Vous êtes sur la page 1sur 22

Automatic Power Factor Correction Using PLC

CHAPTER 1
INTRODUCTION

FACT is one of the leading fertilizer manufacturing companies in India. It is situated at


Udyogamandal, Cochin. Our project is done in Petrochemical division, where the main product
is Caprolactum. At FACT as the machines used are inductive in nature (about 786 Induction
motors), there will be great variations in power factor. So the manual power factor control
presently employed will not be effective. As the manual control may lead to mistakes it will be
better controlled if the system is automated. In this project automatic power factor control is
achieved using PLC. It has many advantages over the present system. It is faster and more
accurate in its working. Our project mainly deals with creating program adequate for power
factor correction.
The supply system in FACT-PD is availed from 3 sources, 1 fed from TG and 2 from
KSEB. The TG supplies major portion of power requirements in FACT-PD and have no need of
power factor control as it will not affect billing. 16MW TG can meet whole power requirements.
Critical loads are connected to TG and non-critical loads are fed from KSEB. FACT
Udyogamandal is receiving power from KSEB at 110 kV. This power is distributed to various
plants at different voltages viz. 11 kV, 3.3 kV and 415 V
The topic for project is AUTOMATIC POWER FACTOR CORRECTION USING
PLC in the PD. Power factor improvement system plays a vital role in billing of FACT. The
study conducted at the capacitor bank of PD of FACT and find out the use of automation on
capacitor bank over present manual system. By doing this project we have in mind the objective
of conversion of manual control to automation using PLC to counteract the undesirable effects of
loads that create a power factor that is less than 1.

Dept. Of EEE, MLMCE

Page 1

Automatic Power Factor Correction Using PLC


CHAPTER 2
ORGANISATION PROFILE

The FACT Fertilizers and Chemicals Travancore Ltd was setup in 1943 for the
manufacture and marketing of fertilizers, chemicals and caprolactum. There are 2 manufacturing
divisions- The FACT Udyogamandal complex which began in 1947, and Cochin division. In
August 1960, FACT became a Kerala State Public Sector Enterprise and from 1962 onwards, a
Govt. of India enterprise. The consultancy unit known as FACT Engineering and Design
Organisation (PEDO) was setup in 1965 and has since diversified into chemicals,
petrochemicals, hydrometallurgy, pharmaceuticals and other areas. The project is done at the PD
of FACT. FACT has since then grown, expanded and branched out in a fantastic maenterprnner
so that today it is not merely one of the biggest fertiliser

enterprises in the country, but also

legend of the modern times and a triumph of the public sector. FACTs annual sales turn over is
around Rs.2937 crores during 2011-12. FACT today has 3 manufacturing divisions, two at
udyogamandal, its birth place, which has by now become an industrial complex of several
industries, and other at ambalamukal close to the Kochi Refinerires Ltd. The overall production,
capacity of the company now is in the range of 3.2 Lakhs tons of nitrogen 1.27 tons of phosphate
and 50,000 tons of caprolactam.
FACT has the widest range of fertilisers which is made available to the farmers spread
over wide area covering the entire south, straight fertilisers like Ammonium Sulphate, Urea,
MOP and also complex fertilisers like Factamfos 20-20-0-13,FACT DAP and a host of NPK
mixtures to suite all crops and all soils. FACT also manufactures various grades of Biofertilisers. FACT has also successfully branched out in to the fields of chemicals and fertilizer
technology,

engineering

and

Design

capability,

Research

and

Development,

Fabrication/engineering services. Here the project concentrate on the power factor control
automatically using PLC.PLC (programmable logic control) also referred to as programmable
controller is to as the name given to a type digital computer commonly used in commercial and
industrial control applications. All PLC monitor input and other variable values make decisions
based on stored program, control output to automate a process or machine.
Dept. Of EEE, MLMCE

Page 2

Automatic Power Factor Correction Using PLC

CHAPTER 3
POWER SYSTEM IN PETROCHEMICHAL DIVISION (PD)

