IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO.

4, JULY/AUGUST 2017 4125

Life Assessment of Electric Arc

Furnace Transformers
Eduardo A. Cano-Plata, Senior Member, IEEE, Oscar J. Soto-Marin, Student Member, IEEE,
and Armando J. Ustariz-Farfan, Member, IEEE

Abstract—Electric arc furnace transformers are very important

in the steel production industry. Currently, it is very common for
companies to buy used transformers considering the huge invest-
ment that represents the acquisition of a new transformer and also
the delay in the purchase transaction. Before accepting a commer-
cial agreement and putting the transformer into operation, it is
necessary to evaluate the level of wear out due to the electrical and
magnetic stresses to which the transformer is subjected. Electrical,
mechanical, and insulation tests, that follow procedures stipulated
in guides and standards, are performed on used transformers dur-
ing the purchase process in order to identify incipient faults and to
determine their general condition. A methodology is proposed to
carry out these tests. In addition, a new model based on fuzzy logic
is implemented to assess the level of wear of the transformer, its
remaining life, and its feasibility of reuse. The fuzzy input variables
of this new model are the results of the tests performed on each
element of the transformer.
Index Terms—Analysis of dissolved gases, arc resistance, arc
stability, electric arc furnace (EAF), fuzzy model, transformer.
Fig. 1. Schematic of the EAF system.

I. INTRODUCTION
HE MAIN objective in a steel manufacturing industry is
T to maximize annual production. A secondary objective is
to minimize the costs related to energy consumption and to the
wear out of electrodes. These will be directly affected by the
electric arc furnace (EAF) operating strategy [1]. In addition,
there should be proper electromagnetic coupling between the
furnace and the feeding system. Thus, the determination of the
maximum power transfer condition of the feeding system at
the time of scrap delivery, and the operating condition that will
keep the arc stable, are both points of great interest in the proper
operation of the system. Fig. 1 shows a schematic representation
of the elements that make up the EAF electrical system.
Manuscript received July 26, 2016; revised December 27, 2016; accepted
March 3, 2017. Date of publication March 28, 2017; date of current version
July 15, 2017. Paper 2016-METC-0636.R1, presented at the 2016 IEEE In-
dustry Applications Society Annual Meeting, Portland, OR, USA, Oct. 2–6,
and approved for publication in the IEEE TRANSACTIONS ON INDUSTRY APPLI-
CATIONS by the Metals Committee of the IEEE Industry Applications Society.
(Corresponding author: Eduardo A. Cano-Plata.)
The authors are with the Department of Electrical, Electronic, and
Computer Engineering, Universidad Nacional de Colombia, Manizales
170003, Colombia (e-mail: eacanopl@unal.edu.co; ojsotom@unal.edu.co; ajus-
tarizf@unal.edu.co).
Color versions of one or more of the figures in this paper are available online
at http://ieeexplore.ieee.org.
Digital Object Identifier 10.1109/TIA.2017.2688408
Due to the nonlinear and stochastic nature of the EAF, furnace
parameters such as voltage and current, real and reactive power,
and resistance and reactance exhibit significant variations es-
pecially during fusion stage [2], [3], subjecting the transformer
to strong electrical and magnetic stresses, which can be above
nominal values.
Consequently, the application of electric and magnetic
stresses above nominal values leads to premature deterioration
or aging of the transformer, and possibly causes anticipated
failure [4], [5].
Due to the large investment in the acquisition of a new EAF
transformer, and the delay in the purchase process (which can
take up to one year), some companies decide to buy used trans-
formers when the installed transformer fails or to restructure
the system by power increase. This alternative is very common
but it becomes necessary that in the receiving process the level
of wear out caused by electrical stresses is evaluated before
accepting a commercial agreement and putting the transformer
into operation [6].
Currently, the processes of reception of used transformers are
based on electrical, mechanical, and insulation tests [7].
Offline and online methods are used to assess the condition
of the transformers and to detect incipient faults. Fig. 2 lists the
main tests used.
The offline methods are usually conventional tests that are
regulated by standards or norms.

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 4126 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 4, JULY/AUGUST 2017

TABLE I
VOLTAGES AND CURRENTS OF THE EAF TRANSFORMER

Tap position LV side HV side LV side EAF load

OLTC voltage (v) current (A) current (kA) (MVA)

1 700 1255 25 30
2 660 1255 26 30
3 620 1255 28 30
4 580 1171 28 28
5 540 1088 28 26
6 500 1004 28 24
7 460 933 28 22
8 420 853 28 20
9 380 770 28 18

Fig. 2. Testing in transformers.

