Design of Power Capacitors For Power Factor Improvement in A Power Distribution System
Design of Power Capacitors For Power Factor Improvement in A Power Distribution System
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Executive Summary
In the power distribution industry today, utility companies are trying to come up with a
solution to increase the efficiency of distributed power. One way of achieving this task is by
improving the power factor of a system by adding power factor correction capacitors. Power
factor improvement is a very important aspect of power distribution. Without a good power
factor, there cannot be an efficient means of transporting energy over long distances due to
the losses associated with moving power through a wire. This action has led to multiple
studies on power factor correction. In order to achieve maximum efficiency, we had to
increase our power factor as close to unity as possible. We accomplished this controlled boost
of power factor by installing the proper number of specifically designed high voltage power
capacitors at the substation.
In designing our capacitors, there were certain design constraints that had to be met and
overcome. Our capacitors were designed according to established IEEE standard 18-1992. In
addition, our capacitor bank was built around an average load on a typical substation. This
typical substation is rated at 15kV and during the peak hours of the day, its load of 3MW
draws a total of 2MVAR of reactive power. Using these typical specifications, a bank of forty
(40) capacitors was designed with each capacitor contributing 50kVAR of reactive power.
These forty (40) capacitors were also economically feasible. Another constraint that had to be
overcome was the capacitors' exposure to environmental conditions. Our capacitors are able
to withstand a corrosive environment and a wide variety of weather conditions such as
extreme temperatures and lightning. Upon meeting all of the design constraints, our capacitors
have long lifetime expectancy.
Due to the fact that using capacitors to correct a power factor has been around for many years,
we are not the first to design and build a high voltage power capacitor. However, the
innovativeness of our project comes into play when one considers the careful insulation
process and materials used to extend the capacitors’ life and efficiency.
The future of capacitor design to correct power factor will be based on finding new materials
that provide better insulation between the foil sheets. Today, researchers are trying to employ
new high- tech polymer as the dielectric in capacitors. This will allow for higher voltages and
smaller physical dimensions of the capacitor to be attained.
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Table of Content
Abstract.....................................................................................................................1
1. Introduction..............................................................................................................1
2. Problem.....................................................................................................................2
3. Objectives..................................................................................................................3
3.1 Reduce Voltage Drop and Energy Loss ....................................................3
3.2 Total Reactive Power of 2MVAR With A
Corrected Power Factor of At Least 90% .................................................4
3.3 Increase System Capacity..........................................................................4
4. Approach...................................................................................................................5
4.1 Reduce Voltage Drop ................................................................................6
4.2 Reduce Energy Loss ..................................................................................6
4.3 A Total Reactive Power of 2MVAR.........................................................6
4.4 Corrected Power Factor of At least 90%...................................................9
4.5 Discharge To 50V In Less Than 5 Minutes ..............................................9
5. Test Specification .....................................................................................................12
5.1 Capacitance Test .......................................................................................12
5.2 AC Withstand Test....................................................................................12
5.3 DC Withstand Test....................................................................................12
5.4 Discharge Test ...........................................................................................12
5.5 Impulse Test ..............................................................................................12
5.6 Loss Factor Test ........................................................................................13
6. Test Certification......................................................................................................13
6.1 Simulation Test Results ......................................................................................13
6.2 Actual Test Results .............................................................................................14
6.2.1 Capacitance Test .......................................................................................14
6.2.2 AC Withstand Test....................................................................................14
6.2.3 DC Withstand Test....................................................................................14
6.2.4 Discharge Test ...........................................................................................15
6.2.5 Impulse Test ..............................................................................................15
6.2.6 Loss Factor Test ........................................................................................15
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7. Summary...................................................................................................................15
8. Future Work .............................................................................................................15
9. Acknowledgement ....................................................................................................15
10. Reference...................................................................................................................16
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Abstract
In today’s booming power market, there are tremendous opportunities for companies that can cut
cost by boosting the efficiency of their power system. This project will exploit this “gold token”
by designing a power capacitor bank to maximize a distribution system’s performance. It will
illustrate how adding capacitors to a system improves the system’s efficiency and conserves
energy. In addition, this project will explain how a capacitor is designed, manufactured, and
tested to help predict the life and long-term performance of capacitors.
1. Introduction
Since the beginning of man’s modernization, electrical energy has been used due to the ease of
transmitting electrical energy and converting it to other forms of energy. Over the course of
history, many techniques have been incorporated to make a power distribution system more
efficient. Historically, power systems were over designed with more capacity than needed at the
time. This action allows for overall growth and expansion of a supplied area. For example, if the
load of a city “several years ago” was figured to be 5MW, then a transmission and distribution
system would be installed with a capacity of 10MW or 15MW in order to allow for possible
growth; however, this is not the case today. Due to expense reductions in the current competitive
power market, utility companies are not spending as much money to increase the capacity of the
power transmission and distribution system. With a low operating cost being the key motivator,
many companies are searching for techniques to improve their system capacity without actually
adding bigger, more expensive power lines, transformers, and generators. The answer to their
search is to maximize the efficiency of their current power system. This idea can be
accomplished by installing high voltage capacitors in order to correct their system power factor.
