The Effects of Series Inductors for Flicker Reduction in Electric Power Systems Supplying Arc Furnaces

Gian Carlo Montanari, Mauro Loggini, Luca Pitti

Universith degli Studi di Bologna Istituto di Elettrotecnica Industriale Viale Risorgimento 2 - 40136 BOLOGNA, Italy

Enrico Tironi, Dario Zaninelli

Politecnico di Milano Dipartimento di Elettrotecnica Piazza Leonard0 da Vinci 32 - 20133 Milano, Italy

Abstract - The purpose of this paper is to assess the effect of a series inductor on the reduction of voltage flicker in electric power systems supplying arc furnaces. The arc furnace is simulated as a voltage generator with variable amplitude during the melting process. The design of the inductor hinges on the fact that, when connected into the electric power system, it should not interfere with the production capacity of the plant itself. The use of a powerful simulation program (EMTP) makes it possible to study a large number of c a s e s and, therefore, to determine the appropriate size of the series inductor for the purpose of reducing voltage flicker. The simultaneous presence of the series inductor with capacitors andlor filters, with the purpose to limit harmonic pollution and improve the power factor, is also discussed.

1. INTRODUCTION

The arc furnace is a highly disturbing load in electric power systems. It generates harmonic and interharmonic currents and voltages in supply networks, and gives rise to flicker effects for other end-users connected to the same feeder. While shunt filters can reduce harmonic pollution in the network, voltage flicker is normally offset by variable capacitor support, i.e., the static var compensator (SVC). This solution is, however, quite expensive, especially for low-power plants. This paper proposes to investigate a means of compensation of flicker consisting in the connection of series inductors. A single-phase electric power system supplying an arc furnace is simulated by the EMTP program [I], in order to examine the different situations related to the actual furnace operation. The electric power system considered for EMTP simulation is shown in Fig. 1. It consists of a 60 MVA arc furnace supplied, via a 0-7803-1462-x/93$03.0001993IEEE

95 MVA HV/MV transformer, from a transmission network with symmetrical short-circuit power of 3500 MVA (data taken from a typical actual plant). In the , is the network short-circuit reactance; RT,, figure, X XT, and , , R X , are equivalent transformer resistance and reactance respectively, Xp is the series reactance inserted for the purpose of flicker compensation. The transformers' main technical data are summarized in Tab.1. Transformer T2 has a variable transforming ratio, so that rated voltage on the secondary winding may vary between 600 and 900 V (it is assumed that the percentage of transformer shortcircuit reactance remains constant with variations in the transforming ratio). The impedance Zc = R, + jX, in Fig. 1 represents the connections between transformer T2 and the electrodes of the arc furnace. Typically, in furnaces of this power, the impedance Z, varies between 3 and 6 m Q with a ratio XJR, between 6 and 10 ([2], [3], [41). In our example, we have: R, = 0.3 mfl, X , = 3 mfl.
2. THE ARC FURNACE MODEL

The model of a single-phase furnace, or of one phase of a three-phase furnace, consists in determining the one-port that, on certain assumptions, simulates the
BUS1
Tl

BUS2

T2

2. -c
P

95 MVA 220/21 kV

60 MVA
2110.6 i 0.9 kV
ARC FURNACE

Fig. I.

EMTP schematic diagram of the electric power system supplying the arc furnace.

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TABLE I.

MAIN TECHNICAL DATA OF TRANSFORMERS T1 AND T2,

PRESENT IN THE DIAGRAM I N FIG. 1 (XTIS THE SHORTCIRCUIT REACTANCE AND P, ARE THE SHORT-CIRCUIT POWER LOSSES)

