minimizing penalty of industrial power consumption by

© International Journal of Research in Engineering and Management

Vol. 4, 2020, pp.52 – 61 www.ijrem.in

52

Minimizing Penalty of Industrial Power Consumption by Engaging APFC

Unit at Micro Distribution in Thermal Power Station-1 Expn NLCIL

R. Senthil Kumar1, L. Vijay Anand2,U. Abinaya3, P. Hariharan4, S. Ajithrao5

1,2 Assistant Professor, 3,4,5UG Scholar,

Department of Electrical & Electronics Engineering,

Erode Sengunthar Engineering College, Erode, Tamil Nadu-638057.

ABSTRACT— In the Thermal Power Station-1 Expn NLCIL at micro distribution unit there are various

motoring loads i.e. (inductive loads)which are continuously running and increasing the inductive load.

So the power factor in that system get reduces due to the inductive reactive power. The reduction in

power factor affects the supply where it is from i.e. the Substations, Generation units, Distributing

transformers, etc. So to avoid this the electricity board has a standard limit regarding the power factor

values and if the power factor goes below the specified limit the electricity company charges penalty to

the respective industrial consumers. Power factor losses represent a significant factor of power losses in

both industrial and domestic units. Various methods have been devised earlier to tackle this problem.

This paper aims to present an indigenous technique and method which could be used for automatic

power factor correction. It is demonstrated in this work that phase difference between voltage and

current can be determined using zero crossing detectors, opto-couplers, EXOR gate and some basic

function of Arduino microcontroller. The phase difference between voltage and current values are

calibrated as phase angle and corresponding power factor is determined. Then the motherboard

calculates the compensation requirement and accordingly switches on different capacitor banks by using

a relay driver. In our project we have used Arduino Nano microcontroller.

Keywords: Power factor, ARDUINO NANO microcontroller, capacitor bank, current transformer,

potential transformer, relay driver.

INTRODUCTION

In the Thermal Power Station-1 Expn NLCIL at micro distribution unit there are various

auxiliary equipment which are continuously running and increasing the inductive load. Because of this

the power factor gets low. The low power factor leads to the increase in the load current, increase in

power loss, and decrease in efficiency of the overall system. In previous various methods, the switching

of the capacitor is manual. In this paper we are using a method of the reactive power compensation by

capacitor switching with automatic control using Arduino Nano microcontroller.

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53

POWER FACTOR

The power factor is the product of the cosine value of voltage and current in the system. The

active power is the real power delivered to the loads such as motors, lamps etc. The reactive power is

used just for the purpose of producing magnetic field for the flow of active power. The apparent power

is the combination of the active and reactive power. The load current of any motor consist of the

resistive component and inductive component. The inductive component consists of leakage current and

magnetizing current. The leakage current is totally dependent on the load current but the magnetizing

component is nearby 20 to 60% of the full load current. The capacitors are employed to reduce inductive

reactance in the induction motor thereby reducing losses in the supply.

SOURCES OF REACTIVE POWER

Inductive loads decrease the power factor.

Transformers

Induction Motors

Induction generators (wind mill generators)

High Intensity (HID) lighting

BENEFITS OF POWER FACTOR CORRECTION

The advantages that can be achieved by applying the power factor correction are:

Environmental benefit-reduction of power consumption due to improved energy efficiency.

Reduced power consumption means less greenhouse gas emissions and fossil fuel depletion by

Power stations.

Reduction of electricity bills.

Extra kVA available from the existing supply.

In transformers and distribution equipment I2R losses decrease.

In long cables reduction of voltage drop.

Extended equipment life- reduced electrical burden on cables and electrical Component.




