Power Factor Correctionof Three Phase Induction Motor Using Switched Capacitor Bankswith PLC

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Power Factor Correction of 3-Phase Induction Motor Using Switched Capacitor

Banks With PLC
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International Journal of Research in Electrical & Electronics Engineering
Volume 2, Issue 2, April-June, 2014, pp. 45-58, © IASTER 2014
www.iaster.com, ISSN Online: 2347-5439, Print: 2348-0025
Power Factor Correction of Three Phase Induction Motor

Using Switched Capacitor Banks with PLC
Gaurav S. Chingale1, Priya R. Patil2 and Arvind R. Singh3
1
Department of Electrical Engineering, College of Engineering, Pune India
2
Department of Electrical Engineering, Shree Ramchandra College of Engineering, Pune, India
3
Electrical Engineering Department, MMCOE, Karvenagar, Pune, India
ABSTRACT
This paper is based on novel power factor improvement of a 3-phase induction motor using switched
capacitor banks with Programmable Logic controller which incorporates development of the
hardware and software in this work. The hardware consists of power-circuit and control-circuit of the
working system and software PLC programs was developed. An on-line process is carried out for
switching on or/and off a group of capacitors with the help of solid state relays from PLC. The main
control strategy is to select the logical pattern to switch the appropriate capacitors depending on
power factor correction requirement through solid state relays. The switching of capacitor-banks
through digital output of the PLC in a proper logic was carried out. The results obtained for power
factor improvement from power analyzer connected across induction motor gives a fine control of
capacitive VAR for improvement of the power factor.
Keywords: Capacitive VAR, Induction Motor, PLL, Power Factor Correction.
I. INTRODUCTION
In past few decades, a considerable development in control devices has made technology quite easy to
use. One of them is Programmable Logic Controller has a great use in industrial automation. Several
applications such as control of electrical machines, distribution networks, manufacturing and process
industries, etc. employs PLC as an automated and efficient means [1-2]. Many factories use PLC’s
in automation processes to reduce the production cost and to enhance quality and reliability. To
obtain accurate industrial system, the use of PLC’s interfaced with working system and computers and
other electric components are greatly appreciated [3-5]. Implementing a PLC to a system is an
automated way for controlling that system. The interfacing of different components of the system set-
up to PLC provides a self-diagnostic means by checking and observing the status of inputs and
outputs of the PLC [6-9].
In order to improve power factor, some devices providing capacitive reactive power should be
connected in parallel with the load. One of such devices can be a capacitor. The capacitors draw a
leading current and partly or completely neutralises the lagging reactive component of load current
[10-11]. This improves the power factor of the load. For three-phase loads, the capacitors can be
connected in delta or star. Capacitors are invariably used for power factor improvement in factories.
They have low losses and require little maintenance as there are no rotating parts. They can be easily
installed as they are light in weight and require no foundation. They can work under ordinary
atmospheric conditions. The power factor of induction motors varies with load, typically from around
0.85 or 0.90 at full load to as low as 0.30 at no-load, due to stator and rotor leakage and magnetizing
reactance [12-13]. Power factor can be improved by connecting capacitors either on an individual
motor basis or by preference on a common bus covering several motors. Power capacitor application
with harmonic currents requires power system analysis to avoid harmonic resonance between
capacitors, transformer and circuit reactance [14]. Common bus power factor correction is
recommended to minimize resonant risk and to simplify system analysis.
45
International Journal of Research in Electrical & Electronics Engineering (O) 2347-5439
ISSN
Volume-2, Issue-2, April-June, 2014, www.iaster.com (P) 2348-0025
The proposed PLC-based system for power factor improvement comprises a Programmable Logic
Controller (PLC) for controlling digital inputs-outputs, and 3-phase squirrel cage induction motor
coupled with a dc generator [16-19]. Capacitors banks of different ratings equipped with solid state
relays and contactors are inserted in the system for achieving the improvement in power factor of the
system. Apart from these elements, power quality analyser has been used to monitor track record of the
setup including voltages, currents, powers and power factor. The digital outputs of PLC activate the
relays through which capacitors are connected. Motors draw two components of current. One
component is in-phase or real current. The other component is reactive or inductive current that is
sometimes referred to as magnetizing current. As load power factor become low, the in-phase
component shrinks faster than the magnetizing component therefore the phase angle gets larger and the
PF gets lower. So requirement for improving the power factor becomes quite significant. Furthermore,
electrical system with low power factor results in increase of energy cost and reduction in system
capacity. Hence the power factor improvement is a challenging task in any industrial process.
The most effective way to improve power factor is use of capacitors in the working system. The
capacitors provide capacitive reactance for the compensation of inductive reactance of the circuit.
Capacitor banks equipped with solid state relays and contactor can be used to achieve the goal of
power factor improvement. Micro-810 PLC for controlling digital inputs-outputs can provide an on-
line process to carry out the switching on or/and off a set of capacitors with the help of solid state
relays and PLC. The control strategy is mainly selecting the switch of appropriate capacitors through
solid state relays.The proposed PLC-based system for power factor improvement shown in Fig. 1. is
employed to a 3-phase squirrel cage induction motor coupled with a dc generator. The control scheme
employs a PLC module to switch on/off three 4PDT relays connecting each set of capacitors to each
phase. Three capacitors-banks sized 2.5, 4, 10 µF are connected to each NO point of each relay.
Capacitors are switched on as per inputs of PLC and program logics. Ladder logic program is built for
the logic to switch on/off the PLC outputs. The PLC outputs activation depends upon the status of
PLC inputs and the logic program downloaded the PLC. Computer is used to develop logical
programs and it is downloaded to the PLC through communication interface module.
Fig. 1. Circuitry for Power Factor Improvement by Capacitors Switching.
II. HARDWARE IMPLEMENTATION

