L&T Reactive Power Management
L&T Reactive Power Management
L&T Reactive Power Management
Products
About us
Larsen & Toubro is a technology-driven USD 8.5 billion company that infuses
engineering with imagination. The Company offers a wide range of advanced
solutions in the field of Engineering, Construction, Electrical & Automation,
Machinery and Information Technology.
L&T Switchgear, which forms part of the Electrical & Automation business, is
India's largest manufacturer of low voltage switchgear, with the scale,
sophistication and range to meet global benchmarks. With over four decades
of experience in this field, the Company today enjoys a leadership position in
the Indian market with growing presence in international markets.
Range of Capacitors 2
Capacitor Technology 7
Reactors-Harmonic Filters 13
Overall Dimension 19
Reactive Power Management Products
Wires
MCCBs
Power Capacitors
MCBs
Capacitor Duty
Contactors
APFC Panels
Reactors
Quasar Meters
Thyristor Switching
Modules
Indicating Devices
1
Range of Capacitors
Power Capacitors
Heavy Duty
Gas Filled
Range from
5-25 kVAr
2
Principles of Power Factor Correction
A vast majority of electrical loads in low voltage industrial installations are inductive in nature. Typical examples are
motors, transformers, drives & fluorescent lighting. Such loads consume both active and reactive power. The active
power is used by the load to meet its real output requirements whereas reactive power is used by the load to meet its
magnetic field requirements. The reactive power (inductive) is always 900 lagging with respect to active power as shown in
figure1. Figure 2 & 3 show the flow of kW, kVAr and kVA in a network.
Active power
kVA kVA
kVAr
kW kVAr kW
Reactive
Power
LOAD LOAD
Capacitor
Flow of active and reactive power always takes place in electrical installations. This means that the supply system has to
be capable of supplying both active and reactive power. The supply of reactive power from the system results in reduced
installation efficiency due to:
l Increased current flow for a given load
l Higher voltage drops in the system
l Increase in losses of transformers, switchgear and cables
l Higher kVA demand from supply system as given in figure 2
l Higher electricity cost due to levy of penalties/loss of incentives
It is therefore necessary to reduce & manage the flow of reactive power to achieve higher efficiency of the electrical
system and reduction in cost of electricity consumed.
The most cost effective method of reducing and managing reactive power is by power factor improvement through
Power Capacitors. The concept of reduction in kVA demand from the system is shown in figure 3.
3
Step 1: Calculation of kVAr required for Industries & Distribution Networks
In electrical installations, the operating load kW and its average power factor (PF) can be ascertained from the electricity
bill. Alternatively, it can also be easily evaluated by the formula: Average PF = kW/kVA
Operating load kW = kVA Demand x Average PF
The Average PF is considered as the initial PF and the final PF can be suitably assumed as target PF. In such cases
required capacitor kVAr can be calculated as sited in below table.
Example to calculate the required kVAr compensation for a 500 kW installation to improve the PF from 0.75 to 0.96
kVAr = kW x multiplying factor from table = 500 x 0.590 = 295 kVAr
Note: Table is based on the following formula: kVAr required = kW (tanØ1 - tanØ2)
where Ø1 = cos-1 (PF1) and Ø2= cos-1(PF2).