The online methods can be invasive and noninvasive. The
latter are mainly oriented to the acquisition and processing of
signals, such as electromagnetic, acoustic, and heat or infrared
waves.
In addition to the tests, the service of an expert is important
to assess the condition of each component of the system [7].
However, there are no available tools to integrate the results
of these tests into a single value to determine the interrelations
and contributions of each element to the reliability of the entire
system. Thus, the calculation of the level of the remaining useful
life of the transformer becomes inaccurate.
This paper proposes the implementation of a new model based
on fuzzy logic [20]–[22] that considers as input variables the
results of the tests applied to each component in the reception
stage. Using the results of this model, it is possible to assess
the wear-out condition of the transformer and to determine the
possibility of its reuse [23], [24].
II. CONCEPTUAL FRAMEWORK
This section presents an introduction to the operation and
specifications of the EAF installation under study and includes
details of the requirements of energy transfer in the transformer.
Afterward, an analysis of the reliability of the transformers feed-
ing the EAF is performed.
A. EAF System Benchmark
The transformer that feeds the EAF is of 30 MVA. The sec-
ondary voltage varies from 380 to 700 V depending on the
position of the on-load tap changer (OLTC). Table I shows
voltage and current values of operation in different positions.
Fig. 3. Behavior of the current seen from the primary six loads of scrap.
The secondary circuit of the transformer is connected to the
electrodes of the furnace through refrigerated flexible cables,
constantly fed by a flow of water.
The automatic control system controls the position of the
electrodes and makes them to fall and get in contact with the
scrap, thus creating an electric arc at that moment, the con-
trol tries to maintain a constant and balanced current, which is
quite difficult due to the irregular shape of the scrap. Conse-
quently, the arc has a stochastic behavior throughout the fusion
process, where current fluctuations vary between short-circuit
values (electrodes are in direct contact with the scrap), to open
circuit (the electrodes are separated from the welding material
and the electric arc becomes extinguished). Currents measured
in a tap-to-tap cycle on the primary transformer side are shown
in Fig. 3.
Due to the low density of the scrap, the furnace receives
several loads until the desired weight is reached (approximately
5 loads of scrap for the 30 tons in the EAF under study).
Since the voltage and current characteristics in an EAF are
nonlinear, all the involved electrical variables also become non-
linear [2]. The processes that take place in this circuit, as well as
the dependences between the electrical parameters of the system
are quite complex [3].
Fig. 4 shows the variations of the EAF parameters as a func-
tion of the current. Here, Parc is the arc power, Q is the reactive
power, P is the active power, Varc is the arc voltage, pf is the
power factor (PF) in the secondary circuit of the transformer,
and Larc is the length of the electrical arc.

