6652 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 55, NO.

6, NOVEMBER/DECEMBER 2019

Overcurrent Protection in Electric Arc Furnaces

S. Arias-Guzman , Student Member, IEEE, A. J. Ustariz-Farfán , Member, IEEE,
and E. A. Cano-Plata , Senior Member, IEEE

Abstract—This article proposes a new adaptive protection setting

methodology for steel manufacturers, aiming to reduce miscoordi-
nation between main feeders and current consumptions due to fault
clearance or high load disconnection. By detecting abrupt changes
in current consumption, the computation of different protection
settings may be achieved. The application of this methodology is
performed through the assessment of a steel manufacturer who
sustained an arc blast of one of their protection cells, and a de-
scription of the way in which the proposal permits avoidance of
such catastrophic conditions.
Index Terms—Adaptive protection, electric arc furnaces, misop-
eration trip, protection coordination, relay simulation.

I. INTRODUCTION
LECTRIC arc furnace (EAF) operation (smelting and re-
E fining) presents a highly variable current consumption and
power quality deterioration, which has been related to unex-
pected power system conditions, including unscheduled power
flows [1], [2] and power quality deterioration for users far from
the steel manufacturers [3].
EAF highly variable current consumption may hide faults
within the steel manufacturer or in EAF operation, which are
generated by unintentional scrap metal or arc electrode contact
with peripheral devices, which causes thousands of kiloamperes
to flow into earth [4], [5].
Protection systems must selectively clear these catastrophic
failures, without disconnecting other loads which must remain
in service [6]. Currently, protection relays allow for parame-
terization of several groups of settings (up to six), each with
its own protection logic [6]. For feeder protection application,
it is possible to change between settings defined offline for
emergency contingencies and those for load increases [7]. For
example, protection setting changes in steady states has been
proposed for distribution systems with renewable resources, to
avoid protection blinding and sympathetic tripping [8], [9].
Fig. 1. One-line diagram of the steel manufacturer being assessed.
However, the availability of several protection settings does
not prevent erroneous protection system operations [10]. 42%
of erroneous operations of protections occur due erroneous
settings/logic (22%) and physical relay failure (20%).
Therefore, this article proposes a new methodology which
aims to reduce the risk of cascade tripping and hidden faults
on steel manufacturers, which occurs as a result of inadequate
protection settings. This is demonstrated with the assessment of
a steel manufacturer that sustained a protection cell arch blast,
owing misoperation of its ANSI 51P protection function.
This article is organized as follows: Section II presents a
steel manufacturer case which relates to an arc blast, Section III
explains the proposed methodology for protection setting com-
putation in real time, Section IV shows the proposed methodol-
ogy of operation in the steel manufacturer’s system, and finally,
conclusions are put forward.

Manuscript received July 15, 2018; revised December 9, 2018 and May 15,
2019; accepted July 26, 2019. Date of publication August 25, 2019; date of
current version October 18, 2019. Paper 2018-METC-0641.R2, presented at
the 2018 IEEE Industry Applications Society Annual Meeting, Portland, OR,
USA, Sep. 23–27, and approved for publication in the IEEE TRANSACTIONS
ON INDUSTRY APPLICATIONS by the Metal Industry Committee of the IEEE
Industry Applications Society. The work of S. Arias-Guzman’s was supported
by COLCIENCAS, by means of the “Convocatoria Doctorados Nacionales
2015” number 727. (Corresponding author: S. Arias Guzman.)
The authors are with the Electrical, Electronic and Computer Engineering
Program, Universidad Nacional de Colombia, Manizales 170003, Colombia
(e-mail: saariasgu@unal.edu.co; ajustarizf@unal.edu.co; eacanopl@unal.
edu.co).
Digital Object Identifier 10.1109/TIA.2019.2937498
II. STEEL MANUFACTURER UNDER ASSESSMENT
This article examines the protection system at a steel manufac-
turer, with a 27 MVA installed capacity. The plant is connected
to the network operator’s 115 kV system, and has two main
transformers, which serve the rolling mills and furnaces. Its
one-line diagram is shown in Fig. 1 and shows eight different
nodes considered in the furnace and rolling mill loads.
In order to perform the assessment of the protection settings, it
is important to have the information regarding the characteristics
of the industrial user as follows.

