Motor Power Factor Compensation

Motor Power Factor Compensation
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The various methods of power factor correction are direct compensation, group compensation and centralized compensation. Depending upon the size and the rate of change of loads in an industry, any one or combination of the above methods can be employed. Specifically, in case of agricultural pump-sets and some small scale industries with a few motor loads, the power factor correction can be done by connecting shunt capacitors directly to the motors. This method of compensation is called direct compensation. This is simple and ideal method for reactive power compensation, as this would result in rating optimization of all the upstream switchgear and cables, which reduces overall system losses. 


Direct motor compensation can be done in two methods and this article briefs the configuration and selection of the same. 

Method - 1

As shown in the figure, the capacitor is connected directly to the motor terminals, after the starter. The capacitors would start supplying reactive power, as soon as the motor is switched ON. This method of compensation can be used for motors with Direct on-line starters. Usually the kVAr rating for a particular motor is given by the respective motor manufacturers, as the kVAr ratings are motor specific. If the motor manufacturer's data are not available, the below given chart can be referred as a ready reckoner, where M kVAr can be selected for various motor ratings (in HP) and motor rpm:

Even though this is the effective method of power factor compensation, there is a limitation in sizing of the capacitors. That is, the maximum kVAr should be decided such that, the rated capacitor current is less than 90% of the motor's no-load current. If this condition is not met, self-excitation may occur, in which the motor acts as a generator. This happens when a motor has enough inertia to keep rotating even after disconnected from the power system and the capacitor is large enough to supply the reactive power needs of the motor. Self-excitation would result in high voltage available at the terminals of the motor and this can damage the contactor and the capacitor. As this method has the limitation in the sizing of maximum kVAr rating, it is not possible to achieve unity power factor.

The Capacitor
MOTOR (hp)3000 rpm1500 rpm1000 rpm750 rpm500 rpm
2.5 1 1 1.5 2 2.5
5 2 2 2.5 3.5 4
7.5 2.5 3 3.5 4.5 5.5
10 3 4 5.5 5 6.5
15 4 5 6 7.5 9
20 5 6 7 9 12
25 6 7 9 10.5 14.5
30 7 8 10 12 17
40 9 10 13 15 21
50 11 12.5 16 18 25
60 13 14.5 18 20 28
70 15 16.5 20 22 31
80 17 19 22 24 34
90 19 21 24 26 37
100 21 23 26 28 40
110 23 25 28 30 43
120 25 27 30 32 46
130 27 29 32 34 49
140 29 31 34 36 52
145 30 32 35 37 54
150 31 33 36 38 52
155 32 34 37 39 56
160 33 35 38 40 57
165 34 36 39 41 59
170 35 37 40 42 60
175 36 38 41 43 61
180 37 39 42 44 62
185 38 40 43 45 63
190 38 43 45 45 65
200 40 42 45 47 67
250 45 50 55 60 70

Method - 2

In this method, the capacitor is connected to the motor before the starter and it is switched through a separate capacitor-duty contactor. As the capacitors are disconnected as soon as the motor is switched off, self- excitation is avoided. Hence, there is no need of any limitations in capacitor sizing and unity power factor can be achieved by this method.


The capacitor size (in kVAr) can be calculated by the below formula:


kVAr = kW (tan Φ 1 - tan Φ 2)

Where Φ1 2 = cos-1 (Initial PF) & Φ2 = cos-1 (Target PF)

The limitations are the manual switching of the capacitors and the extra cost incurred for the contactors. Moreover, when the number of motors increase in future, managing all at a time would be difficult.

Capacitor

Motors with Star-Delta Starter:


Specifically for motor with star-delta starter, it is recommended to use method-2. If capacitors are directly connected to the terminals of the motor, the life of the capacitor drops drastically because of the voltage spikes that happen during every star to delta transition. So it will be safer to connect the capacitor before the star-delta starter, as shown in the above figure.

Points to remember:


  • The operating power factor varies with respect to the percentage loading of the motors. Hence with the varying load, the fixed capacitors would not be able to maintain the unity power factor continuously.
  • After switching off the capacitor, it is very important to maintain a minimum time delay of 30 to 60 seconds, for switching ON the capacitor again. Else, there are more chances of contactor damage because of charged capacitor.
  • If the motor is operated with any drives/converters, it is recommended to detune the capacitors by adding series reactors.
  • It is recommended to use capacitor duty contactors for minimizing the inrush current and hence to maximize the life of contactors and the capacitors

About the Author

author

Sourav Dasmodak,

Product Management & Marketing (Powergear - ACB)

Product Owner of Air Circuit Breaker (ACB) of Lauritz Knudsen for Domestic & International Market. I can talk to you about Electrical Products' Sales, Business Development, Market Expansion, Cracking Critical Strategic Account, handling Key Account & of course how to develop & motivate Channels along with the organizational growth. Having near about one and a half decade of experience across the country with major electrical manufacturers (Top 4).

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