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AbstractThis modern steel making facility relies on reactive TABLE I. HISTORY OF FILTER FAILURES
compensation at the substation level in the form of harmonic
filtering to support voltage for casting operations, and at the melt Date Failure
furnace level in the form of capacitor banks to support LMF 1995 filter bank commissioned
operations. A history of harmonic filter failures at the
substation, and intermittent capacitor unit failures at the melt
1997 cap oil fire and reactor failure
furnace banks, culminated in a recent catastrophic failure of the 1997 rebuilt reactors and replaced failed caps
filter reactor. April 2003 reactor failure phase-B, others damaged
July 2003 new and rebuilt reactors installed
This paper describes the analytical methods used to redesign the Sept 2003 severe reactor failures
harmonic filter to achieve the desired level of compensation yet
avoid future failure of the filter components. Field measurements In addition to the filter failures, other problems included 1)
showed the harmonic filter provided a low impedance path for capacitor failures at the Rounds Caster Filter, #1LMF and
harmonic currents produced during arcing of either or both melt #2LMF, 2) low voltage problems at the Vine St. Sub, and 3)
furnace transformer resulting in overload of the filter reactor. voltage problems at the Bloom Caster EMS and Boiler House.
Preliminary harmonic analysis enabled temporary detuning of
the harmonic filter in the field to avoid this damaging resonance Fig. 1 shows the damage to the reactor following the
condition permitting steel making operations to continue while September 2003 failure. Clockwise from upper left, the
redesigning the filter. Detailed harmonic analysis and filter damage to the Phase-B reactor included: a) iron core hot
design considered a wide range of normal and emergency system enough to melt varnish and blacken paint, b) nuts came off the
conditions, especially the effects of extended line outages by the bolts that sandwich the windings to the core, c) the entire
utility for reconductoring. Recommendations included reactor frame slipped inch or more, and d) Arcing between
specifications for the redesigned harmonic filter as well as Phase-B and ground (Phase-B faulted to ground).
changes to improve performance of the melt furnace capacitor
banks.)
I. INTRODUCTION
The reactive compensation of interest for this steel making
facility was the Rounds Caster Filter (12.6 MVAc at 14.4 kV,
three 1-phase iron core reactors of 1.5 mH rated 600 A), and its
interaction with the melt furnaces and melt furnace capacitors
(#1LMF 14.4 MVAc at 13.8 kV and #2LMF 16.2 MVAc at
14.4 kV). All three capacitor banks are wye-ungrounded. A
history of harmonic filter failures at the substation, and
intermittent capacitor unit failures at the melt furnace banks,
culminated in a recent catastrophic failure of the filter reactor.
Table I shows the history of the repeated failure of the Rounds
Figure 1. Damage to Filter Reactor Following September 2003 Failure
Caster Filter reactor.
137
1-4244-0365-0/06/$20.00 (c) 2006 IEEE
EDGEWATER
JOHNSON
3P 6863 Amps
3P 9994 Amps SLG 6119 Amps
SLG 8911 Amps
SW-3N
SW-3S
OCB-1N
OCB-1S
SW-4S SW-4N
SW-5N
SW-5S
OCB-2N
OCB-2S
SW-6N
SW-6S B2510
B2500
B2000
B2010
CAP LMF2
LOAD-LMF2 CBL-11B1
500 1700 ft
CBL-2A1
1 /phase
500 1700 ft
1 /phase
CB-8A12
CB-8A11
B8000 CASTER 13800 V CB-T910 B8100 CASTER
13800 V
CB-FILTER
CBL-FILTER
500 80 ft
1 /phase
B8110 -FILTER
13800 V
FLTR-CASTER
138
Figure 3. Test of Rebuilt Filter Figure 5. Harmonic Currents at #2LMF During Arcing
Figure 4. Harmonic Currents at #1LMF During Arcing Figure 6. Test of Detuned Filter
139
III. HARMONIC ANALYSIS AND FILTER REDESIGN TABLE II. CRITICAL LOAD FLOW CASES FOR NORMAL AND EMERGENCY
CONDITIONS
Detailed harmonic analysis and filter design considered a
wide range of normal and emergency system conditions, Operating Rounds Vine Sub
especially the effects of extended line outages by the utility for Case Condition 138 kV Lines Filter Load
reconductoring. 1 Nov. 17 Both In Out Full
1A Nov. 20 Both In In Full
A. Load Flow Analysis
2 Nov. 21 Both In Detuned Full
Table II shows load flow cases were selected to study a
wide range of normal and emergency system conditions. The 3 Normal Both In New Full
existing, de-tuned and redesigned filter were considered in the 3A Normal Both In New No Load
analysis. In addition, the utility needed to outage one or the 3B Normal Both In Out Full
other of the 138 kV lines for reconductoring for extended
periods. Such outages for reconductoring weakened the 138
4 Emergency Johnson Out New Full
kV source, and magnified harmonic conditions at the Rounds
4A Emergency Johnson Out New No Load
Filter. These emergency configurations had to be considered in
4B Emergency Johnson Out Out Full
addition to the normal modes of operating the 138 kV supply to
the steel facility. Full-load as well as no-load were considered
5 Emergency Edgewater Out New Full
to determine the extremes of voltage regulation.
