Eskom

Power factor: Sizing guide

Fact Sheet

Reducing Determining the required to correct a lagging power factor

electricity 1 power factor 2 of a 3-phase motor; follow the following
steps:
costs with correction Step #1: Determine the kW and existing
improved requirements power factor.
power factor Step #2: Find the existing power factor in
The total kVAR rating of capacitors required the table on the left (in bold) – then move
This is the third brochure in the power to improve power factor to any desired across the Table to the desired power factor.
factor series - the other two brochures value can be calculated by using the table The number represented is your multiplier
are Power Factor: Basic Overview, published by leading power factor capacitor number.
and Power Factor: Technical Overview manufacturers. Step #3: Multiply the kW by the multiplier
Guides. The aim of this brochure is to Using the Table below: of the desired power factor.
provide sizing and payback information To properly select the amount of kVAR
for power factor correction equipment Capacitor correction factor
and should be read in conjunction with Power factor (Cos θ2) after improvement:
the rest in the series. 1.0 0.99 0.98 0.97 0.96 0.95 0.94 0.93 0.92 0.91 0.90 0.85 0.80
0.50 1.73 1.59 1.53 1.48 1.44 1.40 1.37 1.34 1.30 1.28 1.25 1.11 0.98
0.52 1.64 1.50 1.44 1.39 1.35 1.32 1.28 1.25 1.22 1.19 1.16 1.02 0.89
A facility’s power factor will rarely be at
0.55 1.52 1.38 1.32 1.27 1.23 1.19 1.16 1.12 1.09 1.06 1.04 0.90 0.77
100% if the load is mainly uncompen- 0.57 1.44 1.30 1.24 1.19 1.15 1.11 1.08 1.05 1.01 0.99 0.96 0.82 0.69
sated inductive loads. Improving poor 0.6 1.33 1.19 1.13 1.08 1.04 1.01 0.97 0.94 0.91 0.88 0.85 0.71 0.58

power factor is not difficult and often 0.62 1.27 1.23 1.06 1.01 0.97 0.94 0.90 0.87 0.84 0.81 0.78 0.65 0.52
Power factor (Cos θ1) before improvement:

a guaranteed mechanism of saving on 0.65 1.17 1.03 0.97 0.92 0.88 0.84 0.81 0.77 0.74 0.71 0.69 0.55 0.42
0.67 1.11 0.97 0.91 0.86 0.82 0.78 0.75 0.71 0.68 0.65 0.62 0.49 0.36
expensive electricity supply upgrades
0.7 1.02 0.88 0.81 0.77 0.73 0.69 0.66 0.62 0.59 0.56 0.54 0.40 0.27
and the existing electricity bill. Correct- 0.72 0.96 0.82 0.75 0.71 0.67 0.63 0.60 0.57 0.53 0.51 0.48 0.34 0.21
ly sized power factor correction equip- 0.75 0.88 0.74 0.67 0.63 0.58 0.55 0.52 0.49 0.45 0.43 0.40 0.26 0.13

ment would ensure optimal correction 0.77 0.83 0.69 0.62 0.58 0.54 0.50 0.47 0.43 0.40 0.37 0.35 0.21 0.08