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 CANO-PLATA et al.: LIFE ASSESSMENT OF ELECTRIC ARC FURNACE TRANSFORMERS
Fig. 4. Parameter variation of EAF.
The electric arc starts with priming and lasts until the end
of the melting stage. During this stage, the arc is very unstable
and its length varies considerably due to scrap movement. Ini-
tially, Parc and P increase to a certain maximum value and then
decrease rapidly, as the current increases, until the arc length
reaches zero [3].
On the contrary, Q increases to a maximum value and it is
at this point where the greatest electrical and magnetic stresses
take place in the transformer.
The EAF of the installation under study has a capacity of
30 tons of liquid steel. The total weight of the steel is 33 tons
taking into account an operating point that allows a PF of 0.8,
energy transfer of 28 MW/ 3600 s = 466 kWh/ 60 s, and the
calculation of the remaining steel weight left in the furnace in 3
tons. The fusion requires 400 kWh/ ton, therefore, the estimated
total energy is
Etotal = 400 kWh/ton ∗ 33 ton = 13 200 kWh.
In this way, the time used in the fusion is
13 200 kWh
tfusion = = 1700 s.
466 kWh/60 s
The crane must transport the scrap and it is necessary to consider
the way the furnace is filled. Estimating an average 6 loads at a
rate of 300 s, gives
tloading = 6 ∗ (300 s) = 1800 s.
Additionally, the time estimated for the casting is 600 s. Times
for loading and casting are required only in the fusion stage. The
refining process requires 80 kWh/ton and the available power is
of 24 MW (30 MVA), therefore
Etotal = 33 ton ∗ 80 kWh/ton = 2640 kWh
Pavailable = 24 MW
Prefinig = 243600
MVA
s = 400 kWh/60 s.
Consequently, the fusion time is
2640 kWh
trefining = = 396 s.
400 kWh /60 s
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4127
Fig. 5. Transformer hot spot temperature.
Fig. 6. Cycle of average load.
Thus, the tap-to-tap operation time of the system is given by
ttap−to−tap = tfusion + tloading + tcasting + tprefinig
ttap−to−dtap = (1700 s + 1800 s + 600 s + 396 s)tap-to-tap (7)
= 4496 s.
After defining the load cycle in which the transformer must
operate, the thermal stress to be applied to the transformer is
evaluated in order to estimate the level of wear out for the load
cycle.
(1)
The loadability analysis is performed according to the proce-
dure established in the IEEE Standard C57.91 [24]. Fig. 5 shows
the transient behavior of the hot spot temperature in the winding
according to load fluctuations. The maximum hot spot temper-
(2) ature is 108.3 °C, which is below the nominal temperature of
110 °C according to [25].
It is possible to approach the thermal analysis of the trans-
former, considering an equivalent load for the tap-to-tap load
cycle, which will allow a better understanding of the thermal
requirements in the transformer. For this, an equivalent constant
(3) load that generates the same total losses as a fluctuating load
is estimated and an equivalent load from the point of view of
temperature is assumed [25].
Due to the random behavior of the requested power in the
fusion process observed in Fig. 3, the load cycle for the tap-to-
tap time was estimated according to the transformer operation
data previously shown. The estimated load cycle for the tap-to-
(4) tap time is shown in Fig. 6.
Therefore, the equivalent load for the tap-to-tap load cycle
(5) can be calculated by the following equation [25]:
Loadequivalent =

L21 ∗ t1 + L22 ∗ t2 + L23 ∗ t3 + · · · + L2N ∗ tN
(8)
(6) t1 + t2 + t3 + · · · + tN
 4128
TABLE II
PARAMETERS OF THE WINDINGS
Parameter Value
Overcurrent time 5s
Winding eddy current loss 20%
Current density in windings 6 A/mm2
Resistivity of the conductor material 0.0259 Ω · mm2 / m
Density of the conductor material 8.89 g/ cm3
Specific heat of the conductor material 0.397 J/g °C
Per unit impedance of transformer 6.2%
Impedance of supply 10.27%
where LN means the load in mega volt ampere introduced in
the time tN .
Replacing the load cycle values gives an equivalent load of
Loadequivalent = 20.26 MVA, corresponding to 72.4% of the
nominal load. It is concluded that the thermal requirements, for
the transformer under study, do not suppose a wear or deterio-
ration of the insulating material.
However, as observed in the measurements presented in
Fig. 3, overcurrent values (values up to 200% of nominal value)
take place very frequently in the transformer. The effects of the
overcurrent on the transformer are divided into two categories
[4]: 1) thermal effects; and 2) magnetic forces.
Regarding the thermal effect, the IEEE Standard C57.12.10
[26] establishes 250 °C as the maximum limit of temperature
increase in copper conductors. An approximate expression for
the calculation of temperature increase in conductors after t
seconds is [4]
   2
e 1
t 1+ 100 D2 ρ e S +e Z
θC =
dh
where
θC : temperature rise in degrees centigrade;
e: winding eddy current loss, per cent;
D: current density in windings, A/mm2 ;
ρ: resistivity of the conductor material;
d: density of the conductor material;
h: specific heat of the conductor material;
eZ : per unit impedance of transformer;
eS : per unit impedance of supply.
The estimated maximum time of the overcurrent in the first
moments of the fusion process is 5 s. Table II shows other
parameters to calculate temperature increase in the conductor.
Replacing these values in (9) gives θC = 56 ◦ C. Considering
a hot spot temperature of 125 °C before the overcurrent, the
temperature at the end of the conductor is 181 °C. This value
is below the allowed limit of 250 °C. However, it is important
to consider the high frequency of these overcurrents, which
can lead to deterioration in the insulation paper. Higher current
values might result in permanent deformations in the winding
structure that might lead to mechanical failures or insulation
perforations.
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IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 4, JULY/AUGUST 2017
Fig. 7. Failure rate in time.
B. Reliability of EAF Transformers
The reliability of EAF transformers depends mainly on the
degree of continuous monitoring of the most important func-
tional parameters that define their technical condition. Systems
are subjected to continuous deterioration under normal opera-
tion and transformers are no exception to this rule.
It is possible to track the natural or accidental deterioration
of transformers using modern monitoring equipment and diag-
nostic techniques. [27].
Preventive and corrective maintenance helps to prolong the
estimated life of the transformer, allows the calculation of the
remaining life, and avoids costly losses.
The application of electric and magnetic stresses above the
plate nominal values implies an accelerated wear out. The wear
out can occur immediately or may be the result of accumulated
deterioration over the years. Fig. 7 shows the behavior of the
failure rate.
An analysis of causes and failure modes was performed using
the fuzzy fault tree method on the laboratory records of forensic
(9) analysis of 600 transformers in Colombia.
The traditional method of fault trees allows the evaluation
of reliability based on Boolean algebra. The method allows the
development of complex events, studied as a function of the
basic faults of the elements, to calculate its probability.
To build the fault tree, a complex event called the maxi-
mum event must be systematically decomposed into intermedi-
ate events connected by logical gates AND and OR until reaching
the basic event or the failure cause [28].
Although the calculations of this model are accurate, it must
be taken into account that there is an inherent uncertainty in the
degree of influence of each of the causes of failure in the failure
mode.
Fuzzy logic provides an intuitive and natural way of handling
this uncertainty by regarding the probability of failure as a fuzzy
number. Such a number is a function of two values: The variable
of event occurrence and a probability of currencies of that vari-
able (the fuzzy number corresponding to a confidence interval
value that takes values between 0 and 1).
The confidence interval value represents the belief of the
expert in a selected probability for the fault. These values are
assigned by the expert at each level of the fault tree (basic,
intermediate, and maximum levels).
 CANO-PLATA et al.: LIFE ASSESSMENT OF ELECTRIC ARC FURNACE TRANSFORMERS 4129

