Minimizing Penalty in industrial power consumption PCSIR by engagging Automatic Power Factor Correction Unit

In the modern technological revolution, power is extremely precious and the power systems are becoming very complicated as time passes. As such it becomes essential to transmit each unit of power generated with the increase in distance in minimal loss of power. Nowadays, due to revolution in industr

Project Title

Minimizing Penalty in industrial power consumption PCSIR by engagging Automatic Power Factor Correction Unit

Project Area of Specialization

Cloud Infrastructure,

Project Summary

In the modern technological revolution, power is extremely precious and the power systems are becoming very complicated as time passes. As such it becomes essential to transmit each unit of power generated with the increase in distance in minimal loss of power. Nowadays, due to revolution in industrial sectors, usage of inductive loads has been increased. Due to lagging power factor in the inductive loads, a part of electrical energy is wasting every day. Therefore, there is a serious need to avoid this wastage of energy. Decreasing power factor will increase apparent power (by Pythagoras theorem). Hence industry needs more energy to meet its demand; ultimately the efficiency decreases and utilities suffer with penalties as well as equipment deterioration. This report is concerned with the advancement of a digital power-factor (PF) meter, replacing the electrodynamic type and external IC’s based meters. For the measurement of this quantity (Power Factor) mostly Zero Crossing Detector is used but the method adopted has an accurate and reliable performance for Power Factor measurement with technical upgrades. The method mainly comprises two main components, ZMPT (Potential transformer) which steps down the AC voltage with high accuracy and the current is step down by CT (current transformer). These two values of voltage and current are then sent to measure power factor through Arduino NANO module which is used as a microcontroller and smartly measures six parameters, as Voltage, Current, Apparent Power, Power Factor, Real Power and Reactive Power respectively. Hence this method does not require or need any external calculating Integrated circuit (IC) for taking voltage and current signals then fed to microcontroller. Because using IC’s externally, malfunctioning and heating issues occurs. Therefore the desired output does not achieve. Our circuit comprises fewer components with high precision accuracy and pre-calibrated options to make it feasible to operate.

Project Objectives

The objectives include:

1- The economical importance (elimination of the power factor penalty)
2- Reduction of internal power losses.
3- Payback period.

We need a power factor measurement device for calculating the power factor of a load accurately and precisely. To overcome the problem associated with calibration, a modern, accurate, precise and economical hardware approach is adopted which comprises on ZMPT module and Arduino NANO with interfacing of EMON library

Project Implementation Method

Implementation Method:

To detect the power factor of any load, zero crossing detector method is used. The method of zero crossing detector as from theoretical point of view is simple to understand. By analyzing the zero crossing of voltage and current will ultimately presents the power factor by time formulation also. Therefore we proceed with this method for our project.

Following are the steps taken in our project:

? At the start a potential transformer and a current transformer is used with calculated value.
? Then step down half wave rectifier for voltage and current is designed respectively.
? Then at same instant both zero crossing are measured through LM358 IC.
? The output of both voltage and current in terms of high pulse time of particular wave is given to (XOR) IC.
? As (XOR) IC will estimate the power factor when there is a lagging of current difference in time value occurs and this value will be given to arduino module.
? The time difference value will be calculated by a formula and power factor will be determine and is displayed on screen.

Limitation Of This Method

The design is applicable in ideal conditions, as if we implement theoretical knowledge practically, errors, limitations, problems and flaws occurred as a hurdle in achieving our goal.

Problems Arised And Solutions

Following are the problems observed, with their suitable corrections:
? In designing rectified output is not perfectly sinusoidal so after regulating proper square wave occurs minimizing problem in detecting a zero crossing.
? The problem was detected by observing the waveforms simultaneously on oscilloscope.
? The current in terms of voltage after step down is quite small and cannot be detected by LM358 IC.
? The problem was observed by using Clamp meter then altered by providing suitable gain to output value.
? After this, current wave was inverted square wave which was not suitable to detect. So polarities were adjusted and gain value was set again. The problem was observed on oscilloscope.

Benefits of the Project

the benifits are:

Power Consumption Control

With the advent of power factor measurement it becomes easy to keep an eye on power consumption. It became easier to reach the cause of increased power demand, increased losses, and increased heating in equipment and transmission lines.
 

Handling Capacity

By measuring power factor we can able to implement corrective measures hence we can make most use of the machinery i.e. handling capacity increased.[8] 1.5.3 Running More Load Become able to control voltage drops, current drawn and also run more load within the same power range.

Economic Benefits

Also it is provide economic benefits to the industries as they can control their power consumption and able to remove their name from faulty ones.

Technical Details of Final Deliverable

Deliverables 1: Providing proper algorithm in turning on capacitors automatically and switching of capacitors in order to compensate excessive reactive components, thus improving efficiency and measuring the power factor value.
 

Deliverables 2: Automatic device of power factor correction will minimize human interaction Thereby reduce hazardous accidents at load side and at substations.

Deliverables 3: To determine power factor by the microcontroller and according to that, operating the capacitor banks that ensures the desired amount of power factor correction.    

Final Deliverable of the Project

Hardware System

Type of Industry

Education , Medical , Food , Energy , Legal

Technologies

Cloud Infrastructure, Others

Sustainable Development Goals

Affordable and Clean Energy, Sustainable Cities and Communities, Responsible Consumption and Production

Required Resources

If you need this project, please contact me on contact@adikhanofficial.com