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ARIAS-GUZMAN et al.: OVERCURRENT PROTECTION IN ELECTRIC ARC FURNACES 6653

Fig. 2. Main feeder measured current at the steel manufacturer.

A. Industrial User Network System Equivalent

For this case, the national dispatch center [11] and the indus- Fig. 3. Protection cells. (a) Before fault. (b) Rolling mill breaker after arc
trial user has provided the following parameters. blast.
1) Short-Circuit Power in the Principal Substation 115 kV:
The short-circuit conditions at the point of common coupling TABLE I
(115 kV) are the following: OPERATION SETTINGS BEFORE THE PROTECTION CELL FAULT
1) short-circuit current (Icc ) = 8 300A;
2) short-circuit power (Scc ) = 1 653 MVA.
2) Step-Down 115/13.8 Transformer: The transformer cur-
rently used to change the voltage level in the steel company has
the following characteristics.
1) Power = 30 MVA.
2) Transformation relationship = 115/13.8 (kV).
3) Impedance (Z%) = 10.27% to 25 MVA using X/R = 10.
3) Intermediate Network: The network that links the step-
down transformer from the network operator to the furnace
transformer presents the following characteristics.
1) Nominal current at secondary side = 1 171 A.
not cleared quickly by its backup. In addition, the main circuit
2) Number of conductors per phase = 3, each with 452 A.
breaker R11 had been adjusted to expect a large EAF current
3) Conductor length = 163 m.
leading to the destruction of the R9 protection cell in an arc
4) Conductor Characteristics: 3 × 500 AWG, Cu, 90 °C,
blast, as shown in Fig. 3(b).
with a 15 kV XLPE with the following parameters.
The overcurrent protection settings of relays R1–R11, before
1) Resistance per unit length = 0.1031 mΩ/m.
the fault, are summarized in Table I, referring to the secondary
2) Reactance per unit length = 0.1290 mΩ/m.
current transformer (CT). All of these were configured with an
5) Electric Arc Furnace Operation: The electric arc furnace
inverse IEC curve. Instantaneous settings of relays 5 and 6 are
presents a highly variable consumption that results from the
not selected (NS).
different stages of operation as smelting and refining. The EAF
Coordination between the protection settings of the main
of the industrial user has a capability for 30 T of liquid steel.
circuit breaker (R11), rolling mills (R9, R6, R5, R2, R1), and
The operation of the EAF estimates a power factor of 0.8. The
furnaces (R10, R8, R7, R4, R3) is shown in Fig. 4(a) and (b),
estimated time for the operation of the EAF is about 72 min
respectively. As can be seen on Fig. 4(a) the area between the
with 33 for smelting, 12 for loading of the scrap, 7 for refin-
settings of relay R9 and R11 are imposed by the expected current
ing, and about 20 min of delays. The operation time can vary
of the smelting process of the EAF.
according to the expected production of steel. The maximum
Settings in Table I were selected years before occurrence of
smelting power consumption can vary between 28 and 27 MVA
the fault, which is a typical situation for industrial users [10].
dependent on the use of burners in the process. As shown in
Following this event, the user changed their protection cells and
Fig. 2, the steel manufacturer current measured in the main
settings, as shown in Fig. 5, and listed in Table II.
feeder presents highly variable behavior due the expected power
A series of major changes were made for 51P functions, pick
consumption of the EAF operation. Under normal conditions,
up values in relays R1, R4, R5, R6, R7, R8, R9, R10, and R11
main feeder overcurrent protection settings are expecting the
were reduced, pick up values in R2 and R3 were increased. These
smelting current consumption.
changes in coordination are shown in Fig. 6(a) and (b).
However, the 2016 arc blast is not a case that may be prevented
B. Arc Blast Incident permanently with a group of fixed settings that are computed
In 2016, a fault in the steelmaking user rolling mills should offline. As observed in Figs. 4(a) and 6(a), the delay between
have been cleared by the protection cells shown in Fig. 3(a). the main feeder with rolling mills is a consequence of EAF power
Following the misoperation of circuit breaker R9, the fault was consumption during smelting stage.