Fig. 9. Statistics of transformer failure.

Fig. 8. Windings fault tree.

The operators, triangular norms, t-norm and t-conorm are

used to calculate the values of the fuzzy number and the prob-
ability value of the next level according to the associated logic
gate, as shown in the following equations [27]:
AND(t − norm) : T (x, y) = xy (10)
OR(t − conorm) : S(x, y) = 1 − (1 − x) ∗ (1 − y). (11)
Fig. 10. Transformer life as a function of temperature.
An additional operation, called implication, must be performed
to find the fuzzy number of the level being developed. Implica- Input values for event 1(mechanical damage, see Fig. 8)
tion is the term used in fuzzy logic to describe a logical connector  
between propositions (usually input and output). FuzzyNumber : 0.75 0.6 0.6
.
The extended classical implication operation to allow fuzzy Probaility : 5.6% 1.4% 0.57%
membership functions is [28] Applying the norm operation S(W1,W2,W3) gives
μR (x, y) = max {min [μA (x), μB (y)], 1 − μA (x)}. (12)    
1 − (1 − 0.75) ∗ (1 − 0.60) ∗ (1 − 0.60) 0.96
= .
The following equation describes the operations required to 1 − (1 − 0.091) ∗ (1 − 0.036) ∗ (1 − 0.015) 13.69%
calculate probabilities among the fault tree levels: Using (12) for the implication operation, the calculated fuzzy
    number for event 1 is
T T ∗ norm
←−−− [[A ] [Bk −1 ]]
Bk = Implication (13)
P ←−−−−−−−− P ∗ norm ←−−− μR (x, y) = max {min [0.85, 0.96], 1 − 0.85} = 0.85.
where Bk : matrix resulting from 2 × 1 of the fuzzy number Therefore, the fuzzy values of fuzzy number and probability for
and the probability value after norm and implication operations. event 1 are
k: successive level of the fault tree;  
0.85
AÁ: input matrix of 2 × n of basic events of fuzzy number Event 1 : .
13.69%
and probability;
Bk −1 : calculated matrix of 2 × 1 of basic events of fuzzy The same procedure is implemented in order to find the values
number and probability level (k – 1); of event 2 (cellulose degradation) and also the maximum event
T: calculated fuzzy number of level k; or failure mode.
P: calculated probability value of level k; This same methodology was implemented for fuzzy fault
T∗ : calculated fuzzy number of the norm operation; tree construction of OLTC, bushings, core, tank, and auxiliary
P∗ : calculated probability value of the norm operation. elements. Fig. 9 shows the results of the statistical evaluation.
The development of the fuzzy fault tree for winding failure The results showed that the main failure modes are due to
is presented. Fig. 8 shows the construction of the fault tree in the windings and to OLTC and that the main cause of failure is
which the basic events are the failure cause. the deterioration of the insulating material. This deterioration is

