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Agenda
What is power factor?
What are the costs of low power factor?
What are the solutions to low power factor?
Power factor correction selection considerations
Design considerations and pitfalls
kVA
kVAr
kW
Foam/Fizz
Capacity (KVAR)
Liquid (KW)
Full
Capacity
(KVA)
Demonstration
Power Factor Demonstration Unit
Other Benefits:
Increased system capacity
Improved voltage regulation
Reduced losses in transformers and cables
May reduce harmonics on the power system (with
harmonic filters)
9
+
10
Taxes
Percent Uncorrected PF
Brewery
76-80
Cement
80-85
Chemical
65-75
Coal Mine
65-80
Clothing
35-60
Electroplating
65-70
Foundry
75-80
Forge
70-80
Hospital
75-80
Machine manufacturing
60-65
Metal working
65-70
Office building
80-90
Oil-field pumping
40-60
Paint manufacturing
55-65
Plastic
75-80
Stamping
60-70
Steelworks
65-80
11Textile
65-75
12
14
15
Currently the PF
adjustment is being
increased.
6.5
Price/KWH (cents)
6
5.5
5
4.5
4
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Year
16
17
Existing transformer is
500kVA
Plant needs to add new
production line of 75kW
18
kVA = 500
kW = 400
kVAr =300
19
20
kW =400
kVAr = 100
kW =475
kVAr = 100
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Capacitor Selection
Capacitor selection issues (besides size)
Utility penalties
Installed cost, payback of equipment, and NPV
Load variability
Voltage regulation
Load requirements (Speed of changing PF)
Harmonic resonance
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Effect of Location
R1
Resistive
Load
R2
Motor
Load
Place here for line loss
reduction and voltage
improvement
Place here for utility PF penalty
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26
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MV Capacitors
Pole Mounted
These banks have exposed live parts and
are typically supported on a wood power
pole.
Rack Mounted
These banks have exposed live parts and
are supported on a steel structure. These
banks are usually located in fenced-in
substations.
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TYPE OF CORRECTION
INSTALLED COST,
$/KVAR
$15
Fixed (LV)
$25
Fixed (MV)
$30
Switched (LV)
$50
Switched (MV)
$50
$75
$75
$60
$150
Additional Application
considerations
Switching transients
Potential resonance
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31
Harmonics
Definition
Steady state components of voltage and current at
higher frequencies than 60 Hz (or fundamental
frequency)
Causes
Nonlinear loads, normally electronic loads
In industrial facility, predominately motor drives (AC
or DC), also large UPSs, computer loads, rectifiers
These electronic loads draw non-sinusoidal current
All load current (particularly transformers and motors)
has some amount of harmonic content
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Expected Harmonics
Source
Typical Harmonics*
6 Pulse Drive/Rectifier
12 Pulse Drive /Rectifier
18 Pulse Drive
Switch-Mode Power Supply
Fluorescent Lights
Arcing Devices
Transformer Energization
H = NP+/-1
i.e. 6 Pulse Drive - 5, 7, 11, 13, 17, 19,
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Harmonic Resonance
If a capacitor exists on
the power system
AND
Harmonic producing
loads are in use
You MUST check for
harmonic resonance.
The Self Correcting Problem
Blown Fuses
Failed Capacitor
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36
37
38
Questions
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18 Pulse Drives
HMTs
Active Filters
Broadband Filters
Reactors
Link:http://www.eaton.com/EatonCom/Markets/Electrical/ServicesSupport/Experi
ence/index.htm Simply search on Google for Eaton Experience Center
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Thank You.
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