(1)What happens if i connect a capacitor to a generator load?

Connecting a capacitor across a generator always improves power factor, but it will help depends up on the engine capacity of the alternator, otherwise the alternator will be over loaded due to the extra watts consumed due to the improvement on pf. Secondly, dont connect a capacitor across an alternator while it is picking up or without any other load

CAPTIVE GENSETS S'N!PSIS(

!N"T NEE

CAPACIT!#S $ #IG%T? W#!NG&

The application of LT capacitor banks for the twin ob ectives of reducing k!" demand from the utility and effecting voltage improvement in the LT network has fre#uently caused $enset users into believing that capacitors are superfluous when $ensets operate in standalone mode. %hat is often not reali&ed is that $ensets have limited ability to meet sudden, large demands of reactive power as in encountered in certain process industries. This results in si&ing the $enset too liberally, leading to high capital cost. 'oreover, the running costs are high too, due to part(load efficiencies of $ensets being very poor. )art load operation affects engine life as well. *udicious application of fast acting capacitive compensation can be beneficial to users on all counts. This paper describes the reactive power re#uirements imposed on $ensets by different types of loads, their effect on the engine and the generator and the role of dynamic compensation in optimising the investment on $ensets. 1) INT#! *CTI!N( +.+ The role of power capacitors in improving the power factor and reducing total cost of electricity in an industrial installation is well established with regard to supply of power from the electricity boards,utilities. +.- .t is thus logical to extend the above application of power capacitors when power is drawn from captive diesel gensets to optimise their performance. +./ .t is, however, a common practice that 0$ set users generally switch off capacitors or do not install capacitors at all when the 0$ set is in use. +.1 The primary reason for this situation is the general opinion that capacitors should not be used along with the loads when the 0$ set is in operation. +.2 The basis for such an opinion is the apprehension that the 0$ set may get over loaded due to the fact that the current delivered by the 0$ set is generally considered as the indicator of output by most 0$ set users. .t is well known that use of capacitors will reduce the current drawn from the 0$ set and could thus tempt the user to add more loads on a given 0$ set. The other reason for such an opinion is related to the risks arising due to sustained leading power factor conditions that

would occur with the use of fixed capacitors in variable load situations. The ill effects of leading power factor on the behaviour of the 0$ sets are well recognised. +.3 Technological developments in the recent years have, however, resulted in development of suitable capacitor based 45"CT.!5 )6%54 C6')57S"T.67 84)C9 Systems which are capable of being used along with 0$ sets in a reliable and safe manner. +.: .t is also observed that udicious application of this modern technology can improve the overall efficiency of 0$ set operation and result in considerable economic benefits to the 0$ set user. +.; This paper therefore outlines the various factors which influence the economics of operation of 0$ sets and then proceeds to identify the specific 45"CT.!5 )6%54 C6')57S"T.67 solutions which could be used to achieve a reduction in cost of energy generated by 0$ sets. +) #E,EVANCE !- .)/ P!WE# -ACT!#( .t is widely believed that the average power factor at which a 0$ Set should operate is <.;. The facts stated below are specifically to correct this is technically erroneous conclusion. -.+ "lternators are rated in !olt("mperes 8k!"9. This is logical in the sense that it specifies the maximum current the alternator can deliver at the system voltage. -.- To specify the appropriate power rating of a diesel engine for a particular "lternator we have to first convert k!" to k% and thereafter k% to =>). This can only be done if we assume a certain average )ower ?actor 8)?9 under which the 0$ set would operate. -./ The power factor so assumed should be in line with the average power factor prevalent in the industry. " typical industrial load comprises of induction motors 8typical )? of <.; to <.;29, non(linear loads 8typical )? of <.2 to <.39 and combination of unity )? loads 84esistive heating and incandescent lighting9. >ence assuming an average power factor of <.; for typical industrial loads is considered acceptable by convention. -.1 Conse#uently a power factor of <.; is used for calculating the k%, which is then converted to the =>) rating of the prime mover. @nowing the =>) it is now possible to calculate the power rating of the engine. -.2 .t is, however, important to ensure that under actual operating conditions the k% loading and current loading should not be exceeded. -.3 )ower ?actor of loads supplied by 0$ sets can therefore be improved closer to unity by use of suitable 4eactive )ower Compensation Systems keeping in view the conditions stated in -.2. 0) Para1eters Infl2encing Econo1ics of G Set !peration(