T2

2U0.6i0.9

0.5

behaviour of the electric arc. Such a model must, in addition, be compatible with its representation by means Of the program, which is the One Often used internationally for simulating electric power systems. In this paper, the arc furnace is represented by a controlled-voltage generator set. Measurements On arc furnaces showed that the voltage on the electrodes (referred to ground) has a trapezoidal waveform with a small peak corresponding to passage of the current through zero [2],as shown in Fig. 2. vat indicates the voltage of the arc corresponding to the highest current values; this depends only on the length of the arc and on the characteristics of the gas in which the arc burns, and not on the value of the current absorbed by the furnace [SI. The waveform of Fig. 2 introduces a simplification, because, under real furnace operating conditions, the amplitude of the two half-periods might be different. In the EMTP program, the waveform of Fig. 2 can be realized by a set of sinusoidal voltage generators whose amplitude and phase are shown in Tab. 11, with reference to an arc length I, corresponding to which vat = 100 v. The model of the arc furnace must be able to reproduce the conditions that cause flicker. We assume that the variations in arc length that occur in the furnace during melting are the main causes of flicker {6]. However, flicker may also occur due to changes in the physical and chemical characteristics of the gases in the melting area. A variation in the arc voltage corresponds to these length variations in accordance with the following equation [5]: vat = A BI (1) where A and B are constant (A is the sum of the voltage drop on the electrodes and B is the average

0.002

0.004

1 0.006

I
0.008 t

I
0.012
0.014

0.01

I 0.016

I
0.018

0.02

(4
voj~ge.

Fig. 2.

Waveform ,fan: fumct

TABLE I1 AMPLITUDE AND PHASE OF THE HARMONIC-VOLTAGE

GENERATORS, USED TO REPRESENT THE ARC VOLTAGE IN FIG. 2

harmonic number

amplitude

phase

M
126.50 38.98 17.75 6.157 2.312 4.383 3.925 1.909 -87.89 -86.75 -92.70 -1 12.8 135.8 86.29 65.26 42.00

1 3 5 7 9 11 13 1 5

value of the voltage drop per arc length, usually = 40 V and = 10 V/cm, respectively) and I is the arc length. As regards the instantaneous voltage at the electrodes va, it may be described by the equation:

where:

= k(l/l,J =

A+BZ -

A + BZ,

(3)

The amplitude of the voltage generators representing arc voltage based on 1 = I, (see Tab. 11) is modulated

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by the coefficient k, to take into account the variations in length l(t) of the arc during the melting process. It is assumed that this variation in arc length l(t) is sinusoidal and periodic, with a frequency typically in the range S i 15 Hz (e.g. 10 Hz, close to the maximum sensitivity of human eye to luminous fluctuations). This is the condition that emphasizes the flicker phenomenon and is, in any case, useful for ascertaining the steps to be taken for flicker compensation. Thus we have: l(t) = 1, - T A1 ( 1 +sinPt) (4)
L

the electric power system considered (see Fig. l), AV /V will be calculated at the network feeding bus ( B U ~ I ) ,that is, at the point of common coupling
(PCC).

4. THE EFFECTS OF THE SERIES INDUCTOR ON VOLTAGE FLICKER

where A I is the maximum arc length variation (in the following simulations Q = 20 T rad/s has been taken). Hence (3) becomes: BA1 -(1 +sinRt) 2 k=k(l(t)/lJ = 1 A + BZ, It should be mentioned that this model does not refer to the arc itself (which would involve defining parameters A and B and more detailed research on the physics of the electric arc), but to the voltage on the arc furnace electrodes. What we propose is therefore only a model able to take into account the power absorbed by the furnace and its fluctuations, with the purpose of studying its effects on the electric power system supplying the furnace.

Let us consider the case in which the series inductor is not present in the single-phase electric power system = 0). It is assumed that, presented in Fig. 1 (that is, in these conditions, furnace transformer T2's transforming ratio is equal to 21/0.6kV. In this case, the power and current absorbed by the transformerfurnace system are the rating ones for vat = 220 V. In order to simulate the worst flicker conditions, vat is varied in the range: 4OV .aat s 240 V where 240 V corresponds to the continuous conduction limit and 40 V corresponds to an operating point very close to a short-circuit (the sum of the voltage drop on the electrodes and that in the melting bath is equal to about 40 V). The variation law applied to vat is therefore: vat = 240 - 100 (1 + sin a). In these conditions, at BUS1 of Fig. 1 the flicker effect provides: A VJV = 0.75%.