meaning you pay for exactly what you 0.80 0.75 0.61 0.54 0.50 0.46 0.42 0.39 0.35 0.32 0.29 0.27 0.13
0.82 0.70 0.56 0.49 0.45 0.41 0.37 0.34 0.30 0.27 0.24 0.21 0.08
need and no more.
0.85 0.62 0.48 0.42 0.37 0.33 0.29 0.26 0.22 0.19 0.16 0.14
0.87 0.57 0.42 0.36 0.32 0.28 0.24 0.20 0.17 0.14 0.11 0.08
0.90 0.48 0.34 0.28 0.23 0.19 0.16 0.12 0.09 0.06 0.02
0.91 0.45 0.31 0.25 0.21 0.16 0.13 0.09 0.06 0.02
0.92 0.43 0.28 0.22 0.18 0.13 0.10 0.06 0.03
0.93 0.40 0.25 0.19 0.15 0.10 0.07 0.03
0.94 0.36 0.22 0.16 0.11 0.07 0.04
0.95 0.33 0.18 0.12 0.08 0.04
0.96 0.29 0.15 0.09 0.04
0.97 0.25 0.11 0.05
0.98 0.20 0.06
0.99 0.14
The following are some practical examples of calculating the Example 3:
required correction: An energy audit for a facility provides the following measure-
ments at the load side of the transformer; 480V, 1 200A and
Example 1: 800kW operating load.
If a 150kW electric motor has a power factor before improve- i. Calculate the power factor, and,
ment of 0.75 (Cos Ѳ1), and we require a power factor of = 0.96 ii. Calculate the reactive power (kVAR) in the system
(Cos Ѳ2) – the capacitor correction factor from the Table above
is 0.58. The required kVAR capacity can then be calculated as Solution
C = (150 kW) x 0.58 = 87 kVAR. i) To calculate the power factor, first calculate the KVA in
the system.
If kW or present power factor is not known you can calculate V x A x √3 480 x 1 200 x √3
the required compensation using the following formulas (appli- kWA = = = 1 000 kVA
1 000 1 000
cable for 3 phase supply only) to get the 3 basic pieces of infor-
mation required for calculating kVAR: Substitute the kVA into the power factor formula
kW (Real Power) kW 800
P.F. = P.F. = = = 0.8 or 80% P.F.
kVA (Apparent Power) kVA 1 000

1.73 x 1 x E ii) To calculate the reactive power (kVAR) in the system
kVA =
1 000 requires re-arranging the formula kVA2 = kW2 + kVA2 and
solving for kVAR.
1.73 x 1 x E x P.F. H.P. x 0.746
kW = or kW =
1 000 efficiency
Example 4:
Example 2: The measurement at the main distribution board of a manufac-
What kVAR compensation is required to correct an existing turing facility measures 1 000 kVA and 800 kW. Determine the
power factor of 62% to 95% for a three phase induction motor system kVAR and power factor of the facility. Also determine
operating at 500V and 62A: the kVAR required for achieving a power factor of 0.95 while
providing the same power load of 800 kW.
Where
I = full load current in amps Solution
E = voltage of motor/equipment Measured kVA = 1 000
P.F. = present power factor as a decimal (80% = 0.80) Measured kW = 800
H.P. = rated horsepower of motor/equipment
eff. = rated efficiency of motor as a decimal (83% = 0.83) i) The system kVAR and power factor of the facility

kVAR = √(kVA2 - kW2 = √1 0002 - 8002 = 600 kVAR

NOTE: If the desired power factor is not provided; 95% is a
good economic power factor for calculation purposes kW 800
P.F. = = = 0.8 or 80% P.F.
kVA 1 000
Solution ii) The system kVAR after power factor correction to 0.95
i) Actual power: - System kVA after correction
kW = 500 x 62 x 0.62 x 1.732/1 000 = ~33 kW kW 800
kVA. = = = 843 kVA
ii) The leading reactive power kVAR necessary to raise the P.F. 0.95
power factor to 95% is calculated by multiplying 33kW with - System kVAR after correction
the factor found from the correction Table for capacitor
kVAR = √(kVA2 - kW2 = √ 8432 - 8002 = 265 kVAR
selection (refer above), which would be 0.937.
33kW x 0.937 = 30.92 kVAR ii) iii) The power factor correction kVAR rating
Use 30 kVAR Power Factor Correction kVAR
= kVAR (uncorrected) – kVAR (corrected)
= 600 – 265 = 335 kVAR

