Power factor is a measurement of how efficiently a facility uses electrical energy. A high power factor means that electrical capacity is being utilized effectively, while a low power factor indicates poor utilization of electric power.
Any circuit that has inductive loads such as motors would have some sort of losses in the circuit that affect the whole network. They also act as generators producing current that distort the current in the network and put it out of phase with the volt. When a current passes through motor, the motor will act as a generator of electrical energy at some stages due to – amongst other factors- the magnetic field variation that will cause phase difference between the voltage and current.
Power = Volt * Amperes * Power Factor
Power Factor = Real Power KW/ Apparent Power KVA
If a generator is rated to give 2000 Amps at a voltage of 400 V, it means this is the highest current and voltage value the machine can give without temperature exceeding safe value. Consequently the rating of the generator is given 400*2000/1000 = 800 KVA the phase difference between the voltage and current depends upon the nature of the load and not upon the generator. Thus if the power factor of the load is 1, the 800 KVA are also 800 KW; and the engine driving the generator has to be capable of delivering this power together with the losses in the generator. But if the power factor of the load is 0.5, the power is only 800 KVA*0.5= 400 KW; so the engine is developing only about one-half of the power of which it is capable, though the generator is supplying its rated 800 KVA.
Similarly, the conductors connecting the generators to the load have to be capable of carrying 2000 Amps without excessive temperature rise; consequently they can transmit 800 KW if the power factor is one but only 400 KW at 0.5 power factor for the same rise in temperature.
It is therefore evident that the higher the power factor of the load, the greater is the power that can be generated by a given generator and transmitted by a given conductor.
For a given power, the lower the power factor, the larger must be the size of the generator to generate that power and greater must be the cross-sectional area of the conductor to transmit it; in other words, the greater is the cost of generation and transmission of electrical energy. This is the reason why supply authorities do all they can to improve the power factor of network loads either by installation of capacitors or by use of tariffs which encourage consumers to do so.
SITUATION
A provides for financial, marketing and business communications services around the world. The facility, a world class printing plant, had excessive charges from their electrical power provider based on their facility’s abnormally low power factor levels.
PROJECT
An expert identified the source of the low power factor levels and designed a power factor correction strategy. By installing low harmonic distortion electronically controlled capacitor banks into the facility’s electrical network the power factor level was corrected, thereby eliminating the periodic demand charges from the utility.
RESULTS
Before power factor correction
Annual demand charge = $ 100,023
Average power factor = 0.85
After power factor correction
Annual demand charge =$ 95,285
Average power factor = 0.93
Savings
Annual demand charge savings =$ 4,738
Solution investments (capacitor) =$ 6,882
Return on investment 69%
This is a case study for a Boston USA based business.