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 4130 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 4, JULY/AUGUST 2017

TABLE III
TESTS FOR THE RECEPTION AND MAINTENANCE OF EAF TRANSFORMERS

Element Task Fuzzy Variable Maintenance

Monthly Annual

Oil tests:
Total Dissolved Combustible Gases (TDCG) Before and after any test x1 6 months
Polymerization degree x2 6 months
Moisture x3 6 months
Acidity x4 6 months
Dielectric strength x5 6 months
Interfacial tension x6 6 months
Power factor (PF) x7 6 months
Oil screen tests Main tank and tap change x8 6 months
Electrical tests:
Impulse test Before buying x9
Applied potential test Before buying x1 0
Induction potential test Before buying x1 1
Ratio test Before buying x1 2
Regulation test Before buying x1 3
Efficiency test, full load Before buying x1 4
Copper loss Before buying x1 5
Core loss Before buying x1 6
Data Reading sheet: X
Record of discharge pulses Maximum oil temperature x1 7 X
Temperature indicators Maximum winding temperature x1 8 X
Thermometers Internal and external of oil and water flow x1 9 X
Switch meter Record of number of operations x2 0
Operating tests Testing of protection devices x2 1 X
Protection system:
Overvoltage arresters Oil leaks and overheating x2 2 X
Discharge meters Record of discharge meters x2 3 X
Conservator: Oil leakage control X
Buchholz relay Indicator reading testing x2 4 X
Oil level indicator Change of dehydrating breather if pink x2 5 X
Breathers x2 6
Switch: Inspection and testing of the engine control X
Motor driving unit Inspection of the drive shaft coupling x2 7 X
Transmission shafts Control of the limit switch x2 8 X
Upper position indicator Check position of top tap x2 9 X
Record of number of operations X
Off-load tap changer Check electrical and mechanical interlocks x3 0 X
Control cabinet Collection of gas and oil x3 1 X
Relay RS Filter change, manometer reading x3 2 X
Oil leakage inspection X

manifested in the decrease of the basic insulation level and in
the reduction of the mechanical resistance of the paper, which
protects the integrity of the windings.
The phrase adopted by engineers “the life of the transformer
is the life of its solid insulation” [5] comes from the fact that the
restoration of the paper requires the change of the transformer
windings.
Many researchers have recognized that the behavior of ther-
mal deterioration of insulation materials might be best repre-
sented by Svante Arrhenius’s equation of 1880 [28], [29]
 
15000
L = 9.8 ∗ 10−18 ∗ e θ H −2 7 3
. (14)
higher values of temperature will cause a gain or loss of life,
respectively.
This model will be used in the output space of the fuzzy model
implemented in this paper to calculate the remaining life of the
transformer.
III. RECEPTION PROPOSAL OF EAF TRANSFORMERS
A description of phases proposed for acceptance or rejection
of used transformers is presented. The first phase corresponds
to the identification of the fuzzy variables used in the proposed
model. Table III shows a total of 32 variables.

Fig. 10 shows the graphical representation of this equation. It is A. Phase 1: Transformer Reception
assumed that for a temperature of 110 °C, which is the nominal This procedure aims to describe the instructions for the re-
temperature of hot spot [24], there will be a loss of life in the ception and evaluation of the remaining life of the transformer.
insulation of one in per unit (no wear). Consequently, lower or This will allow the decision making of acceptance or rejection.

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 CANO-PLATA et al.: LIFE ASSESSMENT OF ELECTRIC ARC FURNACE TRANSFORMERS 4131