Use the multiplier table for capacitor selection (refer Table above)
when the kW load, uncorrected power factor and the desired
power factor are known; as shown in examples above.
Example 5: Solution
Billing based on kW demand charges The kVA demand can be reduced if the power factor is raised.
An industrial plant has a demand of 1 000 kW and operates Usually, 95% is a good economic power factor when the de-
at 80% power factor. The electricity utility supplying power to mand charges are based on kVA charges.
this facility requires a minimum power factor of 85% and levies
a kW demand charge (penalty) of R80.00 in the electricity bill. i) The present power factor = kW / kVA = 400 / 520 = 77%
Determine the savings possible by improving the power factor ii) Present demand charge = 520 x R30 = R15 600
to the minimum required target of 0.85 along with the payback
iii) Assume the target new power factor to be 95%. This would
period when investing on power factor correction.
reduce the present 520 kVA demand down to 421 kVA.
The calculation as follows:
Solution
Reduced kVA = kW / modified power factor = 400 / 0.95
i) The monthly kW billing amount is determined with the ratio
= 421 kVA
of the target power factor to the existing power factor, times
kW demand. iv) Modified demand charge = 421 x R30 = R12 630
kW billing on power factor is 0.80. v) Likely Savings = R15 600 - R12 630 = R2 970
The monthly kW billing: 1 000kW x 0.85 target P.F. / 0.80
vi) The kVAR required to increase the power factor from
existing P.F. = 1 062 kW
0.77 to 0.95
Total demand charge @ R80.00 = 1 062kW x R80.00
The multiplying factor = 0.5 (from the capacitor estimation
= R84 960
Table above)
ii) kVAR required to increase the power factor from 0.8 to 0.85
Therefore kVAR required = 0.5 x 400 = 200 kVAR
The multiplying factor = 0.13 (from the capacitor estimation
Table above) vii) The power factor correction investment
Therefore kVAR required = 0.13 x 1 000 = 130 kVAR Cost of 200 kVAR power factor correction (on a 480 volt
system, installed power factor correction cost is assumed
iii) Power factor correction investment
to be R150 per kVAR)
Cost of 130 kVAR power factor correction (on a 480 volt
200 kVAR x R150.00 = R30 000
system, installed power factor cost is assumed to
be R150 per kVAR) viii) The payback period
130 kVAR x R150.00 = R1 950 Monthly savings on demand charge = R2 970
Investment on power factor correction = R30 000
iv) The kW billing on the new power factor of 0.85
Simple payback = cost/ savings = R30 000 / R2 970
The monthly kW billing: 1 000kW x 0.85 target P.F. / 0.85
= approx 10 months.
modified P.F. = 1 000 kW
(NOTE: The savings will continue thereafter).
Modified demand charge @ R80.00
= 1 000kW x R80.00 = R80 000
In addition, by installing the 200 kVAR power factor correction
v) The payback period an additional 20% capacity is immediately available for new
Monthly savings on demand charge electrical loads without installing any new transformers, power
= R84 960 - R80 000 = R4 960 lines or distribution equipment.This is important because in crit-
Investment on power factor correction = R1 950 ical times the new transformers and power lines may be difficult
Simple payback = cost/ savings = R1 950 / R4 960 to get in time, and their costs, in most cases, would exceed the
= approx 3.9 months. R30 000 spent for power factor correction.
(NOTE: The savings will continue thereafter)

Example 6:
Billing based on KVA demand charges
An industrial plant is operating at 400 kW and maximum de-
mand of 520 kVA. The facility has electricity contract based kVA
demand charges, which will reduce as the power factor is im-
proved. The demand charges rate is fixed @ R30.00 per month
per kVA.

Determine the savings possible by improving the power factor

along with the payback period of the investment in power fac-
tor correction.
Example 7: Example 8:
Billing based on kW and KVAR demand charges Increased system capacity
A hotel complex with majority of HVAC and lighting loads has A facility electrical system is operating with the following electri-
a contract with power factor which includes an energy charge cal characteristics:
for kWh, a demand charge based on kW and another demand kVA = 1 000 kW = 800 kVAR = 600 P.F. = 0.80.
charge based on kVAR. The kVAR charge is R15 per month for Calculate how much spare capacity can be released by improv-
each kVAR demand in excess of 1/3 (33.3%) of the kW demand. ing the power factor to 0.95.
The operating electrical characteristics involved are 1 800 kVA,
1 350 kW and 1 200 kVAR. Calculate the possible savings on Solution
reducing the kVAR demand charges with the correction of the The uncorrected system can only support 800 kW loads at a
power factor along with the simple payback. power factor of 0.80.
The graph below (taken from the Technical Overview brochure)
Solution: shows the empirical relationship of the system capacity against
i) The excess kVAR demand can be eliminated by correcting the existing factor. From the graph it is found that improving the
the power factor. kVAR demand in excess of 1/3 (33.3%) of power factor from 0.8 to 0.95 will release approximately 20%
the kW demand can be calculated as: system capacity.
1 350 kW
1 200 kVAR = = 750 kVAR x 1 System Capacity vs Power Facor
3 80
Released System Capacity %

