Product Power Factor Correction Panel

Power Factor Correction

Majority of the loads in the industries are highly inductive in nature such as induction motors, welding equipments, arc furnaces andfluorescent lightings. There may be a few resistive loads for heaters and incandescent bulbs. Very rarely industries may have capacitive loads such as synchronous motors. Net industrial load is highly inductive causing a lagging power factor. If this poor power factor is left uncorrected, the industry will require a high maximum demand from Electricity Board and also will suffer a penalty for poor power factor. These two factors of high kVA demand and penalty for poor factor will inflate the monthly Electricity Bill. Since Power Factor can be corrected to near unity there can be huge saving from the Electricity Bills. Standard practice is to connect power capacitors in the electrical network at appropriate places to compensate the inductive nature of the load.

Features

  • 1Ø and 3Ø Welding Equipments
  • Wind Turbine Generators
  • Robotic Machinery
  • Steel Rolling Mills
  • Elevators, Cranes, Presses
  • IT Companies, Hospitals 
  • Water Treatment Plants
  • Air-conditioning etc

ISO 9001:2008 Certified

Benefits

  • Substantial reduction in kVA demand and avoids penalty for low Power Factor
  • Additional loads may be added for improved productivity without need for increased demand
  • Considerable reduction of Transformer and line losses
  • Reduction in voltage drop resulting in better system voltage regulation 
  • Reduction in maintenance, capital cost and longer life of distribution equipments due to lesser current in the system
  • Reduction in voltage fluctuation and circuit reactance
  • Reduction in reactive power demand from the supply system since PFC Panel compensates the reactive power of inductive loads
  • Payback for the PF Panel is normally within 8-12 months

ICD SOLUTION FOR REACTIVE POWER COMPENSATION SYSTEM

  • Calculated fixed capacitor banks with manual ON/OFF switch with or without de-tuned reactor
  • Contactor switched Power Factor Correction Systems (APFC) - RPC 9520
  • Thyristor switched Power Factor Correction Systems (DPFC) - RPD 9520
  • Special Type DPFC Panel to correct individual phases separately for unbalanced system either line to line or line o neutral - RPD9550

APFC Panel:

  • Here automatic Power Factor correction takes place with respect to load requirements through PF Controller and contactor switching
  • Use of Capacitor duty contactors limit the inrush current during switching and enhance the life of the capacitor

DPFC Panel:

  • Power Factor correction takes place using fast PF controller and Thyristor Switching modules
  • Most effective power factor correction takes place for fast fluctuating and dynamically varying loads

DPFC Panel  for Unbalanced System:

  • Here Power Factor Correction takes place by use of ultra fast PF Controller and Thyristor Modules for capacitor switching along with suitable de-tuned reactor
  • Most suitable for 2 phase welding machines, furnace and unbalanced loads and compensation is possible even load is operated for few cycles

ADVANTAGES OF USING THYRISTOR SWITCHING MODULES

  • Real time Power Factor correction is possible
  • Thyristor switching ensures nearly zero current through capacitors during switching, avoiding system transients thus improving power quality
  • Capacitor lifetime is very much extended
  • Infinite number of switching operations since no mechanical moving contacts are involved
  • Switching at zero voltage difference between Thyristor and Capacitor facilitates immediate re-connection of capacitor banks ensuring fast correction
  • Fast response time of 5 - 20 ms. Cycle to cycle compensation is possible

Technical Specification :

 

