufacturer. This factor so selected is then multiplied with load KW for suggesting total KVAr compensation. However, this method has inherent disadvantages of over/under calculation of compensation capacity and selecting transformer size. Thus resulting in higher initial capital investment. In this paper, the proposed technique is based on a comprehensive load data of the equipment to be installed thus resulting in a very realistic approach at planning stage thus bringing about a much optimized cost of electricity bill as well as equipment cost in the transmission system.

I.

INTRODUCTION

POWER LOADING OF AN INSTALLATION

The power factor in industrial plants is usually lagging due to the inductive nature of induction motors, transformers, lighting, induction heating furnaces, etc. This lagging power factor has two costly disadvantages for the power user. First, it increases the cost incurred by the power company because more current must be transmitted than is actually used to perform useful work. This increased cost is passed on to the industrial customer by means of power factor adjustments to the rate schedules. Second, it reduces the load handling capability of the electrical transmission system which means that the industrial power user must spend more on transmission lines and transformers to get a given amount of useful power through his plant. Reactive power is needed to generate the magnetic fields required for operation of an inductive piece of equipment, sometimes called wattles power. The load does not consume this component of electricity. A good analogy of this is purchasing a beverage that is packed in a recyclable container. We need the container to consume the product but we do not consume the container. The inductive component is analogous to the container since the power factor

In order to design an installation, the actual maximum load demand likely to be imposed on the power supply system must be assessed. To base the design simply on the arithmetic sum of all the loads existing in the installation would be extravagantly uneconomical, and bad engineering practice. The aim is to show how all-existing and projected loads can be assigned various factors to account for diversity. Demand factor Df and simultaneity factor Ks are used which is the ratio of Maximum demand to connected load. The values given to the factors are based on experience and on records taken from actual installations. The determination of these factors is the responsibility of the designer, since it requires a detailed knowledge of the installation and the conditions in which the individual circuits are to be exploited i.e. depends upon the nature of activities of the consumer and to some extent upon the production load of the industry. For this reason, it is not possible to give precise values for general application.

http://www.libsou.com

III.

PROBLEMS WITH CONVENTIONAL POWER COMPENSATION PRACTICE

IV.

A SIMPLISTIC TECHNIQUE FOR POWER FACTOR COMPENSATION

In this method table from manufacture of electrical equipment is used. That is based on the formula

KVAr = KW (tan 1 tan 2 )

Where 1 & 2 are the angles of initial PF1 and target PF2, respectively.
KVAr = KW (multiplying factor from table provided by the manufacturer )

This scheme has got many associated problems. The main disadvantage is that you have to deal with assumptions i.e. you dont have exact known values for computations. An in-accurate assumption can lead to non-precise and inaccurate results (because values of initial PF and expected load are unknown unless assumed suitably or ascertained from electricity bill if exists). But for the corporate customers having their own grid system (with meters installed at one/two points) and the customers own 11KV distribution system comprising of multiple substations we dont have the values of power factor and load. A nonaccurate assumption may lead to power quality problem. Finally this technique cannot precisely optimize the PF and load therefore compensation will also be non-precise. Further the size of transformer and other allied equipment will also be disproportionate. It will negatively affect capital cost of substation equipment.
TABLE I Average power factor of common electrical equipments. Type of Load Fluorescent lamps Neon lamps Lighting Sodium discharge lamp Arc lamps Fans Resistance furnaces Induction Furnace Arc furnaces Induction furnaces Welders AC Arc welders AC resistance welders Fractional HP motors 0.75kW 1HP Induction Motors 7.5kW 75kW 160kW 250kW 10HP 100HP 220HP 340HP

To start with the type of customers end-use devices and their power consumption behavior is studied. Different loads are aggregated in categories for example induction motor, lighting, electronic, air-conditioning and induction furnaces loads etc Nominal PF values are selected as given in Table I, because, it is difficult to forecast individual loads PF. In this paper Demand factor is used for individual load category and Simultaneity factor is used as an overall factor for the installation although both are the same terms by definitions. Practical approach will be used for selecting values of these factors for each installation so that it has engineering justifications and a reduced (optimized) investment cost of static condensers and their controls. The compensation will be worked out on low tension (LT) side of the supply transformer. V. If Rated power in kW = Pr Demand factor = DF Nominal power factor = Cos Then Calculated power
Pc = Pr DF

MATHEMATICAL MODEL.

scholar search
Find

Reactive power = and

Pc tan Cos 1

www.libsou.com
Approximate Power Factor 0.60-0.80 0.40-0.50 0.7 0.30-0.70 0.50-0.80 0.6 0.85 0.60-0.80 0.30-0.40 0.65 0.40-0.75 0.70-0.80 0.70-0.85 0.70-0.85 0.75-0.88 0.80-0.90

Q of all categories i.e.

Cos s = Cos tan 1

Calculate Power factor of the system (CosS)

Q P
c

i. If Q is reactive power of all categories of loads, Qc is

Apply simultaneity factor to find Qs at target power factor.

reactive power compensation and Qs is system reactive power. Then Qc = Q Qs

ii. iii. iv.

Size of Transformer is S=P2 +Qs2 Total cost of compensation = Rs.Qc x @/KVAr Penalty per month before compensation =Rs. 2 (P.F target P.F system ) x Max demand x @ of Fixed Charges/kW
Pay back period = Total Cost of Compensation Power Factor Penality per Month

v.

http://www.libsou.com

Fig. 1 Power Triangle

VI.