The power system in FACT-PD is divided into three sections - one fed from a turbo
generator and the other 2 fed from K.S.E.B. The TG of 16MW capacity & it supplies the major
portion of FACT-PD power requirements. The total load of FACT-PD is approximately 12.1 MW
& the whole of the power requirement of PD can be met by the 16MW TG. The TG can be used
for back feeding the other divisions in times of severe power crisis.
The 110 KV incoming lines from the K.S.E.B are terminated at the UDL ALIND Panel.
In UDL, the 110KV is stepped down into 11KV by 4 power transformers rated 15MVA and
12.5/20MVA power transformers. From there, it is taken to 11KV switch board through 2
incomers, incomer 1 & incomer 2. The TG and the incomer from UDL are connected to 4 bus
bars which are joined by bus couplers. BUS 1 & BUS 2 are connected to the 2 incomers from
UDL and BUS 3, BUS 4 are connected to the TG.
There are 4 capacitor banks named PQRS which is of two 500 and two 1000 KVAR for
power factor improvement. The 11 KV is stepped down to 3.45 KV using power transformers
rated 6.3 MVA 11/3.45 KV. The 3.3 KV switchboards are connected to 34 motors. The 11KV is
stepped down to 415 V by 1.6 MVA 11/0.433 KV transformers. Thus from the 11KV
switchboard, the supply is taken to two 415 V switchboards MPCC 1 and MPCC 2. Similarly the
11KV switchboard is connected to another 2 415V switchboards PPCCI 1 and PPCC 2. This is
done by 10 step down transformers of rating 11/0.415 KV 1.6 MVA. Most of the connected load
in FACT-PD is motors. There were a total of 786 motors and these motors are connected to 3.3
KV & 415V switchboard

Dept. Of EEE, MLMCE

Page 3

Automatic Power Factor Correction Using PLC


CHAPTER 4
POWER FACTOR

Power factor is a measure of how efficiently electrical power is consumed. In the ideal
world power factor is unity. Unfortunately in the real world power factor is reduced by highly
inductive loads to 0.7 or less. This induction is caused by equipment such as lightly loaded
electric motors, luminary transformers and florescent lighting ballasts and welding sets, etc.
Power factor is the ratio of true power or watts to apparent power or volt amps. They are
identical only when current and voltage are in-phase than the power factor 1.0.Power in the ac
circuit is very seldom equal to the direct product of the volts and amps.
In order to find the power of a single phase ac circuit the product of volts and amps must
be multiplied by the power factor. Ammeters and voltmeters indicate the effective value of volts
and amps. True power or watts can be measured with a wattmeter. If the true power is 1870 watts
and the volt amps reading is 2200. Then the power factor is expressed in decimal or percentage.
Thus power factors of 0.8 are the same as 80%. Low power factor unusually associated with
motors and transformers. An incandescent bulb would have a power factor of close to 1.0. A 1hp
motor about 0.80. With low power factor loads, the current flowing through the electrical system
components is higher than necessary to do the required work. This result in excess heating,
which can damage or shorten life of equipment. It does how ever become a problem in industry
where multiple large motors are used. Power Factor Correction Capacitors are normally used to
correct this problem.
For a DC circuit the power is P=VI, and the relationship also holds for the instantaneous power
in an AC circuit. However, the average power in an ac circuit expressed in terms of the rms
voltage and current is
Pavg = VIcos
Where is the phase angle between voltage and current. The additional term is called the power
factor.