Initial PF Target PF
0.9 0.91 0.92 0.93 0.94 0.95 0.96 0.97 0.98 0.99
0.4 1.807 1.836 1.865 1.896 1.928 1.963 2.000 2.041 2.088 2.149
0.42 1.676 1.705 1.735 1.766 1.798 1.832 1.869 1.910 1.958 2.018
0.44 1.557 1.585 1.615 1.646 1.678 1.712 1.749 1.790 1.838 1.898
0.46 1.446 1.475 1.504 1.535 1.567 1.602 1.639 1.680 1.727 1.788
0.48 1.343 1.372 1.402 1.432 1.465 1.499 1.536 1.577 1.625 1.685
0.5 1.248 1.276 1.306 1.337 1.369 1.403 1.440 1.481 1.529 1.590
0.52 1.158 1.187 1.217 1.247 1.280 1.314 1.351 1.392 1.440 1.500
0.54 1.074 1.103 1.133 1.163 1.196 1.230 1.267 1.308 1.356 1.416
0.56 0.995 1.024 1.053 1.084 1.116 1.151 1.188 1.229 1.276 1.337
0.58 0.920 0.949 0.979 1.009 1.042 1.076 1.113 1.154 1.201 1.262
0.6 0.849 0.878 0.907 0.938 0.970 1.005 1.042 1.083 1.130 1.191
0.62 0.781 0.810 0.839 0.870 0.903 0.937 0.974 1.015 1.062 1.123
0.64 0.716 0.745 0.775 0.805 0.838 0.872 0.909 0.950 0.998 1.058
0.66 0.654 0.683 0.712 0.743 0.775 0.810 0.847 0.888 0.935 0.996
0.68 0.594 0.623 0.652 0.683 0.715 0.750 0.787 0.828 0.875 0.936
0.7 0.536 0.565 0.594 0.625 0.657 0.692 0.729 0.770 0.817 0.878
0.72 0.480 0.508 0.538 0.569 0.061 0.635 0.672 0.713 0.761 0.821
0.74 0.425 0.453 0.483 0.514 0.546 0.580 0.617 0.658 0.706 0.766
0.75 0.38 0.426 0.456 0.487 0.519 0.553 0.590 0.631 0.679 0.739
0.76 0.371 0.400 0.429 0.460 0.492 0.526 0.563 0.605 0.652 0.713
0.78 0.318 0.347 0.376 0.407 0.439 0.474 0.511 0.552 0.699 0.660
0.8 0.266 0.294 0.324 0.355 0.387 0.421 0.458 0.499 0.547 0.608
0.82 0.214 0.242 0.272 0.303 0.335 0.369 0.406 0.447 0.495 0.556
0.84 0.162 0.190 0.220 0.251 0.283 0.317 0.354 0.395 0.443 0.503
0.85 0.135 0.164 0.194 0.225 0.257 0.291 0.328 0.369 0.417 0.477
0.86 0.109 0.138 0.167 0.198 0.230 0.265 0.302 0.343 0.390 0.451
0.87 0.082 0.111 0.141 0.172 0.204 0.238 0.275 0.316 0.364 0.424
0.88 0.055 0.084 0.114 0.145 0.177 0.211 0.248 0.289 0.337 0.397
0.89 0.028 0.057 0.086 0.117 0.149 0.184 0.221 0.262 0.309 0.370
0.9 0.029 0.058 0.089 0.121 0.156 0.193 0.234 0.281 0.342
0.91 0.030 0.060 0.093 0.127 0.164 0.205 0.253 0.313 0.313
0.92 0.031 0.063 0.097 0.134 0.175 0.223 0.284
0.93 0.032 0.067 0.104 0.145 0.192 0.253
0.94 0.034 0.071 0.112 0.160 0.220
0.95 0.037 0.078 0.126 0.186
4
Step 2: Selection of Capacitors
Selecting the type of Capacitor is the first decision to be made. Power Factor Correction Capacitors can be classified
as follows:
l Standard duty
l Heavy duty
l Ultra Heavy duty
Permissible Maximum
Over Voltage Peak Inrush switching
Duty Over Current Temperature
@rated Currents operations/
Voltage 440V year
Standard Duty 1.5 x In 1.1 Un 200 x In -250C to 550C 5000
It is strongly recommended that the above table be followed as a guideline for selecting the appropriate capacitor for a
given application. While choosing the type of duty it is also very important to identify the % age non-linear load in the
system. The method of calculating the % age non-linear load is shown below:
Calculation of Non - linear Load:
Example:
Installed transformer rating = 1000 kVA
Non - linear loads = 100 kVA
%non - linear loads= (non - linear loads / transformer rating) x 100
= (100 / 1000) x 100
= 10%
Examples of non - linear load
UPS, Arc / induction furnace, Rectifiers, AC / DC Drives, Computer, CFL lamps, CNC machines, etc.