The two ma or factors that influence the economics of 0$ set operation areA B 'echanical ?actors B 5lectrical ?actors

The mechanical factors are related to the various engine aspects such as, proper lubrication, cooling, air intake systems, maintenance etc., since these issues are considered common to all situations and they are not dealt with in this paper. It however is to be understood that for proper performance of the engine these factors are paramount and should be addressed with great care on a continuous basis. The electrical factors can be broadly classified into the followingA B "lternator 5fficiency B )ower losses occurring in the electrical distribution network. B "verage k% loading on the 0$ Set. 0)1) Alternator Efficienc3( The efficiency of an alternator is a function of the total losses that occur within the alternator. ?or practical purpose we can consider these as iron and copper losses, since other losses such as windage and friction losses etc are negligible. The iron losses are generally considered to be constant irrespective of loading of the machine. >owever the copper losses in the alternator are proportional to the s#uare of the current delivered by it. >ence any reduction in current supplied by the alternator shall result in reduced losses. These losses shall be e#uivalent to a given amount of energy, which is a function of the time for which the alternator operates. Since this energy is supplied by the prime mover, loss reduction ultimately leads to lesser fuel consumption. The simplest technology for reducing current in a given load is to ensure that it operates at the highest feasible power factor. The following example gives an approximate calculation to show the impact of improvement of alternator efficiencyA Consider a / )hase, 1+2!, 2<>&, 2<< k!" 0$ set used in an .ndustry for 3<<< hours,year with an average load of approximately -2< k% at <.32 )?. %hat is the fuel saving if )? is improved to <.C/D The full load copper loss of the alternator is +k% and average yield of the 0$ set is / k%h , litre of fuel 8>S09. 4ated Current of "lternator E 3C2.3< " Current at <.32 )? E 2/2 "

Copper loss at this current E :.+ k% Current at <.C/ )? E /:1 " Copper loss at this current E /.2 k% Saving in copper losses E :.+(/.2 k% E /.3 k% ?or 3<<< hour operation E /.3 x 3<<< k%h E-+,3<< k%h 0$ set yield E / k%h , litre of >S0, )otential Saving in >S0 fuel E -+3<<,/ litres per year E :,-<< litres per year )otential Savings in 4s. F 4s.+2 , litre E 4s. +,<;,<<< per year. "fter due consideration to changes in loading pattern, losses occurring in ).? improvement systems etc., practically about 2<G of this saving can be achieved. The e#uipment re#uired to achieve this power factor improvement is a 45"CT.!5 )6%54 C6')57S"T.67 system, the pay back period for which could be less than years. The risks of overloading of the 0$ Set and sustained leading )ower ?actor conditions occurring are totally eliminated with the use of this technology. NOTE: It is to be ensured under all operating conditions that the effective k loading of the machine should never e!ceed the capability of the prime mover irrespective of all other issues. 0)+) Po4er ,osses occ2rring in the Electrical distri52tion net4or6( The total losses occurring in the electrical distribution network, is a function of the current flowing through the network and the resistance offered by the current carrying conductors,switchgear used. Conse#uently, reduction of current can be realised by installing 4)C Systems in the network as close to the load as feasible. This will have the added benefit of reducing losses between the alternator and the point of connection of the 4)C Systems thereby resulting in further fuel savings. %hile the exact savings will be case specific to each network, it will be reasonably accurate to say that savings similar to those mentioned in /.+ can be achieved by the use of a well(engineered scheme.