The technology of designing power capacitors for power factor improvement has existed for
more than a century. It had changed very little up until about 25 years ago. The main
advancements that have been made have to do with new dielectrics and insulation materials.
These new materials, allow for greater electrical strength and an overall decrease in the bulky
size of a capacitor. Nonetheless, the purpose of building and installing power capacitors remains
the same, which is to conserve energy and save money.
Power factor is defined as the cosine of the phase displacement angle by which the total current
leads or lags the circuit voltage (Bhouraskar S.N). To improve power factor, the lag between the
total current and total voltage should be as close to zero as possible. In a purely capacitive
circuit, current leads the voltage by 90 degrees, and in a pure inductive circuit, current lags the
voltage by 90 degrees. With these small bits of knowledge, one can deduct that a capacitor is a
good reactive power generator. Therefore, placing a specifically designed capacitor in an
inductive circuit helps to reduce the lag between the current and voltage thus keeping the
“money burning” reactive current off the transmission lines.
Since the current in the system is reduced, more loads can be added to the substation, which
allows for a more cost-effective way to add capacity to a power system rather than constructing
another more expensive transmission and distribution circuit. An additional benefit of adding
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power capacitors is the fact that they raise the voltage level at the substation where they are
installed. Overall, this will help to strengthen the power system and provide better power quality
across the entire network.
2. Problem
Since the beginning of power production, there has been concern about the efficiency of power
transmission and distribution. There are two main issues that drive this concern. The first
concern is economics while the second is power quality. If one can deliver power at a more
efficient rate than his rival, then he will be chosen as the major power supplier simply because he
can offer power at a less expensive price than his rival.
In order to offer power at a premium price, one has to minimize his losses associated with
sending energy through a wire. To minimize the losses incurred when transmitting power, the
overall power system must be made more efficient by minimizing the voltage drop between the
generator and the substation, and decreasing the current present on the power lines. The way to
accomplish this task is by addressing what is known as power factor correction. The power factor
of a system is the ratio of the real power (generated by the "power-producing-current") to the
apparent power (total current present). It expresses how efficiently the AC electrical power is
transmitted and overall used. Inefficiency in a power system translates to wasted power, and as
with any type of business, a utility company certainly does not like to waste its product.
In an energy system, the majority of electrical loads are inductive loads such as induction
motors. These types of loads produce electromagnetic fields in order to operate. Inductive loads
draw two kinds of power from the utility system: real and reactive. The real or active power is
the power that actually performs the work of creating motion, light, or heat while reactive power
produces the electromagnetic fields necessary for the operation of induction motors. The real
power is measured in kilowatts (kW) and the reactive power is measured in kilovolt-ampere-
reactive (kVAR). These two types of power are combined to make up apparent power, which is
the product of the voltage and current magnitudes; hence, it is measured in kilovolt-amperes
(kVA).
If the reactive power needed by a load increases while the real power needed stays the same,
there will be more current drawn through the wires. This increase in current will in turn increase
the voltage drop and power loss in the transmission line. Generally speaking, real power
generates money while reactive power on a distribution system costs money.
In order to produce the reactive power that is required by the inductive loads, power factor
correcting devices known as power capacitors will be designed to function as small reactive
power generators at the substation. A single capacitor alone cannot produce the large amounts of
reactive power required by an energy system; nonetheless, a bank of capacitors can be operated
collectively to supply a relatively endless amount of reactive power. Upon producing this
reactive power, there will be less current present on the overall utility system. This reduction of
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current leads to an increased voltage at the substation; hence, the voltage drop has been
minimized.
Upon correcting the power factor, there can be an efficient means of transporting energy through
the power lines. With this increase in efficiency, a company can realize greater profits and in the
end, provide a better quality product at a less expensive rate than previously. In other words, the
company’s good fortune can be turned into the consumer’s good fortune.
3. Objectives
1. We will reduce voltage drop in transmission lines going to the substation which will in
turn increase the substation voltage by 5% (around 750 volts).
2. We will reduce the current in power lines by 15% in order to reduce the energy lost in
power lines by 30%.
3. We will provide a total of 2MVAR reactive power to the substation for necessary
power factor correction.
7. Our capacitor will be enclosed in a stainless steel container with two porcelain
bushings so it can withstand harsh environmental elements.
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energy loss has been reduced. Once this energy loss has been reduced, the cost of
transmitting power becomes less expensive since there is a more efficient operating power
system.
