- Calculate Size of Capacitor Bank Annual Saving in Bills and Payback Period for Capacitor Bank.
- Electrical Load of (1) 2 No’s of 18.5KW,415V motor ,90% efficiency,0.82 Power Factor ,(2) 2 No’s of 7.5KW,415V motor ,90% efficiency,0.82 Power Factor,(3) 10KW ,415V Lighting Load. The Targeted Power Factor for System is 0.98.
- Electrical Load is connected 24 Hours, Electricity Charge is 100Rs/KVA and 10Rs/KW.
- Calculate size of Discharge Resistor for discharging of capacitor Bank. Discharge rate of Capacitor is 50v in less than 1 minute.
- Also Calculate reduction in KVAR rating of Capacitor if Capacitor Bank is operated at frequency of 40Hz instead of 50Hz and If Operating Voltage 400V instead of 415V.
- Capacitor is connected in star Connection, Capacitor voltage 415V, Capacitor Cost is 60Rs/Kvar. Annual Deprecation Cost of Capacitor is 12%.
Calculation:
- For Connection (1):
- Total Load KW for Connection(1) =Kw / Efficiency=(18.5×2) / 90%=41.1KW
- Total Load KVA (old) for Connection(1)= KW /Old Power Factor= 41.1 /0.82=50.1 KVA
- Total Load KVA (new) for Connection(1)= KW /New Power Factor= 41.1 /0.98= 41.9KVA
- Total Load KVAR= KWX([(√1-(old p.f)2) / old p.f]- [(√1-(New p.f)2) / New p.f])
- Total Load KVAR1=41.1x([(√1-(0.82)2) / 0.82]- [(√1-(0.98)2) / 0.98])
- Total Load KVAR1=20.35 KVAR
- OR
- tanǾ1=Arcos(0.82)=0.69
- tanǾ2=Arcos(0.98)=0.20
- Total Load KVAR1= KWX (tanǾ1- tanǾ2) =41.1(0.69-0.20)=20.35KVAR
- For Connection (2):
- Total Load KW for Connection(2) =Kw / Efficiency=(7.5×2) / 90%=16.66KW
- Total Load KVA (old) for Connection(1)= KW /Old Power Factor= 16.66 /0.83=20.08 KVA
- Total Load KVA (new) for Connection(1)= KW /New Power Factor= 16.66 /0.98= 17.01KVA
- Total Load KVAR2= KWX([(√1-(old p.f)2) / old p.f]- [(√1-(New p.f)2) / New p.f])
- Total Load KVAR2=20.35x([(√1-(0.83)2) / 0.83]- [(√1-(0.98)2) / 0.98])
- Total Load KVAR2=7.82 KVAR
- For Connection (3):
- Total Load KW for Connection(3) =Kw =10KW
- Total Load KVA (old) for Connection(1)= KW /Old Power Factor= 10/0.85=11.76 KVA
- Total Load KVA (new) for Connection(1)= KW /New Power Factor= 10 /0.98= 10.20KVA
- Total Load KVAR3= KWX([(√1-(old p.f)2) / old p.f]- [(√1-(New p.f)2) / New p.f])
- Total Load KVAR3=20.35x([(√1-(0.85)2) / 0.85]- [(√1-(0.98)2) / 0.98])
- Total Load KVAR1=4.17 KVAR
- Total KVAR=KVAR1+ KVAR2+KVAR3
- Total KVAR=20.35+7.82+4.17
- Total KVAR=32 Kvar
Size of Capacitor Bank:
- Site of Capacitor Bank=32 Kvar.
- Leading KVAR supplied by each Phase= Kvar/No of Phase
- Leading KVAR supplied by each Phase =32/3=10.8Kvar/Phase
- Capacitor Charging Current (Ic)= (Kvar/Phase x1000)/Volt
- Capacitor Charging Current (Ic)= (10.8×1000)/(415/√3)
- Capacitor Charging Current (Ic)=44.9Amp
- Capacitance of Capacitor = Capacitor Charging Current (Ic)/ Xc
- Xc=2 x 3.14 x f x v=2×3.14x50x(415/√3)=75362
- Capacitance of Capacitor=44.9/75362= 5.96µF
- Required 3 No’s of 10.8 Kvar Capacitors and
-
Total Size of Capacitor Bank is 32Kvar
Protection of Capacitor Bank
Size of HRC Fuse for Capacitor Bank Protection:
- Size of the fuse =165% to 200% of Capacitor Charging current.
- Size of the fuse=2×44.9Amp
- Size of the fuse=90Amp
Size of Circuit Breaker for Capacitor Protection:
- Size of the Circuit Breaker =135% to 150% of Capacitor Charging current.
- Size of the Circuit Breaker=1.5×44.9Amp
- Size of the Circuit Breaker=67Amp
- Thermal relay setting between 1.3 and 1.5of Capacitor Charging current.