When an inductor is inserted in series to the MV line supplying the furnace (reactance 5 in Fig. l), the furnace power - and therefore its production capacity As described in [7] and [8], with each voltage must not be reduced. Hence a variation in transformer fluctuation measured by the flickermeter, whatever its T2's transforming ratio is needed. In the plant contrend and amplitude, we can associate an "equivalent" cerned in this research, transformer T2 has a secondary sinusoidal fluctuation at frequency 8.8 Hz. This voltage that may vary between 600 and 900 V in 60-V equivalent voltage fluctuation (AV,) has an amplitude steps. such that it causes the same disturbance, and therefore The following two criteria are examined for insertion the same response from the flickermeter. One can of the inductor in the power system: therefore use, as an indicator of the level of voltage 1. Constant short-circuit power, S , , of the reactanceflicker, the parameter AV,/V, that is, the equivalent transformer-furnace system. voltage variation evaluated at 8.8 Hz, referring to the 2. Constant energy absorbed by the arc furnace during RMS voltage. This index is usually expressed as a the melting process. percentage, and the value of 0.25% corresponds to the The use of a powerful simulation program enables a flicker perceptibility threshold. The UIE flickemeter has large number of cases to be studied, thus making it been implemented by EMTP in order to derive the possible to determine the appropriate size (in relation to values of AV,/V for any modulation frequency of the the size of the system) of the series inductor that can voltage generators used for arc furnace modelling. In limit voltage flicker.

3. FLICKER MEASUREMENT DURING SIMULATION

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The values of the series reactance inserted in the plant and the relevant values of the secondary voltage of transformer "2, in accordance with the first criterion, are given in Tab. 111. Tab. IV shows the values of AV,N at BUSl (the point of common coupling) obtained from simulations with EMTP for the different series reactance values reported in Tab. 111. Tab. IV also explains the ratio $4 between the series reactance and the total reactance of the power system (evaluated at the same voltage levels). According to the second criterion, the values of the series reactance inserted in the plant, and the relevant values of the secondary voltages are shown in Tab. V. Tab. VI gives the consequent AV N values, measured at BUSl and resulting from the E h simulations. The voltage flicker index AV,N calculated as a function of the ratio X /X,is shown in Fig.s 3 and 4, with respect to the af6rementioned criteria 1 and 2, respectively . As can be seen from Tab.s IV and VI, and from Fig.s 3 and 4, insertion of the series inductor into the arc-furnace supply system greatly reduces the voltage flicker present at the point of common coupling. Moreover, the following comments can be drawn. - The first criterion of keeping constant the shortcircuit power Sfof the series reactance-transformerfurnace system shows that it is possible to obtain a flicker reduction even when the short-circuit ratio (defined as SCR = S J S , where S, is the shortcircuit power of the transmission network at the feeder bus - BUSl in Fig. 1) remains constant. The second criterion, on the other hand, leaves the energy absorbed by the furnace in the melting process unchanged, and this is also the criterion used in [3] to study the effect of the SVCs. - The two design criteria are compared in Fig. 5, which shows the points corresponding to the same secondary-voltage value of the transformer (ai and bi, with i = 1,2, ... 6 respectively). It is emphasized that the second criterion, i.e. constant energy absorbed by the furnace, allows more significant flicker reduction. - The influence of the short-circuit power S, of the transmission network supplying the system is shown in Fig. 6, where AVq/V is given as a function of the ratio Xp/X, for different values of the shortcircuit ratio (SCR). The three-dimensional Fig. 7 shows the variations of AV,N both with SCR and fit. Fig. 7 indicates that, given the same %/xt, flicker is reduced as SCR increases,

TABLE I11
S E E OF SERIES REACTANCE ACCORDING TO THE FIRST CRITERION.
V

Series reactance

Secondary nominal

(a)
0.635 1.125 1SO5 1.795

voltage
0.66 0.72 0.78 0.84 0.90

2.045

TABLE IV
AV,/V, AT THE POINT OF COMMON COUPLING (BUS]), WlTH SIZE OF THE SERIES REACTANCE ACCORDING TO IS THE RATIO OF THE SERIES THE FIRST CRITERION. X& REACTANCE TO THE TOTAL REACTANCE OF THE POWER SYSTEM (EVALUTED AT THE SAME VOLTAGE LEVELS).