54

PROPOSED SYSTEM

The microcontroller is the heart of the automatic power factor correction unit. It processes the algorithm

which are specified by the user to ensure the variation in the

powerfactorinspecifyinglimitandmaintainpowerquality.Thecurrenttransformer and voltage transformer

are used to get the current and voltage signal which are input to the microcontroller. The automatic

power factor correction unit detects the phase lag between the voltage and current waveform by using

zero crossing detector to determine the existing power factor as shown in the fig.1.1. To bring it to unity,

it is required to connect capacitor bank in parallel with the system. The number of capacitor that is to be

connected for compensation is determined by the algorithms in microcontroller. When the power factor

is not near to unity then the microcontroller sends the signal to relay driver unit which will switch the

number of capacitor. So that the auxiliary power consumption gets reduced which in turn maintains the

power factor nearer to the unity and the penalty can be avoided which is issued to Thermal Power

Station-1 Expn NLCIL.

Fig.1 Proposed Block Diagram of APFC Unit.




55

CIRCUIT DIAGRAM

Fig.2 Proposed Circuit Diagram.

The fig.2.1 shows the complete circuit diagram of the proposed project.

The current transformer and potential transformer are used to get the current and voltage

signal which are input to the microcontroller.

The voltage and current lag value is measured by zero crossing detector in the

microcontroller.

To bring it nearer to unity, it is required to connect the capacitor banks in parallel with the

load.

The number of capacitor banks to be connected for compensation is determined by the

algorithm as shown in the flow chart 4.1.

When the power factor is not nearer to unity then the microcontroller sends the signal to relay

driver unit which will switch the number of capacitors to be added to bring the power factor

nearer to unity i.e. 0.96 in the project.




56

HARDWARE SETUP

Fig.3 Hardware Setup.

The fig.3.1 is the hardware setup of the project. It has various hardware components with it and they all

are connected as the circuit diagram shown in fig.2.1.

HARDWARE COMPONENTS

Transformer

Potential Transformer

Current Transformer

LCD Display

Zero crossing detector

Microcontroller (ARDUNIO NANO)

Relay driver

Capacitor

SOFTWARE REQUIREMENTS

Proteous simulation software

Arduino sketch software




57

ALGORITHM

The below drawn flow chart 4.1 is the step by step procedure for the program and function of the

microcontroller.

Fig. 4 Flow chart Algorithm of the APFC Unit.

GET VOLTAGE

SIGNAL FROM PT

START

GET CURRENT

SIGNAL FROM CT

MEASURE THE PHASE SHIFTANGLE

BETWEEN CURRENT AND VOLTAGE VALUE

CALCULATE POWER FACTOR

& DISPLAY

IS POWER

FACTOR >=0.96

APPLY CAPACITORS

PARALLEL TO THE

SUPPLY

YES NO




58

POWER FACTOR FOR DIFFERENT CAPACITOR BANKS

The below table shows the various power factor values for various capacitors connected.

VARIOUS AUXLIARY EQUIPMENTS OF THE MICRO DISTRIBUTION SYSTEM AT

THERMAL POWER STATION-1 EXPN NLCIL.

The below table shows the Auxiliary Equipment and their power consumption in Micro Distribution System at

Thermal Power Station-1 Expn NLCIL.

EXAMPLE CACULATIONS FOR CWP AND FD FAN IN THERMAL POWER STATION-1

EXPN NLCIL.

SL.NO DESCRIPTION BFP CEP ID FAN FD FAN CWP MILL CONVEYERS

1 Capacity(KW) 3500 630 2600 1510 1450 1000 500

2 Voltage(V) 6600 6600 6600 6600 6600 6600 6600

3 Full load current(A) 356.5 64.5 271 154 163 107 52

4 Frequency (HZ) 50 50 50 50 50 50 50

5 Speed (RPM) 1489 1483 995 1490 497 500 1481

6 Power factor 0.89 0.89 0.89 0.80 0.80 0.82 0.82

CWP:

Capacity = 1450 KW

Voltage = 6600 V

Current = 163 A

Frequency = 50 HZ

Cosф1 = 0.80 Ф1= cos-1(0.8)

tanф1= 0.7497

cosф2= 0.85

ф2=cos-1(0.85) = 31.78

tanф2=0.619

To find reactance:

Q =P (tanф1-tanф2) Q=1450(0.1307)

Q =189515VAR

To find capacitance:

C = KVAR/2𝜋FV2

C = 189515/1.36847776×1010 C = 1.38µF

Resultant power factor = 0.96

FD COOLING FAN:

Capacity = 1510 KW

Voltage = 6600 V

Current = 154 A

Frequency = 50 HZ

Cosф1 = 0.80

Ф1 = cos-1(0.80) = 36.86

tanф1 = 0.7497

cosф2 = 0.85

ф2 = cos-1(0.85) = 31.78

tanф2 = 0.619

To findreactance:

Q = P (tanф1-tanф2)

Q = 1510(0.1307)

Q = 197357VAR

To find capacitance:

C = KVAR/2𝜋𝐹𝑉2

C = 197357/1.3684777×1010

C = 1.44µF

Resultant power factor = 0.97




59

RESULT

Fig.5 capacitance connected count 0 p.f = 0.76Fig.6 capacitance connected count 1 p.f = 0.80

Fig.7 capacitance connected count 2 p.f = 0.86Fig.8 capacitance connected count 3 p.f = 0.90

Fig.9 Capacitance connected count 4 p.f = 0.96

Thus the power factor has been successfully corrected from 0.76 to 0.96. So that the auxiliary power consumption

gets reduced from 9.5% to 8% nearly 1.5% of auxiliary power consumption is reduced and the penalty is

prevented. And also the supply side is also protected from high I2R losses and heating effect. Thus the APFC unit

works and maintains the power factor at a leading but lagging value and protects the whole Electricity Grid. And

the auxiliary power consumption gets reduced which in turn maintains the power factor nearer to the

unity and the penalty can be avoided which is issued to Thermal Power Station-1 Expn NLCIL.




60

CONCLUSION

This project has proposed the automatic method of power factor correction by using the

microcontroller (Arduino Nano) which has more advantages over the various conventional methods of

the power factor compensation. The switching of the capacitor is done automatically by using the relay

and thus the power factor correction is more accurate. Thus we have presented the possible automatic

method for the correction of the power factor. Installation of capacitor bank for power factor correction

will be a profitable on both side i.e. consumers and electric flow. Installation of capacitor bank can

reduce reactive current consumption further minimize the losses. By observing all aspects of the power

factor it is clear that power factor is the most significant part for the utility company as well as for the

consumer. Utility companies get rid from the power losses while the consumer are free from low power

factor penalty charges. The automatic power factor correction using capacitive load banks is very

efficient as it reduces the cost by decreasing the power drawn from the supply as it operate

automatically, manpower are not required and the power factor correction using capacitive load bank

can be used for the industry purposes. By applying this project in the micro distribution unit at Thermal

Power Station-1 Expn NLCIL. the auxiliary consumption is reduced from 9.5% to 8%, thereby 1.5% of

auxiliary power consumption is reduced. By doing so the industry is prevented from the penalty and

some amount of power was been saved. This project has been successfully applied in micro distribution

unit at Thermal Power Station-1 Expn NLCIL, reducing the auxiliary consumption of energy. Hence

power consumption is also reduced and the industry was safe guarded from penalty.

REFERENCES

[1] Ararso Taye M.Tech, Electrical Engineering Department, Parul University, India, ‘’Design and

simulation of automatic power factor correction for industry application’’ [Taye*, Vol.5 (Iss.2):

February, 2018] ISSN: 2454-1907 DOI: 10.5281/zenodo.1173999, IEEE.

[2] Waqas AliHaroon Farooq Mohsin Jamil Ata Ur Rehman Rana Taimoor Dept. of Electrical

Engg.(RCET), niversity of Engg. and Tech. Lahore, Lahore, Pakistan, ” Automatic power factor

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[3] Yasin Kabir,1,*Yusuf Mohammad Mohsin1, Department of Electrical and Computer

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[4] Maryam Nabihah Zaidi1,*, Adlan Ali1 1Department of Electrical Engineering

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61

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