The proposed PLC-based system for power factor improvement comprises a Micro-810 PLC for
controlling digital inputs-outputs, and 3-phase squirrel cage induction motor coupled with a dc
generator and capacitors-bank equipped with protection relays and contactor.
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A. Induction Motor
The PLC is implemented for a 3-phase squirrel cage induction motor having a technical specification
given in Table-I. The induction motor drives a dc generator which is connected to resistive load lamp
banks. The three-phase supply is connected to three-phase main switch. The relay and contactor
technical specification is also tabulated in table-II.
Table I Induction Motor Technical Specifications; Table II Relay and Contractor Technical
Specifications
Type Squirrel cage
Connection type star Input Output
Input voltage Type Coil Load Current
250/440 V ac Relays Voltage Voltage
Input current 3.9/2.25 A 3 phase 24V dc 250V ac 5A
Rated power 2.25 kW 3-phase,
Contactor 230V ac 690V ac 10A
Rated speed 3wires
1500 rpm
Input frequency 50 Hz
No. of poles 4
Fig.2 Wiring Connection between Contactor and Relays
B. The Capacitors-bank
For smooth variance of power factor correction form power factor 0.35 to 0.85 to achieve unity power
factor the set-up required three set of capacitor banks. Each bank is connected between each phase
and neutral in star. In each bank there are three capacitors rating from 2.5µF, 4µF and 10µF with
voltage rating 250V line to neutral. These capacitors come into circuit system by activation of the
relays activated with output of PLC.
C. The PLC and Programming Software
The Micro-810 PLC belongs to Micro-800 Programmable Controller family. It has 12 point versions,
with 8A relay-based output and features embedded smart relay function bocks that can be configured
from a 1.5’’LCD and keypad. Programming can be done through a program download via USB
Adapter programming port using Connected Components Workbench software. The software supports
IEC standard ladder logic programming languages, function block diagram and structure text.
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III. SOFTWARE IMPLEMENTATION