It is necessary to carry out electrical tests to establish the

operation condition of the transformer according to design pa-
rameters. Table III shows the electrical, mechanical, and insu-
lation tests that must be taken into account in the reception and
maintenance program of EAF transformers. The first column
corresponds to the part on which the test is to be performed, the
second defines specific tasks or clarifications about the test, the
third has the numbering of the fuzzy variables for the construc-
tion of the model, and columns four and five show the periods
in which the tests are to be performed.
The tests performed on the “oil-paper” insulation system are
some of the most important controls that can be done to the
transformer in order to establish the condition of the differ-
ent parameters involved in insulation deterioration. Pyrolysis, Fig. 11. Fuzzy model to assess the EAF transformer.
hydrolysis, and oxidation [30] are the most widely accepted
mechanisms of paper insulation deterioration.
Dissolved gases, polymerization degree, moisture, acidity,
dielectric strength, and PF are the main variables that can be
evaluated to determine the condition of the insulating material
[11]. The diagnosis of these variables is focused on determining
the condition of the oil-paper insulation or the level of aging.
This approach can provide valuable information on the condition
of the transformer [30].
Table III shows the conventional electrical tests that define the
operating condition of the transformer. The results of these tests
determine whether the machine is operating properly without
any internal problems, especially in the windings. Fig. 12. Relation of sets in the Takagi–Sugeno system.
In addition, the transformer should be evaluated in the recep-
tion process by an expert to determine the operation and con-
dition of all auxiliary elements, such as temperature indicators,
equation [20]:
pressure indicators, valves, oil leakage, or any other anomaly
outside the parameters of normal operation, see Table III.
n
wi ∗ yi
y0 = . (16)
i=1
wi
B. Phase 2: Fuzzy Model Development
This section presents a new method for the estimation of the Therefore, Fig. 11 shows the transformer model implemented
parameters and the introduction of the fuzzy model. in the Takagi–Sugeno inference system. In this way, it is very
The construction of the fuzzy model is based on the Takagi– easy to see the model to evaluate the condition of a transformer
Sugeno system [20], where the fuzzy inference system is com- of EAF defined by the fuzzy logic model proposed in this paper.
posed of rules, see (15). Each rule has input variables associated The optimal number of fuzzy sets of the model is determined
with fuzzy sets, which are related to a linear output equation by applying “fuzzy cluster” methods. To do this, a partition
of the universe of the output variable is done, in this case the
Arrhenius equation, and then the input space is projected, which
If x1 is A11 and...and xn is A1n then y1 = f (x1 , . . . , xn )
are the sets of input variables (see Fig. 12).
If x1 is A21 and...and xn is A2n then y2 = f (x1 , . . . , xn )
.. The criterion used to obtain optimal fuzzy sets of the model is
. to minimize the distance between the output data and the center
If x1 is Am 1 and...and xm n is Am n then ym = f (x1 , . . . , xn ). of each cluster.
(15) After an iterative procedure of optimization of distances, the
The input variables x1 , . . . , xn of each rule correspond to the set number of fuzzy sets or clusters is obtained as well as the degree
of values shown in Table III; A11 , . . . , Am 1 are the fuzzy sets of belonging of the output data to each set for an error index
that comprise all the possible values of the input variable x1 . given. This technique seeks to find subsets with a certain degree
The linear output equations of each rule define the trajectory of similarity within a data collection, which correspond to the
of a nonlinear equation, in this particular case, the Arrhenius space of the output variable, and then projecting them to the
equation. input space.
The contribution value of each rule, that is, ym is considered The criterion used in the optimization process is defined by
in the complete solution of the system by means of the following the regularity criterion (RC), which is defined by the following

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 4132 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 4, JULY/AUGUST 2017

TABLE IV
VALUES OF REGULARITY CRITERION

Model Input variables RC

1 A11 0.623
2 A21 0.745
3 A31 2.467
4 A41 3.456
5 A11 , A21 0.845
6 A11 , A31 0.567
7 A11 , A41 0.496
8 A11 , A21 A31 0.345
9 A11 , A21 A41 1.341
10 A11 , A31 A41 , 0.932
11 A21 , A31 A41 , 2.016

equation:

K A  A 
B  B 
i=1 y (i) − y
AB
(i) + K i=1 y (i) − y
AB
(i)
RC = Fig. 13. Comparison of models.
2
(17)
where KA and KB are the number of data of two sets from
the adjusted set, y A (i) and y B (i) are the outputs of sets A and
B, y A B (i) is the estimated output for the set A with the model did not achieve the objectives even after having the heat transfer
repaired, the system reordered using a foamy slag technique,
identified using a dataset B, and y B A (i) is the estimated output
for the set B with the model identified using the dataset A. and arrangements made to work at higher power and voltage
For example, for the variable total dissolved combustible levels. Thus, the decision was made to get a new transformer.
The objectives of the new strategy were as follows:
gases (TDCG), that corresponds to the fuzzy variable x1 , four
fuzzy sets are proposed (A11 , A21 , A31 y, A41 ) for the opti- 1) to reduce the tap-to-tap time, thereby increasing annual
mization model. Thus, it is possible to build 15 = (24 − 1) production;
2) to operate the EAF at a high PF using long arcs in order
fuzzy models. First, four fuzzy models must be built with one
input variable each. For each model, the RC is calculated as to reduce electrode consumption.
shown in Table IV. The model with lower RC is selected for 11 The old transformer failed after launching this strategy. The
transformer of 14 taps, 13 800/100–400 V and 24/28 MVA was
combinations.
The heuristic method was one of the first methods of identifi- urgently replaced by a transformer of 9 taps, 13 800/380–700 V
cation for fuzzy linguistic models. This method is based on the and 27/30 MVA found in Pittsburgh, PA, USA. The replacement
was manufactured in 1969 and has more than 15 years of not
experience and knowledge of the expert.
The case study proposed in this paper is carried out by apply- being used. It is considered that this transformer has a wear-out
level and must be evaluated before setting it into operation. This
ing the knowledge acquired over several years of maintaining
transformers for the steel industry. It considers the application is the challenge of the technique previously presented. Table V
of a nonlinear equation that uses two sets B11 and B21 to rep- shows the results of the tests carried out on the transformer. In-
sulation and electrical tests were performed, and the assessment
resent the behavior of the Arrhenius model. See the following
equation: of an expert in each of the auxiliary components of the machine
was considered.
y = (−1 + B11 −3 + B21 ). (18) According to the report results, the transformer is in good con-
dition and is able to operate normally. To evaluate the remaining
The benefit of using (18) lies in a smaller number of clusters to
life using the conventional method, the laboratory issued a di-
represent the behavior of the Arrhenius model, which translates
agnosis on the condition of the transformer.
into lower computational cost. Fig. 13 compares the results of
Table VI shows the results of the gas chromatography analysis
the three models: Arrhenius, complete fuzzy model, and the
performed on the assessed transformer. The values of key gases
nonlinear equation model.
are in parts per million (ppm). Fig. 14 shows the graph of gas
In this comparison, the values of TDCG were used as the
percentages. The report stated that the concentration of TDCG
input space. As observed in Fig. 13, the nonlinear equation has
was within normal limits, and based on the DP = 953, the
a better fit in a wider range of input variables taking into account
estimated remaining life of the transformer was at 97%.
only two clusters.
Fig. 15 shows a photograph of the transformer.
The implementation of the methodology proposed in this
IV. APPLICATION TO A CASE STUDY
paper shows that the remaining life of the transformer is
An installation of an arc furnace in a steel production industry 0.959 p.u. The transformer was installed after the evaluation
in Colombia is considered in this case study. The installation and has been properly operating for the last 10 years.

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 CANO-PLATA et al.: LIFE ASSESSMENT OF ELECTRIC ARC FURNACE TRANSFORMERS 4133

TABLE V
RESULTS OF THE TRANSFORMER TEST REPORT

Fuzzy variable Fuzzy variable description Measure value

Oil tests:
x1 TDCG 1073.59
x2 Polymerization degree 953
x3 Moisture 8 mg/kg (ppm)
x4 Acidity < 0.02 (mg KOH)/(g of oil)
x5 Dielectric strength 37 kV
x6 Interfacial tension 36.3 mN/m
x7 Power factor (PF) 0.22%
x8 Oil screen tests Good condition
Electrical tests:
x9 Impulse test 100%
x1 0 Applied potential test 100%
x1 1 Induction potential test 100%
x1 2 Ratio test 0.04%
x1 3 Regulation test 1.3%
x1 4 Efficiency test, full load 99.7%
x1 5 Copper loss 209.4 kW
x1 6 Core loss 31.5 kW
Data Reading sheet:
Fig. 15. Assessed EAF transformer.
x1 7 Record of discharge pulses Good condition
x1 8 Temperature indicators For cleaning
x1 9 Thermometers For cleaning TABLE VII
x2 0 Switch meter Good condition CHARACTERISTICS OF THE EVALUATED TRANSFORMERS
x2 1 Operating test Good condition
Protection test:
Characteristics of the machine Application range
x2 2 Overvoltage arresters Good condition
x2 3 Discharge meters Good condition
Power range 15–100 MVA
Conservator:
Voltage range high side 13.2–34.5 kV
x2 4 Buchholz relay Good condition
Voltage range low side 200–700 kV
x2 5 Oil level indicator Good condition
Chronological age range 5–30 years
x2 6 Breathers For cleaning
Measurement type Online
Switch:
x2 7 Motor driving unit Good condition
x2 8 Transmission shafts Good condition
x2 9 Upper position indicator Good condition
x3 0 Control cabinet With oxidation
x3 1 Off-load tap changer Good condition
x3 2 Relay RS Good condition

