Power Factor Corrector
Power Factor Corrector
ahead of time
PFC
Power factor correction systems
R
ahead of time
Founded in 1969, ORTEA SpA is a leading company in ORTEA is well established in the global market.
manufacturing and engineering voltage stabilisers and magnetic Thanks to strategically positioned offices and distributors and
components. efficient commercial relations, ORTEA’s products are installed
Over forty years in the business and ongoing technical research and working in a large number of countries.
have made of ORTEA a competitive and technologically
advanced company. Close co-operation between design,
production and marketing enables to meet the requirements of a
constantly growing number of customers.
In 1996 ORTEA joined ICAR Group, made of Italian and
European industrial units specialised in manufacturing
capacitors and power factor correction systems.
www.ortea.com
Power Factor Correction: why? A system working with low power factor shows the
In an electric circuit, the current is: following disadvantages:
– in phase with the voltage when the load is resistive (e.g., – High power loss in transmission/distribution energy
resistors) lines
– lagging when the load is inductive (e.g., motors, off- – High voltage drop
load transformers) – Oversized design of generating, transporting and
– leading when the load is capacitive (e.g., transforming plants
capacitors). Hence the importance of solving or at least reduce the
For example, the total current (I) absorbed by a motor is effects generated by low power factor. Capacitors are
given by the vector sum of: used for this purpose.
– IR, active current due to the load resistive component
– I L , reactive current due to the load inductive Power Factor Correction: how?
component. By installing a capacitor battery, it is possible to reduce the
reactive power absorbed by the inductive loads
connected thus increasing the power factor.
I There are several ways to perform the power factor
IL correction and the choice depends on daily load duty-
I = £ IR2 + IL2 cycle, load distribution and type of service.
The main choice is between distributed or centralized
IR power factor correction.
If the correction system is distributed, the units are located
The following powers are directly associated with the in the vicinity of each load for which the power factor
above currents: needs to be corrected.
– P, active power linked to the load resistive component If the correction system is centralized, a single automatic
– Q, reactive power linked to the load inductive capacitor bank is installed upstream all the loads and
component immediately downstream the point where the power
– A, apparent power. factor is measured (for example, inside the MV/LV
distribution transformer cabin on in the main distribution
The mean value of the reactive power in a wave period is nil. switchboard).
Therefore, the reactive power does not contribute towards Technically speaking, the distributed system is the solution
the generation of mechanical work and constitutes an to prefer: capacitors and load follow the same profile during
additional burden for the energy supplier, forcing it to daily service, which makes the power factor correction
oversize its generators and transmission/distribution lines. systematic and strongly linked to the affected load.
The parameter that defines the absorption of inductive Moreover, in case of distributed configuration, both the
reactive power is called power factor (φ) and is user and the Distributing Body benefit from the reactive
represented by the ratio between active and apparent power reduction. In industrial plants, for example, savings
power. are achieved in terms of tariffs but also in terms of better
design of all the electric lines in the facility connecting the
A A = £P2 + QL2 MV/LV cabin to the loads.
Q Another noticeable advantage prided by this type of
φ P correction, is that the installation is simple and not
cosφ =
A expensive. Power factor correction systems and loads are
P
energised and de-energised at the same time, thus
Assuming there are no harmonics in the system, the exploiting the same protections against overload and
power factor is equal to the cosine of the angle between short-circuit.
the voltage vector and the current vector (cosφ): The daily load duty-cycle is of critical importance when
choosing the most suitable power factor correction
I system. Very often, not all the loads work at the same time
IL and some are operative only for a few hours during the
φ day. In this case, it is clear that the distributed
configuration would be too expensive due to the high
IR V number of correction systems that would need to be
The power factor decreases when the reactive power installed and the idle time of several units.
increases. The distributed configuration is most efficient when the
3
majority of the required reactive power is concentrated on The formula is: QC = P x (tanφ1 - tanφ2 )
few high power loads working for many hours during the
day. A Q L QC
The centralized configuration, on the other hand, is
suitable for situations where there are many diverse loads
working sporadically. In this case, the bank power is
A’
much lower that the overall power that would be
φ1 QL’
necessary with a distributed configuration.