The Micro-810 PLC has Connected Components Workbench design and configuration software that
offers controller programming, device configuration and integration with HMI editor. Based on
proven Rockwell Automation and Microsoft Visual Studio technology, Connected Components
Workbench software can help minimize initial machine development with free IEC 61131-3 standard
software download. The control scheme for achieving our goal of power factor improvement employs
a PLC module to switch on/off three 4PDT relays connected in each phase as in Fig. 3. Three
capacitors of each sized 2.5µF, 4µF and 10µF are connected to each NO pt of each relay. Capacitors
are switched on as per inputs of PLC and program logics. Ladder logic program is built for the logic
to switch on/off the PLC outputs. The PLC outputs activation depends upon the status of PLC inputs
and the logic program downloaded the PLC. Computer is used to develop logical programs and it is
downloaded to the PLC through communication interface module.
Fig.3. Interfacing of Relays with Micro-810 PLC

A. Programming for the Control Scheme
We have three relays say, RELAY-1, RELAY-2 and RELAY-3. Each relays has three inputs and
three outputs. The three input points of each relay are connected to the three-phase supply coming
through the three-phase contactor. The three outputs of each relay are connected to same sized
capacitor, say RELAY-1 with 2.5 µF capacitor, RELAY-2 with 4 µF capacitor and RELAY-3 with
10µF capacitor. PLC gives command to activate these three relays in a proper sequence to get
required improvement in the power factor.
Firstly, the power factor to be read out using the measuring unit and then it is to be checked whether
the present reading of power factor showing the measuring unit is equal to the desired power factor.
The desired power factor is the sufficient value of the power factor which enough to stand on the
required criteria defined by the user. Then there will be two cases which arises. In the first, the present
reading and the desired power factor are equal. In this there is no need for changing the present
configuration of the system. In the second case, the two variables differs each other. So in this case
there is a need of power factor correction by changing the system configuration. Now the change in
configuration requires to follows the next better pattern of inputs which adds more capacitance to the
system circuit. If the next pattern fulfill the required criteria then circuit is configured this very next
pattern otherwise keep going to the next better configuration pattern till the required criteria meet or
maximum available capacitance is added to the circuit. PLC output signals generated depend upon the
status (ON or OFF) of its inputs as well as the logic of the programming downloaded into it.
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Table III Control Scheme for Switching of Capacitors

Input 10 µF (DO0) 4 µF (DO1) 2.5 µF (DO 2) C- total
Pattern Status Status Status in µF
1 0 0 0 0.0
2 0 0 1 2.5
3 0 1 0 4.0
4 0 1 1 6.5
5 1 0 0 10.0
6 1 0 1 12.5
7 1 1 0 14.0
8 1 1 1 16.5
From Table III, it is following patterns are observed:

µF capacitor ON only when input pattern of 2, 4, 6 and 8.
4 µF capacitor ON only when input pattern of 3, 4, 7 and 8.
10 µF capacitor ON only when input pattern of 5, 6, 7 and 8.
Based on this pattern we can make a PLC program (Ladder logic diagram) whose inputs and outputs
are as in Table IV.
Table IV Inputs and Outputs to PLC for Control Scheme Program
INPUTS ADDRESS
Manual Switch for Relay 1
DI 0
to connect only 2.5 µF capacitors-bank directly
DI 1
to connect only 4 µF capacitors-bank directly
DI 2
to connect only 10 µF capacitors-bank directly
Switch to load directly to maximum capacitance i.e. for input pattern 8. DI 3
Switch to start / increase counter pulse value DI 4
Switch to stop all connections of capacitor i.e.
DI5
for input pattern 1, also to reset counter to zero pulse value
Switch to decrease counter pulse value provided DI 3 is false. DI 6
OUTPUTS
Relay 1for connection of only 2.5 µF capacitors-bank DO 0
Relay 2 for connection of only 4 µF capacitors-bank DO 1
Relay 3 for connection of only10 µF capacitors-bank DO 2
The ladder logic program for this control scheme is shown in Fig. 4.The program has four Rungs as--
Rung-1: For counter pulse generation.
Rung-2: for activation of RELAY-1.
Rung-3: For activation of RELAY-2.
Rung-4: For activation of RELAY-3.
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(a) Rung-1: For Counter Pulse Generation
(b) Rung-2: For Activation Of RELAY-1.
(c) Rung-3: For Activation Of RELAY-2.
(d) Rung-4: For Activation Of RELAY-3

