APFC Control Panel
An APFC (Automatic Power Factor Correction) Control Panel is
used to improve the power factor in industrial and commercial
electrical systems by automatically switching capacitor banks
based on real-time reactive power demand.
1. Purpose of APFC Panel
- Improves Power Factor (PF): Maintains PF close to unity (0.98 to 1.0)
- Reduces Penalties: Avoids utility penalties for low PF
- Enhances Efficiency: Reduces losses, optimizes power consumption
- Prevents Overloading: Reduces strain on transformers and generators
2. Components of APFC Control Panel
A. Enclosure (Panel Body)
- Material: Mild Steel (MS), Stainless Steel (SS), or Polycarbonate
- Protection Rating: IP54, IP55, IP65 for industrial use
- Cooling System: Exhaust fans or air conditioning for heat dissipation
B. Power Factor Controller (PFC Relay)
- Automatic Switching: Steps-based capacitor bank switching
- Measurement Parameters: Voltage, Current, Power Factor, Reactive Power
- Brands: Schneider Electric, Siemens, L& T, ABB, Socomec
C. Capacitor Banks
- Type: APP (Aluminum Polypropylene), MPP (Metalized Polypropylene), Heavy Duty
- Capacitor Ratings: 5 kVAR, 10 kVAR, 25 kVAR, 50 kVAR, 100 kVAR
- Detuned Reactors: Used to prevent harmonics (3%, 5.67%, 7% reactor)
D. Contactor & Switching Devices
- Capacitor Duty Contactors: Specifically designed for capacitive switching
- Thyristor Switching Modules: For fast response in dynamic loads
- MCBs & MCCBs: Overload and short circuit protection
E. Busbar & Wiring
- Busbar Material: Copper or Aluminum
- Cable Type: High-quality, heat-resistant wiring
- Ferruling & Labeling: Proper identification for ease of maintenance
F. Meters & Indicators
- Digital Multifunction Meter: Displays Voltage, Current, PF, kVAR, kW
- LED Indicators: ON/OFF status of capacitor banks
- Alarm System: For capacitor failure or overvoltage conditions
3. Operating Principle of APFC Panel
- Real-Time Monitoring: The APFC relay measures the power factor.
- Automatic Capacitor Switching: Based on the power factor, it switches capacitor banks ON/OFF.
- Correction & Stabilization: Maintains the PF close to unity (1.0).
- Overvoltage & Harmonic Protection: Uses reactors to limit voltage spikes and
harmonics.
4. Types of APFC Panels
- Fixed APFC Panel: For stable loads with constant power factor correction.
- Automatic APFC Panel: For fluctuating loads with real-time correction.
- Thyristor-Based APFC Panel: Fast response for high-speed switching applications.
5. Application Areas
- Industries: Manufacturing, Steel Plants, Textile Mills
- Commercial Buildings: Malls, Hospitals, IT Parks
- Utility Substations: Grid Power Management
- Renewable Energy: Solar & Wind Power Systems
6. Advantages of APFC Panels
- Reduced Power Losses – Optimizes system efficiency
- Lower Electricity Bills – Eliminates reactive power penalties
- Improved Voltage Stability – Enhances performance of electrical systems
- Extended Equipment Life – Reduces stress on transformers & generator