5A Emergency Edgewater Out New No Load
Table III shows the necessity for reactive compensation to 5B Emergency Edgewater Out Out Full
achieve proper voltage support at the 13.8 kV Vine Street
substation (Case 1). Full compensation by the filter results in
acceptable power factor and voltage support (Case 1A). The Operating without Johnson 138 kV line (Case 4) results in
detuned filter provides about 2/3rd of the rated compensation, acceptable voltages provided a change is made in the power
and enough voltage support to enable steel making operations transformer tap. When the Edgewater 138 kV line is out of
to continue (Case 2). Further improvement in the voltage service, no such change in tap is needed to regulate voltage to
regulation is achieved with the redesigned harmonic filter acceptable levels. In the extreme case of no load (Cases 3A,
(Case 3) at full compensation. 4A and 5A), the capacitor will be switched off.
Noted that the transformers T-1S and T-4N tap set at 134.55 kV (Tap 4 -0.975 pu) for all study cases
Except for Study Cases 1, 4, 4A and 4B as noted (*), the transformer tap set at 131.1 kV(Tap 5 - 0.95 pu)
140
B. Harmonic Analysis TABLE IV. HARMONIC CASES FOR NORMAL AND EMERGENCY
CONDITIONS
Table IV shows the harmonic case conditions selected to
study the interaction between the harmonic filter, melt Operating Rounds Vine Sub
furnaces, and melt furnace capacitors. Of particular interest Case Condition 138 kV Lines Filter Load
was the percent voltage and current THD at the following 1 Nov. 17 Both In Out Full
locations: 13.8 kV LMF Furnace #1, 13.8 kV LMF Furnace #2, 1A Nov. 20 Both In In Full
the 13.8 kV Rounds Caster Substation, and 138 kV incoming
lines Johnson and Edgewater. The cases were selected to 2 Nov. 21 Both In Detuned Full
redesign the Rounds Caster Filter, keeping each capacitor
voltage and current THD within IEEE Std. 18-1992 standard 3 Normal Both In New Full
limits, and keeping the reactor current within the continuous
rating of the reactor. 4 Emergency Johnson Out New Full
Table V shows the excessive currents seen by the filter
reactor match those measured in the field (Case 1A). De- 5 Emergency Edgewater Out New Full
tuning the filter resulted in currents within the reactor
continuous current rating, again the system model agreed with
Table VI shows the parallel resonant and series resonant for
field measurements (Case 2). Having proved the system
the harmonic filter. The parallel and series resonant points here
model, the filter was redesigned resulting in continuous current
are reported at the local 13.8 kV bus. However, care was taken
within the reactor rating (Case 3). The redesigned filter was
in each case to check the resonant points as reflected to the 138
checked for weaker 138 kV systems with Johnson out-of-
kV bus. The existing filter was series tuned to 4.78th (Case
service (Case 4) and Edgewater out-of-service (Case 5) giving
1A). The filter was temporarily series detuned to 5.65th in the
acceptable filter loading and system harmonic distortion in both
field to prevent reactor overload and provide about 2/3rd of the
cases.
rated reactive compensation for voltage support (Case 2).