It is recommended to permanently connect the φ2
correction unit only if the daily reactive power absorption
is sufficiently regular, otherwise the unit must be handled P
in order to avoid the power factor to swap to a leading where:
value. QC = capacitive reactive power to be installed (kvar)
Should the reactive power absorption be very P = installed active power (kW)
changeable during the plant operating time, it is QL,QL’ = inductive reactive power before and after the
recommendable to choose an automatic correction installation of the capacitor bank
system splitting the bank into several steps. The manual A, A’= apparent power before and after the power factor
operation can be foreseen only when the correction unit correction.
needs to be operated only a few times during the day. Said formula can also be written as: QC = k x P
where k can be easily calculated with the table below.
Power Factor Correction: how much?
The choice of the capacitor bank power to install (QC) Example: assuming that the installed load absorbs an
depends directly on: active power equal to 300kW with a starting power factor
– desired cosφ2 value equal to 0,70 and that an increase to 0,95 is desired, the
– starting cosφ1 value coefficient k can be obtained from table 1: k = 0,692
– installed active power. QC is therefore equal to: QC = 0,692 x 300 = 207,6kvar
4
Initial Final power factor
power factor 0,90 0,91 0,92 0,93 0,94 0,95
0,40 1,807 1,836 1,865 1,896 1,928 1,963
0,41 1,740 1,769 1,799 1,829 1,862 1,896
0,42 1,676 1,705 1,735 1,766 1,798 1,832
0,43 1,615 1,644 1,674 1,704 1,737 1,771
0,44 1,557 1,585 1,615 1,646 1,678 1,712
0,45 1,500 1,529 1,559 1,589 1,622 1,656
0,46 1,446 1,475 1,504 1,535 1,567 1,602
0,47 1,394 1,422 1,452 1,483 1,515 1,549
0,48 1,343 1,372 1,402 1,432 1,465 1,499
0,49 1,295 1,323 1,353 1,384 1,416 1,450
0,50 1,248 1,276 1,306 1,337 1,369 1,403
0,51 1,202 1,231 1,261 1,291 1,324 1,358
0,52 1,158 1,187 1,217 1,247 1,280 1,314
0,53 1,116 1,144 1,174 1,205 1,237 1,271
0,54 1,074 1,103 1,133 1,163 1,196 1,230
0,55 1,034 1,063 1,092 1,123 1,156 1,190
0,56 0,995 1,024 1,053 1,084 1,116 1,151
0,57 0,957 0,986 1,015 1,046 1,079 1,113
0,58 0,920 0,949 0,979 1,009 1,042 1,076
0,59 0,884 0,913 0,942 0,973 1,006 1,040
0,60 0,849 0,878 0,907 0,938 0,970 1,005
0,61 0,815 0,843 0,873 0,904 0,936 0,970
0,62 0,781 0,810 0,839 0,870 0,903 0,937
0,63 0,748 0,777 0,807 0,837 0,870 0,904
0,64 0,716 0,745 0,775 0,805 0,838 0,872
0,65 0,685 0,714 0,743 0,774 0,806 0,840
0,66 0,654 0,683 0,712 0,743 0,775 0,810
0,67 0,624 0,652 0,682 0,713 0,745 0,779
0,68 0,594 0,623 0,652 0,683 0,715 0,750
0,69 0,565 0,593 0,623 0,654 0,686 0,720
0,70 0,536 0,565 0,594 0,625 0,657 0,692
0,71 0,508 0,536 0,566 0,597 0,629 0,663
0,72 0,480 0,508 0,538 0,569 0,601 0,635
0,73 0,452 0,481 0,510 0,541 0,573 0,608
0,74 0,425 0,453 0,483 0,514 0,546 0,580
0,75 0,398 0,426 0,456 0,487 0,519 0,553
0,76 0,371 0,400 0,429 0,460 0,492 0,526
0,77 0,344 0,373 0,403 0,433 0,466 0,500
0,78 0,318 0,347 0,376 0,407 0,439 0,474
0,79 0,292 0,320 0,350 0,381 0,413 0,447
0,80 0,266 0,294 0,324 0,355 0,387 0,421
0,81 0,240 0,268 0,298 0,329 0,361 0,395
0,82 0,214 0,242 0,272 0,303 0,335 0,369
0,83 0,188 0,216 0,246 0,277 0,309 0,343
0,84 0,162 0,190 0,220 0,251 0,283 0,317
0,85 0,135 0,164 0,194 0,225 0,257 0,291
0,86 0,109 0,138 0,167 0,198 0,230 0,265
0,87 0,082 0,111 0,141 0,172 0,204 0,238
0,88 0,055 0,084 0,114 0,145 0,177 0,211
0,89 0,028 0,057 0,086 0,117 0,149 0,184
5
Power Factor Correction: harmonics in electric lines
Current distortion (i.e., harmonics) is generated by non- The waveform of the current generated by a non-linear
linear loads such as inverter, arc-welding machines, load is still periodic and can be represented as the sum of
saturated transformers, rectifiers, and so on. several sinusoidal waves at different frequency (one
Their connection to the mains causes several problems in wave at 50Hz called fundamental and the others at
an electric system: f re q u e n c y m u l t i p l e o f t h e f u n d a m e n t a l c a l l e d
harmonics).
