Technical Articles
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.
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.
| MOTOR (hp) | 3000 rpm | 1500 rpm | 1000 rpm | 750 rpm | 500 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 |
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.
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.
Abhinav L Purkar,
Manager Product Management & Marketing (PMM)Abhinav Purkar is a Product Management, Marketing, and Application Engineering professional with over 10 years of experience in the Power Quality domain. He has extensive expertise in power quality analysis, harmonic mitigation, reactive power compensation, energy efficiency, and electrical system optimization, helping customers improve system reliability and operational performance. With proven experience in product lifecycle management, market development, portfolio growth, and go-to-market strategy, Abhinav has successfully driven initiatives that enhance customer value and strengthen market presence. His strong technical foundation, combined with strategic business acumen, enables him to bridge the gap between customer requirements and innovative product offerings.
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