Upgrading Older Capacitor Banks is Important

As an inexpensive source of reactive power, capacitor banks bring many benefits to a facility.  They are widely deployed to avoid penalties on utility bills, lower distribution losses, increase transformer/Genset capacity, maintain nominal voltage, and to reduce energy losses resulting in decreased carbon emissions. When coupled with reactors, capacitor banks can filter harmonics generated by Variable Frequency Drives (VFDs) and other non-linear loads that otherwise distort both voltage and current waveforms. This helps reduce the risks of premature insulation breakdown in motor windings and transformers, excessive heating, nuisance tripping of circuit breakers, and operational problems with sensitive equipment.

Capacitor banks often operate reliably for years and it is not uncommon for organizations to lose awareness of the equipment's age or condition, and experience unexpected and painful end-of-life failures.

Electrical network conditions and capacitor bank life expectancy

1. High operating temperatures and harmonic levels which accelerate the aging of the capacitors and electronic components

2. Resonance conditions which cause insulation breakdown inside the reactors and amplify harmonic currents

3. Fluctuating loads which trigger frequent capacitor step switching and increase switch wear and electrical and thermal stress on the capacitor

4. Neglect of maintenance and operation testing e.g. exhaust and intake air filters, wiring, terminal, and fuse integrity, contactor locking, and capacitor degradation

These adverse operating conditions often evolve over time and may provide no obvious early indication of problems until a surprise in-service failure. Operators should therefore take a proactive approach, scheduling annual or semi-annual maintenance to avoid unexpected failure.

CaseStudy-18-year-old capacitor bank unexpectantly failing powering down the site, causes $50k a month in utility penalties

A large food packager in the central US experienced dual reactor failures inside its 5 MVAR and 4 MVAR, 4.16 kV capacitor banks. Installed in 2003, these banks had operated reliably up to the point, maintaining power factor above the threshold demanded by the local utility.
When the unexpected failure occurred, personnel took immediate action to order replacement reactors. However, when the time came to perform the replacement, the additional failure of the main incoming switch led to major damage. Following the standard procedure, the contractor opened the incoming main switch to remove the feeding power and closed the ground switch as a safety precaution. Unfortunately, the incoming switch's spring mechanism failed to disconnect the power, resulting in a line-to-ground short circuit causing significant damage to the main switch and other components. The short circuit also triggered the feeder breaker to open at the utility substation, powering the site down and stopping production for 8 hours.

Given the extent of the damage, repairing the banks was no longer a viable long-term solution. The operator was forced to replace the two banks, which took six months during which the company incurred $50k per month in power factor penalties.

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