ABB targets power factor savings at process plants
5 Apr 2011
London – Power factor (PF) is a big issue for UK industry that impacts energy efficiency and electricity bills as well as the reliability and availability of network infrastructure.
PF is the relationship between the active and reactive power on an electricity distribution network. If it is 100% efficient then the PF would be 1. All UK electricity suppliers impose a penalty charge when power factor is lower than 0.95
Equipment such as AC motors, arc welders, furnaces, fluorescent lighting and air conditioning can cause a poor PF. The more inductive loads on a network then the more likely it is to have a poor PF, according to ABB which has introduced equipment to help increase network PF.
ABB’s new Vector series of automatic capacitor banks is designed to provide a PF correction (PFC) solution for industrial and commercial low voltage networks. It employs a dry capacitor technology delivered in a modular system.
Target industry markets include mining, chemicals, pulp & paper, cement, plastics, petrochemical and food & beverage.
The company cites and example of a food manufacturing company with a maximum demand of 637 kW and a PF of 0.85.
With the cost of a PFC system, including installation, estimated at £5,800, the company could achive potential annual savings in reactive power charges and authorised supply capacity (ASC) equivalent to a return on investment of 1.3 years.
Similarly, a ceramics manufacturer with maximum demand of 665kW and a PF of 0.78 could get a return on investment of 1.6 years – based on a cost of PFC including installation of £8,000.
Power factor correction – the potential benefits
Installing PFC equipment can provide a number of customer benefits:
· Eliminating expensive utility penalties for a poor power factor
· Improved energy efficiency – reduced system currents and kW losses
· Security of supply - reduction in peak currents prevents fuse failure and loss of supply
· Release additional capacity – to take advantage of the full current capacity available in existing transformers, switchgear and supply cables
· Increase system load without the need to invest in additional infrastructure
· Reduced kWh losses mean that less power needs to be generated, so less CO2 is produced
· Increased service life of infrastructure – since the amount of heat generated within cables, switchgear, transformers and other equipment is reduced.