– Rotating machinery: generation of eddy torques (and It is generally not recommended to correct the power
consequent vibrations) that undermine the mechanical factor in a system with high harmonic content without
structure. The loss increase causes undesired any device dealing with the harmonics.Even though
overheating and isolation damage. capacitors able to withstand high overloading could be
provided, power factor correction performed only via
– Transformers: increase of core and winding losses, with capacitors actually increases the harmonic disturbance
potential winding damage. The potential presence of and the related negative effects.
DC voltage or current components may saturate the The best solution for this type of issue is the detuned filter
magnetic core, thus increasing the magnetizing obtained by connecting reactances in series to the
current. capacitors. The reactances shift the system resonance
frequency below the lowest existing harmonic thus
– Capacitors: overheating and voltage increase, both protecting the capacitors and avoiding dangerous
causing a reduction of the expected life. resonance phenomena.
6
Power Factor Correction Power Factor Correction:
with distorted current conclusions
In many industrial or tertiary electrical plants, the presence In a plant with power factor lower than 0.9, the payback of
of non-linear loads (inverters, welding machines, lamps, the installation costs will be most likely achieved within a
PCs, drives, etc.) causes a distortion in the current, few months.
numerically represented by the parameter THDI%. If the Beyond the reduction/elimination of potential penalties
current is sinusoidal, then THDI% is nul. The more the from the energy bills, the technical and economical
current is distorted, the higher the THDI%. benefits deriving from the installation of a power factor
In systems with highly distorted current, the power factor correction system are listed below:
correction units are provided with blocking (or detuning) – decrease of the losses in lines and transformers due to
filters. The reactances stop the current harmonics from the lower absorbed current
reaching and damaging the capacitors. – decrease of line voltage drop
– optimization of the plant sizing.
7
Used capacitors Reactive power regulators
Inside ORTEA power factor correction systems there are The reactive power regulator is, together with the
only three-phase polypropylene metalized high gradient capacitors and reactors (in detuned filter cabinets), the key
capacitors. component of the automatic power factor correction
T h e s u b s t a n t i a l d i ff e re n c e w i t h t h e s t a n d a rd system.
polypropylene capacitors is the mode with which the It is in fact the «intelligent» element, responsible for the
dielectric film is metallized: if in the standard capacitors the verification of the power factor of the load, in function of
metal layer thickness deposited on the surface of the film which controls the switching on and off of the capacitors
is constant, for those «high gradient» the metal layer has a batteries in order to maintain the power factor of the
suitably modulated thickness. system beyond the target.
The metallization thickness modulation allows to greatly The reactive power regulators RPC used in automatic
improve the capacitors (and therefore of the power factor ORTEA power factor correction systems are designed to
correction systems which are the fundamental provide the desired power factor while minimizing the
component) in terms of: wearing on the banks of capacitors, accurate and reliable
in measuring and control functions are simple and intuitive
– Increase in power density (kvar/dm3) with a in installation and consultation.
consequent power size reduction of the power factor The flexibility of ORTEA regulators allows you to modify all
correction systems; the parameters to customize its operation to fit the actual
characteristics of the system to be corrected (threshold
– Robustness improvement against voltage surges, for g power factor, sensitivity of step switching, reconnecting
eater reliability even in systems with the presence of time of the steps, presence of photovoltaics, etc.).
voltage fluctuations due to the network or maneuvers As described below, the ORTEA regulators offer important
on the system; features as for the maintenance and management of the
power factor correction bank, aimed at identifying and
– Improved behavior of the internal short circuit solving problems, which could lead to its damage with
withstand. consequent life expectancy reduction.
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PFC103
Automatic power factor correction systems
Main characteristics
Power factor correction systems indicated for the plants
where the current harmonic distorsion, without capacitors
installed has values lower than 12%.