0)0) A7erage 6W loading pattern on the alternator( 0)0)1 This is the most significant factor in terms of the fuel consumed by a 0$ set. The graph shown as fig. + gives a typical curve of k%h,litre yield of 0$ sets versus the percentage loading of the set. .t can be seen that most optimum performance is achieved as the loading tends towards ;<G of the capability of the machine. Conse#uently, it should be the endeavour of all the 0$ set users, particularly those who are using the set as the prime source of power supply, to achieve optimum loading. 0)0)+ .n order to understand typical loading pattern of 0$ sets, it is necessary to go into the process of how a 0$ set rating is selected. The selection process of a 0$ set involves the following stepsA B STEP 1A Listing of all loads in terms of their operating k% and )ower ?actor. B STEP +A "ggregate loading based on the step + multiplied by a suitable demand factor. 8Since all loads may not operate simultaneously9. B STEP 0A )roviding additional k% capacity to meet short term peak load re#uirements which arise due to various load characteristics such as starting of induction motors, operation of traction loads such as lifts, cranes etc., intermittent operation of welding machines etc., B STEP 8A )roviding yet more additional k% capacity in the form of a derating factor, due to the fact that some loads are harmonic generating loads. Typical examples are 0C motors, variable speed drives and other devices, which have thyristor based operation. B STEP 9A )rovision of additional k% capacity to meet future needs. Conse#uently, the resultant rating of the 0$ set arrived at by this process is generally higher than needed for regular operation. .t is, therefore, #uite common to find that most 0$ sets are loaded only between 1< to 3<G of their capacity for a ma ority of the operating period. "s a result the practical k%h ,litre of >S0 achieved is lower than the actual capability of the machine. .t is therefore obvious that if the loading can be increased significant savings in fuel economy can be achieved. ?or exampleA ( B .f total units generated E +<,<<,<<< k%h,year >S0 Consumption F 3<G loading 84efer ?ig +9 E +<,<<,<<<,/.< litres E /,//,//2 litres >S0 Consumption F ;<G loading 84efer ?ig +9 E +<,<<,<<<,/.3 litres E -,::,:;< litres

B "nnual Savings in >S0E 22,222 litres B "nnual Savings in 4s. E 22,222 x 4s.+2,litre E 4s. ;,//,/-2 ,( B Saving in 4s.,k%h E 4s. <.;/ per unit generated. "E#$TI%E &O E" $O'&EN(#TION ()(TE'( can enable *.+ set users to reconfigure their loads , *.+ sets to achieve better percentage loading on the machines. #s a result reduction in cost , k h can be attained. 8 .n order to highlight the practical issues and benefits involved in using 4)C SHST5'S, typical cases are given belowA 8)1 Case 1( 8)1)1 P#!:,E;A "n .ndustry has power supply connection from the 5lectricity =oard and has a captive 0$ set, which is used if there is an interruption in 5lectricity =oard )ower Supply or when incoming )ower Iuality is considered unsuitable. The 0$ set, therefore, operates for an average of -<<< hrs per year. This industry has a -2< k!" 0$ set which is loaded at an average of +-< k% at <.: )?. .n addition, there are 1< k% of other loads within the same installation, which are not loaded on the 0$ set due to capacity restrictions that arise during occurrence of short(term peak loads, such as motor starting, and intermittent welding load. 0ue to this, productivity in the .ndustry is lowered when the 0$ Set is in operation. 0uring the period when 5lectricity =oard supply is available all loads can be operated. .s it possible to B "educe the cost of electricity consumed from the Electricity -oard. B Improve &roductivity when *+ (et is in operation. B "educe the cost of electricity generated by the *+ (et. 8)1)+ S!,*TI!NA " well(designed 4eactive )ower Compensation Scheme can provide the solution as followsA