3.2. Total Reactive Power of 2MVAR With A Corre cted Power Factor of At Least 90%
In order to correct the power factor from 0.7 to 0.9 or higher on our typical substation,
2MVAR of reactive power is needed. To achieve this large amount, many capacitors will
be operated collectively to form a bank of capacitors. In an average daily usage of a
substation, the 2MVAR of capable reactive power will not be fully utilized all of the time
since the loads present on the system will vary throughout the day. For this reason, the
capacitor bank will be divided into 8 sections with one control switch each section. A
section may be energized only a fraction of time depending on the overall power factor
rating of the system at that time. In order to accomplish this subsection design, there will be
a total of 40 capacitors in the bank supplying 50kVAR each. Therefore, 5 capacitors with
250kVAR will operate on each control switch; hence, requiring eight control switches. If
the power factor is lower than 0.9 on our system, a proper amount of switches will be closed
(introducing 250kVAR into the system from each section energized) until the power factor
is 0.9 or higher. Nonetheless, if the power factor looks as if it might pass 1.0, a proper
amount of switches can be opened to maintain the power factor around 0.95 or slightly
below. With this type of system, the power factor can be "fine-tuned" with the capacitor
bank to produce optimum results throughout the day.
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increase the system capacity by 20%, and although there are other factors that determine the
amount of customers that a generation plant can serve, we will drastically improve the
amount of load that a generation plant can supply power too.
4. Approach
Low power factor arises from an inductive load that draws a large amount of reactive power to
produce the magnetic field that it needs to operate. The reactive power needed by the load can be
drawn from the generator but this causes large losses to be incurred on the transmission and
distribution system. To reduce these losses and raise the power factor of the system, reactive
power needs to be injected into the power system fairly close to the load. There are several ways
to generate reactive power in a power system.
A very economical reactive power generator is a passive capacitor bank. When a capacitor is
energized, the voltage across the terminals cannot change instantaneously. When an AC voltage
is placed on the capacitor, the current waveform will be a sine wave like the source voltage but
its phase will be 90 degrees ahead of the voltage waveform. This leading current, when injected
into the power system by the capacitor bank, will offset the lagging current of the inductive load.
The capacitor is charged and discharged two times during the AC voltage cycle. An inductor is
also charged and discharged during the same cycle. The phase shifts between the current and
voltage in inductors and capacitors show that the inductor is charging at the same time that the
capacitor is discharging and vice versa. This relationship shows how the capacitors supply the
reactive power that the inductive circuits need for magnetic fields.
A simple capacitor is built by separating two conducting plates with an insulating material. The
following equation shows that capacitance is a function of the area of the plates, the distance
between the plates, and the permittivity of the insulating material between.
ε oε r S
C= S = surface area
d
d = distance between plates
Power capacitors are constructed by winding aluminum foil and a dielectric material (paper or
plastic) into circular coils. These coils are then connected in series and parallel combination and
stacked together in an insulated container. When designing a capacitor, the number of coils, the
length and the width of the foil, and the thickness of the insulating dielectric material needs to be
determined. Once the size and the number of coils are determined, the size of the required
capacitor container can be calculated. For our design, we will use polypropylene as the insulating
material and aluminum foil as the conductor.
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4.1. Reduce Voltage Drop
Voltage drop across a transmission line is caused by the increasing amount of current that is
drawn by the loads. This means there is a high consumption of reactive power by the loads
especially big motors or generators. When one of these monsters starts, there will be a
significant voltage drop across the transmission line as more and more current is needed. In
order to solve the problem of voltage drop, capacitors are used. Capacitors have been known
to store energy and this energy is reactive. This is a perfect solution because reactive power
can now be supplied to big motors and generators and this eventually decrease the demand
of reactive power from the distribution center or substation. When the problem is being
solved, energy can now be used in the most optimum level due to the addition of capacitors
in the system. These capacitors will be activated once there is a need for reactive power. The
effect can be shown below:
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Therefore, each capacitor in the bank will be rated for 50kVAR. The capacitor bank will be
connected to a 15kV substation. The following formula is used to find the capacitance of
each capacitor in the bank form the rated power and the substation voltage.
Q
C= Q = power of the capacitor
V
2πf ( LL ) 2 f = system frequency (60Hz)
3 VLL = substation line-to-line voltage
Once the capacitance is known, the size of the foil and dielectric needed to construct the
capacitor can be determined. The thickness of the dielectric, polypropylene, was determined
by taking into account the maximum voltage stress that the paper could withstand. The
maximum voltage stress of the polypropylene is 2000kV/cm. The line to neutral voltage in
the substation is a factor of √3 lower than the line-to- line voltage. This voltage of 8.66kV is
the voltage that will be placed across each capacitor in our bank. If the thickness of the
paper dielectric in the capacitor is chosen to be 0.02mm and the capacitor will have 6 coils
in series then the voltage stress across each coil will be given by the following equation.
