POWER FACTOR

Basics
and
Benefits of Improvement
 POWER FACTOR BASICS
• In all industrial electrical distribution systems, the major loads are
resistive and inductive. Resistive loads are incandescent lighting and
resistance heating. In case of resistive loads the voltage (v) , current (I),
resistance relations are linearly related, i.e. V= I x R and Power (kW) = V x I

• Typical Inductive loads are A.C. Motors, Transformers and ballast –type
lightings. Inductive loads require two kinds of power : a) Active power
(kW) to perform the work and b) Reactive power ( KVAr) to create and
maintain electro-magnetic field.

• The vector sum of the active power and reactive power make up the total
(or apparent) power used which is measured in KVA
 • The active power (shaft power required) in KW and the reactive power required in (KVAr)
are 900 apart vectorially in a pure inductive circuit i.e. reactive power lagging active
power. The vector sum of two is called the apparent power KVA.

KW
Active Power
Cos ф
KVAR
Reactive Power
PF = KW / KVA KVA
= Cos ф Total Power

KW, KVAr and KVA Vector Diagram

• The ratio of KW to KVA is called the Power Factor which is always less than or equal to unity.
Theoretically, if the loads have unity power factor, maximum power can be transferred for
the same distribution system capacity.

• However, as the loads are inductive in nature, with the power factor ranging from 0.2 to 0.9,
the electrical distribution network is stressed for the capacity at low power factor.
 EXAMPLES
A Starch Industry had installed a 1500 KVA transformer. The initial demand of the plant was
1160 KVA with power factor of 0.70 . The % loading of transformer was about 78%
( 1160/1500 = 77.3 %) .

To improve the power factor and to avoid the penalty, the unit had added about 410 KVAr
capacitor in motor load end. This improves the PF to 0.89 and reduced the required KVA to
913 which is vector sum of KW and KVAr.
KW=812 KW=812
Cos ф =0.70 Cos ф =0.89
KVAR=
KVAR =828 828-410=418
KVA=1160 KVA=913

PF =812/1160 PF= 812/913

= 0.70 = 0.89

After improvement, the penalty will be avoided and the 1500 KVA transformer is
now
loaded only to 60% capacity. The transformer can now also be loaded more in the
future.
 ADVANTAGES OF PF IMPROVEMENT

• Reactive component of the network reduced and

so also the total current in the system from the
source end.

• I2 R losses of the system are reduced because of

reduction in current.

• Voltage level at the load end is increased.

• KVA loading on the source Generators,

transformers and lines up to capacitor reduces
giving capacity relief.

• A high power factor can help in utilizing the full

capacity of the electrical system
COST BENEFITS OF PF IMPROVEMENT
• Reduction in KVA demand ( Maximum
demand) charges in utility bill.

• Distribution losses (KWH) reduced within the

plant network.

• Better voltage at motor terminals and

improved performance of motors.

• A high power factor eliminates penalty

charges imposed when operating at low
power factor.

• Reduction in investment on kVA rating of

transformers , Cables, switchgear etc as its
delivering load reduces.
 SELECTION AND LOCATION OF CAPACITORS
KW / KVA = Cos ф1 Example: The utility bill shows an average power factor
of 0.72 with an average kw of 650 . How much KVAr is
KVAr / KVA = Sin ф1
required to improve the power factor to 0.95.
KVAr/ KW = Sin ф1 / Cos ф1
KVAr/ KW = Tan ф1 Cos ф1 = 0.72 , tan ф1 = 0.963
KVAr = KW X Tan ф1 Cos ф2 = 0.95 , tan ф2 = 0.329

KVAr required = KW ( tanф1 – tanф2)

= 650 ( 0.963 -0.329 ) = 412 KVAr
KVAr required to improve the power factor
from Cos ф1 to Cosф2 will be
KVAr = KW ( tan ф1 – tan ф2 )

• The primary purpose of capacitors is to reduce the maximum demand. Maximum benefits
of capacitors is derived by locating them as close as possible to the load.

• At this location , its KVAr are confined to the smallest possible segment, decreasing the
load current .This in turn will reduce power losses of the system substantially .

• Power losses are proportional to the square of the current . When power losses are
reduced, the voltage at the motor terminals increases ,thus motor performance also
increases.
OPERATIONAL PERFORMANCE OF CAPACITORS
• This can be made by monitoring capacitor charging current via the rated charging current.

• The capacity of fused elements can be replenished as charging current.

• The portable analyzer can be used for measuring KVAr delivered as well to charging current.

• Capacitors consume 0.2 to 6.0 watt per KVAr, which is negligible in comparison to benefits

Some basic checks for the Capacitors :

• Nameplates can be misleading with respect to rating . It is good
to check by charging current.

• Capacitor boxes may contain only insulated compound and

insulated terminals with no capacitor element inside.

• Capacitors for single phase motor starting and those used for
lighting circuit for voltage boost are not power factor capacitor
units and these cannot withstand power system conditions.
 POWER FACTOR CORRECTION OF MOTORS
• Induction motors are characterized by power factor less than unity i.e. lagging PF.
It leads to lower overall efficiency and higher overall operating cost.

• The capacitors are connected in parallel with motor to improve power factor.

• The impacts of PF correction include :

• reduced KVA demand (and hence reduced utility demand charges),

• reduced I2R losses in cables upstream of the capacitors (and hence reduced energy
charges),

• reduced voltage drop in the cables (leading to improved voltage Regulation).

• This increases the overall efficiency of the plant.

• The size of capacitors required for a particular motor should not exceed 90% of the
no load KVAr of the motor.
 CAPACITORS RATING FOR DIRECT
CONNECTION TO MOTORS
Capacitors Rating ( KVAr) for Motor Speed
Motor Rating ( HP)
3000 1500 1000 750 600 500
5 2 2 2 3 3 3
7.5 2 2 3 3 4 4
10 3 3 4 5 5 6
15 3 4 5 7 7 7
20 5 6 7 8 9 10
25 6 7 8 9 9 12
30 7 8 9 10 10 15
40 9 10 12 15 16 20
50 10 12 15 18 20 22
60 12 14 15 20 22 25
75 15 16 20 22 25 30
100 20 22 25 26 32 35
125 25 26 30 32 35 40
150 30 32 35 40 45 50
200 40 45 45 50 55 60
250 45 50 50 60 65 70