5
Step 3: To Avoid Risk of Resonance
To make a choice between the use of Capacitors or Capacitors + Filter reactors. This is important, because it is necessary
to avoid the risk of “Resonance” as the phenomena of “Resonance” can lead to current and harmonic amplification which
can cause wide spread damage to all Electrical & Electronic equipment in the installation including Capacitors. This can
be avoided by installing capacitor + filter reactor.
Caution: It is safer to select a combination of “Capacitor + Filter reactor” so as to ensure that PF improvement is achieved
in a reliable manner and the risk of resonance is avoided.
6
Capacitor Technology
Capacitors are used in many diverse applications, and many different capacitor technologies are available. In low voltage
applications, LT cylindrical capacitors which are made in accordance with metallized polypropylene technology have
proved to be most appropriate and also the most cost effective. Dependent on the nominal voltage of the capacitor, the
thickness of the polypropylene film will differ.
Electrodes (metallized)
Polypropylene Film
Non-metallized Edge
Design of LT Capacitor
Self - Healing
At the end of service life, or due to inadmissible electrical or thermal overload, an insulation breakdown may occur. A
breakdown causes a small arc which evaporates the metal layer around the point of breakdown and re-establishes the
insulation at the place of perforation. After electric breakdown, the capacitor can still be used. The decrease of
Capacitance caused by a self-healing process is less than 100 pF. The self-healing process lasts for a few microseconds
only and the energy necessary for healing can be measured only by means of sensitive instruments.
Point of Breakdown
Top View
Non-conductive Insulating Area
7
Over pressure Tear - off Fuse
At the end of service life, due to inadmissible electrical or thermal overload, an overpressure builds up and causes an
expansion of the cover. Expansion over a certain limit causes the tear-off of the internal fuses. The active capacitor
elements are thus cut-off from the source of supply. The pressure within the casing separates the breaking point so rapidly
that no harmful arc can occur.
Operating Condition
8
Standard Duty Capacitors
L&T Standard Duty Capacitors are metalized polypropylene capacitors from 1kVAr to 25kVAr in cylindrical
configuration and 5-50kVAr in box type configuration. These capacitors come with a stacked winding and are
impregnated with a biodegradable soft resin. These capacitors are self healing type.
The Capacitors come with an over pressure disconnector and finger proof terminals. They can be used to
provide effective power factor correction in industrial and semi industrial applications.
Technical Details
Cylindrical Box
Range (kVAr) 1 - 25 5 - 100
Standards IEC 60831 IEC 60831
Impregnation Resin Resin
Over Voltage withstand
10% 12 h in 24 h 12 h in 24 h
15% 30 m in 24 h 30 m in 24 h
20% 5m 5m
30% 1m 1m
Over Current withstand 1.5*In 1.5*In
Inrush Current withstand 200*In 200*In
No of Operations/ year 5000 5000
Terminals Clamptite Clamptite
0
Ambient Temperature ( C) -25 / D -25 / D
Operating Losses Dielectric <0.2W / kVAr <0.2W / kVAr
Total Operating losses <0.45W / kVAr <0.45W / kVAr
9
Heavy Duty Capacitors
L&T Heavy Duty Capacitors are available from 1-30kVAr in cylindrical and box type construction. These capacitors have
an inrush current withstand of 300 In and an overload withstand capacity of 1.8 In. These capacitors have all features of
standard capacitors however; these are dry type capacitors.
The Capacitors are subjected to an extended period of drying after which the casing is filled with an inert gas to prevent
corrosion of the winding elements and inner electrical contacts. Compact design ensures space saving. Heavy Duty
capacitors have a long life of 130000 hours.
