A Simscape based Framework for Pre-Installation Evaluation of Passive Filter Efficiency in Industrial Power Systems

Nonlinear loads in industrial electrical systems cause harmonic distortion, reactive power losses, and reduced efficiency. While passive filters offer proven mitigation, accurately predicting their performance before installation remains challenging due to the cost and complexity of physical testing. Conventional analytical methods rely on simplified assumptions that poorly represent real facility conditions. This paper presents a digital replica-based simulation framework that predicts passive filter performance using measured voltage and current waveforms (≤80 μs resolution) from target facilities. Developed in MATLAB Simulink with Simscape Electrical, the framework incorporates detailed transformer modelling derived from systematic parameter extraction and simulates both filter-active and bypass modes to calculate active power, reactive power, total harmonic distortion, power factor, and energy consumption. Validation across five real-world installations (1400 A to 3200 A ratings) demonstrated average absolute prediction error of 0.99% and relative error of 0.42% for energy savings. Simulated results consistently predicted reductions in active power (4.9–12.1%), reactive power (5.7–8.3%), and THD (10.3–13.7%), alongside power factor improvements (1.1–1.4%) across all phases. Unlike analytical approaches requiring idealized load models, this data-driven methodology directly incorporates facility electrical signatures, eliminating significant modelling uncertainty. The framework provides facility managers and filter suppliers with a scalable, non-invasive tool for quantifying energy-saving potential before capital investment, reducing financial risk and supporting evidence-based procurement decisions.