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6654 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 55, NO. 6, NOVEMBER/DECEMBER 2019
Fig. 4. Offline coordination. (a) Main feeder with rolling mills. (b) Main feeder
with ladde and arc furnace.
Fig. 5. New rolling mill protection cells.
TABLE II
NEW PROTECTION RELAY PROTECTION SETTINGS
This power consumption is variable, in accordance with its
operation stage (smelting or refining), as shown in Fig. 2, and
may even be off for maintenance or scrap filling. Even with
the application of relays which allow for the selection of several
groups of settings, changes between groups can take up to 16 000
cycles to come into force, in accordance with the user’s offline
selection. Therefore, another possibility arises for online com-
putation of protection settings, with user operational changes.
Below, the new proposal and improvement available for further
protection relay operations is explained.
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Fig. 6. New offline coordination. (a) Main feeder with rolling mills. (b) Main
feeder with ladde and arc furnace.
Fig. 7. Proposed adaptive protection setting methodology.
III. PROPOSED METHODOLOGY
EAF power consumption is the main condition for protection
setting computation for steel manufacturers. Even so, the EAF
operation may vary between smelting, refining, filling, and dis-
connection processes. Detecting these EAF operational changes
could enable protection setting adaptation to steel manufacture
operations.
Therefore, this investigation proposes the methodology
shown in Fig. 7 to compute the adaptive protection settings for
the main feeder relay for the steel manufacturer, in real time.
First, the steel manufacturer operation was simulated, includ-
ing variable EAF consumption, using the model proposed in [12]
and [13]. The characteristics of protection feeders, transformers,
and adjustments were acquired from the iron and steel producer.
Initially, the protection settings in Table II were used to begin
the simulation and were uploaded to the protection relay models
proposed in [14].
ARIAS-GUZMAN et al.: OVERCURRENT PROTECTION IN ELECTRIC ARC FURNACES
Fig. 8. Adaptive 50P/51P ANSI function protective settings.
In the occurrence of a fault the steel manufacturer will suffer
topological changes according to clearance using the overcurrent
protective function following the inverse curve (Tinv ) posed in
[15]
 
k that on-line operations reduce to a simple function evaluation
Tinv = + B TD for M > 1
Mα − 1
 
C
Tinv = TD for 0 < M < 1
1 − M2
where
Tinv Inverse TCC trip time;
k,B,α,C Constants according to the type of TCC curve;
M Relation between measured and pick up current;
TD Constant of time delay.
Constants k, B, α, and C are defined according to the type of
selected TCC curve, between the standards IEC Std. 60255 and
IEEE Std. C37.112 [15].
Major changes to main feeder current consumption are de-
tected using the Tensor-VSA technique [16]. The Tensor-VSA
technique detects major deviations between the measured cur-
rent ia (t), ib (t), ic (t) and the estimated value of a time sample
(tk ) ia (tk ), ib (tk ), ic (tk ), which had been obtained via a Kalman
Filter with a k sample difference. The Kalman filter has been
applied as in [17] If a major difference is detected, a model
predictive control (MPC) is used to estimate the operation of
the steel manufacturer and the required protection settings to
modify on the overcurrent relay settings as shown in Fig. 8.
MPC refers to a class of algorithms that compute a sequence
of manipulated variable adjustments in order to optimize the
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6655
Fig. 9. Principle of MPC applied to 50P/51P ANSI function settings.
future behavior of a plant [18]. The principle of MPC is shown
in Fig. 9, x represents the state variable that needs to be con-
trolled to a specific range. The available control is represented
by the variable u that represents all protection settings in the
50P/51P model (PUk , TDk , Curvek , ITk ). At a current time
Ts, the explicit MPC allows to solve an optimization problem
off-line for a given range of operating conditions of interest.
Therefore, EMPC computes the optimal control action off line
as an explicit function of the state and reference variables, so
[18].
In this case, the input of control u at tk + Ts will be a different
(1) protection setting’s according to the tap-to-tap operation stage
computed to be send at time tk + Tc to the protection relays
before the predicted horizon tk + Tp .
If a topological or operational change is detected or predicted
due the tap-to-tap cycle, where the protection coordination could
present miss operations, the explicit MPC will compute the new
required protection settings according to the offline optimization
procedure. This process is shown in Fig. 8 as the detection of
the fault allows to compute the optimum protection settings
using the explicit model predictive control and send it to the
overcurrent protective model.
Since the location and maximum expected value of currents
during tap-to-tap cycle are known, or can be simulated with
appropriated EAF models [12], [13], the offline optimization
function is computed for different operating conditions of the
EAF. A tap-to-tap stage change from furnace charging and turn-
over to smelting and refining can be predicted through a signal
send to a central unit to initialize the furnace operation. This
procedure is shown in Fig. 10.
Performing the measuring of the consumption current and
through the knowledge of the different tap-to-tap stages, the
operation of the industrial user is predicted by the EMPC by
mean of (2) though the measurement of each relay current
between branches and nodes (SMbn ). Through SMbn protection
6656 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 55, NO. 6, NOVEMBER/DECEMBER 2019

