Automatic Power Factor Correction (APFC) Panel – Design, Operation & Maintenance

Course Duration: 4 Weeks (Flexible based on requirements)
Mode: Online / Offline / Workshop-Based
Target Audience: Electrical Engineers, Technicians, Maintenance Personnel, and Industrial Electricians
Prerequisites: Basic knowledge of Electrical Systems, Power Factor, and Switchgear

Module 1: Fundamentals of Power Factor & Reactive Power (Week 1)

1. Introduction to Power Factor

   • Definition and importance of Power Factor

   • Active, Reactive, and Apparent Power

   • Effects of Poor Power Factor on Electrical Systems

2. Causes and Consequences of Low Power Factor

   • Inductive Loads (Motors, Transformers, Fluorescent Lamps, etc.)

   • Impact on Electricity Bills and Penalty Charges

   • Voltage Drop and Increased Losses

3. Power Factor Improvement Techniques

   • Capacitor Banks and their Role

   • Static vs. Automatic Power Factor Correction (APFC)

   • Harmonics and their Impact on Power Factor

Module 2: APFC Panel Components and Working (Week 2)

4. Understanding APFC Panel Components

   • Capacitor Banks (Types and Ratings)

   • APFC Relay – Working and Selection

   • Contactor Selection for Capacitor Switching

   • Protective Devices (MCBs, MCCBs, Fuses, etc.)

   • Harmonic Filters and Reactors

5. Working Principle of APFC Panels

   • Real-Time Power Factor Monitoring

   • Automatic Switching of Capacitors

   • Load Variation and Dynamic Compensation

Module 3: APFC Panel Design & Sizing (Week 3)

6. Design Considerations for APFC Panels

   • Sizing of Capacitors based on Load Profile

   • Selecting APFC Relay and CT Ratio

   • Wiring Diagram and Connection Schematics

7. Harmonic Mitigation Techniques

   • Need for Detuned Reactors

   • Effects of Harmonics on Capacitors

   • Methods to Reduce Harmonic Distortion

Module 4: Installation, Testing & Maintenance (Week 4)

8. Installation & Commissioning of APFC Panels

   • Site Selection and Mounting

   • Cable Sizing and Wiring

   • Earthing and Safety Considerations

9. Testing & Troubleshooting of APFC Panels

   • Pre-Commissioning Tests

   • Common APFC Panel Issues and Solutions

   • Measuring Power Factor and Verifying Performance

10. Maintenance & Safety of APFC Panels

• Routine Inspection and Cleaning

• Checking Capacitor Health (Leakage, Overheating, etc.)

• Preventive Maintenance Schedule

Final Assessment & Certification

• Hands-on Project: Designing an APFC Panel for a given load

• Final Test: MCQs and Practical Troubleshooting Scenarios

• Certification: Successful candidates receive a course completion certificate