ARCHITECTURE OF COMPENSATION CALCULATING SYSTEM

A comprehensive architectural and design overview of Compensation Capacity calculation of low voltage power distribution system has been shown in Fig. 2. This application will facilitate in calculating KVAr capacity and report preparation in a user-friendly way. The rate of fixed charges and cost per KVAr are selected from Table II & III respectively.
TABLE II Rate of Fixed charges as per Electricity Tariff
TARIFF LOAD

scholar search
www.libsou.com
Rs 300 Rs 290 Rs 280 Rs 220 Rs 216 Rs 214 Rs 214
FIXED CHARGES / KW

B2 B3 B4 C1 C2 C3 C4

41 - 500KW Up to 5000KW at 11KV/33KV For all loads at 66/132/220KV Above 20KW and up to 500KW at 400V For loads not exceeding 5000KW For all loads 66/132/220KV For non-profitable organization For all loads: 66/132/220KV For non-profitable organization

TABLE III Average Cost/KVAr of different types of Capacitors

Type of Capacitor COST / KVAr

Oil Filled capacitors Polypropylene Standard Polypropylene Overrated Polypropylene Overrated with detuned reactors

Rs 1250 Rs 1500 Rs 1600 Rs 1900 Fig. 2 System Flow Chart

http://www.libsou.com

Its salient features are: As far as Platform is concerned on the front end Microsoft Visual Basic 6.0 has been used as a major development tool and Seagate Crystal Report (version 8) has been used for report purpose. Microsoft Access has been used as database management system and the program operates in Microsoft windows to calculate the following. Provides computerized calculation of compensation capacity. System KVA and hence size of Transformer. Total cost of compensation (Rs.) Low power factor penalty per month (Before compensation). Payback period. Form I is used as categories Information screen to enter all detail about the load categories and Form II is used as Data input screen, this is the main input screen and all the requisite data is entered using this window.
Fig. 4 Form III: Print Report

Once results are computed, the same is stored in database and an out put report is generated. It can now be viewed and printed in Report form for analysis and distribution. VII. SELECTION OF COMPENSATION SYSTEM

scholar search
www.libsou.com
Fig. 3 Form I: Categories Information

The commonly applied rule will be used for the choice of control. Where the KVAr rating of the capacitor is less than, or equal to 15% of the supply transformer rating, a fixed value of compensation will be used to reduce investment cost of controls and above 15% level an automaticallycontrolled system will be used.

QC ST

Where Qc = compensation KVAr

ST = KVA of Transformer

http://www.libsou.com

VIII.

CASE STUDY

To utilize the system in an actual working environment, a case of Bilal Engg Industry is taken as an example with total connected load of 387kW. The industry has nine different categories of load with known rated power, nominal PF, demand factor, simultaneity factor, Rate of fixed charges, cost per KVAr and Target PF. Traditional Method We have got connected load of 387 KW. Now our process starts with a few assumptions. First of all we assume starting values for expected load and initial PF as follows: Suppose Expected Load = 250 KW Initial PF = 0.8 Then at target power factor of 0.95, we get a factor of 0.4211 from the table. Then KVAR = 250 x 0.421 = 105 KVAR If load = 387 KW then required compensation will 163 KVAR. Using Newly Developed Software: On entering the known data, the system has automatically calculated the following: 1. Compensation capacity 2. System KVA 3. Total cost of compensation 4. Low PF penalty per month before Compensation 5. Pay back period. The results are shown in Fig. 4.

Fig. 5 Form II: Compensation Capacity Calculation

scholar search
www.libsou.com

IX.

CONCLUSION

This technique of compensation capacity calculation enable the user to achieve optimum reactive power management in the electrical installation for ensuring maximum savings and reducing cost of electricity consumed under given load conditions.

http://www.libsou.com

X.

REFERENCES

[1] Robert B. Morgan,Improving Power Factor for Greater Efficiency-Part 1, pp. 64-76, September 1994 EC&M. [2] Donald Beeman. Industrial power system hand-book. Edition Ist Mc Graw Hill Book Company, INC 1955. [3] Mr. Edwin COEY C Electrical Installation Guide According to IEC International Standards Schneider Group France, pp. E1-E25, 1996. [4] Low Voltage Capacitor and Capacitor Banks, ALPES Technologies France 2000. [5] M.M.abdul Aziz, Power Factor and your Utility bill in Egypt. IEEE 2003. [6] G.T.Heydt, Electric power quality 2nd edition, p. 106. [7] S.L Bhatia. A Hand Book of Electrical Engineering, pp. 631-646.

XI .

BI BLIOG RAPHY

M. A.Choudhry (M 1994) was born in Multan in Pakistan on March 15, 1957. He graduated from the University of Engineering and Technology Lahore. He received his MS from the George Washington University Washington DC and PhD from Virginia Tech, Blacksburg Virginia. His employment experience include the teaching at University of Engineering and Technology Taxila. His Special fields of interest include Power distribution, Power electronics, Power Quality, Control & Automation. He is member of PES, IAS, CS of IEEE. He is working on the executive committee of IEEE chapter Islamabad. Wazir Zada was born in Swat in Pakistan on April 20, 1965. He graduated from the University of Engineering and Technology NWFP Peshawar, and has got vast experience of erection, commissioning and operation of power distribution system. He is doing his MS in electrical power from University of engineering and Technology Taxila.

scholar search
www.libsou.com

http://www.libsou.com