Fig. 10. Tap-to-tap tracking for adaptive protection coordination.

Fig. 11. Steel manufacturer EAF measured current.

coordination sequence priority is defined

n n2 n... nn
⎡1 ⎤
b1 I12 −I12 0 0
⎢ ⎥
b2 ⎢ I1n 0 0 −I1n ⎥ (2)
SMbn = ⎢ . .. ⎥
⎢
b... ⎣ .. .. .. ⎥.
. . . ⎦
bm I1n ··· ··· −I1n
Fig. 12. Steel manufacturer main feeder measured current.

The above matrix allows monitoring the user operation vari- TABLE III
ations, which were programed as the change between the filling CURRENT CONSUMPTION DURING THE TAP-TO-TAP OPERATION STAGES
of scrap and arc initiation. When a fault is detected, the related
relay is eliminated in the corresponding row of the SMbn ma-
trix, in accordance with measured magnitude, which allows the
identification of the new operation through EMPC. This process
is shown in the following chapter.

IV. SETTINGS ASSESSMENT

This article was applied to the steel user after the failure that
generated an arc blast in the rolling mill protection cells (relay
R9), as shown in Fig. 3.
In order to modify the relay settings, the steel manufacturer
simulation was performed, and all relay settings were selected,
as listed in Table II. The operation of the EAF presents highly
variations due the tap-to-tap cycle as is shown in Fig. 11 for the
current consumption during a full cycle of operation.
The current magnitudes on the main feeder, rolling mills, and
arc furnace circuits were measured to detect possible topological
or operational changes obtained from the simulation for each
time step. This current consumption of all loads is visible on
the main feeder as shown in Fig. 12, where the EAF behavior
imposes the current consumption.
As it can be seen in Figs. 11 and 12 the current does not always
presents the high value due to melting operation. There are some
intervals in which the EAF will be charging the scrap or in a
turn-over operation. Between this time intervals the fundamental
(60 Hz) current consumption will be low in the main feeder of
the steel manufacturer user and on the feeders of the furnace and
rolling mills. This is listed in Table III for the different tap-to-tap
cycle.
In this condition, the fixed protection settings of the main
feeder shown in Table II will have a great delay with the furnace
and rolling mill feeders during furnace charging and turn-over,
as shown in Fig. 13 with the shadowed interval between the TCC
curves of relay 9 and 11.
For this steel manufacturer, the SMbn in (2) was developed,
as explained in the proposed methodology, following the or-
der shown in Fig. 10 for said steel manufacturer’s nodes and
branches. The fundamental current magnitudes in each position
in (3) were obtained from the simulation for each time step
as shown in Table III. If all steel user loads were in operation
(maximum load condition), all the setting groups would need to

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ARIAS-GUZMAN et al.: OVERCURRENT PROTECTION IN ELECTRIC ARC FURNACES 6657

Fig. 13. Actual coordination of the steel manufacturer and the time delay
between the main feeder and the rolling mill. Fig. 15. Steel manufacturer R11 measured current.

TABLE IV
NEW SETTING GROUP, DUE TO LARGE LOAD DISCONNECTION

Fig. 14. Current measured at EAF feeder R4.

