High voltage capacitor banks and harmonic filters ensuring stable grid operation and optimized power factor in industrial plants
At the new facility of Shanghai Beite Technology Company, three 10/0.4 kV transformers supply power to a range of equipment, including medium-frequency furnaces, dryers, and precision milling machines. Although the low-voltage side was equipped with reactive power compensation units, the rectifier-based variable-frequency loads produced substantial harmonic distortion. Some capacitor banks failed due to harmonic interference, and the compensation capacity was insufficient.
Monitoring at the 10 kV assessment point showed the system’s power factor averaged around 0.8, resulting in monthly penalty charges and increased operational costs.
Considering installation conditions and cost efficiency, Wenlida installed a 10 kV high-voltage reactive power compensation system in the substation. The configuration consisted of three capacitor banks rated at 600 kvar, 800 kvar, and 1000 kvar, allowing three-stage automatic switching according to load conditions at 25%, 50%, and 100%. The power quality system successfully improved the average power factor to approximately 0.95, reducing energy costs and enhancing power quality across the plant.
View MoreAt Qidong Xinglongyuan Ruifu Foundry Company, the casting workshop operated multiple medium-frequency furnaces, which generated high-order harmonics, causing voltage distortion, low power factor, and poor power quality throughout the facility. The 10 kV incoming line fed two busbar sections across the plant, amplifying harmonic effects.
We installed a 10 kV high-voltage filtering and compensation system with three filter branches H5, H7, and H1, and a total capacity of 3,480 kvar (model W-TAL10-3840-3). The three capacitor cabinets operate under automatic switching control, ensuring optimal reactive power compensation and harmonic mitigation. Both voltage and current harmonics met national standards, and the system maintained a power factor above 0.9, ensuring stable and efficient operation of the foundry’s electrical network.
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