B 0uring the period when the .ndustry is using supply from the 5lectricity =oard the 4)C system can ensure consistently high )?, thereby achieving demand savings and reduction in losses and elimination of any )? penalty. Conse#uently, cost of electricity consumed from the 5= will be minimised. B The same 4)C system can be also used when the .ndustry is using supply from the 0$ set. B The fast acting property of the 4)C system will reduce the peak load re#uirements that are to be met from the 0$ set J 4efer ?ig -. This is achieved by providing instantaneous compensation from the 4)C system during conditions when motors are started and , or welding machines are being operated. This will enable the .ndustry to transfer the 1< k% of additional load on to the 0$ set and ensure that productivity is improved when the 0$ set is in operation. B 0ue to better loading, the 0$ set efficiency will improve in line with the graph shown in fig.+. Conse#uently the cost per unit of 5lectricity generated by the 0$ set will reduce from 4s. 2./<,k%h to 4s 1.2<,k%h i.e. a saving of +2G as explained below. B =efore the use of 4)C System, the loading factor of 0$ set was 3<G, conse#uently giving an yield of, say, / k%h,litter. Taking into account 4s. <./<,unit of electricity generated towards the cost of maintenance and upkeeping of 0$ set, the cost per unit of electricity generated works out to be 4s. 2./<,k%h. B "fter connecting the 4)C system and transferring the additional 1< k% load to 0$, the loading factor would improve to ;<G and conse#uently the yield would improve to /.3 k%h,litre.Taking into account the cost of maintenance of 0$, the cost per unit of electricity generated works out to be 4s. 1.2<,k%h. B >ence a net saving of 4s. <.;<,k%h generated i.e., a saving of approximately +2G is achieved. 8)+ Case +( 8)+)1 P#!:,E;A "n .ndustry has no power supply connection from the local 5lectricity =oard. .t has captive 0$ sets that are used as the supply source. The 0$ sets, therefore, operate for an average of 2<<< hrs per year. This industry has a + x +<<< k!" K - x 2<< k!" 0$ sets operating in parallel and loaded at an average of C3< k% at <.: )?. The loading of 0$ sets is done keeping a provision for short( term peak load re#uirements that arise due to starting of induction motors, and operation of lifting cranes. .n addition extra provision is also made for certain non(linear loads 8thyristor loads9 which generate harmonics i.e. 0C motors and L)S systems. The total energy generated per year is 1;,<<,<<< k%h. Total fuel K maintenance costs of the 0$ Sets is 4s. -22 lakhs per year resulting in a cost of 4s. 2./+ per k%h.

B Can the cost of electricity generated by the 0$ Set be reducedD

8)+)+ S!,*TI!NA " well designed 4eactive )ower Compensation and "ctive ?ilter System can provide the solution as followsA B The fast acting property of the 4)C system will reduce the peak load re#uirements that are to be met from the 0$ set. This is achieved by providing instantaneous compensation from the 4)C system during conditions when motor starting,crane operation is taking place. B The harmonics generated by the non(linear loads will be eliminated by the "ctive ?ilter System B Lastly the current drawn from the 0$ Sets will reduce B Conse#uently the same C3< k% load can now be supplied from + x+<<< k!" K+ x 2<< k!" operating in parallel. B 6ne 2<< k!" 0$ set need not be operated. B 0ue to better loading, the 0$ set efficiency will improve in line with the graph shown in fig.+. Conse#uently, the cost per unit of electricity generated by the 0$ set will reduce as shown in the calculation below. B 0$ Sets were initially operating at 3<G loading factor. "s per figure +, the 0$ set yield at 3<G loading factor is / k%h , Litre. The total diesel consumption for + no. +<<< k!" and - noMs 2<< k!" 0$ set is +3,<<,<<< litres. B %hen the C3< k% load is transferred to + no. +<<< k!" and + no. 2<< k!" 0$ sets, the loading factor will improve to ;<G and the 0$ set yield will be now /.3 k%h , litre. The total diesel consumption will be now +/,1<,<<< litres. B The annual saving in diesel consumption will be -,3<,<<< litres, which amounts to approximately 4s.1< Lakhs per year. B Total savings per year 82<<< hrs. operation9 E 4s. 1< Lakhs. B Taking into account a fixed cost of 4s. <./< , k%h towards maintenance and upkeep of 0$ set, the net savings , k%h of generation of electricity works out to be 4s. <.;< , k%h. This is about +2 G of saving. 9) #eacti7e Po4er Co1pensation and Acti7e -ilter Sol2tions