- Thermal relay setting of C.B=1.5×44.9 Amp
- Thermal relay setting of C.B=67 Amp
- Magnetic relay setting between 5 and 10 of Capacitor Charging current.
- Magnetic relay setting of C.B=10×44.9Amp
- Magnetic relay setting of C.B=449Amp
Sizing of cables for capacitor Connection:
- Capacitors can withstand a permanent over current of 30% +tolerance of 10% on capacitor Current.
- Cables size for Capacitor Connection= 1.3 x1.1 x nominal capacitor Current
- Cables size for Capacitor Connection = 1.43 x nominal capacitor Current
- Cables size for Capacitor Connection=1.43×44.9Amp
- Cables size for Capacitor Connection=64 Amp
Maximum size of discharge Resistor for Capacitor:
- Capacitors will be discharge by discharging resistors.
- After the capacitor is disconnected from the source of supply, discharge resistors are required for discharging each unit within 3 min to 75 V or less from initial nominal peak voltage (according IEC-standard 60831).
- Discharge resistors have to be connected directly to the capacitors. There shall be no switch, fuse cut-out or any other isolating device between the capacitor unit and the discharge resistors.
- Max. Discharge resistance Value (Star Connection) = Ct / Cn x Log (Un x√2/ Dv).
- Max. Discharge resistance Value (Delta Connection)= Ct / 1/3xCn x Log (Un x√2/ Dv)
- Where Ct =Capacitor Discharge Time (sec)
- Cn=Capacitance Farad.
- Un = Line Voltage
- Dv=Capacitor Discharge voltage.
- Maximum Discharge resistance =60 / ((5.96/1000000)x log ( 415x√2 /50)
- Maximum Discharge resistance=4087 KΩ
Effect of Decreasing Voltage & Frequency on Rating of Capacitor:
- The kvar of capacitor will not be same if voltage applied to the capacitor and frequency changes
- Reduced in Kvar size of Capacitor when operating 50 Hz unit at 40 Hz
- Actual KVAR = Rated KVAR x(Operating Frequency / Rated Frequency)
- Actual KVAR = Rated KVAR x(40/50)
- Actual KVAR = 80% of Rated KVAR
- Hence 32 Kvar Capacitor works as 80%x32Kvar= 26.6Kvar
- Reduced in Kvar size of Capacitor when operating 415V unit at 400V
- Actual KVAR = Rated KVAR x(Operating voltage / Rated voltage)^2
- Actual KVAR = Rated KVAR x(400/415)^2
- Actual KVAR=93% of Rated KVAR
- Hence 32 Kvar Capacitor works as 93%x32Kvar= 23.0Kvar
Annual Saving and Pay Back Period
Before Power Factor Correction:
- Total electrical load KVA (old)= KVA1+KVA2+KVA3
- Total electrical load= 50.1+20.08+11.76
- Total electrical load=82 KVA
- Total electrical Load KW=kW1+KW2+KW3
- Total electrical Load KW=37+15+10
- Total electrical Load KW =62kw
- Load Current=KVA/V=80×1000/(415/1.732)
- Load Current=114.1 Amp
- KVA Demand Charge=KVA X Charge
- KVA Demand Charge=82x60Rs
- KVA Demand Charge=8198 Rs
- Annual Unit Consumption=KWx Daily usesx365
- Annual Unit Consumption=62x24x365 =543120 Kwh
- Annual charges =543120×10=5431200 Rs
- Total Annual Cost= 8198+5431200
-
Total Annual Cost before Power Factor Correction= 5439398 Rs
After Power Factor Correction:
- Total electrical load KVA (new)= KVA1+KVA2+KVA3
- Total electrical load= 41.95+17.01+10.20
- Total electrical load=69 KVA
- Total electrical Load KW=kW1+KW2+KW3
- Total electrical Load KW=37+15+10
- Total electrical Load KW =62kw
- Load Current=KVA/V=69×1000/(415/1.732)
- Load Current=96.2 Amp
- KVA Demand Charge=KVA X Charge
- KVA Demand Charge=69x60Rs =6916 Rs————-(1)
- Annual Unit Consumption=KWx Daily usesx365
- Annual Unit Consumption=62x24x365 =543120 Kwh
- Annual charges =543120×10=5431200 Rs—————–(2)
- Capital Cost of capacitor= Kvar x Capacitor cost/Kvar = 82 x 60= 4919 Rs—(3)
- Annual Interest and Deprecation Cost =4919 x 12%=590 Rs—–(4)
- Total Annual Cost= 6916+5431200+4919+590
-
Total Annual Cost After Power Factor Correction =5438706 Rs
Pay Back Period:
- Total Annual Cost before Power Factor Correction= 5439398 Rs
- Total Annual Cost After Power Factor Correction =5438706 Rs
- Annual Saving= 5439398-5438706 Rs
-
Annual Saving= 692 Rs
- Payback Period= Capital Cost of Capacitor / Annual Saving
- Payback Period= 4912 / 692
-
Payback Period = 7.1 Years
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