Fig. 4. PLC Ladder Logic Program of Control Scheme for Rung 1 (Fig A) To 4 (Fig D).
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IV. EXPERIMENTAL RESULTS AND OBSERVATIONS
PLC has been used for switching capacitors of different values in the prescribed control scheme. The
result shows values of currents, voltage, power, power factor in Table VI to Table XIII. The result
shows how the power factor goes on improving by compensation of motor equivalent inductive
reactance X eqv by addition of capacitor bank ‘C µF’ to the motor equivalent circuit as in Fig. 5.
Fig.5. Motor Equivalent Circuit.
Fig. 6. Waveforms of Phase Voltages ( Va ,Vb ,Vc ) and Currents ( I a , I b , I c ) without Adding any Capacitor
in the Circuit
Figure 6, shows the phase to neutral voltage and current waveform obtained from power analyser in
the motor equivalent circuit without capacitor. Table-V shows the results obtained from power
analyser to get all the circuit parameters in the running condition of the motor with load. It shows
magnitude of voltages, currents, active power, reactive power, apparent power and power factor in
each phase without capacitor connected in the system.
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Table V: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Control Scheme Input Pattern- 1
Voltage, Magnitude Phase Power Values PF Values
Current Values Angleº
Va 247.29 0.00 Pa 0.081 cos a 0.6132
Vb 247.14 -119.74 P 0.101 cos 0.5711
b b
Vc 248.35 118.97 Pc 0.089 cos 0.6264

c
Pnet 0.27 cos 0.6037

net
Ia 1.061 -51.63 Qa 0.067

Ib 1.042 -173.02 Qb 0.073
Ic 1.027 -69.07 Qc 0.084
Qnet 0.22
I La 1.061 -51.63 Sa 0.105
I Lb 1.042 -173.02 Sb 0.125
I Lc 1.027 -69.07 Sc 0.122
Snet 0.35
ICa - -
ICb - -
ICc - -
Table VI: Results for 3-Phase Induction Motor with Load and with Capacitor Banks
Control Scheme Input Pattern-2
Va 248.45 0.00 Pa 0.080 cos a
0.7714
Vb 247.95 -119.66 Pb 0.102 cos b
0.8076
Vc 247.45 118.89 Pc 0.087 cos c
0.7272
Pnet 0.27 cos net
0.7689
Ia 0.765 -30.56 Qa 0.051
Ib 0.803 -148.49 Qb 0.059
Ic 0.765 80.52 Qc 0.069
Qnet 0.18
I La 1.056 -59.07 Sa 0.119
I Lb 1.066 -174.83 Sb 0.118
I Lc 1.089 75.68 Sc 0.121
Snet 0.32
ICa 0.581 -91.82
ICb 0.580 148.43
ICc 0.576 30.30
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Table VII: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Va 247.50 0.00 Pa 0.075 cos a
0.8430
Vb 247.03 -119.12 Pb 0.102 cos b
0.8647
Vc 248.16 118.26 Pc 0.090 cos c
0.8728
Pnet 0.27 cos net
0.8302
Ia 0.739 -27.22 Qa 0.044
Ib 0.727 -141.85 Qb 0.047
Ic 0.750 84.81 Qc 0.043
Qnet 0.18
I La 1.050 -60.79 Sa 0.017
I Lb 1.042 -173.35 Sb 0.113
I Lc 1.054 75.95 Sc 0.110
Snet 0.32
ICa 0.592 -91.84
ICb 0.595 148.54
ICc 0.603 30.24
Table VIII: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Va 247.55 0.00 Pa 0.075 cos 0.8639
a
Vb 248.67 -119.16 Pb 0.102 cos 0.8685