4eactive )ower Compensation systems basically comprise of a microprocessor controller to sense the load power factor and,or 4eactive power, current and give commands to connect or disconnect the re#uired k!"4 to achieve the desired conditions as programmed in the controller. The k!"4 is provided by suitably si&ed power capacitors , reactors arranged in appropriate steps. The 4)C system hence should have suitable switching devices to connect or disconnect the power capacitors along with protection devices like fuses and relays. The type of switching and controlling devices used in 4)C system depends upon how fast the reactive power is to be introduced into or withdrawn from the electrical system. This, in turn, is dependent upon the type of electrical load to be compensated. .f the response time Nt rN of the system is greater than or e#ual to 2 seconds, contactor switching with suitable discharge devices can be used. >owever if Nt rN is less than 2 seconds, controlled switching using thyristors is re#uired. .f Nt rN is less than or e#ual to + second, it is necessary to use a fast acting special purpose controller to operate the whole system. The contactor(switched 4eactive )ower compensation systems are popularly referred to as A2to1atic Po4er -actor Correction (AP-C) s3ste1s) The thyristor switched systems are known as ( CS)) 9)1 Contactor S4itched AP-C S3ste1s) ")?C systems have a response time, which is #uite sufficient for fairly steady and , or slow varying loads. %hen a contactor switches off a capacitor, a voltage e#ual to the value of line voltage at the instant of switching off, is retained at the capacitor terminals. =efore this capacitor can be reconnected, sufficient time has to be given for the terminal voltage across it to discharge to a safe value, so as to avoid damaging the capacitor. 9)+ 3na1ic Co1pensation 3na1ic Co1pensation S3ste1s

This system features controlled switching of power capacitors using thyristors and associated control , firing circuits for reduced response time. .n this system, it is possible to switch in capacitors at the instant when its voltage is e#ual to that of line voltage, thereby eliminating the need for capacitors to discharge. =ased upon the point of sensing dynamic compensation system can be classified as !pen or Closed loop. 2.-.+ !pen ,oop .f the load operation , switching is sensed directly and feedback given to the dynamic compensation system, this is termed as open loop dynamic compensation system. The response time in this arrangement is very short and hence this scheme is usually used for instantaneous compensation. .t is also possible to operate this

system by an external command, which is given ust before the operation of the load. Conse#uently this system can be operated in N pre( trigger N mode and therefore has the smallest response time.

9)+)+ Closed ,oop .f the load conditions are sensed as the combination of load and capacitor currents, then this is termed as closed loop dynamic compensation. .n this arrangement the dynamic compensation system works similar to a contactor switched ")?C system, but with a much faster response. 9)0 Acti7e -ilter "ctive filter is the state of the art technology solution for eliminating harmonics generated from LT non(linear loads, like variable fre#uency drives, L)S, etc. The active filter works on the principle of generating counter(harmonic currents in phase opposition to that generated by the non(linear load which results in cancellation of all harmonic currents. Thus the non(linear load in combination with active filter presents itself as a harmonic free load to the network. The active filter adapts itself to the re#uirements of the load on a continuous real time basis. The reader is advised to refer to the companion paper titled O>"4'67.C '.T.$"T.67 .7 LT "C 75T%64@S( T>5 CL5"4.7$ '.ST N on this sub ect, published in this seminar for more detailed information on active filters. <) C!NC,*SI!N .t is a general practice to oversi&e the rating of 0iesel $enerator Sets due to various technical and other reasons. 6ver(si&ing results in a lower loading factor on 0$ Sets during their normal operation, leading to increased running cost. !arious other issues such as load sharing, escalating fuel cost also have adverse impact in terms of productivity and profitability for the 0$ Set user. .t has been a practice to avoid the use of capacitors in networks that are supplied by 0$ Sets. The evolution of Capacitor "pplication technology as outlined in this paper makes it practical to improve loading factor on 0$ sets, reduce power losses and finally, lower the cost per k%h generated. The udicious use of well(engineered capacitor based 4eactive )ower Compensation technologies can therefore result in improved 0$ set performance, reduced energy cost and better productivity in installations , networks supplied by 0iesel $enerating Sets.