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Power Factor Correction: A Guide For The Plant Engineer: Technical Data SA02607001E
Power Factor Correction: A Guide For The Plant Engineer: Technical Data SA02607001E
Power Factor Correction: A Guide For The Plant Engineer: Technical Data SA02607001E
Contents
Description Page
Description Page
Part one: power factor Part two: harmonics
What is power factor?. . . . . . . . . . . . . . . . . . . . . . 2 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Should I be concerned about What are harmonics? . . . . . . . . . . . . . . . . . . . . . 19
low power factor?. . . . . . . . . . . . . . . . . . . . . . . . . 3 What are the consequences
What can I do to improve power factor?. . . . . . . . 4 of high harmonic distortion levels?. . . . . . . . . . . 20
How much can I save by installing IEEET 519 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
power capacitors?. . . . . . . . . . . . . . . . . . . . . . . . . 5 How are harmonics generated? . . . . . . . . . . . . . 21
How can I select the right capacitors What do power factor correction
for my specific application needs? . . . . . . . . . . . . 9 capacitors have to do with harmonics?. . . . . . . . 22
How much kVAR do I need? . . . . . . . . . . . . . . . . 9 How do I diagnose a potential
Where should I install capacitors harmonics-related problem? . . . . . . . . . . . . . . . . 22
in my plant distribution system? . . . . . . . . . . . . 15 How can harmonics problems be eliminated? . . 22
Can capacitors be used in nonlinear, What is a passive harmonic filter? . . . . . . . . . . . 22
nonsinusoidal environments? . . . . . . . . . . . . . . . 17
Do I need to perform a system analysis
What about maintenance? . . . . . . . . . . . . . . . . . 17 to correctly apply harmonic filters?. . . . . . . . . . . 23
Code requirements for capacitors. . . . . . . . . . . . 17 What is Eaton’s experience
Useful capacitor formulas. . . . . . . . . . . . . . . . . . 18 in harmonic filtering?. . . . . . . . . . . . . . . . . . . . . . 23
Technical Data SA02607001E Power factor correction:
Effective November 2010 a guide for the plant engineer
kVA
kW- = PF
COS θ = ----------
Hot Plate kVAR
kVA
θ
Figure 1. kW Power
kW
100 kW
100
PF = -------- = 70%
142
105
kVA
33
kVAR
θ
100 kW
100
PF = -------- = 95%
105
Capacitor
Power Factor Improved to 95%
Line Current Reduced 11%
COS θ 1 = 100
---------- = 70% PF
142
COS θ 2 = 100
---------- = 95% PF
105 67 kVAR
re Capacitor
e fo Added
B 70% PF
A 100 kVAR
kV Before Before
2
14
r
Afte
kVA
105 33 kVAR
θ1 95% PF
After
θ2 After
To calculate savings:
Normal 400 kW billing demand
First 40 kW @ $10.00 = $ 400.00
Next 160 kW @ $ 9.50 = $1520.00
Bal. 200 kW @ $ 9.00 = $1800.00
Total 400 kW $3720.00 normal monthly billing
New billing:
kW × 0.90 = 400 × 0.90 = 375 kW demand
New power factor 0.96
Case 1
Assume a 400 kW load demand at 81% power factor.
Tariff structure:
Demand charge is: 480 kVA
578A 317
$635.00 for the first 200 kW demand kVAR
$ 2.80 per kW for all addition
Reactive demand charge is: 75% PF
Original
$ 0.60 per kVAR in excess of 50% of kW demand Condition θ
In this example, kW demand = 400 kW,
therefore 50% = 200 kVAR which will be furnished at no cost. 360 kW
474 kVA
kW or Adj
Cos θ = PF = 570A
kVA Hyp 148
95% PF kVAR
Corrected
kvar or Opp θ
Tan θ =
kW Adj
450 kW
This ratio is the basis for the table of Multipliers (See Table 5).
A plant has a 500 kVA transformer operating near capacity.
It draws 480 kVA or 578A at 480V. The present power factor
is 75%, so the actual working power available is 360 kW.
Solution:
To correct 400 kW from 81% to 90% requires 400 x 0.240
(from Table 6) = 96 kVAR. (Use 100 kVAR.) The approximate cost
for this capacitor is $1250.00. The payoff is about 23 months.
Charges for kVAR vary from about 15 cents to a dollar, and free
kVAR ranges from 25% (97% power factor) to 75% (80% power
factor) of kW demand.
( original
new power factor )
2
% reduction losses = 100 – 100 × power factor
1.00 1.00
0.90 0.90
1.0
Original Power Factor
0
0.9
5
0.9
0
0.80 0.80
0.8
0
0.70 0.70
0.70
0.60 0.60
0.60
0.50 0.50
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
A For use with three-phase, 60 Hz NEMA Classification B Motors to raise full load power factor to approximately 95%.
NNote: Applies to three-phase, 60 Hz motors when switched with capacitors as single unit.
NNote: Use motor manufacturer’s recommended kVAR as published in the performance data sheets for specific motor types: drip-proof, TEFC, severe duty,
high-efficiency, and NEMA design.