Dept. Of EEE, MLMCE

Page 4

Automatic Power Factor Correction Using PLC

POWER FACTOR = cos =

R
Z

From the phasor diagram for AC impedance, it can be seen that the power factor is R/Z. For a
purely resistive AC circuit, R=Z and the power factor is 1.
4.1 IMPORTANCE OF POWER FACTOR
A power factor of 1 or unity power factor is the goal of any electric utility company
since if the power factor is less than 1, they have to supply more current to the user for a given
amount of power use. In so during, they incur more losses. They also must have larger capacity
equipment in place than would be otherwise necessary. As a result, an industrial facility will be
charged a penalty if its power factor is much different from 1.
Industrial facility tends to have a leading power factor where the current lags
the voltage (like an inductor). This is primarily the result of having a lot of electric induction
motors. The windings of motors act as inductors as seen by the power supply. Capacitors have
the opposite effect and can compensate for the inductive motor windings. Some industrial sites
will have large banks of capacitors strictly for the purpose of correcting the power factor back
toward one to save on utility company charges. The power factor of an AC electrical power
system is defined as the ratio of the real power flowing to the load to the apparent power in the
circuit,[1][2] and is a dimensionless number between 0 and 1. Real power is the capacity of the
circuit for performing work in a particular time. Apparent power is the product of the current and
voltage of the circuit. Due to energy stored in the load and returned to the source, or due to a
non-linear load that distorts the wave shape of the current drawn from the source, the apparent
power will be greater than the real power.
Linear loads with low power factor (such as induction motors) can be corrected with a
passive network of capacitors or inductors. Non-linear loads, such as rectifiers, distort the current
drawn from the system. In such cases, active or passive power factor correction may be used to
counteract the distortion and raise the power factor. The devices for correction of the power
factor may be at a central substation, spread out over a distribution system, or built into powerconsuming equipment.
Dept. Of EEE, MLMCE

Page 5

Automatic Power Factor Correction Using PLC

4.2.

LINEAR CIRCUITS
In a purely resistive AC circuit, voltage and current waveforms are in step (or in phase),

changing polarity at the same instant in each cycle. All the power entering the load is consumed.
Where reactive loads are present, such as with capacitors or inductors, energy storage in the
loads results in a time difference between the current and voltage waveforms. During each cycle
of the AC voltage, load does not change the shape of the waveform of the current, but may
change the relative timing (phase) between voltage and current. Extra energy, in addition to any
energy consumed in the load, is temporarily stored in the load in electric or magnetic fields, and
then returned to the power grid a fraction of a second later in the cycle. The "ebb and flow" of
this nonproductive power increases the current in the line. Thus, a circuit with a low power factor
will use higher currents to transfer a given quantity of real power than a circuit with a high power
factor. A linear Circuit containing purely resistive heating elements (filament lamps, cooking
stoves, etc.) have a power factor of 1.0. Circuits containing inductive or capacitive elements
(electric motors, solenoid valves, lamp ballasts, and others) often have a power factor below 1.0.

Fig. 4.1: Voltage, current, power relationship for linear circuit


Instantaneous and average power calculated from AC voltage and current with a zero
power factor (

Dept. Of EEE, MLMCE

). The blue line shows all the power is stored temporarily in


Page 6

Automatic Power Factor Correction Using PLC


the load during the first quarter cycle and returned to the grid during the second quarter cycle, so
no real power is consumed.

4.3

DEFINITION AND CALCULATION

AC power flow has the three components: real power (also known as active power) (P),
measured in watts (W); apparent power (S), measured in volt-amperes (VA); and reactive power
(Q), measured in reactive volt-amperes (var).
The power factor is defined as:

In the case of a perfectly sinusoidal waveform, P, Q and S can be expressed as vectors that form
a vector triangle such that:

If

is the phase angle between the current and voltage, then the power factor is equal to

the cosine of the angle,

, and:

Since the units are consistent, the power factor is by definition a dimensionless
number between 0 and 1. When power factor is equal to 0, the energy flow is entirely reactive,
and stored energy in the load returns to the source on each cycle. When the power factor is 1, all
the energy supplied by the source is consumed by the load. Power factors are usually stated as
"leading" or "lagging" to show the sign of the phase angle.
If a purely resistive load is connected to a power supply, current and voltage will change
polarity in step, the power factor will be unity (1), and the electrical energy flows in a single
direction across the network in each cycle. Inductive loads such as transformers and motors (any
Dept. Of EEE, MLMCE