During the fault interval, the current registered in the rolling
mill presents an increment in the current consumption due to
be set to their maximum group the voltage sag generated by the fault. Even so, the increment
in the current is not comparable with the operation of the EAF
SMbn = and in most extreme cases can go to 200% of the rolling mill
⎡ ⎤ consumption [19]. The ridethrough capability of the rolling mill
I12 −I12 0 0 0 0 0 0 will depend on the drive used on the rolling mill [20], [21].
⎢0 I23 −I23 0 ⎥
⎢ 0 0 0 0 ⎥ After the fault was cleared, the total demand current will be
⎢ ⎥
⎢0 I24 0 −I24 0 0 0 0 ⎥ close to the operation of furnace charging and turn-over. Since
⎢ ⎥
⎢0 0 ⎥ EAF operation represents the largest need for current at the steel
⎢ 0 I35 0 −I35 0 0 ⎥.
⎢ ⎥ manufacturer, disconnection of the arc furnace feeder leads to
⎢0 0 I36 0 0 −I36 0 0 ⎥
⎢ ⎥ a decrease in the current to be cleared in both steady state and
⎣0 0 0 I47 0 0 −I47 0 ⎦ short-circuit conditions.
0 0 0 I48 0 0 0 −I48 Therefore, after disconnecting the electric arc furnace feeder,
(3) readjustment of feeder operation settings, between the substa-
tion and the steel user, is necessary. This constitutes a new
With this condition, a fault near the electric arc furnace, pro- setting/logic group required for main feeder protection. As a
tected by relay R4, as well as its clearance, was simulated. The result of the above, calculations were performed for the new
current fault is shown in Fig. 14 for the fundamental component protection operations settings.
extracted by means of a Kalman filter. These new settings are presented in the summary in Table IV
Fig. 14 shows the fault current after a short-circuit fault oc- for the overcurrent relays that remained after EAF feeder over-
curred at the EAF terminals at three seconds, and its subsequent current protection clearance. The new coordination is shown in
clearance by the R4 relay in 100 ms, as shown in the trip order in Fig. 16, and highlights the difference between the settings in
Fig. 14. As the fault occurs, the proposed methodology detects Tables II and IV.
an abrupt change in main feeder current magnitude, as shown in Without this modification, a fault in the remaining connected
Fig. 14. loads, (whether rolling mill or ladle furnace) would be hidden
For these simulation conditions, the fundamental current mea- from the main feeder, in the offline settings presented in Tables I
sured in the main feeder relay (R11) are shown in Fig. 15. and II, as was shown in Figs. 4(a) and 6(a).