b
Vc 248.89 119.26 Pc 0.090 cos 0.8691

c
Pnet 0.27 cos 0.8642

net
Ia 0.629 -18.78 Qa 0.034

Ib 0.614 -133.28 Qb 0.035
Ic 0.633 93.62 Qc 0.037
Qnet 0.17
I La 1.043 -61.36 Sa 0.105
I Lb 1.048 -172.86 Sb 0.107
I Lc 1.086 75.89 Sc 0.109
Snet 0.31
ICa 0.638 -91.85
ICb 0.647 -149.90
ICc 0.633 30.67
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Table IX: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Va 247.35 0.00 Pa 0.085 cos a
0.9013
Vb 248.13 -118.56 Pb 0.101 cos b
0.9028
Vc 248.47 118.41 Pc 0.089 cos c
0.9018
Pnet 0.28 cos net
0.9021
Ia 0.564 Qa 0.023
Ib 0.558 Qb 0.026
Ic 0.569 Qc 0.021
Qnet 0.15
I La 1.046 -61.30 Sa 0.089
I Lb 1.072 -174.27 Sb 0.086
I Lc 1.016 74.13 Sc 0.083
Snet 0.29
ICa 0.704 -90.46
ICb 0.714 149.81
ICc 0.708 30.51
Table X: Results for 3-Phase Induction Motor with Load and without Capacitor Banks

Va 248.60 0.00 Pa 0.098 cos a
0.9093
Vb 248.66 -118.58 Pb 0.093 cos b
0.9061
Vc 247.76 119.34 Pc 0.096 cos c
0.9197
Pnet 0.28 cos net
0.9118
Ia 0.547 -22.04 Qa 0.019
Ib 0.551 -141.46 Qb 0.013
Ic 0.538 99.86 Qc 0.012
Qnet 0.14
I La 1.058 -58.21 Sa 0.076
I Lb 1.021 -172.53 Sb 0.073
I Lc 1.049 74.24 Sc 0.072
Snet 0.29
ICa 0.725 -90.49
ICb 0.731 149.60
ICc 0.728 28.83
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Table XI: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Va 248.17 0.00 Pa 0.093 cos a
0.9282
Vb 247.79 -118.63 Pb 0.092 cos b
0.9265
Vc 247.70 119.35 Pc 0.096 cos c
0.9370
Pnet 0.28 cos net
0.9306
Ia 0.533 -16.58 Qa 0.007
Ib 0.524 -135.77 Qb 0.008
Ic 0.516 105.26 Qc 0.011
Qnet 0.13
I La 1.049 -58.18 Sa 0.054
I Lb 1.040 -172.95 Sb 0.057
I Lc 1.030 74.45 Sc 0.051
Snet 0.28
ICa 0.765 -90.49
ICb 0.752 149.63
ICc 0.746 30.09
Table XII: Results for 3-Phase Induction Motor with Load and without Capacitor Banks
Va 247.32 0.00 Pa 0.094 cos a
0.9485
Vb 248.14 -118.70 Pb 0.093 cos b
0.9510
Vc 247.77 119.23 Pc 0.097 cos c
0.9521
Pnet 0.28 cos net
0.9505
Ia 0.498 -6.67 Qa 0.005
Ib 0.485 -126.80 Qb 0.002
Ic 0.503 114.52 Qc 0.007
Qnet 0.12
I La 1.045 -58.22 Sa 0.038
I Lb 1.041 -172.68 Sb 0.041
I Lc 1.034 74.30 Sc 0.034
Snet 0.27
ICa 0.783 -90.44
ICb 0.791 149.57
ICc 0.789 29.61
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From above Tables V to Table XII, we observed that power factor progressively goes on increasing
with control scheme input pattern-1 to input pattern-8 respectively. This is because of addition of
capacitors in the working circuit. From input pattern-2 to input pattern- 8, the value of capacitance
goes on increasing and thereby compensating the lagging current in the system. The power factor is
increased linearly after addition of the capacitor in the circuit.
Fig. 7. Power Factor Increment Trend.
It is observed when no capacitor is added to the system the power factor was 0.6037 and then on adding
capacitors power factor progressively increases up to maximum value 16.5µF yields this power factor to
0.9505. So, it can be notice that it is a fine improvement in power factor. Figure 7, shows the power
factor improvement trend observed by switching the capacitor banks for various input pattern. The
power factor increases effectively and the required power factor correction for induction motor on load
is achieved. However addition of capacitors in the circuit causes distortion in the supply current because
of creation of Harmonics in the supply current. It can be observed from chart of harmonics in Fig. 8 (a to
c) below with total harmonic distortion not increasing more than 10 %.
56
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Fig. 8. Charts of Harmonics in Supply Currents