Above sizes are intended to provide a corrected power factor of approximately 95% at full load. Because of the limited number of capacitor
ratings available, it is not possible to raise every motor PF to 95%.
To calculate kVAR required to correct power factor to a specific target value, use the following formula:
kVAR(required) =
hp × 0.746
% EFF ( √1 PFa
– PFa 2
=
√1 – PFt2
PFt )
Where
hp: motor nameplate horsepower
%EFF: motor nameplate efficiency (enter the value in decimal)
PFa: motor nameplate actual power factor
PFt: target power factor
NNote: Consult the motor manufacturer’s data sheet to verify the maximum kVAR of capacitors that can be directly connected at motor terminals. To avoid
self-excitation, do not exceed the maximum kVAR rating that is specified by the motor manufacturer.
A 90°C Copper Type THHN, XHHW, or equivalent, applied at 75°C ampacity. Rate current based on operation at rated voltage, frequency, and kVAR. Consult National Electrical Code for other wire types.
Above size based on 30°C ambient operation. (Refer to NEC table 310-16.)
NNote: Fuses furnished within capacitor assembly may be rated at higher value than shown in this table. The table is correct for field installations and reflects
the manufacturer’s suggested rating for overcurrent protection and disconnect means in compliance with the National Electrical Code.
Motor Thermal
Feed C B Overload A
Motor
Fused Motor
Safety Starter
Switch or
Breaker
4
5 1
Start:
Close 6-7-2-3-4 4A 2 A
Transfer: Wye Start: B 5
Open 6-7 Line 7 Motor Close 1-2-3-7-8
Run: 3 B Stator Delta Run: Motor
Close 1-5 Close 1-2-3-4-5-6 7 Stator
6
Line
2 C
1 8
Start: 6 9
Close 1-2-3 3 A
Second Step: 5 8
Open 4-5-6 Line Motor
Third Step: 2 B Stator Start:
6
Close 7-8-9 4 7 Close 1-2-3
Run: 3 A
1 C Close 4-5-6
5
Line Motor
2 B Stator
Nomenclature: Miscellaneous
C = Capacitance in μF Power factor = Cos θ = kW
kVA
V = Voltage
A = Current
Tan θ = kVAR (See Table 6.)
k = 1000 kW
Single-phase kW = V × A × PF
Additional data 103
√
Simplified voltage rise: Three-phase kW = 3 × V × A × PF
103
% V.R. = kVAR (cap.) × % transformer reactance
% V.R. = kVAR (cap.)kVA
× %(transformer)
transformer reactance
kVA (transformer) Single-phase kVA = V × 3A
10
Losses reduction: √
Three-phase kVA = 3 × V 3× A
(( ))
2
% L.R. = 100 – 100 original PF 2 10
% L.R. = 100 – 100 improved original PFPF
% V.R. = kVAR (cap.) ×
kVAR (cap.) % transformer
improved PF
× %(transformer)
reactance
transformer reactance
% V.R. = kVA kVA × 103
% V.R. = kVAR
Operation (cap.)kVA
at other × %(transformer)
than transformer
rated voltage reactance
and frequency: Single-phase line current (A) =
V
(( ))
2
Actual
% V.R. = kVARkVAR (cap.)
(output) ×Rated
kVA
= kVAR actual
%(transformer)
transformer voltage
reactance 2
Note: Use of voltages kVA (transformer)2 actual
rated voltage
the voltage
N (output)and frequencies above rated values can be kVA × 103
Actual kVAR
% L.R. = 100
dangerous. – 100
Consult ((= Rated
original
the factory
% L.R. = 100 – 100 improved
kVAR
PF
forPF
original
improved
)) rated
any unusual
PF
PF
2 voltageconditions.