70
This implies that a 750 kVAR supply, if corrected with Power
60
Factor correction, can do away with the extra demand charges.
50
ii) Estimated annual electricity bill savings 40
R15 demand charge x 750 kVAR x12 months = R11 250 30
savings per annum 20 20%

iii) Estimated cost of 750 kVAR power factor correction 10

The assumed cost of 480 volt, 50 Hz power factor correction 0

. 4 0 . 4 5 .50 .55 .60 .65 .70 .75 .80 .85 .90 .95 1.00
is R150 per kVAR.
Corrected Power Facor
Therefore, the total investment for 750 kVAR power factor
correction will be
750 kVAR x R150 = R112 500
800 kW + 20% = 960 kW
iv) The simple payback period The corrected system will now be capable of supporting
R11 250 annual savings against the R112 500 power factor 960 kW loads.
correction investment: Hence, the system capacity has been increased by
The power factor correction will pay for itself in 10 months, 160 kW (20%).
and NOTE: will continue to produce the savings thereafter.
Example 9: The original facility system losses of 5% are then reduced by
Lowering losses 5 x 36 /100 = 1.8%
Assume the facility system wide losses = 5%, with a current As a result the monthly kWh bill is reduced by 1.8%, in
power factor of 0.80. Estimate the reduction in losses when the additional savings.
power factor correction is made at the load points to unity.
(Unity = 1.0 = 100%). An MS Excel spreadsheet to automatically calculate most
of the above is available
Solution: http://www.eskom.co.za/sites/eas/Energy%20solutions/Pages/Power-
Improving the power factor at the load points will relieve the Factor.aspx.
system of transmitting reactive current. Less current will result It is important to note that these calculations is indicative
in lower losses in the facility distribution system since losses are and the design needs to be done by a professional.
proportional to the square of the current (12R).Therefore, fewer
kilowatt-hours will need to be purchased from the electricity Conclusions
utility.
Improving power factor is a proven way of
3
An estimate of the reduction in electricity losses can be made increasing the efficient use of electricity by utilities
using the following equation: and consumers.
% Reduction of Power Losses
Original Power Factor 2 Economic benefits for consumers may include reduced ener-
= 100 - 100 gy costs, lower cable and transformer losses, improved voltage
Improved Power Factor
conditions and benefits due to released and additional system
or = 100 - 100 (0.80
1.0
2

( capacities.
= 100 - 100 (0.64)
= 36% Power Factor Correction is an effective, proven, and efficient
means of improving electricity consumption.
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References:
a) The economics of improving power factor, Ed Kwiatkowski, BSEE, MS, Staco Energy Products Co,
6
November 2, 2010, https://www.csemag.com/articles/the-economics-of-improving-power-factor/
b) http://www.capacitorconverters.com
c) http://thegrid.rexel.com
d) Commonwealth Sprague Capacitor, Inc. Power Factor Correction, A Guide for the Plant Engineer. 1987. Gustafson, R. J. Fundamentals
of Electricity for Agriculture. AVI Publishing Co. Inc., pp. 35-58.1980.
e) McCoy, G. A; Douglass, J. G. An Energy Management Guide for Motor Driven Systems. Bonneville Power Admin- istration. Draft,
December 1995.
f) PDH Course E144, Power Factor in Electrical Energy Management, PDH Center, A. Bhatia, B.E. 2012, PDHcenter.com
g) Square D Company. Low Voltage Power Factor Capacitors. 1985.
h) Power factor correction: a guide for the plant engineer, EATON, Cleveland, USA
i) Turner, W.C. Energy Management Handbook. John Wiley and Sons, pp. 337-345. 1982.
j) U.S. Energy Information Administration, Empirical Relationship of System Capacity vs. Power Factor.

Power factor: Sizing Guide Fact Sheet

Issued by Energy Advisory Service February 2020
Eskom Holdings SOC Ltd Reg No 2002/015527/30
Job 3431