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Validation and Reception of Electric Arc Furnace Transformers
Validation and Reception of Electric Arc Furnace Transformers
Abstract - The electric arc furnace transformer is one of the linear. This makes all the involved electrical variables also
most important devices in the steelmaking industry. Installing nonlinear [2]. The processes taking place in this circuit as
used transformers is very common nowadays taking into well as the dependencies between the electrical parameters of
account the huge investment that represents the acquisition of a
the system are quite complex [3]. Figure 3 shows the
new one. The transformer is subjected to electrical stress, thus it
is necessary to assess the wear and tear levels in the reception variations of the EAF parameters as a function of the current.
process before accepting a trade agreement and before setting Here: PARC is the arc power, Q is the reactive power, P is the
the device into operation. Analysis parameters are the input active power, VARC is the arc voltage, pi is the power factor
variables of a new fuzzy model to calculate the remaining life of measured in the transformer secondary and LARC is the length
the transformer. of the electric arc.
I. INTRODUCTION
-I-- ....... / -VafC'O,l(V)
r- " /
-p
-tare (em)
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
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 Page 2 of 6
of each of its components [7]. However, there are no specific It is possible to track natural or accidental deterioration of
methods to integrate the results of these tests and to identify transformers by using modern monitoring equipment and
the interrelations and contributions of each element to the diagnostic techniques.
reliability of the entire device. Thus, the assessment of the Preventive and corrective maintenance helps extend the
level of remaining life of the entire transformer becomes estimated life of the transformer and also to calculate the
inaccurate. remaining life; therefore, avoiding high cost losses.
This paper proposes the implementation of a new model The application of electric and magnetic stress above the
based on fuzzy logic [8][9] that considers as input variables plate nominal values involves an accelerated wear and tear
the results of the tests performed on each component in the degree. Wear and tear might take place immediately or might
reception process It is possible to assess the wear and tear be the result of accumulated deterioration over the years.
condition of the transformer using this model and in turn Figure 4 shows failure rate behavior.
decide whether its reuse is feasible [ 1 0][ 1 1 ].
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978-1-4799-8397-1/16/$31.00 © 2016 IEEE
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Page 3 of 6 2016-METC-0636
dR the transformer.
=
Ae-(EIKT) (1)
dt
The process of reception and maintenance of EAF
In this equation, dRidt is the reduction o f R property transformers should consider electrical and mechanical tests,
regarding time, A is the integration constant, K is the gas which are specified in Table I.
constant or Boltzmann constant, T is the absolute temperature
of hot spot and E is the activation energy of the wear and tear Some types of electrical tests include:
reaction (High values of E lead to faster wear and tear. Small • Insulation resistance
values of E lead to slow wear and tear).
• Transformer ratio (TTR)
Equation (2) shows the rule of the chemical reaction • Loss angle (Tangent delta)
developed by Svante Arrhenius in 1 880. The original form of
Arrhenius equation might be obtained from the integration of However, oil testing is probably one of the most important
equation ( 1 ) as follows: 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].
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2016-METC-0636 Page 4 of 6
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
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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
•
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
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978-1-4799-8397-1/16/$31.00 © 2016 IEEE
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978-1-4799-8397-1/16/$31.00 © 2016 IEEE
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