In today’s world, improperly designed power factor correction systems can lead to various issues in practical applications, resulting in shorter lifespans than expected. These problems include tripped circuit breakers, fuse failures, overheating, or burning of reactors, as well as capacitor failures, contactor sticking, and thyristor faults. During the design and manufacture of capacitor banks, our company performs comprehensive circuit calculations. This includes properly matching detuned reactors and capacitors, determining the correct reactor ratio, and selecting the proper capacitor voltage. For panel switching, the necessary criteria for choosing contactors or thyristors are decided in collaboration with our customers. Meticulous attention is given to all aspects, from selecting fuses to properly sizing and ventilating the panels. In addition to inductive loads, our company also encounters capacitive and single-phase loads in commercial facilities like plazas, hospitals, and hotels. To address these requirements, we design and manufacture IGBT-based power factor correction systems. This design allows for separate compensation of each phase as either inductive or capacitive, with a response time faster than 1 ms. Our low and medium voltage harmonic filter reactors are specially designed and manufactured according to customer and field needs. These reactors stand out with their high linearity ratios, low losses, and long operational lifetimes. Additionally, we utilize capacitors and switching elements imported from our solution partners, who are world leaders in their respective fields, in our power factor correction systems and capacitor banks.
Power Factor Correction Systems
What are Power Factor Correction Systems?
Power factor correction is an effective solution for minimizing energy losses in electrical systems, from production to consumption. These systems ensure the efficient and effective operation of electrical infrastructure by supplying the reactive energy required by motorized and ballasted equipment in enterprises. Power factor correction systems are essential for maintaining reactive power balance in electrical power systems. Reactive power is the difference in phase angle between current and voltage, arising from inductive and capacitive loads. Inductive loads increase reactive power, reducing the power factor. This can lead to energy loss and decreased system efficiency. Power factor correction systems, typically consisting of capacitor banks, provide a capacitive load to balance reactive power. When integrated into the electrical system, these banks balance inductive reactive power and improve the power factor, thereby enhancing energy efficiency.
Power Factor Correction Systems – Reactors
Reactors are a fundamental component of power factor correction systems, controlling the reactive power generated by inductive loads. Ergun Elektrik has developed a series of reactors tailored for diverse industrial applications. The company designs and manufactures various reactor models to enhance power factor and mitigate harmonic distortions. These include:
- LV Detuned
(Harmonic Filter) Reactors - Inductive Load
(Shunt) Reactors - MV Iron Core Detuned
(Harmonic Filter) Reactors - MV Air Core Detuned
(Harmonic Filter) Reactors - MV Current Limiting
(Inrush) Reactors
LV Detuned (Harmonic Filter) Reactors
LV Detuned Reactors are designed to mitigate harmonic distortions in industrial environments, improving power factor, optimizing energy efficiency, and preserving system stability.
Inductive Load Reactors
Inductive Load Reactors are employed to mitigate the reactive power imbalance caused by inductive loads within electrical systems, thereby enhancing the power factor and reducing energy costs.
MV Iron Core Detuned Reactors
MV Iron Core Detuned Reactors are employed at medium voltage, where they function as harmonic filters. These devices effectively control harmonic distortions within the electrical grid, thereby enhancing overall system performance.
MV Air Core Detuned Reactors
OG Air Core Detuned Reactors are commonly employed in medium voltage applications, distinguished by their compact design and high performance. These reactors effectively mitigate harmonic distortions in the system through efficient harmonic filtering.
MV Current Limiting Reactors
MV Current Limiting Reactors are employed in medium and high voltage systems to mitigate current fluctuations arising from abrupt load variations, thereby preserving system stability.
Power Factor Correction Systems - Banks
Ergun Elektrik manufactures capacitor banks that are designed to regulate and optimize power factor in accordance with international quality standards. These capacitor banks feature user-friendly designs while ensuring efficient system operation. The company offers the following types of capacitor banks:
- LV Detuned
Capacitor Bank - LV Thyristor Switching
Detuned Capacitor Bank - LV IGBT Based Hybrid
Capacitor Banks - MV Detuned
Capacitor Bank - MV Capacitor
Bank - Reactive Power
Controller - Inductive Load
Banks
LV Detuned Capacitor Bank
Industrial facilities employ capacitor banks equipped with detuned reactors to mitigate harmonic distortions and improve power factor.
