Page 1 of 6 2016-METC-0636

Validation and Reception of Electric Arc Furnace Transformers

E. A. Cano-Plata o. J. Soto-Marin A.J. U stariz-Farfan

Senior Member, IEEE Student Member, IEEE Member, IEEE
Universidad Nacional de Colombia Universidad Nacional de Colombia Universidad Nacional de Colombia
eacanopl@unal.edu.co ojsotom@unal.edu.co ajustarizf@unal.edu.co

Abstract - The electric arc furnace transformer is one of the
most important devices in the steelmaking industry. Installing
used transformers is very common nowadays taking into
account the huge investment that represents the acquisition of a
new one. The transformer is subjected to electrical stress, thus it
is necessary to assess the wear and tear levels in the reception
process before accepting a trade agreement and before setting
the device into operation. Analysis parameters are the input
variables of a new fuzzy model to calculate the remaining life of
the transformer.
linear. This makes all the involved electrical variables also
nonlinear [2]. The processes taking place in this circuit as
well as the dependencies between the electrical parameters of
the system are quite complex [3]. Figure 3 shows the
variations of the EAF parameters as a function of the current.
Here: PARC is the arc power, Q is the reactive power, P is the
active power, VARC is the arc voltage, pi is the power factor
measured in the transformer secondary and LARC is the length
of the electric arc.

Index Terms- Transformer, Fuzzy logic, Arc heating, -

stability, furnaces, Chemical analysis of dissolved gases. - -Pafc(MW)
--a (MVAr)
-
r-.. -P(MW)

I. INTRODUCTION
-I-- ....... / -VafC'O,l(V)

r- " /
-p

-tare (em)

The primary objective of a steelmaking industry is to � .2'

maximize annual production. The secondary objective is to � ""'"�
minimize costs related to energy consumption and the wear V /' ""
and tear of electrodes, which are obviously directly affected
;' V - \�
- V ....�
..
by the operating strategy of the EAF. There should be a good 4 9 14 19 24 29 34 39 44

fit between the furnace and the feeding system. Determining Current (kA)
-
the condition of the maximum transfer of the supply power Fig. 3. EAF parameter variation

system at the time of scrap feeding and the operating

condition that will keep the arc stable become very important
for proper system operation.
Figure 1 shows a diagram of the EAF electrical system
elements.
The electric arc starts with the primer and lasts until the
end of the melting stage. The arc is very unstable during the
melting stage and its length varies considerably due to scrap
movement. The greatest fluctuations of active and reactive
power take place during this stage. [4]. Thus, the unstable
behavior of the arc is the main source of electrical and
mechanical stress in the transformer [5]. Consequently, the
application of electric and magnetic stress above nominal
values leads to accelerated wear and tear in the transformer
and even early failure.

New EAF transformers are very expensive and some

companies opt for purchasing used transformers when
existing devices fail or when systems are repotentialized.
This is a very common alternative. However, due to the
electrical stress to which EAF transformers are subjected, it is
necessary to assess the level of wear and tear of the
transformer during the reception process and before accepting
a trade agreement and setting it into operation.

Fig. I. Diagram of the EAF system Currently, electrical and mechanical tests, and also
insulation checks [6] are carried out during the reception
The voltage and current characteristics of an EAF are not process of used transformers in order to assess the condition

