We have a power plant here, where in generator sets provide for 100% of our electrical needs in the factory. We improved the factory’s power factor from 0.8 to 0.95. Aside from increased power capacity, are there any savings in terms of fuel consumption when we improve the power factor? If yes, how do we compute for that? Need help! thanks!
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Since you’re now generating less current for a given amount of power to be used by the load, there should be some modest savings in resistance losses in the circuitry between the generator and the load: transformers and power lines and such. You’d have to know the actual resistance of these to figure how much more money you’ve been using to keep the conductors warm.
I think this was a problem on a final exam for a power course I took, but they would have had to give us the resistance, I think. Maybe you can dig it out of the power factor, but I don’t think so.
What is the MW rating of the generator and what is its normal loading? What is the fuel source for the generation?
The power factor having improved toward unity will lower the operating temperature of the generator and the transformers. This in itself will eventually save money due to reduced maintenance costs and longevity of the equipment.
If your generator is not operating at its maximum capacity already then it’s difficult to gauge the cost savings. If your generator was being limited by the winding, lube oil, bearing, or cooling water temperatures and correcting the power factor reduced these temperatures by the windings not needing to be cooled as much, and then you were able to increase MW output then the cost comparison would be easy. If you are running at a load lower than the maximum rating of the generator then you will have to look at fuel consumption over a longer period to see the effect. I proved this empirically at a fluidized-bed biomass plant I used to operate and maintain.