Technical Details
10% 12 h in 24 h 12 h in 24 h 12 h in 24 h
15% 30 m in 24 h 30 m in 24 h 30 m in 24 h
20% 5m 5m 5m
30% 1m 1m 1m
Over Current withstand 1.8*In 1.8*In 1.8*In
Inrush current withstand 250*In 250*In 300*In
No. of Operations / year 8000 8000 8000
Terminals Faston / Screw Faston / Screw Faston / Screw
Ambient Temperature (0C) -25 / D -40 / D -25 / D
Operating Losses Dielectric <0.2W / kVAr <0.2W / kVAr <0.2W / kVAr
Total Operating Losses <0.35W / kVAr <0.35W / kVAr <0.35W / kVAr
10
Ultra Heavy Duty Capacitors
The winding element of Ultra Heavy Duty Capacitors consists of a dielectric polypropylene film and an electrode of double
sided metalized paper. The winding construction achieves low losses and high pulse current withstand capability. Oil is
used for impregnation of the capacitor. Oil impregnation enables good heat dissipation from the winding element to the
aluminum can's surface, thus preventing hot spots in the winding element. The capacitor is designed to operate under
ambient temperatures upto 70 degrees.
Technical Details
Cylindrical
Range (kVAr) 5 - 30
Standards IEC 60831
Impregnation Oil
Over Voltage withstand
10% 12 h in 24 h
15% 30 m in 24 h
20% 5m
30% 1m
Over Current withstand 3*In
Inrush Current withstand 500*In
No. of Operations/ year 20000
Life (hrs) 300000
Terminals Clamtite
0
Ambient Temperature ( C) -40 to 70
Operating Losses Dielectric <0.2W / kVAr
Total Operating Losses <0.35W / kVAr
11
All Polypropylene (APP) Type Capacitors
The LTAPP range of all polypropylene capacitors are designed for super heavy duty applications. These capacitors are
impregnated with a Non PCB type oil for superior performance. The LTAPP capacitors come with a steel enclosure and
have an internal fuse for over pressure disconnection. These capacitors have a high peak inrush current withstand and
are ideal for use with detuned harmonic reactors.
Technical Details
M-10 Threaded
Brass Terminal
60 60
7
70
5
10
L
w
L1
Rating L W H
(kVAr) (mm) (mm) (mm) L1
12
Reactors - Harmonic Filters
The increasing use of modern power electronic apparatus (drives, uninterruptible power supplies, etc) produces
nonlinear current and thus influences and loads the network with harmonics (line pollution). The capacitance of the power
capacitor forms a resonant circuit in conjunction with the feeding transformer. Experience shows that the self-resonant
frequency of this circuit is typically between 250 and 500 Hz, i.e. in the region of the 5th and 7th harmonics. Such a
resonance can lead to the following undesirable effects:
l Overloading of capacitors
l Overloading of transformers and transmission equipment
l Interference with metering and control systems, computers and electrical gear
l Resonance elevation, i.e. amplification of harmonics
l Voltage distortion
These resonance phenomena can be avoided by connecting capacitors in series with filter reactors in the PFC system.
These so called “detuned” PFC systems are scaled in a way that the self-resonant frequency is below the lowest line
harmonic and the detuned PFC system is purely inductive as seen by harmonics above this frequency. For the base line
frequency (50 or 60 Hz usually), the detuned system on the other hand acts purely capacitive, thus correcting the reactive
power.
Technical Details
Class of Protection I
Ambient Temperature 40
13
Thyristor Switching Modules
The usage of new technologies in modern industry has negative impacts on electric power quality of the main supply
networks, e.g. frequent high load fluctuations and harmonic oscillation. Excessive currents, increased losses and
flickering will not only influence the supply capacity but will also have a significant impact on the operation of sensitive
electronic devices.