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 2016-METC-0636
of each of its components [7]. However, there are no specific
methods to integrate the results of these tests and to identify
the interrelations and contributions of each element to the
reliability of the entire device. Thus, the assessment of the
level of remaining life of the entire transformer becomes
inaccurate.
This paper proposes the implementation of a new model
based on fuzzy logic [8][9] that considers as input variables
the results of the tests performed on each component in the
reception process It is possible to assess the wear and tear
condition of the transformer using this model and in turn
decide whether its reuse is feasible [ 1 0][ 1 1 ].
II. CONCEPTUAL FRAMEWORK
A. EAF system benchmark
An installation of an arc furnace in a steel production
industry in Colombia is considered as a case study. In this
case, the replacement of the existing transformer is
imperative as it has failed to fulfill the expected objectives
after the heat transfer system was improved by re-ordering a
new technique of foaming slag. In addition, arrangements
were made to the transformer to work at other power and
voltage levels.
The objectives of the new installation are as follows:
• To reduce the tap-to-tap time in order to increase
annual production.
• To operate the EAF at a high power factor (PF)
using long arcs in order to decrease electrode
consumption.
It is necessary to determine the operating conditions of the
electric arc and the system parameters in order to identify the
EAF transformer parameters. The effects of transformer
selection are analyzed using mathematical models. The
results of the selection are shown below.
A transformer of 1 4 taps, 400/600 V, 27/30 MVA, and also
the proper conditions for its replacement are considered in
this case The replacement considered is a transformer of 1 6
taps, 4501750 V, 40/50 MVA which records time of use and
wear and tear levels. An evaluation and assessment of the
replacement should be performed before setting it into
operation
B. Reliability ofEAF Transformers
The reliability of EAF transformers depends mainly on the
degree of continuous monitoring of the most important
functional parameters that define technical conditions. Any
device under normal operating conditions is subjected to
continuous deterioration. Transformers are not exceptions.
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Page 2 of 6
It is possible to track natural or accidental deterioration of
transformers by using modern monitoring equipment and
diagnostic techniques.
Preventive and corrective maintenance helps extend the
estimated life of the transformer and also to calculate the
remaining life; therefore, avoiding high cost losses.
The application of electric and magnetic stress above the
plate nominal values involves an accelerated wear and tear
degree. Wear and tear might take place immediately or might
be the result of accumulated deterioration over the years.
Figure 4 shows failure rate behavior.
O ��t� ------------��--------�
1 t2
Fig. 4. Failure rate in time
CIGR E statistics showed that the winding and the core are
the main failing elements in power transformers. See Figure
5 [ 1 2].
This deterioration is manifested by either:
• Reduction of mechanical strength.
• Decrease of the basic insulation level (BIL).
These effects are consequences of wear and tear or
deterioration of the insulating material.
Auxiliary
Windings +
5%
Bushings
14%
Fig. 5. Transformer failure statistics [3]
Mathematical models are used to estimate the remaining
life of the transformer and its wear and tear level which
directly depends on the state of oil deterioration [5][ 1 2].
Many research studies have concluded that the behavior of
thermal deterioration of insulation materials might be better
represented by the reaction rate equation [6].
2
Page 3 of 6 2016-METC-0636

dR
=
Ae-(EIKT)
dt
In this equation, dRidt is the reduction o f R property
regarding time, A is the integration constant, K is the gas
constant or Boltzmann constant, T is the absolute temperature
of hot spot and E is the activation energy of the wear and tear
reaction (High values of E lead to faster wear and tear. Small
values of E lead to slow wear and tear).
Equation (2) shows the rule of the chemical reaction
developed by Svante Arrhenius in 1 880. The original form of
Arrhenius equation might be obtained from the integration of
equation ( 1 ) as follows:
the transformer.
(1)
The process of reception and maintenance of EAF
transformers should consider electrical and mechanical tests,
which are specified in Table I.
Some types of electrical tests include:
• Insulation resistance
• Transformer ratio (TTR)
• Loss angle (Tangent delta)
However, oil testing is probably one of the most important
controls that can be performed in a transformer.
Oil test results help to determine possible damage to the
main winding and to the insulation material and also to
(2) decide whether an arc has been produced [4].

R Dielectric strength, humidity, interface voltage, specific

=
Ae-(EIKT) (3) weight, neutralization number (acidity), and color are some of
t the tests that can be performed to the insulation material to
determine the deterioration condition and properties.