8.66
= 6
0 .2
kV
= 722
cm
The voltage stress of each coil is conservatively designed to be lower than the breakdown or
maximum stress of the insulating dielectric, in our case, polypropylene. This conservatism is
needed so that transients and other short-term increases in voltage will not cause the voltage
across each coil to exceed the breakdown voltage stress.
When coils are placed in series in the capacitor, the capacitance of each coil will be higher than
the total capacitance by a factor of the number of series coils.
Coils in series
Ccoil = 6(Cap)
= 6(1.901)
= 11.4µF
To reduce the capacitance of the coils in series, more coils can be placed in parallel with the
series coils. The parallel coils will be reduced in capacitance by a factor of the number of coils
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that are placed in parallel. In our design, we will use two (2) coils in parallel to reduce the
capacitance of each series value.
Coils in parallel
Coil Series
Ccoil =
2
11.4 µF
=
2
= 5.7 µF
Based on these calculations, our 50kVAR capacitor will have 12 coils inside it. There will be two
(2) coils in parallel and six (6) coils in series. Each coil will have a capacitance value of 5.7µF.
The following diagram shows how the coils will be connected inside the capacitor.
To find the amount of foil and dielectric required for each coil, the equation that relates
capacitance to area and separation distance is used. The formula for area of foil and dielectric is
determined to be:
The permitivity of the polypropylene was found to be 2.2. By applying this value to the formula,
the area is found to be 5.884m2 . For our capacitor, the area of foil and dielectric that is needed is
2.942m2 . We will use 5” (12.7cm) wide dielectric and the length needed will be 23.165m per
coil. The following diagram shows how the coils will be wound.
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4.4. Corrected Power Factor of At Least 90%
The current acceptable level of power factor is 90% or above. Power factor is nothing but
the ratio between real power and apparent power. As known, capacitors supply reactive
power. In other words, the supply of reactive power no longer has to be provided by the
distribution center or substation. Instead, the capacitors take over this job.
When this happens, reactive power supplied by the substation will go down; thus decreasing
the apparent power and increasing the power factor as shown in the following equation:
real power
Power Factor =
apparent power
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Figure 4. Whole 2MVAR Capacitor Bank Layout
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Figure 5. Partial Layout Of 2MVAR Capacitor Bank With Dimension Calculation
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5. Test Specification
In order to properly test the capacitor, there were six tests that were performed. The tests
included a capacitance test, a DC withstand test, an AC withstand test, a discharge test, a
lightning impulse test, and a loss factor test. These tests were performed according to IEEE
standard 18-1992.
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capacitor will be subject to three positive impulses. The capacitor will be tested in wet
condition and at a voltage of 125kV.
6. Test Certification
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Available system capacity
2000
1500
1000
0.7 0.8 0.9
power factor
Figure 5. System capacity increased as power factor is being increased from 0.7 to 0.95
Power Losses
80
power loss (kW)
70
60
50
40
30
0.7 0.8 0.9
power factor
Figure 6. Power losses decreased as power factor is being increased from 0.7 to 0.95
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6.2.4. Discharge Test
The capacitor successfully discharge to less than 50kV in less than 5 minutes when it was
disconnected from the power source.
7. Summary
Quality and economics are the two most important factors that must be considered when
designing a product to sale to the public. As long as there is a need for power, there will be a
need for an efficient way to produce and distribute energy to customers. The method to
accomplish is by installing power correction capacitors to improve the power factor rating in a
distribution system. The design of these capacitors must be flawless or they will not perform as
they are designed. With this in mind, there are countless man- hours being spent, even years, to
guarantee this quality. Hopefully, there can be some improvements that will make a capacitor
even more efficient. Indeed, capacitors are favorite in power distribution system and will
continue to remain that way as long as there is a need for quality and an economically feasible
energy supply.
8. Future Work
Capacitors will continue to play an important role in energy conservation especially power factor
correction until the next generation of devices come to existence. In the mean time, capacitors
will continue to serve their purpose and the design of capacitors will continue to get more and
more advanced. In the future, it will not be surprising if capacitors can correct power factor
rating to unity because of advancement in technology and manufacturing ability.
9. Acknowledgement
We wish to acknowledge Dr. Stanislaw Grzybowski and Dr. Joseph Picone of Mississippi State
University for their expertise and continued support of our project. We also wish to acknowledge
the Department of Electrical and Computer Engineering of Mississippi State University for
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allowing us to conduct tests in their High Voltage Laboratory. Dr. Grzybowski's knowledge in
high voltage engineering and power capacitor contributed to the success of this project. Finally,
we would like to thank Dr. Picone for the proper instruction concerning project management.
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