TABLE VI
RESULTS OF TDCG

Concentration of Gases ppm % -Fuel gases

H2 —Hydrogen 0.00 61.9%

CH4 —Methane 83.18 7.5%
CO—Carbon Monoxide 220.17 4.9%
C2 H4 —Ethylene 6.09 0.7% Fig. 16. Statistical distribution of the expected life of the transformer lot in
C2 H6 —Ethane 124.74 0.8% Colombia.
C2 H2 —Acetylene 0.00 0.0%
Total Dissolved Combustible Gases 434.18 100.0%
In addition to this study, a 600 EAF transformer lot was evalu-
ated using this methodology. These transformers are distributed
in the territory of Colombia.
The results of gas analysis were considered as the fuzzy in-
put variables of the model in this study. Table VII shows the
technical characteristics of the transformer lot selected for the
study.
The proposed nonlinear model was used for this analysis and
two clusters of the input variable were used. The figure shows
that the expected life of the transformer lot is 26 years. Fig. 16
shows the distribution of the expected life of these transformers.
Finally, the methodology proposed to estimate the remain-
Fig. 14. Percentages of key gases. ing life of EAF transformers might be applied to reception

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 4134 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 53, NO. 4, JULY/AUGUST 2017
programs of used transformers, maintenance programs, and even
new transformers.
V. CONCLUSION
The unstable behavior of the electric arc and the high values of
reactive power are the main causes of the electric and magnetic
stress that bring about problems of quality in both the system
and the transformer, thus a condition of premature aging in the
transformer.
By integrating the transformer test results and using the
Takagi–Sugeno model, it is possible to assess the level of wear
or the condition of the transformer in order to determine the
feasibility of its reuse.
The fuzzy model considers many variables. This case study
took into account the experience in maintenance of EAF trans-
formers to make its relation with the fuzzy logic only in the
most representative variables through the Pareto equilibrium.
This has allowed the creation of a new model, which uses fuzzy
logic with fewer variables and in turn less computational cost,
see (18).
It is possible to assess the remaining life of a transformer by
implementing a fuzzy model from the input variables shown in
Table III. The implementation of this new model allowed the
evaluation of the technical condition of 600 transformers that are
currently in operation. Fig. 15 shows the trend of the remaining
life of these transformers. It can be observed that the graph has
a behavior similar to the normal statistical distribution.
ACKNOWLEDGMENT
The authors would like to thank the Universidad Nacional
de Colombia; Manizales, Colombia, the Group of Distribution
and Power Networks—GREDyP; and the Laboratory of Power
Quality and Power Electronics.
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Eduardo A. Cano-Plata (S’96–M’98–SM’15) was
born in Neiva, Colombia, in 1967. He received the
B.Sc. and specialist engineering degrees in electri-
cal engineering from the Universidad Nacional de
Colombia, Manizales, Colombia, in 1990 and 1994,
respectively, and the doctorate degree in engineering
from the Universidad de Buenos Aires, Buenos Aires,
Argentina, in 2006.
Since 1994, he has been a Full Professor with
the Universidad Nacional de Colombia. He is cur-
rently the Director of the Transmission and Distri-
bution Network Group—GREDyP, Manizales. His research interests include
power quality, power electronics, power systems grounding, and smart grids.
 CANO-PLATA et al.: LIFE ASSESSMENT OF ELECTRIC ARC FURNACE TRANSFORMERS 4135

Oscar J. Soto-Marin (S’15) was born in El Cairo, Armando J. Ustariz-Farfan (S’08–M’12) was
Colombia, in 1977. He received the B.Sc. and M.Sc. born in Urumita, Colombia, in 1973. He received
(Laureate thesis) degrees in electrical engineering, the bachelor’s degree in electrical engineering and the
from the Universidad Nacional de Colombia, Maniza- master’s degree in electric power from the Universi-
les, Colombia, in 2005 and 2015, respectively, where dad Industrial de Santander, Bucaramanga, Colom-
he is currently working toward the Ph.D. degree in bia, in 1997 and 2000, respectively, and the Ph.D.
electrical engineering. degree in electrical engineering from the Universi-
His research interests include power quality and dad Nacional de Colombia, Manizales, Colombia, in
power systems grounding. 2011.
He is an Associate Professor and a Researcher with
the Department of Electrical, Electronic, and Com-
puter Engineering, Universidad Nacional de Colombia. His research interests
include power definitions under nonsinusoidal conditions, power quality, and
power electronics.

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