(4) The results of these tests help to determine the condition

of the internal parts of the transformer, but a full dissolved
This model relates life of the electrical insulation to simple gas analysis (DGA) provides a more complete picture of
fatigue (thermal deterioration) of the transformer. As transformer deterioration. This information will allow
described in the equation, the transformer lifetime decreases predictions of internal problems and the implementation of
as temperature increases during normal operation. Figure 6 the respective actions.
shows the representation of equation (4).
In addition, the reception and maintenance process must
include a thorough assessment of each element of the entire
��40 h----+----r--�--�
+-,,---+----�--�
device such as oil leaks, paint stripping, overheating and any
_35 +--y-+----�--� anomaly outside the normal operating parameters.
� 30
� 25 +
�
E 20 A description of the main elements involved in the
�
15 r---� reception process, which should also be considered in the
=r=-
IO +----+----�--_?��
�-r --
maintenance plan is detailed below.
60 80 100 120 140 160
Temperature 1) Temperature Meters
Temperature meters do not show a process of deterioration
Fig. 6. Lifetime of the transformer as a function of temperature with time and do not require maintenance. Their failure rate
is constant in time. However, operation and performing tests
Activation energy E is the most important parameter in the must be done during the reception process.
study of wear and tear because it causes the breakdown of
polymer chains in the insulation. This is the only parameter 2) Pressure ReliefDevices
that determines the wear and tear of the insulation material Pressure relief devices do not deteriorate with time and
[6]. require no maintenance; however normal operation tests
should be performed during reception.
III. PROPOSAL FOR RECEPTION OF EAF TRANSFORMERS
3) Current Transformers
A. Phase 1: Reception of transformers Physical inspections and transformation ratio assessments
during reception show loose connections, short circuits or
This procedure aims to describe the instructions for the
poor device operation.
reception and assessment of the remaining life of the device,
which will help making the decision of accepting or rejecting
3
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 2016-METC-0636 Page 4 of 6

4) Valves leaks, or obstructions.

Valves are mounted on the tank. Valves used for drainage,
filling, or oil extraction should be cleaned and checked for

TABLE I
RECEPTION AND MAINTENANCE OF EAF TRANSFORMERS USING DIFFUSE VARIABLES

Fuzzy Maintenance
Element Reception task
variables Monthly Annual
Electric tests: x
Insulation resistance After repairs xl Yes
Transformation ratio Switch work x2 Needed x
Insulation Tan delta All the protection devices x3
Performance tests x4
Oil tests
Gas Chromatography analysis Sample collection using a syringe x5 6
months
Oil screen testing Main tank and change oil cap x6 6
months
Read data sheet: X
Impulse discharge record Oil maximum temperature x7 X
Temperature indicators Winding maximum temperature x8 X
Thermometers Internal and external of oil and water flow x9 X
Switch meter Record of number of operations xlO
Performance tests Protection device testing xii X
Conservator: Oil leakage control X
Buchholz relay Indicator reading test x12 X X
Oil level indicator Dehydrating breather change, if of pink color xl3 X
Protection system:
Overvoltage dischargers Oil leaks and overheating x14 X
Discharge meters Record of discharge meters xl5 X
Switchboard: Inspection and testing of the engine control X
No load tap changer Electrical and mechanical interlock testing x16 X
Load tap changer Operation control for all other taps x17
Control cabinet Oil and gas extraction xl8 Needed X
ReiayRS Filter change, manometer readings. x19 X X
Oil leak inspection X
Performance tests
Inspection and cleaning

the color of the dehydrating breather. The dehydrating

5) Grounding connectors
An inspection should be done to verify that grounding
connectors are not loose and also that do not show signs of
overheating. Overheating can initiate current circulation.
6) Oil conservator tank
A transformer equipped with an oil conservator
should have the dehydrating breather tested. A
dehydrating breather is blue and becomes pink
absorbing moisture. It is important to keep it in
condition.
The oil conservator tank should be inspected in order to
control oil leaks and to periodically record its level. This tank
might have more than one compartment and each
compartment must be equipped with a vent. The oil tank
should also be inspected for conservator leaks and to check
breather should be replaced after becoming pink.
7) Buchholz relay
The Buchholz relay might be used to detect gases, low oil
levels or strong oil movements. This device detects any gas
accumulation in the oil. Performance and operation testing
tank should be carried in the alarm system, which usually sends an
new alarm signal to the control board.
after
good Any large gas expansion inside the tank moves the oil into
the conservator tank, which in turn moves a hinged valve.
This can be observed using a visible float through a glass
window or through a shot of a small valve at the top of the
device.
4