operating Three-phase line current (A) =
√3 × V
(( (( ))
2
% L.R. = 100 – 100 original PF 2
Reduced
Actual
% L.R.kVAR
voltage:
= 100=–Rated originalactual
100 improved
kVAR
kVAR actual
Actual kVAR = Rated improved
PF frequency
PF
rated frequency
PF frequency )) Capacitor current (A) = (2πf) CV ×10–6
(( ))
2
Actual kVAR (output) = Rated rated actual voltage 2
kVARfrequency
Single-phase capacitor current = kVAR × 10
3
Actual kVAR (output) = Rated kVAR actual
rated voltage
voltage
rated voltage V
(( )) (( ))
2
Actual kVAR (output) = Rated 208kVAR2 actual voltage 2
kVAR (208) = kVAR (240) = actual
0.75 voltage
rated voltage Three-phase capacitor current = kVAR × 10
3
Reduced
Actual kVAR frequency:
(output) = Rated 208kVAR2
kVAR (208) = kVAR (240) 240 rated voltage
= frequency
0.75 √3 × V
(10 kVAR @ 240V = 7.5 kvar240
Actual
Actual
(10 kVAR
kVAR
kVAR
= Rated
= Rated
@ 240V
kVAR
= 7.5kVAR
((
actual
@actual
208V)
kvar @rated
frequency
rated frequency
208V)frequency
))
(( (( )) ))
Actual kVAR = Rated kVAR actual actual
2
frequency
frequency kVA =
kW (kW motor input)
Actual(120)
kVAR==kVAR
Rated 120
kVAR rated =frequency
0.25 PF
kVAR (240)
Examples: 120
240 rated
2
frequency
(( ))
2
kVAR (120) = kVAR (240) 208 2 = = 0.75
0.25
kVAR
(10 kVAR(208)
@= kVAR = (240) 240@ 120V)
208 hp × 0.746
Voltage
kVAR (208) =240V
reduction:
kVAR 2.5 kVAR
(240) 240 = 0.75 (kW motor input) =
(10 kVAR @ 240V = 2.5 kVAR 240@ 2120V) efficiency
(10
kVAR
(10
kVAR @=
(208) 240V
kVAR=7
=
(240) (( ))
.5 kvar208
kVAR (208) = kVAR (240) @ 208V)
kVAR @ 240V 7.5 kvar
@ 208V)0.75
208 2 =
240
240
= 0.75
(Amperes)
(Amperes)
(10 kVAR @ 240V = 7.5 kvar120 @ 208V) Approximate motor kVA = motor hp (at full load)
(( ( )) )
2
kVAR
(10 (120)
kVAR @ =240V
kVAR = (240)
7.5 kvar120 2 = 0.25
@ 208V)
kVAR
kVAR (50 Hz)
(120) == kVAR
kVAR 240 50 ==0.25
(60 Hz)
(240) 0.83
(( ( )) )
240 50
60 = 0.83
kVAR
(10 kVAR(50 @
Hz)240V
= kVAR (60
= (240)
2.5 Hz)
120@60
kVAR
2
120V)
kVAR
(60 (120)
kVAR @ = kVAR
@ 240V
480V, =602.5HzkVAR
= 240
50 @
120 kVAR,
2 = 0.25
480V, 50 Hz)
(10
kVAR kVAR
(120) 120V)
= 0.25 Table 8. Standard Data
(60 kVAR @=480V,
kVAR60(240)
Hz = 240
50 kVAR, 480V, 50 Hz) (Amperes)
(10 kVAR @ 240V = 2.5 kVAR @ 120V)
(10 kVAR @ 240V = 2.5 kVAR @ 120V)
(Amperes) Amperes / kVAR
Voltage μF / (Amperes)
kVAR Total Single-Phase Three-Phase
61.2 (Amperes)
kVAR (50 Hz)reduction:
Frequency
50
((
= kVAR (60 Hz) 50 = 0.83
kVAR (50 Hz) = kVAR (60 Hz) 60 = 0.83
60
)) 208
240 46.0
4.81
4.17
2.78
2.41
kVAR
(60
kVAR
(50 Hz)
kVAR
(50 @
= kVAR
Hz)480V,
(60=Hz)
60 Hz
= kVAR
50
(60 kVAR @ 480V, 60 Hz = 50 kVAR,
50 =
50 kVAR,
(60 Hz) 60
60
((
480V,
=480V, ))
0.83 50 Hz)
0.83 50 Hz)
480
600
11.5
7.37
2.08
1.67
1.20
0.96
(60 kVAR @ 480V, 60 Hz = 50 kVAR, 480V, 50 Hz)
(60 kVAR @ 480V, 60 Hz = 50 kVAR, 480V, 50 Hz) 2400 0.46 — 0.24
4160 0.153 — 0.139
Introduction
Volts
There has been much discussion and interest in recent years
on the subject of power quality. Whereas in the past, power Fundamental
received from the electric utility and used by an industrial plant was
generally a pure sinusoidal waveform—for example, clean power—
more frequently today, industrial plants are finding that they have
to deal with the problem of “dirty” power. Dirty power is a slang 5th Harmonic
expression used to describe a variety of voltage and current
contaminations on the pure sinusoidal waveform. Dirty power
can come in the form of short-term transients or steady-state,
continuous distortions. In addition, the sources of dirty power can
be external to a plant (as might be the case if a neighboring plant
is contaminating the utility’s distribution system), or the source can
reside within the plant itself.
Harmonic distortion is a specific type of dirty power that is usually
associated with an industrial plant’s increased use of adjustable Time
speed drives, power supplies, and other devices that use solid-state
switching. However, harmonic distortion can be generated by
any of a variety of nonlinear electrical devices existing within a Figure 17. Fundamental and 5th Harmonic
manufacturing plant or within nearby plants. Because harmonic
distortion can cause serious operating problems in certain plant
environments, it is important that the plant engineer or facilities
personnel understand the fundamentals of harmonic distortion,
know how to recognize the symptoms of this problem, and know Volts
what can be done to solve the problems once they are identified.
V2 + V3 + ... +Vn
Vthd =
V1
where: V1 = fundamental voltage value
Vn (n = 2, 3, 4, etc. …) = harmonic voltage values
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Electrical Sector
1111 Superior Avenue
Cleveland, OH 44114 USA
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