The solution is dynamic power factor correction system. With the thyristor module we provide the main component-“The
Electronic Switch”- for dynamic power factor correction. The LT-TSM module series offers fast electronically controlled,
self-observing thyristor switches for capacitive loads up to 200 kVAr, that are capable to switch PFC capacitors within a
few milliseconds nearly without a limitation to the number of switchings during the capacitor lifetime. These switching
modules are easy to install, have a fast reaction time of 5 msec and come with a built in display of operations, faults and
activation.
Technical Details
14
Network of Thyristor Switching Modules
Dynamic PFC Network: Single stage
Capacitor
branch
L1
L2 (S)
L3 (T)
N
PE
Input Controller signal
Fuse superfast
+-
125A at 50 kVAr Signal
10-24VDC
63A at 25 kVAr
L1 fault /”On” L3 fault /”On”
operation operation
LT TSM
electronic thyristor-module
for capacitor switching
C1 L1 L3 C3
Filter
Discharge
Resistor EW-22
Power
Capacitor
supply meas.
voltage voltage meas. current
Vb Vm Im (5A/1A) 1st Capacitor 2nd Capacitor 3nd Capacitor
branch branch branch
L1 k
L2 (S)
L3 (T)
N
PE
T2A
T2A
Input
(controller signal)
+- +- +-
power factor Signal
10-24VDC
Signal
10-24VDC
Signal
10-24VDC
controller
BR6000-T12 L N L N K I L1 fault /”On” L3 fault /”On” L1 fault /”On” L3 fault /”On” L1 fault /”On” L3 fault /”On”
operation operation operation operation operation operation
a b P1 1 2 3 4 56
C1 L1 L3 C3 C1 L1 L3 C3 C1 L1 L3 C3
+24V-
Filter
Discharge
Resistor EW-22
Power
Capacitor
15
Automatic Power Factor Correction Panel
Modern power networks cater to a wide variety of electrical and power electronics loads, which create a varying power
demand on the supply system. In case of such varying loads, the power factor also varies as a function of the load
requirements. It therefore becomes practically difficult to maintain consistent power factor by the use of fixed
compensation i.e. fixed capacitors which shall need to be manually switched to suit the variations of the load. This
will lead to situations where the installation can have a low power factor leading to higher demand charges and levy of
power factor penalties.
In addition to not being able to achieve the desired power factor it is also possible that the use of fixed compensation can
also result in leading power factor under certain load conditions. This is also unhealthy for the installation as it can result in
over voltages, saturation of transformers, maloperation of diesel generating sets, penalties by electricity supply
authorities etc.
Consequently the use of fixed compensation has limitations in this context. It is therefore necessary to automatically vary,
without manual intervention, the compensation to suit the load requirements.
This is achieved by using on Automatic Power Factor Correction (APFC) system which can ensure consistently
high power factor without any manual intervention. In addition, the occurrence of leading power factor will be prevented.
APFC products are fully automatic in operation and can be used to achieve:
lConsistently high power factor under fluctuating load conditions
lElimination of low power factor penalty levied by electrical supply authorities
lReduced kVA demand charges
lLower energy consumption in the installation by reducing losses
lPreventive leading power factor in an installation
Salient Features:
Modular design which allows easy handling by the user and also capable of being extended/upgraded. The incoming
switchgear provided has 9 kA, for 5 to 25 kVAr & 25 kA, for 25 < 50 kVAr fault interrupting capability. Copper busbar system
suitable for withstanding 50 kA fault current. Minimal joints in all the connections to ensure better reliability and lower
losses.