Series reactance
0 0.635 1.125 1SO5 1.795 2.045

0. 24 0.220 0.294 0.351 0.399

0.752 0.681 0.617 0.567 0.525 0.480

TABLE V
SIZE OF SERIES REACTANCE ACCORDING TO THE SECOND CRITERION.

Series reactance
(Q)

Secondary norminal voltage

0.66 0.72 0.78 0.84 0.90

0.979 1.725 2.371 2.855 3.285

as is known From technical literature on the subject. Insertion of the series inductor might limit the range

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TABLE VI
AV,/V AT THE POINT OF COMMON COUPLING (BUSI), WlTH SIZE OF THE SERIES REACTANCE ACCORDING TO THE SECOND CRITERION. X& I S THE RATIO OF SERIES REACTANCETOTHETOTAL REACTANCEOFTHEPOWER SYSTEM (EVALUATED AT THE SAME VOLTAGE LEVELS).

of variation of the transformer's secondary voltage, thus affecting arc furnace power regulation. However, regulation of power in the arc furnace at high currents is mainly carried out varying the position of the electrodes.
5. EFFECT OF INSERTION OF SERIES INDUCTORS AND FILTERS ON HARMONIC DISTORTION

Series reactance (fJ)

0 0.979 1.725 2.371 2.855 3.285

0.179 0.302
0.414 0.462

0.640 0.562 0.469

0.416

The insertion of series inductors into the electric power systems supplying arc furnaces likely interacts with furnace harmonic generation, which consists of
-

-1

04-

0.35 0
0 45

01

0 2

03

0.4

0.5

06

XP/Xt

005

01

015

0.2 XP/Xt

025

03

035

04

Fig. 5 .

Fig. 3.

Effect of the series reactance 5 .on voltage flicker reduction with constant short-circuit power Sf of the reactance-transformer-fumace system. The short-circuit ratio a t BUSl is 58.
1.1

Comparison between the equivalent voltage variations at 8.8 Hz (AV IV %) as a function of X,,lX, with the two cs criteria for inserting X,,: a) keeping constant the fumace short-circuit power SF; b) keeping constant the energy absorbed by the furnace. The two curves show the points corresponding to the same transforming ratio of the fumace transfonner (al, b l , etc.).
1

0.8

09

08

5
K:

07

06 05
0 4

03

Fig. 4.

Effect of the series reactance X,, on voltage flicker reduction with constant energy absorbed by the arc furnace. The short-circuit ratio a t BUSl is 58 for Xp = 0.

Fig. 6.

Effect of series reactance X,, on voltage flicker reduction for different short-circuit ratio values (SCR).

1500

1 0

Fig. 7.

t 8.8 Hz ( A V & ' Equivalent voltage variation n function of the SCR and the ratio XplX,.