Page 7

Automatic Power Factor Correction Using PLC


type of wound coil) consume reactive power with current waveform lagging the voltage.
Capacitive loads such as capacitor banks or buried cable generate reactive power with current
phase leading the voltage. Both types of loads will absorb energy during part of the AC cycle,
which is stored in the device's magnetic or electric field, only to return this energy back to the
source during the rest of the cycle.
For example, to get 1 kW of real power, if the power factor is unity, 1 kVA of apparent
power needs to be transferred (1 kW 1 = 1 kVA). At low values of power factor, more apparent
power needs to be transferred to get the same real power. To get 1 kW of real power at 0.2 power
factor, 5 kVA of apparent power needs to be transferred (1 kW 0.2 = 5 kVA). This apparent
power must be produced and transmitted to the load in the conventional fashion, and is subject to
the usual distributed losses in the production and transmission processes.
Electrical loads consuming alternating current power consume both real power and
reactive power. The vector sum of real and reactive power is the apparent power. The presence of
reactive power causes the real power to be less than the apparent power, and so, the electric load
has a power factor of less than 1.
4.4

POWER FACTOR CORRECTION OF LINEAR LOADS


A high power factor is generally desirable in a transmission system to reduce

transmission losses and improve voltage regulation at the load. It is often desirable to adjust the
power factor of a system to near 1.0. When reactive elements supply or absorb reactive power
near the load, the apparent power is reduced. Power factor correction may be applied by an
electric power transmission utility to improve the stability and efficiency of the transmission
network
Power factor correction brings the power factor of an AC power circuit closer to 1 by
supplying reactive power of opposite sign, adding capacitors or inductors that act to cancel the
inductive or capacitive effects of the load, respectively. For example, the inductive effect of
motor loads may be offset by locally connected capacitors. If a load had a capacitive value,
inductors (also known as reactors in this context) are connected to correct the power factor

Dept. Of EEE, MLMCE

Page 8

Automatic Power Factor Correction Using PLC

Fig 4.2: Capacitor bank


1. Reactive Power Control Relay; 2. Network connection points; 3. Slow-blow Fuses; 4.
Inrush Limiting Contactors; 5.Capacitors (single-phase or three-phase units, delta-connection);
6. Transformer for controls and ventilation fans)
An automatic power factor correction unit consists of a number of capacitors that are
switched by means of contactors. These contactors are controlled by a regulator that measures
power factor in an electrical network. Depending on the load and power factor of the network,
the power factor controller will switch the necessary blocks of capacitors in steps to make sure
the power factor stays above a selected value.
4.5.

NON-LINEAR LOADS

A non-linear load on a power system is typically a rectifier (such as used in a power supply), or
some kind of arc discharge device such as a fluorescent lamp, electric welding machine, or arc
furnace. Because current in these systems is interrupted by a switching action, the current
contains frequency components that are multiples of the power system frequency. Distortion
power factor is a measure of how much the harmonic distortion of a load current decreases the
average power transferred to the load.

Dept. Of EEE, MLMCE

Page 9

Automatic Power Factor Correction Using PLC


Fig.4.3: Nonlinear loads

Sinusoidal voltage and non-sinusoidal current give a distortion power factor of 0.75 for this
computer power supply load.
4.6.

NON-SINUSOIDAL COMPONENTS

Non-linear loads change the shape of the current waveform from a sine wave to some other form.
Non-linear loads create harmonic currents in addition to the original (fundamental frequency) AC
current. Filters consisting of linear capacitors and inductors can prevent harmonic currents from
entering the supplying system.
In linear circuits having only sinusoidal currents and voltages of one frequency, the
power factor arises only from the difference in phase between the current and voltage. This is
"displacement power factor". The concept can be generalized to a total, distortion, or true power
factor where the apparent power includes all harmonic components. This is of importance in
practical power systems that contain non-linear loads such as rectifiers, some forms of electric
lighting, electric arc furnaces, welding equipment, switched-mode power supplies and other
devices.

4.7.

WHAT DOES IT DO TO ELECTRICITY BILL?

In a 3 phase supply, kW consumed is (VOLTS x AMPS x 1.73 x Power Factor) / 1000. The
Electricity Company supply you VOLTS x AMPS and they have to supply extra to make up for
the loss caused by poor Power Factor. When the power factor falls below a set figure, the
electricity supply companies charge a premium on the kW being consumed, or, charge for the
whole supply as kVA.

