Power Factor correction in establishments with solar installations

Power Factor correction in establishments with solar installations
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Solar Power generation is growing very fast in INDIA and 40 GW capacity added just in last decade. The Indian government has also set a target of 175 GW generation capacity by 2022 & 450 GW generation capacity by 2030. There is continuous increase in Solar power generation by industries & households, in conjunction with power from Utility. This will reduce power consumption from Utility & consumers will get savings in electricity bill. Along with the benefit, there is a minor challenge in maintaining Power Factor in above establishments with solar plant. The same is explained in this article along with suitable solution.


The installation of solar panels in industries could have a negative impact on the overall power factor at the metering point. When solar inverter starts generating active power, there is equal reduction of active power that is drawn from the grid. Whereas the loads continues to draw reactive power from the grid at the same level, unlike the active power. In this scenario, there will be reduction in PF value. The same is explained below:

Solar Off & APFC Off

In Diagram 1 (with Solar OFF & APFC OFF), PF value is 0.86 (calculated as PF = kW / kVA = 1000 / 1166).


In Diagram 2 (with Solar ON & APFC OFF), PF value has reduced to 0.78 (calculated as PF = kW / kVA = 750 / 960)


In both the above cases – with or without solar generation the reactive power demand is constant (600 kVAr) for the active load (1000 kW). But still the calculated PF value drops (0.86 to 0.78) as soon as solar starts generating 250 kW and power drawn from utility reduces to 750 KW. This results in increased electricity bills, depending on type of billing – kWh or kVAh.


Generally, in industries to maintain PF, Automatic Power Factor Correction panels are installed with power capacitors that are controlled by APFC controllers. Traditional APFC controllers are capable of 2 quadrant operation only. This means the APFC controllers can understand power flow in these 2 scenarios –


1) Active power import from grid (+ve kW) & Reactive power import from grid (lagging PF)

2) Active power import from grid (+ve KW) & Reactive power export to grid (leading PF)


These controllers can operate satisfactorily in systems which does not have solar installations or with solar generation power less than total load demand.

Solar Generation Power

As explained in Diagram No.3 - for the load demand of 1000 KW, Solar panels are generating 500 kW (< load) while the rest of the power i.e, 500 KW is drawn from utility. The 2 Quadrant APFC controller functions normally and 600 kVAr reactive power will be contributed by the capacitors in APFC panel and nil reactive power from Utility (PF = 1).


But at times, solar generation could exceed the full load demand and then the power flow will be in either of below 2 scenarios, in addition to above mentioned power flow scenarios:

3) Active power export to grid (Solar ON & net –ve kW) & Reactive power import (lagging PF)

4) Active power export to grid (Solar ON & net –ve kW) – Reactive power export (leading PF)


In the above two scenarios, the active power value is depicted as negative since it is exported to grid. So traditional APFC controllers calculate instantaneous PF as negative value, and assumes it as leading PF. Thus the controller will not switch ON any capacitors during net-power export and loads will start drawing reactive power from grid. Hence there will be drop in average PF and increased electricity bill to consumer.

APFC Controllers Calculate

As explained in Diagram No. 4 – for the load demand of 1000 kW, Solar panels are generating 1500 kW (more than load requirement) and the surplus active power i.e., 500 kW is being exported to grid. Since the calculated PF here by 2 quadrant APFC controller is -ve value (PF = -500/781 = -0.64), it assumes as leading PF and switches off all capacitor banks. Eventually, the load starts drawing entire 600 kVAr reactive power from Utility. This results in drop of average PF at the tariff meter. The ‘-ve' sign in diagram depicts the active power export to grid from load.

Solution

To avoid this problem, customers should use APFC controllers that are capable of sensing actual “kVAr demand” by the load at any power flow scenario. In other words, APFC controller need to sense and operate in 4 quadrants as explained below -

APFC Controller
Excess Generation from Solar Panels

As explained in Diagram no. 5 – even though active power is being exported to grid (500 KW) due to excess generation from solar panels (1500 KW) than load demand (1000 KW), APFC controllers with feature of “4 Quadrant sensing” can maintain unity PF by switching on required capacitor banks (600 kVAr) and avoid drawing reactive power from grid. Hence at the tariff meter, the PF value can be maintained at the desired level, whether with or without excess solar power generation.


Even though modern solar inverters can be programmed to generate Reactive Power (kVAr) as well, it comes at the cost of Active Power output (kW). Maximum Apparent Power (kVA) generation of solar inverters are fixed and configuring Reactive Power output will reduce Active Power output from the inverter. Hence in order to maximise the ROI of Solar Power Plant, the best option is to configure only Active Power generation to the full capacity in solar inverters and use only APFC panels, with 4 Quadrant APFC controller, for accurate PF improvement. Renewable energy is need of the hour for sustainable future. At the same time, it is equally necessary to understand and take care of Power Quality.

About the Author

author

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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