%) as a

characteristic and non-characteristic harmonics, besides E , non-multiple harmonics (or inter-harmonics [9]). Interharmonics are caused by the arc length time-variation introduced in order to reproduce the conditions that give rise to flicker, as can be mathematically deduced from (2) and (5). As an example, Fig. 8 shows the spectral analysis of the line current and voltage at BUS2 (see Fig. 1) in the presence of a series inductor with = (W 2.045 Q and secondary transformer voltage equal to Fig. 8. Spectral analysis of the line current (a) and of the voltage (b) at BUS2 in Fig. 1 , with $ = 2.045 l l and secondary 900 V (the frequency step of the bar representation of transformer voltage q u a l to 900 V (frequency step of the Fig. 8 is 10 Hz). bar representation ie 1 0 Hz). In these conditions, definition of distortion factor might be a debatable topic. According to IEEE 519, current and voltage total harmonic distortion are reference waveform (usually that at power supply frequency), while inter-harmonics are connected with calculated as [lo]: voltage amplitude variation and, hence, flicker. Therefore, eq. (6) seems still appropriate for distortion estimate, since inter-harmonics are involved in flicker measurements. Tab.s VI1 and VI11 give the percentage values of the where h is an integer, Ah is the amplitude of. the THD (defined by eq. (6) with N = 25) in respect of the harmonic of order h, A, is the amplitude of the current absorbed by the furnace and of the voltage in fundamental harmonic and N is usually lower than 50. BUS2, for different values of series reactance inserted Therefore, only multiple harmonics are considered. In at the supply side of the furnace transformer (Fig. 1). the case of arc furnaces producing flicker, both fundamental and multiple harmonics are modulated (see It can be noted that the current distortion rises as the Fig. 8), so that several inter-harmonics are present, series reactance value increases. In fact, increasing the with an almost continuous harmonic spectrum. furnace transformer's transforming ratio in accordance However, distortion factor is intended to evaluate the with the criteria previously given, we are working with deviation from sinusoidality of a single period of the ever longer arcs that amplify the non-linearity of the
f

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TABLE VI11 load. It is precisely the range of variations in arc length connected with transformer secondary voltage that TOTAL DISTORTION ACCORDING TO EQ. (6) OF THE determines the degree of current distortion. This is CURRENT ABSORBED BY THE FURNACE AND OF THE supported comparing Tab.s VI1 and VIII, where we see VOLTAGE IN BUS2, WITH SERIES REACTANCE DESIGNED TO KEEP CONSTANT THE ENERGY ABSORBED BY THE that, having fixed the secondary voltage, the current FURNACE. THD no longer depends on the design criterion used. VOLTAGE Secondary CURRENT The voltage distortion at BUS2, and then at the point of nominal voltage THD THD common coupling, remains almost constant as the value (kv) (96) (96) of series reactance rises, for the design criterion of constant energy absorbed by the furnace, while slightly 0.6 4.48 1.93 0 increases for the other criterion (Tab. VII). 4.79 1.91 0.979 0.66 Summarizing, insertion of series inductors, together 1.90 1.725 0.72 5.04 with capacitors or filters, can bring the electric plant to 2.371 5.26 1.89 0.78 comply with standard limits on both flick:er and 5.45 1.88 2.855 0.84 distortion factor. Filters can conveniently replace 5.61 1.88 3.285 0.9 capacitors for power factor correction and distortion compensation. Indeed, the use of filters, even in electric plants with relatively small voltage distortion, has the aim to correct power factor avoiding the dangerous transformer 900 V, a filter tuned to the third-harmonic resonance situations which can easily occour when (i.e. R F = 0.125 il, L F = 4.99 mH, CF = 226 pF, compensation is made by capacitor banks. For this [12], [13], [14]) is able to bring the power factor to purpose, filters can be tuned to low-order harmonics, values higher than 0.95. It is interesting to observe that e.g. with tuning frequency lower than 150 Hr!. Their the filter does not give significant contribution to flicker effectiveness for distortion compensation can not be reduction, since AV,/V % is 0.48 in the absence of properly evaluated by single-phase simulations, due to filter and 0.50 in the presence of filter. the different kinds of harmonic orders and components involved. Referring to the plant till now considered, with 6. CONCLUSIONS %= 2.045 il and secondary voltage of the furnace The investigations on the effects of series inductor TABLE VI1 insertion into plants supplying furnaces, with the object TOTALDISTORTION ACCORDING TO EQ. (6) (OF THE of reducing voltage flicker, has been realized by means CURRENT ABSORBED BY THE FURNACE AND OF THE of EMTP simulation. The arc furnace has been VOLTAGE IN B U S , WITH SERIES REACTANCE DESIGNED described by a voltage generator with a waveform TO KEEP CONSTANT THE SHORT-CIRCUIT POWER OF THE similar to that typically measured at the terminals of an REACTANCE-TRANSFORMER-FURNACE SYSTEM. arc furnace and an amplitude that varies periodically Secondary CURRENT VOLTAGE during the production process. nominal voltage THD THD Insertion in the electric power system of a series orv) (96) (%'I inductor has to be accompanied by variation in the 0.6 4.48 1.93 secondary voltage of the furnace transformer, in order 0.66 4.79 2.06 0.635 not to affect the production capacity of the furnace. 1.125 0.72 5.05 2.1.5 Design of the series inductor was calculated in 0.78 5.26 2.2!4 accordance with two different criteria: that of keeping 0.84 1.795 5.45 2.33 constant the short-circuit power of the inductor0.9 5.61 2.38 transformer-furnace system, or that of keeping constant the energy absorbed by the furnace. With both criteria, a remarkable reduction in flicker due to the presence of the series inductor has been noted. Therefore, this seems to represent an economical, technically-simple
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means of dealing with the problem of voltage flicker in electric power systems supplying arc furnaces, which might be alternative, or used in addition, to the staticvar compensator. Moreover, insertion of series inductors is able to reduce the voltage distortion at the MV side of the HVMV transformer and, therefore, at the point of common coupling. Hence, combination of series inductances (eventually designed into the transformer) and capacitors and/or filters can provide power factor correction and distortion compensation, besides flicker 1imitation. Further research on this subject should seek to: - define more accurate models for the simulation of arc furnaces; - extend the study to three-phase circuits.