4.8.

WHAT CAUSES POWER FACTOR TO CHANGE?

Inductive loads cause the AMPS to lag behind the VOLTS. The wave forms of VOLTS and
AMPS are then "out of phase" with each other. The more out of phase they become then the
Dept. Of EEE, MLMCE

Page 10

Automatic Power Factor Correction Using PLC


lower the Power Factor. Power Factor is usually expressed as Cos Phi. ()

Fig. 4.4: power triangle


In 3 phase supplies the Power can be measured as a triangle. Active power is the base line
and is the real usable power measured in kW. Reactive power is the vertical or the part of supply
which causes the inductive load. The reactive power in is measured in kV(kilo volt-amperes
reactive).Apparent power is the hypotenuse. This is the resultant of the other two components
and is measured in kVA.
4.9.

WHY DO I NEED POWER FACTOR CORRECTION?


Capacitive Power Factor correction (PFC) is applied to electric circuits as a means of

minimising the inductive component of the current and thereby reducing the losses in the supply.
The introduction of Power Factor Correction capacitors is a widely recognised method of
reducing an electrical load, thus minimising wasted energy and hence improving the efficiency
of a plant and reducing the electricity bill. It is not usually necessary to reach unity, ie Power
Factor 1, since most supply companies are happy with a PF of 0.95 to 0.98
The low power factor is mainly due to the fact that most of the power loads are inductive
and, there-fore, take lagging currents. In order to improve the power factor, some device taking
leading power factor should be connected in parallel with the load. One of such devices can be a
capacitor. The capacitor draws a leading current and partly or completely neutralizes the lagging
reactive component of load current. This raises the power of the load.

Dept. Of EEE, MLMCE

Page 11

Automatic Power Factor Correction Using PLC


Normally, the power factor of the whole load on a large generating station is in the region
of 08 to 09. However, sometimes it is lower and in such cases it is generally desirable to take
special steps to improve the power factor. This can be achieved by the following equipment:
1. Static capacitors. 2. Synchronous condenser. 3. Phase advancers.

4.10

STATIC CAPACITOR
Power factor can be improved by connecting capacitor in parallel with the equipment

operating at lagging power factor. The capacitor (generally known as static capacitor) draws a
leading current and partly or completely neutralizes the lagging reactive component of load
current. This raises the power factor of the load. For three-phase loads, the capacitors can be
connected in delta or star as shown in Fig. 6.4. Static capacitors are invariably used for power
factor improvement in factories.

Fig 4.5: Static capacitor


Advantages
(i) They have low losses.
(ii) They require little maintenance as there are no rotating parts.
(iii) They can be easily installed as they are light and require no foundation.
(iv) They can work under ordinary atmospheric conditions.
Dept. Of EEE, MLMCE

Page 12

Automatic Power Factor Correction Using PLC


Disadvantages
(i) They have short service life ranging from 8 to 10 years.
(ii) They are easily damaged if the voltage exceeds the rated value.
(iii) Once the capacitors are damaged, their repair is uneconomical
CHAPTER 5
PRESENT POWER FACTOR CONTROLLING SYSTEM AT FACT
Presently Power factor is controlled manually at FACT by using 4 capacitor banks,
among which two banks is of 500 KVAR and other two is of 1000 KVAR. The better power
factor control is possible if the number of capacitor bank is increased by lowering the KVAR
ratings.
The manual control has its own disadvantages since continues checking is impossible.
Here the operators check by intervals of one or two hours. The lagging and leading power factor
in between the intervals will not be checked and corrected which cause great loss in terms of
billing and efficiency of machine. Since KSEB will provide incentives(0.25% of net energy
charges for every 0.01 increase in power factor from 0.9 to 1.0) to every 0.1 increase in power
factor, its correction at perfect time is of important which is not possible to done manually. Now
there is a power factor meter at control room which reads according to load variation. The
operators adjust the capacitor bank by switching it as per the power factor meter display. Power
factor controlling of TG set is done automatically and have no effect on billing.