Use of high energy density metallized polypropylene
capacitors assures elevated performances, high
resistance to strong voltage overload, low losses and
small dimensions.
Generalities
– Zinc-passivated metallic enclosure painted with
epossidic dust paint, colour RAL 7035.
– Auxiliary transformer to separate power and auxiliary
circuit parts.
– Load-break switch with door interlock.
– Contactors with damping resistors to limit capacitors’
inrush current.
– Self-extinguish cable according to IEC 50267-2-1
standards.
– Microprocessor power factor correction relay.
– Three phase self-healing high energy density metallized
polypropylene capacitors with rated voltage:
Un = 415V.
9
PFC103
Automatic power factor correction systems
Type Power Steps Steps Load-break Icc Regulators Fan IP20 Cabinet Weight
size switch WxDxH (type)
[kvar] [no.] [kvar] [A] [kA] [no.] [mm] [Kg]
H
H
H
H
W D W D W D W D
Technical characteristics
Rated operational voltage Ue = 415V
Rated frequency 50Hz
Max current overload In (tray) 1.3xIn
Max current overload In (capacitors) 1.3xIn (cont.)/2xIn (380s)/3xIn (150s)/4xIn (70s)/5xIn (45s)
Max voltage overload Vn (tray) 1.1xVn
Max voltage overload Vn (capacitors) 3xVn
Insulating voltage 690V
Temperature range (tray) -5/+40°C
Temperature range (capacitors) -25/+55°C
Discharge device On each bank
Use Indoor
Service Continuous
Capacitors connection Delta
Operation devices Contactors
Total losses ca. 2W/kvar
Inner surface finish Zinc passivation
Applicable standards (tray) IEC 61439-1/2 IEC61921
Applicable standards (capacitors) IEC 60831-1/2
10
PFC503
Automatic power factor correction systems
Main characteristics
Power factor correction systems indicated for the plants
where the current harmonic distorsion, without capacitors
installed has values lower than 27%.
Use of high energy density metallized polypropylene
capacitors assures elevated performances, high
resistance to strong voltage overload, low losses and
small dimensions.
Generalities
– Zinc-passivated metallic enclosure painted with
epossidic dust paint, colour RAL 7035.
– Auxiliary transformer to separate power and auxiliary
circuit parts.
– Load-break switch with door interlock.
– Contactors with damping resistors to limit capacitors’
inrush current.
– Self-extinguish cable according to IEC 50267-2-1
standards.
– Microprocessor power factor correction relay.
– Three phase self-healing high energy density metallized
polypropylene capacitors with rated voltage:
Un = 525V.
11
PFC503
Automatic power factor correction systems
Tipo Power Steps Steps Load-break Icc Regulators Fan IP20 Cabinet Weight
size switch WxDxH (type)
[kvar] [no.] [kvar] [A] [kA] [no.] [mm] [Kg]
H
H
H
W D W D W D
Technical characteristics
Rated operational voltage Ue = 415V
Rated frequency 50Hz
Max current overload In (tray) 1.3xIn
Max current overload In (capacitors) 1.3xIn (cont.)/2xIn (380s)/3xIn (150s)/4xIn (70s)/5xIn (45s)
Max voltage overload Vn (tray) 1.1xVn
Max voltage overload Vn (capacitors) 3xVn
Insulating voltage 690V
Temperature range (tray) -5/+40°C
Temperature range (capacitors) -25/+55°C
Discharge device On each bank
Use Indoor
Service Continuous
Capacitors connection Delta
Operation devices Contactors
Total losses ca. 2W/kvar
Inner surface finish Zinc passivation
Applicable standards (tray) IEC 61439-1/2 IEC61921
Applicable standards (capacitors) IEC 60831-1/2
12
PHF203
Automatic power factor correction systems with detuning choke
Main characteristics
Power factor correction systems indicated for the plants
where the current harmonic distorsion, without capacitors
installed has values higher than 27%.
Use of high energy density metallized polypropylene
capacitors assures elevated performances, high
resistance to strong voltage overload, low losses and
small dimensions.
Generalities
– Zinc-passivated metallic enclosure painted with
epossidic dust paint, colour RAL 7035.
– Auxiliary transformer to separate power and auxiliary
circuit parts.
– Load-break switch with door interlock.
– Contactors with damping resistors to limit capacitors’
inrush current.
– Self-extinguish cable according to IEC 50267-2-1
standards.
