Alternating Current Power Factor Monitoring and Correction Bryan Underwood Advisor: Prof. Gutschlag Power Factor is the ratio of the active power to the apparent power P.F. = Complex Power Diagram P S = VI * cos( ) VI Poor power factor is due to inductive loads such as induction motors in air conditioners and refrigerators A very low power factor usually results in the power company charging more on a utility bill Ameren Illinois requires Residential customers (rate DS-1) and Light Industrial Non-Residential customers (rate DS-2, DS-3) to maintain a power factor of 0.90 while Heavy Industrial Non-Residential customers (rate DS-4) must maintain a power factor of 0.951 If the power factor falls below the minimum specified by Ameren and ComEd, they require corrective devices to be installed Pacific Gas and Electric (PG&E) charges 0.6% more on a utility bill for each percentage point below a power factor of 0.852 About 60% of the electrical load in the United States is due to AC electric motors3 According to the U.S. Energy Information Administration (EIA), only about 25,000 out of 200,000 manufacturing companies participate in power factor correction (PFC)4 Increased I2R losses in transmission lines due to the additional current requirements needed to provide excess reactive power reduces efficiency, capacity, and profit margins Increased current requirements result in higher transmission line, transformer, and switch gear current ratings Usually done by capacitor banks ◦ Generate “negative” reactive power http://accessscience.com/content/Reactive-power/802370 Hampden Type WRM-100 3-Phase Motor 220 V 1.4 A 1725 RPM 1/3 HP Power Factor & Efficiency vs. Output Power (W) 0.9 Power Factor & Efficiency 0.8 0.7 0.6 0.5 Power Factor Efficiency 0.4 0.3 0.2 0.1 0 0 50 100 Output Power (W) 150 200 250 SATEC PM172E-N 3-Phase Programmable Power Meter SATEC Power Analysis Software V1.4 Build 5 Configure basic setup of meter, set trigger points, and view event logs and waveforms Larger meters have more relay inputs and outputs to permit more incremental values of capacitors to be switched as needed for more precise control of the power factor More programming options provide more robust control for better power factor correction news.thomasnet.com directindustry.com Potter & Brunfield KRPA-11AG-120 Power Relays Capacitance is added to each line and can be varied from 1.6uF to 50uF Resistors are placed in series with the capacitor banks to reduce inrush currents I 120[V ] 4.8[ A] 25[] 120 0 Current through resistor I 0.450395 84.6159 [ A] 266 .433 84.6159 with 10uF Capacitor Power losses Current w/ 20uF Power losses P I 2 R (0.450395)2 * 25 5.07139[W ] I 120 0 0.889119 79.3252 [ A] 134 .965 79.3252 P 19.7633[W ] Current w/ 30uF Power losses I 120 0 1.30597 74.2121 [ A] 91.8857 74.2121 P 42.639[W ] Relay coils are energized from SATEC meter when the power factor drops below a certain point ◦ Line current is also monitored to ensure no switching occurs when no load is present Capacitors are added to the circuit in parallel with the motor ◦ Placed in parallel to maintain the same line voltages into the motor Power factor can be varied over any desired range to avoid electric utility company charges Project system maintains a power factor of above 0.98 Experimental Results Source Power Factor vs. Motor Power Factor 1.3 -0.7 1.2 -0.8 10 uF Source Power Factor 1.1 -0.9 Meter 1 20 uF Meter 0.9 30 uF 0.8 Meter 0.7 40 uF Meter 0.6 0.5 0.3 0.45 0.6 Motor Power Factor 0.78 Complete the theoretical circuit model and compare with experimental results ◦ Research how the meter calculates its values Write tutorial on how to use power meter ◦ Will use as an appendix for final paper Write final paper 1 http://www.ameren.com/sites/aiu/Rates/Documents/AIel14rtds4.pdf http://www.ameren.com/sites/aiu/Rates/Documents/AIel48rdimf.pdf 2 http://www.pge.com/includes/docs/pdfs/mybusiness/customerservice/energystatus/powerquality/power%20factor--revised-8-907.pdf 3 http://www.pge.com/includes/docs/pdfs/mybusiness/customerservice/energystatus/powerquality/power%20fa ctor--revised-8-9-07.pdf 4 http://www.eia.gov/emeu/mecs/mecs2002/data02/excel/table8.1_02.xls Motor Load Apparent Power (VA) Power Factor Active Power (W) Motor Speed (RPM) No Load 345 0.312 107 1777 ¼ Load 354 0.435 156 1705 ½ Load 394 0.554 216 1683 ¾ Load 419 0.658 276 1677 Full Load 520 0.776 405 1585