Design of a master power factor controller for an industrial plant with solar photovoltaic and electric vehicle chargers

The power factor of industrial facilities is typically inductive. The case study in this paper was based on a typical Malaysian 11-kV on-grid industrial system with renewable energy sources and electric vehicle charging station connected. The integration of renewable energy sources reduces energy consumption from the grid; it consecutively reduces greenhouse gas emissions. However, the integration of renewable energy sources such as solar photovoltaic operating at unity power factor results in a reduction of the industry's power factor. According to the Malaysian Distribution Code, the power factor of a medium voltage industrial system should be more than 0.85 lagging. A long-term low power factor will reduce the related electrical equipment lifespan and increase the monthly electricity bills. A classic method to overcome this issue was by installing reactive power compensator devices, such as the synchronous condenser, static VAr compensator and static synchronous compensator. Studies had revealed that solar photovoltaic with appropriate control system design could perform short-term reactive power compensation. The control techniques used are either power factor control, active power control, reactive power control or any combination of them. However, neither the reactive power compensator devices nor the solar photovoltaic with a control system can regulate the industry's power factor to an intended value throughout its operation. Thus, this paper presents a simple, relatively cost-effective design of a master power factor controller that is capable of regulating the industry's power factor to an intended value throughout its operation with a single preset reference. In this research, an industry-grade system comprises an industrial load installed with a power factor-controlled capacitor bank, a power factor-controlled solar photovoltaic system, a bidirectional current-controlled electric vehicle charging system based on CHAdeMO 1.1 standard charging protocol and a master power factor controller was designed using the Matrix Laboratory/Simulink software. This paper has provided simulation results as proof that each of the designed equipment was functioning appropriately. The results also proved that the proposed master power factor controller was capable of regulating the power factor of the industrial system to above 0.85 lagging throughout its operation.

Automated summary

This paper discusses a case study of a typical Malaysian 11-kV industrial system with renewable energy sources and an electric vehicle charging station. The integration of renewable energy sources reduces energy consumption from the grid and greenhouse gas emissions, but lowers the industry's power factor. The paper proposes a simple and cost-effective design of a master power factor controller to regulate the industry's power factor to an intended value.