– Microprocessor power factor correction relay.
– Three phase self-healing high energy density metallized
polypropylene capacitors with rated voltage:
Un = 525V.
– Three-phase detuning chokes with tuning
frequency 180Hz.
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PHF203
Automatic power factor correction systems with detuning choke
Type
Type Power Steps
Steps Steps
Steps Banks
Banks Load-break
Load-break IccIccRegulators
Regulators FanFan IP20
IP20Cabinet
Cabinet Weight
Weight
size
size switch
switch DxWxH
DxWxH(type)
(type)
[kvar] [no.]
[no.] [kvar]
[kvar] [kvar]
[kvar] [A]
[A] [kA]
[kA] [no.]
[no.] [mm]
[mm] [Kg]
[Kg]
PHF203-100
PHF203-100 100 88 2x12.5-25-50 25-2x50
2x12.5-25-50 25-2x50 250
250 17 17 RPCRPC
8BGA
8BGA 3 3 600x700x1700
600x700x1700(32)
(32) 200
200
PHF203-150
PHF203-150 150 12
12 2x12.5-25-2x50 25-50-75
2x12.5-25-2x50 25-50-75 400
400 25 25 RPCRPC
8BGA
8BGA 2 2 800x700x1700
800x700x1700(33)
(33) 240
240
PHF203-200
PHF203-200 200 88 2x25-3x50
2x25-3x50 50-2x75
50-2x75 630
630 25 25 RPCRPC
8BGA
8BGA 2 2 800x700x1700
800x700x1700(33)
(33) 300
300
PHF203-250
PHF203-250 250 10
10 2x25-4x50
2x25-4x50 50-2x100
50-2x100 630
630 25 25 RPCRPC
8BGA
8BGA 2 2 800x700x1700
800x700x1700(33)
(33) 430
430
PHF203-300
PHF203-300 300 66 6x50
6x50 3x100
3x100 800
800 35 35 RPCRPC
8BGA
8BGA 2 2 800x700x1700
800x700x1700(33)
(33) 500
500
PHF203-400 400 8 2x50-3x100 100-2x150 2x630 25 RPC 8BGA 2+2 2x(800x700x1700)(2x33) 600
PHF203-500 500 10 2x50-4x100 100-2x200 2x630 25 RPC 8BGA 2+2 2x(800x700x1700)(2x33) 860
PHF203-600 600 6 6x100 3x200 2x800 35 RPC 8BGA 2+2 2x(800x700x1700)(2x33) 1000
PHF203-750 750 10 2x75-4x150 150-2x300 3x630 25 RPC 8BGA 2+2+2 3x(800x700x1700)(3x33) 1290
PHF203-900 900 6 6x150 3x300 3x800 35 RPC 8BGA 2+2+2 3x(800x700x1700)(3x33) 1500
PHF203-1000 1000 10 2x100-4x200 200-2x400 4x630 25 RPC 8BGA 2+2+2+2 4x(800x700x1700)(4x33) 1720
For higher powers, two or more PHF units of the same size can be connected in parallel, using the characteristic of the regulator to act as «master/slave».
Type 32 Type 33
H
H
W D W D
Technical characteristics
Rated operational voltage Ue = 415V
Rated frequency 50Hz
Max current overload In (tray) 1.3xIn
Max current overload In (capacitors) 1.3xIn (cont.)/2xIn (380s)/3xIn (150s)/4xIn (70s)/5xIn (45s)
Max voltage overload Vn (tray) 1.1xVn
Max voltage overload Vn (capacitors) 3xVn
Insulating voltage 690V
Temperature range (tray) -5/+40°C
Temperature range (capacitors) -25/+55°C
Discharge device On each bank
Use Indoor
Service Continuous
Capacitors connection Delta
Operation devices Contactors
Total losses ca. 6W/kvar
Inner surface finish Zinc passivation
Applicable standards (tray) IEC 61439-1/2 IEC61921
Applicable standards (capacitors) IEC 60831-1/2
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The belief that product quality and Customer satisfaction are the APPROVED MANAGING SYSTEM
core of a modern organisation, led to the implementation of an
ISO9001:2008 certified Company Managing System.
The achievement of the ISO14001:2004 and
OHSAS18001:2007 accreditation was a natural integration in
order to optimise the Company's performance, showing at the
same time the commitment towards environmental and safety at
work issues.
ISO9001 ISO14001 OHSAS18001
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