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6658 IEEE TRANSACTIONS ON INDUSTRY APPLICATIONS, VOL. 55, NO. 6, NOVEMBER/DECEMBER 2019
Fig. 16. Coordination between main feeder and rolling mill loads. (a) Offline
coordination before 2016 event. (b) Offline coordination after 2016 event.
(c) Adaptive proposed methodology results, due to EAF disconnection.
Fig. 17. Coordination comparison of the steel manufacturer during furnace
charging and turn-over. (a) Main feeder and rolling mills using fixed settings.
(b) Main feeder and rolling mills with adaptive settings.
In a more detailed example, during some intervals of the
tap-to-tap cycle the loads of the steel manufacturer will lack
of a proper backup from the main feeder in case of a fault.
For this purpose, the proposed methodology uses the measured
fundamental current consumption to detect the abrupt change
of tap-to-tap cycle and compute new protection settings. During
furnace charging and turn-over, new settings are computed due
the low current consumption and provide shorter time delays for
back up protection from the main feeder, as listed in Table IV.
This is shown in Fig. 17(b) where the time delay between
the main feeder and the rolling mill feeder has been reduced as
compared with Fig. 17(a).
Contrary to the process presented in this article, methods [15],
[22], and [23] require the construction of the branch to nodes
matrix for each of the user’s stationary states.
Additionally, they only represent the connection between
nodes. The above delay determines the relays that require op-
eration setting modification and protection system coordination
for the following reasons:
1) It requires that the system be in a stable state after the
system relay operation, does not allow for continuous
monitoring for identification of changes in normal user
operation.
2) The traditional method verifies whether there is a group of
adjustments which can address the new topology, after a
determined amount of time offline, as selected by the user.
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Both methods present a delay in the identification of setting
group changes, which are required by the protections system.
This delay may not be fast enough to avoid the risk of arc blast
events, as shown in Fig. 3.
The automation process proposed in this article aims to
achieve adaptive settings, which follow the dynamic steel man-
ufacturer changes, to avoid miscoordination that could lead to
catastrophic faults.
Also, through the Kalman filter computation of the fundamen-
tal component is possible to identify the change in the expected
consumption and therefore identify topological changes through
the EMPC.
V. CONCLUSION
This article presents a simulation environment for electric arc
furnaces which allows for quantification of protection system
sensitivity. It demonstrates the way in which electric arc furnace
operation impacts the protection system settings, considering
the larger deviations in coordination with remaining loads, after
electric arc furnace disconnection.
The calculation of the settings/logic group adjustments nec-
essary for the system may be performed within the protection
operation times, considering the intrinsic time, which varies be-
tween 10 and 40 ms, in accordance with the protection function,
instantaneous overcurrent (10–15 ms), distance protection (15–
25 ms), differential protection (20–40 ms), and power switch
operation (115, 230 kV), which varies between 3 and 5 cycles
(60–100 ms).
Lastly, the MATLAB environment employed in this simula-
tion process offers considerable potential for signal generation,
such that it may be easily used to create a series of protection
tests that are composed of current and voltage signals for steel
manufacturers’ stages of operation.
A. Future Work
Arias-Guzman et al. in [24] a fault occurrence that lead to
a subsequent arc blast incident. Proposed methodologies as
the one shown in this article aim to reduce the occurrence of
such incidents. Future work on adaptive protection coordination
methodologies will include the consideration of the use of the
communication protocol IEC 61850 GOOSE [25] used currently
by the protection industry has extended its capabilities to com-
municate high-speed information between local relays or other
devices on the LAN. Examples include breaker position, breaker
trip, interlocking, and load-shedding commands [7]. Looking
forward on the possibilities of the proposed methodology is add
the detection and prediction through EMPC to the communica-
tion IEC 61850 protocol.
Also, the response of the rolling mill to the voltage sag due
a fault on a close load is presented alongside an increment in
the harmonic content of the current and voltage. Therefore, the
power quality distortion due the rolling mill response would
as additional information to identify a fault condition on the
steelmaking manufacturer.
ARIAS-GUZMAN et al.: OVERCURRENT PROTECTION IN ELECTRIC ARC FURNACES
ACKNOWLEDGMENT
The authors gratefully acknowledge the Power Quality and
Power Electronics Research Group—GICEP and the Trans-
mission and Distribution Network Group—GREDyP for their
collaboration.
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S. Arias-Guzman (S’14) was born in
Manizales, Colombia, in 1990. He received the
B.Sc. degree in engineering, and the M.S. degree in
electrical engineering from the National University of
Colombia, Manizales, in 2013 and 2016, respectively.
He is currently working toward the Ph.D. degree
in engineering and electrical engineering in the
National University of Colombia.
His research interests include voltage sags,
segmentation, and Kalman filtering.
A. J. Ustariz-Farfán (S’08–M’12) was born in Uru-
mita, Colombia, in 1973. He received the B.S. degree
in electrical engineering, the M.S. degree in electrical
power from the Universidad Industrial de Santander,
Bucaramanga, Colombia, in 1997 and 2000, respec-
tively, and the Ph.D. degree in electrical engineering
from the Universidad Nacional de Colombia, Bogotá,
Colombia, in 2011.
He is a Researcher and Associate Professor with
the Electrical, Electronic and Computer Engineer-
ing Department, Universidad Nacional de Colombia,
Manizales, Colombia. His research interests include power definitions under
nonsinusoidal conditions, smart grids, power quality, and electronic power. He
is currently the Director of the Power Quality and Power Electronics Research
Group–GICEP.
E. A. Cano-Plata (S’96–M’98–SM’15) was born in
Neiva, Colombia, in 1967. He received the B.Sc. de-
gree and Specialist Engineering degree from the Uni-
versidad Nacional de Colombia, Manizales, Colom-
bia, in 1990 and 1994, respectively, both in electric
engineering, and the doctoral degree in engineering
from the Universidad de Buenos Aires, Buenos Aires,
Argentina, in 2006.
Since 1994, he has been a Full-Time Professor with
the Universidad Nacional de Colombia, Manizales,
Colombia. His research interests include power qual-
ity, electronic power, power system grounding, and smart grids. He currently
directs the Transmission and Distribution Network Group– GREDyP.