16
MINI VAr - Automatic Power Factor Control Panel suitable for 3Ph, 440V AC 50 Hz Auto
Rated Frequency 50 H
Short Circuit Rating 9 kA, for 5 to 25 kVAr & 25 kA, for 25 < 50 kVAr
Altitude 1000 m
Duty Continuous
0 0
Ambient temperature -5 C to + 40 C
Installation Indoor, wall mounted, in a well ventilated non-dusty environment, cable entry from bottom
Incomer A four pole MCB, upto 25 kVAr, and a three - pole MCCB, above 25 kVAr
Using FRLS cable, of adequate section
Internal wiring Cylindrical, dry type three phase units (see table for step ratings)
Capacitors The capacitors are equipped with discharge device, and over pressure device
Three pole Capacitor duty contactors of adequate ratings for respective steps
Contactors A microprocessor based relay with 4 / 6 output contacts for switching contactors
The Controller Protection Having PF indication, built in time delays, and alarm indication for CT reversal
apart from the protections associated with the capacitor itself, there is a thermostat
which disconnects the entire panel in the event of excessive temperature rise in the
enclosure.
As a safety measure, an inter lock is provided so that when the front door
is opened, the entire panel will trip.
17
Overall Dimensions of APFC Panel
R Y B
APFCR
H
Air filter
Unit
36
20
TH
25 200
Front view Side view
Gland plate
70
Top view
Rating L H M Notes:
kVAr mm mm mm Recommended
l front access : 800mm
Recommended
l side clearance : 200mm
</= 25 350 600 250 Paint
l shade : ral 7035
Powder coated
Upto 50 500 700 400 Tolerance
l on dimensions : ±10mm
Cable
l entry : bottom
L T C C S 3 2 5 B 2
C - Cyl S - Std 3P - 3
B - Box H - Heavy 1P - 1
X - Super
Heavy
U - Ultra
18
Overall Dimension
Cylindrical Type Capacitors
Standard Duty
FAST-ON
Terminal 6.35 x 0.8 d±1+4
(1)
Assembly
Sr. Voltage Power (Q) kVAr Capacitance Rated current Dimension Cat. Nos.
h±3+a (expansion)
No (V) (µf) (A) in (mm2)
Marking
h±2
Label
h±3+1
50Hz 60Hz 50Hz 60Hz DxH
h±3
1 440 1.0 1.2 5.5 1.31 1.57 53 x117 LTCCS301B2
3 440 3.0 3.6 16.5 3.94 4.72 63.5 x 130 LTCCS303B2 d±1
16
M12
4 440 4.0 5.0 22.2 5.25 6.30 63.5 x 130 LTCCS304B2
+1
16
5 440 5.0 6.0 27.5 6.56 7.87 63.5 x 154 LTCCS305B2 M12
Toothed Locked
Washer
6 440 7.5 9.0 41.0 9.8 11.8 75 x 162 LTCCS307B2 DIN 6797-JB
7 440 10.0 12.0 55.0 13.1 15.7 75 x 198 LTCCS310B2 Hexagon nut
Tightening torque DIN 439-BM12
d
=12NM 16.7
8 440 12.5 15.0 68.5 16.4 19.7 75 x 270 LTCCS3121B2
19.6
9 440 15.0 18.0 82.2 19.7 23.6 75 x 270 LTCCS315B2
Marking
Ultra Heavy Duty
5±0.5
h+40
Sr. Voltage Power (Qn) Capacitance Rated current Dimension Cat. Nos.
h
Torque
T = 1.2 Nm
19.6±0.5
d+d1
16.8±0.5
19
Heavy Duty
Sr. Voltage Power (Qn) Capacitance Rated current Dimension Cat. Nos.
No (Vn) (kVAr) (µf) (A) in (mm)
H
Label
W
2 Slots 7 x 14
W1
Standard Duty
Sr. Voltage Power (Qn) Capacitance Rated current Dimensions Cat. Nos.
No ( Vn ) (kVAr) (µf) (A) in (mm)
Heavy Duty
Sr. Voltage Power (Qn) Capacitance Rated current Dimensions Cat. Nos.
No (Vn) (kVAr) (µf) (A) in (mm)
20
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Product improvement is a continuous process. For the latest information and special applications, please contact any of our offices listed here.
SP 50481 R1 220210