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Page 5 of 6 2016-METC-0636

B. Phase 2: Development of the Fuzzy Model Table II shows the proposed model which calculates the
This section provides a parameter estimation method for a life of the transformer using four variables in a nonlinear (6)
fuzzy model [9]. equation of a heuristic approach. This methodology can be
applied at the reception process of a used transformer. The
Heuristics was one of the fIrst identifIcation methods for model implementation results will decide the deterioration
the linguistic fuzzy models [9]. This method is based on the degree of the device.
experience and knowledge of the expert. Figure 7 shows the statistical distribution of life in used
It is very easy to view the model in order to assess the transformers. Six hundred (600) transformers distributed in
actual condition of an EAF transformer, defIned by the Colombia, and the variables x 1 and x2 on Table II were taken
equation: into account. The expected life of the installed transformer
(EIKT) (EIKT) lot was quickly calculated to be 1 8 years.
R i : IF X11S Ane -
.
and ... and xn IS Aine -
.

(5) 4S

thenYi is B,
� :� . .

�� 30
25
�
. .
Where Xj, . . . ,Xn are the input variables of the fuzzy model 20
15 . .

shown in Table I, Au, . . . ,Ain are the fuzzy sets associated with � 10
•

the Arrhenius model and implemented in equation (4) for Z

each component in Table I. Finally, Yi is the output variable o 2 4 6 8 10 12 � 16 18 W 22 � U 28 �

with B; as its corresponding fuzzy set and i is the number of Span live
Fig. 7: Statistical distribution of expected life in a transformer J.Qtin
rules. Colombia

IV. IMPLEMENTATION OF THE Fuzzy MODEL Finally, the new method used to calculate the remaining
Data shown in Table I suggest the following nonlinear life of electric arc furnace power transformers can be applied
model: to reception processes of used transformers or also to
maintenance programs.
(6)
CONCLUSIONS
Having Xl> 1 and x2<4. Taking into account this system of
equations, a set of 26 data points was used to build the model. • Using the proposed maintenance program, It IS
See Table I. possible to assess the wear and tear condition of
transformers and the probability for reuse.
Two adjustment variables (X3 and X4) are also included to • The unstable behavior of the electric arc is the
the system input to validate the identifIcation model. The leading cause of electric and magnetic stress,
premise and the consequence of the fuzzy system are which causes quality problems in both the system
determined using equation (5). and the transformer. This can lead to premature
deterioration in the transformer.
Four input variables (xl, x2, x3 Y x4) are proposed using • It is possible to calculate the remaining life of
the Heuristic method, which gives the possibility to build a transformer by implementing a fuzzy model and
4
1 5=(2 - 1 ) fuzzy models. First, four fuzzy models are built; by using the input variables shown in Table I. A
each with an input variable. Table II shows the regularity
new model was developed using equation (6).
criteria RC [9] calculated in each model. The model with the
The results for the EAF transformers in Colombia
lowest RC is selected.
are shown in fIgure 7.
TABLE II:
REGULARITY CRITERIA VALUES OF THE HEURISTIC
Model Input RC ACKNOWLEDGMENTS

variables The authors wish to thank Universidad Nacional de

1 Xl 0.623 Colombia, the Engineering Program and specifIcally the
2 X2 0.745 Automation Line Research Program in Manizales. The
3 X3 2.467 authors also appreciate the support received from the dean of
4 X4 3.456 the Engineering and Architecture Program at Universidad
5 Xl�2 0.345 Nacional de Colombia, Manizales Branch.
6 Xl,X3 0.567
7 Xl,X4, 2.34 REFERENCES

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 2016-METC-0636 Page 6 of 6

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