V. CONCLUSION
Implementing a PLC to an induction motor has resulted in a well automated way for improving power
factor based on the mentioned strategy in the work. The interfacing of different components of the set-
up to PLC has provided a self-diagnostic means by checking and observing the status of inputs and
outputs of the PLC in an automotive way. The experiment performed for the capacitor switching logic
shows a fine control of capacitive VAR for improvement of the power factor.
By connecting analog extension module analog quantities like Speed of the motor and Voltage can be
read and a closed-loop control systems can be implemented. By using analog extension modules it is
possible to get the characteristics like Speed-torque, speed-frequency, torque-current etc. By
connecting required number of electrical devices, it can be extend to develop the SCADA system
and those types of systems are more reliable. The Programming methodology used in this dissertation
work is Ladder logic programming. The Proficies Machine Edition also offers various other
programming platforms like FBD, ST, IL etc. Programs can be developed using these platforms.
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Power Factor Correction of 3-Phase Induction Motor Using Switched Capacitor

Article · April 2014

Gaurav Chingale Arvind R. Singh

SEE PROFILE SEE PROFILE

The user has requested enhancement of the downloaded file.

Power Factor Correction of Three Phase Induction Motor

Keywords: Capacitive VAR, Induction Motor, PLL, Power Factor Correction.

Fig. 1. Circuitry for Power Factor Improvement by Capacitors Switching.

II. HARDWARE IMPLEMENTATION

Fig.2 Wiring Connection between Contactor and Relays

C. The PLC and Programming Software

III. SOFTWARE IMPLEMENTATION

Fig.3. Interfacing of Relays with Micro-810 PLC

Table III Control Scheme for Switching of Capacitors

From Table III, it is following patterns are observed:

(a) Rung-1: For Counter Pulse Generation

(b) Rung-2: For Activation Of RELAY-1.

(c) Rung-3: For Activation Of RELAY-2.

(d) Rung-4: For Activation Of RELAY-3

IV. EXPERIMENTAL RESULTS AND OBSERVATIONS

Fig.5. Motor Equivalent Circuit.

Vc 248.35 118.97 Pc 0.089 cos 0.6264

Pnet 0.27 cos 0.6037

Ia 1.061 -51.63 Qa 0.067

Vb 248.67 -119.16 Pb 0.102 cos 0.8685

Vc 248.89 119.26 Pc 0.090 cos 0.8691

Pnet 0.27 cos 0.8642

Ia 0.629 -18.78 Qa 0.034

Control Scheme Input Pattern-6

Fig. 7. Power Factor Increment Trend.

Fig. 8. Charts of Harmonics in Supply Currents

[7] M. Pineda-Sánchez, R. Puche-Panadero, M. Riera-Guasp, A. Sapena-Baño, J. Roger Folch,

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