Details

212.5 kVAr

350 kVAr 

500 kVAr

750 kVAr

System Voltage 3 Ph 400V/415V/440V - 20% to 10% 3 Ph 400V/415V/440V - 20% to 10% 3 Ph 400V/415V/440V - 20% to 10% 3 Ph 400V/415V/440V - 20% to 10%
Frequency 50Hz +/-3% 50Hz +/-3% 50Hz +/-3% 50Hz +/-3%
Capacitor Heavy Duty Gas Filled MPP / APP Heavy Duty Gas Filled MPP / APP Heavy Duty Gas Filled MPP / APP Heavy Duty Gas Filled MPP / APP
Reactor Winding Aluminium / Copper Aluminium / Copper Aluminium / Copper Aluminium / Copper
Reactor Impedance 5.67%/ 7%/ 14% 5.67%/ 7%/ 14% 5.67%/ 7%/ 14% 5.67%/ 7%/ 14%
Capacitor/Reactor - Make* Reputed as per offered BOQ Reputed as per offered BOQ Reputed as per offered BOQ Reputed as per offered BOQ
PF Controller - Make* ICD ICD ICD ICD
Switching Device Thyristor / Capacitor duty contactor Thyristor / Capacitor duty contactor Thyristor / Capacitor duty contactor Thyristor / Capacitor duty contactor
Operation Steps** 17 in Step of 12.5 kVAr 14 in Step of 25 kVAr 10 in Step of 50 kVAr 15 in Step of 50 kVAr
Capacitor Bank in KVAr** 3 x 50, 2 x 25 and 1 x 12.5 6 x 50,2 x 25 10 x 50 6 x 100, 3 x 50
Thyristor ratings for Capacitor Bank Suitable rating as per CAP, Bank Suitable rating as per CAP, Bank Suitable rating as per CAP, Bank Suitable rating as per CAP, Bank
Incomer Rating  400A MCCB 630A MCCB 1000A MCCB / ACB 1600A ACB
Switch Gear - Make* Reputed as per offered BOQ Reputed as per offered BOQ Reputed as per offered BOQ Reputed as per offered BOQ
Bank Protection 100A, 63A and 32A MCCB / FUSE 100A and 63A MCCB / FUSE 100A MCCB / FUSE 100A  and  200A MCCB / FUSE
Protection when Voltage Sensing fails Included in PFC Included in PFC Included in PFC Included in PFC
Over Temperature Protection Provided Provided Provided Provided
Alarms with relay output OC, OV, Over/Under Compensation OC, OV, Over/Under Compensation OC, OV, Over/Under Compensation OC, OV, Over/Under Compensation
Tolerance in kVAr 8.75 17.5 35 35
Corrected PF 0.995 0.995 0.995 0.995
Auto Manual Selection Through keypad in PFC Through keypad in PFC Through keypad in PFC Through keypad in PFC
kVAr / Current meter for Capacitor  Optional - ICD Make Optional - ICD Make Optional - ICD Make Optional - ICD Make
Parameter settings by keypad Included Included Included Included
Display of set / actual values PF and kVAr PF and kVAr PF and kVAr PF and kVAr
Panel Type Cubicle / Compartmentalized Cubicle / Compartmentalized Cubicle / Compartmentalized Cubicle / Compartmentalized
Panel Mounting Floor Mounted Floor Mounted Floor Mounted Floor Mounted
Panel Dimensions*** 2100(H) x 800(W) x600(D) mm 2100(H) x 1300(W) x600(D) mm 2300(H) x 1500(W) x700(D) mm 2300(H) x 2500(W) x700(D) mm
Panel Temperature Rise 20° C above ambient 20° C above ambient 20° C above ambient 20° C above ambient
Ambient 45° C, Rh-90% @ 25° C  45° C, Rh-90% @ 25° C  45° C, Rh-90% @ 25° C  45° C, Rh-90% @ 25° C 
Cooling type  Force Cooled  Force Cooled  Force Cooled  Force Cooled
Panel Enclosure Protection As per IP42 As per IP42 As per IP42 As per IP42

 Note: Alternate ratings also done depending on site study analysis and customer requirement
           

  • For all these items refer to the respective product manuals for detailed specifications.
  • Alternatively customers specifications can be adopted - 1:1:1:1 - 1:2:4:8
  • Panel Drawing submitted for Approval
  • Specifications are subject to change without prior notice due to continuous improvement in product development.

 

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