Dept. Of EEE, MLMCE

Page 13

Automatic Power Factor Correction Using PLC

Fig. 5.1: High voltage capacitor banks

5.1

Single line Diagram of capacitor bank

Dept. Of EEE, MLMCE

Page 14

Automatic Power Factor Correction Using PLC

CHAPTER 6
DETAILS ABOUT PLC

Fig. 6.1: PLC system overview

Dept. Of EEE, MLMCE

Page 15

Automatic Power Factor Correction Using PLC


A Programmable Logic Controller, or PLC, is more or less a small computer with a builtin operating system (OS). This OS is highly specialized to handle incoming events in real time,
i.e. at the time of their occurrence.
The PLC has input lines where sensors are connected to notify upon events (e.g.
temperature above/below a certain level, liquid level reached, etc.), and output lines to signal any
reaction to the incoming events (e.g. start an engine, open/close a valve, etc.).
6.1

LADDER DIAGRAM
The system is user programmable. It uses a language called "Relay Ladder" or RLL

(Relay Ladder Logic). The name of this language implies that the control logic of the earlier
days, which was built from relays, is being simulated.
Ladder diagrams are specialized schematics commonly used to document industrial
control logic systems. They are called "ladder" diagrams because they resemble a ladder, with
two vertical rails (supply power) and as many "rungs" (horizontal lines) as there are control
circuits to represent.
A program consists of instructions that accomplish specific Tasks. The degree of
complexity of a PLC program depends upon the complexity of the application, the number and
type of input and output devices, and the types of instructions used. Ladder logic (LAD) is one
programming language used with PLCs. Ladder logic incorporates programming functions that
are graphically displayed to resemble symbols used in hard-wired control diagrams. The left
vertical line of a ladder logic diagram represents the power or energized conductor. The output
coil instruction represents the neutral or return path of the circuit. The right vertical line, which
represents the return path on a hard-wired control line diagram, is omitted. Ladder logic
diagrams are read from left-to-right and top-to-bottom. Rungs are sometimes referred to as
networks. A network may have several control elements, but only one output coil.

Dept. Of EEE, MLMCE

Page 16

Automatic Power Factor Correction Using PLC

Fig. 6.2 : Ladder logic diagram

6.3

THE PLC'S PURPOSE IN LIFE


The PLC is primarily used to control machinery. A program is written for the PLC which

turns on and off outputs based on input conditions and the internal program. In this aspect, a PLC
is similar to a computer. However, a PLC is designed to be programmed once, and run repeatedly
as needed. In fact, a crafty programmer could use a PLC to control not only simple devices such
as a garage door opener, but their whole house, including switching lights on and off at certain
times, monitoring a custom built security system, etc.
Most commonly, a PLC is found inside of a machine in an industrial environment. A PLC
can run an automatic machine for years with little human intervention. They are designed to
withstand most harsh environments.
6.4

HISTORY OF PLCS

Dept. Of EEE, MLMCE

Page 17

Automatic Power Factor Correction Using PLC


When the first electronic machine controls were designed, they used relays to control the
machine logic (i.e. press "Start" to start the machine and press "Stop" to stop the machine). A
basic machine might need a wall covered in relays to control all of its functions. There are a few
limitations to this type of control.
Relays fail.
The delay when the relay turns on/off.
There is an entire wall of relays to design/wire/troubleshoot.
A PLC overcomes these limitations; it is a machine controlled operation.
6.5 MAINLY USED PLCs
ABB
Siemens
Omron
Allen-Bradley
GE-Fanuc
Telemecanique
Keyence

CHAPTER 7
PROJECT DESCRIPTION

As the part of project we visited the Petrochemical Division of FACT whose electrical
load connected in KSEB is 4.5MW.The load is supplied from KSEB and TG set of
16MW of which 7.5MW is utilized.