L. Di Stasi, "Electric Furnaces" (in Italian), Patron Ed., Bologna (Italy) 1976. L. Bisiach, L. Campestrini, C. Malaguti, "Technical and operational experiences for mitigating interferences form high-capacity arc furnaces", International Conference on Large High Voltage Electric Systems (CIGRk), Paris (France) September 1992. UIE Disturbances Study Committee, "VIE Flickermeter,finctional anddesign specif cations", Bulletin UIE, 1983. IEC Publication 868, "Flickermeter, finctional and design specifcations", 1986. E. Tironi, D. Zaninelli, "Interharmonics in electrical plants" (in Italian), L'Energia Elettrica, vol. 64, N.3, March 1987. [ 101 IEEE 5 19, "IEEE Guidefor h a m n i c control and reactive power compensation of static power REFERENCES converter", IEEE, 198 1. [ 1 11 B. Bhargava, "Arc furnace flicker measurements "ATP:Alternative Transient Program Rule Book, and control", IEEE Transactions on Power Leuven EMTP Center, Leuven (Belgium), July Delivery, vol. 8 , N. 1, January 1993. 1987. [12] J. Arrillaga, D.A. Bradley, P.S. Bodger, "Power W.S.Vilcheck, D.A. Gonzales, "Measurements system harmonics",John Wiley & Sons, 1985. and simulations combined for state-of-the-art [ 131 G.C. Montanari, M. Loggini, "Voltagedistortion harmonic analysis", Industry Applications Society compensation in electrical plants supplying static Annual Meeting, Pittsburgh (PA), USA, October power converters", IEEE Transactionson Industry 1988. Applications, vol. 23, N. 1 , January/February L. Campestrini, L. Lagostena, G. Sani, A. Bellon, 1987. R. Manara, E. Nazarri, "Flicker control in high [ 14) C.K. Duffey, R.P. Stratford, "Update of harmonic power arc furnaces and cumulative flicker analysis standard IEEE-5 19: IEEE recommended in HV networks", Proc. of 11th International requirements for harmonic control in electric conference on Electricity Distribution, Likge power systems", IEEE Transactwns on Industry (Belgium) 22-26 April, 1991. Applications, vol. 25, N. 6, Novembermecember S.R. Mendis, D.A. Gonzales, "Harmonic and 1989. transient overvoltage analysis in arc furnace power systems", IEEE Transactions on Industry Applications, vol. 28, N. 2, MarchiApril 1992.

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