LV Thyristor Switching Detuned Capacitor Bank
Thyristor Switching Detuned Capacitor Bank employs advanced thyristor technology to control power factor and enhance energy efficiency in facilities with fast-changing loads.
LV IGBT Based Hybrid Capacitor Banks
IGBT-Based Hybrid Compensation Panels employ advanced IGBT technology combined with static VAR generators (SVGs) to improve power factor and reduce energy costs. These panels are effective in both industrial and commercial settings.
MV Detuned Capacitor Bank
MV detuned capacitor banks are designed to optimize power factor and improve system performance through integrated harmonic filtering capabilities.
MV Capacitor Bank
MV capacitor banks are employed to manage and stabilize the power factor within the electrical grid. They are extensively utilized in medium voltage electrical systems.
Reactive Power Controller
The reactive power controller is a key device utilized to manage and regulate reactive power within electrical systems, thereby optimizing power factor. It represents a crucial element in enhancing energy efficiency across industrial environments.
Inductive Load Banks
Inductive load banks serve to enhance energy efficiency and mitigate costs by optimizing the reactive power profile within low-voltage electrical networks. They function through staged configurations comprising inductive load reactors, and can additionally be deployed in certain solar power generation facilities.
Power Factor Correction Systems – Imported Products
Ergun Elektrik’s portfolio also encompasses imported products sourced from reputable solution partners who adhere to global manufacturing standards. These imported products, which align with Ergun Elektrik’s own quality criteria, contribute to the reliable performance of their power factor correction systems. The imported products within Ergun Elektrik’s portfolio include the following:
- LV Power Capacitors
Electronicon - MV Power Capacitors
Epcos - Contactors
Benedict - Tyristor Switches
Beluk - Discharge Reactors
Electronicon - Static Var Generator
(SVG) Modules Epcos - Surge Capacitors
Epcos
LV Power Capacitors – Electronicon
Electronicon LV power capacitors, engineered and produced in Germany for industrial uses, serve to correct power factor and enhance energy efficiency within electrical systems.
MV Power Capacitors – Epcos
Epcos MV power capacitors enhance power factor optimization in electrical grids, thereby diminishing energy dissipation and enhancing overall system performance.
Contactors – Benedict
Engineered and manufactured in Austria, Benedict contactors serve as reliable and durable power switching devices in electrical circuits.
Tyristor Switches – Beluk
Beluk thyristor switches designed and manufactured in Germany are semiconductor devices used for controlling and switching loads in electrical systems. They offer high reliability and precise control.
Discharge Reactors – Electronicon
Electronicon discharge reactors facilitate the safe dissipation of energy stored in capacitors, thereby improving the safety and longevity of electrical grid infrastructure.
Static Var Generator (SVG) Modules – Epcos
EPCOS static Var generator modules leverage advanced power semiconductors to optimize power factor and mitigate harmonic distortions, thereby ensuring high energy efficiency and reliability.
Surge Capacitors – Epcos
EPCOS surge capacitors are employed to mitigate fluctuations and regulate voltage variations within electrical systems, thereby improving system stability and prolonging equipment lifespan.
Types of Power Factor Correction Systems
The different types of power factor correction systems each offer unique advantages tailored to specific applications or system requirements. Implementing the appropriate power factor correction solution enhances energy efficiency, lowers operational costs, and ensures the safety of electrical systems. Three primary categories of power factor correction systems exist: Individual Compensation, Partial Compensation, and Global Compensation. Let us examine these system types in greater detail.
In individual compensation, reactive power sources are directly connected to the terminals of individual consumers in fixed stages. This method uses capacitors tailored to each consumer to balance reactive power. This approach, commonly employed for asynchronous motors, offers several benefits:
- Lowering power requirements,
- Minimizing penalties associated with reactive power usage,
- Preventing transformer overloading,
- Reducing cable losses.
Partial compensation is used, where multiple consumers share a common contactor instead of having dedicated capacitors. This collective approach offers several benefits:
- Minimizing penalties for reactive power consumption,
- Reducing the apparent power demand,
- Preventing transformer overloading and enabling higher load capacity,
- Decreasing cable losses.
In global compensation, capacitors are switched on based on the reactive power required for control by the reactive power controller at the main panel of the system. This method is preferred in large, high-power facilities. Its benefits include:
- Monitoring power factor from a single location,
- Cost-effectiveness,
- Preventing over compensation.