Dept. Of EEE, MLMCE

Page 18

Automatic Power Factor Correction Using PLC


Power factor of TG is automatically corrected and no effect on billing. But KSEB provide
incentives for the improvement of power factor, simultaneously it protect the various machines
used. The power factor is improved by using 4 capacitor banks of rating two 500KVAR and two
1000KVAR.
As it was designed earlier the rating is high. It will be more convenient to correct the
power factor if the rating is of low range. Power factor controlled by adjusting capacitor bank is
done manually. The manual control has its own disadvantages since continuous checking is
impossible. At FACT the operator check the power factor by an intervals of one or two hours.
The lagging and leading power factor in between the interval will not be noticed and corrected
which cause great loss in terms of billing and efficiency of machines. KSEB will provide
incentive to every 0.1 increase in power factor. S
As the checking interval of power factor is of great significant it is better to control the
capacitor bank automatically. Automatic control can be done by using PLC. Ladder structure is
used to program and connected to capacitor bank. It will be better to reduce the capacitor range,
as now its minimum range is 500KVAR. The precise controlling is possible if the present rating
is reduced to lower values.
7.1. PROPOSED SYSTEM
In this study, as noted above the better power factor improvement is not possible at
FACT. With this project we understood that the power factor improvement can be done more
accurately and perfectly by introducing low rating capacitor bank and adjusting it with
automatically by using PLC.
According to this study we concentrated to improve the power factor and would like to
propose 4 capacitor banks with ratings of 300 KVAR, 500 KVAR, 800 KVAR and 1600KVAR
for better performance. By this arrangement it will be possible to adjust over a small variation of
power factor with the most suitable ratings. It provides minimum capacitance of 300 KVAR
(presently 500 KVAR) and is able to provide any rating by selecting required capacitor bank.
Most of intermediate value of capacitor bank can be inserted with this rating from 300 KVAR to
3100KVAR.For example, 700KVAR can be inserted by switching ON 300 KVAR and 400

Dept. Of EEE, MLMCE

Page 19

Automatic Power Factor Correction Using PLC


KVAR bank. Similarly by switching on all the four capacitor bank 3100 KVAR can be obtained.
Besides this if we are using automatic controller using PLC, it will be possible to adjust capacitor
bank without any defect. PLCs not only are capable of performing the same tasks a hard-wired
control, but also capable of many more complex applications. In addition, the PLC program and
electronic communication lines replace much of the interconnecting wires required by hardwired control. Therefore, hard-wiring, though still required to connect field devices, is less
intensive. This also makes correcting errors and modifying the application easier. Some of the
additional advantages of PLCs are as follows:
Smaller physical size than hard-wire solutions.
Easier and faster to make changes.
PLCs have integrated diagnostics and override functions.
Diagnostics are centrally available.
Applications can be immediately documented.
Applications can be duplicated faster and less expensively.
7.2. DESIGN OF CAPACITOR BANK
In fact there are two power sources available
1. TG (turbo generator): 7.5MW
2. KSEB: 4.5MW
TG power factor is already automatically controlled and no effect on billing. We have to correct
only the KSEB power factor.
Maximum load: 4.5MW
Minimum load: 2MW
We have to correct the power factor in between 0.80 to 0.995
At maximum load
We have find out how much reactive power is injected to the system
Cos 1 =0.80
Cos 2 =0.995
And the using the relation KVAR= MW*(tan2-tan1)
Dept. Of EEE, MLMCE

Page 20

Automatic Power Factor Correction Using PLC


MW=4.5, tan1=0.75, tan2=0.100
KVAR=4.5*(0.100-0.75)
=2925 KVAR
We Choose 3100 KVAR
At minimum load
MW=2, tan1=0.75, tan2=0.100
KVAR=2*(0.100-0.75)
=1500KVAR
We choose capacitor banks of ratings
C1=300KVAR
C2 =400KVAR
C3=80000KVAR
C4=1600KVAR
These capacitor banks are injected to the power system under suitable condition.

7.3 FLOW CHART

Dept. Of EEE, MLMCE

Page 21

Automatic Power Factor Correction Using PLC

Fig. 7.1: flowchart to develop the ladder logic

Dept. Of EEE, MLMCE

Page 22

Vous aimerez peut-être aussi