1 4002 CAP1 at LMF1 13.800 13.800 100.00% 760 602 126.15% 16.11 14.40 111.86%
2102 CAP2 at LMF2 14.504 14.400 100.72% 915 650 140.87% 20.2206 16.20 124.82%
8111 FILTER at Caster OUT OF SERVICE OUT OF SERVICE OUT OF SERVICE
1A 4002 CAP1 at LMF1 13.965 13.800 101.20% 798 602 132.46% 16.92 14.40 117.52%
2102 CAP2 at LMF2 14.612 14.400 101.47% 930 650 143.18% 20.65 16.20 127.50%
8111 FILTER at Caster 15.023 14.400 104.33% 640 505 126.69% 15.53 12.60 123.25%
2 4002 CAP1 at LMF1 13.621 13.800 98.70% 746 602 123.83% 16.07 14.40 111.57%
2102 CAP2 at LMF2 14.555 14.400 101.08% 917 650 141.18% 20.35 16.20 125.60%
8111 FILTER at Caster 14.095 14.400 97.88% 406 397 102.29% 9.57 9.90 96.64%
3 4002 CAP1 at LMF1 13.860 13.800 100.43% 756 602 125.49% 16.16 14.40 112.24%
2102 CAP2 at LMF2 14.570 14.400 101.18% 920 650 141.64% 20.40 16.20 125.91%
8111 FILTER at Caster 14.164 14.400 98.36% 573 577 99.25% 13.97 14.40 97.04%
4 4002 CAP1 at LMF1 13.457 13.800 97.51% 720 602 119.44% 15.15 14.40 105.24%
2102 CAP2 at LMF2 14.498 14.400 100.68% 986 650 151.80% 21.57 16.20 133.14%
8111 FILTER at Caster 13.804 14.400 95.86% 566 577 98.09% 13.36 14.40 92.78%
5 4002 CAP1 at LMF1 13.659 13.800 98.98% 726 602 120.51% 15.53 14.40 107.85%
2102 CAP2 at LMF2 14.607 14.400 101.44% 967 650 148.88% 21.37 16.20 131.89%
8111 FILTER at Caster 14.004 14.400 97.25% 572 577 99.07% 13.73 14.40 95.34%
141
TABLE VI. RESONANT CONDITIONS FOR THE FILTER BANK AND BOTH 0.10E+03 Z Ohm Log
10.
1A LMF#1 221 3.68 N/A N/A N/A N/A 0.00 0.50 1.00 1.50 2.00 2.50
X 1.0E+01 Freq(PU)
32.
10.
3.2
1
3.2 1
1.0 1
1
1.0
0.32
0.32
0.10
0.10 0.32E-01
0.32E-01 0.10E-01
X 1.0E+01 Freq(PU)
1:8100CASTER 8100CASTER Mod=0 F1
CASE 2
CASE 1A
Figure 7. Frequency Scan at Rebuilt Harmonic Filter (Case 1A) Figure 9. Frequency Scan at Redesigned Harmonic Filter (Case 3)
142
TABLE VII. HARMONIC FILTER SPECIFICATION (REDESIGNED FILTER) REFERENCES
Specification Value
[1] IEEE Standard 519-1982, IEEE Recommended Practice and
System Voltage 13,800 Volts
Requirements for Harmonic Control in Electric Power Systems, IEEE,
System Frequency 60 Hz
1992, tables 10.2 and 10.3, pp. 77-78.
Filter Tuning (series resonant) 389 Hz (6.48th harmonic) [2] ANSI/IEEE Standard 18-1992, IEEE Standard for Shunt Powr
Capacitors, IEEE Standards Board 1992, ANSI 1993, section 5.2.3, p. 4.
Capacitor rated KVA (total three phase) 14,400 kVAc [3] D. Carnovale, V. Lorch, T. Dionise, T. Gerstnecker, Electric Arc
Total of 48 cans of 300 KVAR per can Furnace Harmonic Filter Failure, Analysis and Repair, AISE
Conference Proceedings, Memphis, TN, October 2002, pp. 4-5.
Capacitor rated KVA (single phase) 4,800 kVAc
Capacitor rated Voltage 14,400 Volts (phase to phase)
Capacitor rated Voltage 8,314 Volts (line to neutral)
Capacitor of Low Stress Design 1500 Volts per mil or better
IV. RECOMMENDATIONS
Based on the field measurements and harmonic analysis,
the authors make the following recommendations:
Replace the existing filter with the redesigned filter.
The specifications for the redesigned filter are given in
Table VII. Significant design improvements included
the increased voltage rating of the capacitors, and the
increased continuous current rating of the reactor.
Build the tuning reactor with several taps to
accommodate changes in the utility short circuit MVA,
since the parallel frequency is dependent on the utility
short circuit MVA.
Prevent the capacitor fuse failure as well as reduce the
voltage stress on the LMF #1 capacitors by replacing
the 14.4 MVAc capacitor bank rated 13.8 kV with 18
MVAc capacitor bank rated 15.125 kV.
Similarly for LMF#2, replace the 16.2 MVAc capacitor
bank rated 14.4 kV with 18 MVAc capacitor bank
rated 15.125 kV.
For the redesigned filter bank and the two capacitor
banks, make use of extreme duty capacitors that allow
125% of rated voltage rms. These capacitors exceed
the 110% of rated voltage rms required per ANSI/IEEE
Standard 18-1992.
Perform additional Harmonic Analysis prior to any
changes of the utility short circuit MVA, i.e. upgrades
or modifications to the 138 kV grid, as well as addition
or removal of generation.
143