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EAF

The document outlines the Electric Arc Furnace (EAF) control system, detailing power supply arrangements, control and protection systems, and electrode regulation. It discusses the operational controls for the furnace, including safety interlocks and maintenance practices to minimize energy consumption. Additionally, it highlights recent upgrades to the hydraulic regulation system and modifications made to improve the performance and lifespan of the VCB (Vacuum Circuit Breaker).

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shadab alam
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4 views

EAF

The document outlines the Electric Arc Furnace (EAF) control system, detailing power supply arrangements, control and protection systems, and electrode regulation. It discusses the operational controls for the furnace, including safety interlocks and maintenance practices to minimize energy consumption. Additionally, it highlights recent upgrades to the hydraulic regulation system and modifications made to improve the performance and lifespan of the VCB (Vacuum Circuit Breaker).

Uploaded by

shadab alam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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EAF CONTROL SYSTEM

TOPICS TO BE DISCUSSED

• Power Supply Arrangements


• Control System
• Protection System
• Technical Data
• Electrode Regulation System
POWER SUPPLY ARRANGEMENT

INCOMING INCOMING
FEEDER - 1 FEEDER - 2

INCOMING INCOMING
ISOLATOR ISOLATOR
(VCB) (VCB)

OUT GOING
VCB

TO ARC FURNACE
TRANSFORMER
CONTROL SYSTEM

• VCB Control
• Furnace Operation Control
• Electrode Regulation Control
VCB CONTROL
• Incoming Supply - 11kv
• Incoming Feeder - Inline and Standby
• Outgoing Feeder
• Closing voltage 110 VDC
• Tripping 110 VDC
• Stand by Batteries
• CTs on Primary and Secondary
• PT on Primary
• Backup Fuses for all the circuits
FURNACE OPERATION CONTROL
• Following Operations are being done in Furnace-
1. Roof Up/Down, 2. Roof In/Out, 3. Tilting Front/Back,
4. Slag Door Open/Close and 5. Electrode Movement
• Two Operator Desks have been provided to operate the
Furnace
1. Main (Local) Operator Desk- For all the operations
2. Auxiliary (Remote) Operator Desk- For Tilting while
Tapping
• All the operations of the Furnace have been provided with
separate Push Buttons
• All the operations are controlled through PLC with all the
safety interlocks
ELECTRODE REGULATION CONTROL

• Impedance Module Control System


• PLC Based Control System

In both the system the Arc Voltage and Arc


Current are compared for the movement of
Electrodes
PROTECTION SYSTEM

• Transformer Protection
• Furnace Protection
TRANSFORMER PROTECTION SYSTEM
• Primary and Secondary Over current
• Primary Earth Fault
• Static Earthing Device
• Buchholz Relay
• Pressure Relief Valve
• Lock out Relay
• Oil Flow and Water Flow
• Oil and Winding Temperature
FURNACE PROTECTION SYSTEM

• Front Tilt (45 Degree)


• Back Tilt (15 Degree)
• Roof Out Safety
• Electrode Adjustment
• Water Cooled Cable Water Failure
• Bus Tube water Failure
• Roof and Panel Water Failure
Transformer Details
• Tap Changer- ON Load Tap changer
• 12.5MVA/14 MVA
• Taps- 16
• Arc Voltage- 145 - 340V
• Arc Current- 27 - 21 KA
• Constant power (12.5MVA) - 6 taps
• Constant current (27KA) - 10 taps
•Duty cycle 14MVA – 1 1/2hrs, 9MVA-2hrs, 0MVA
– 3/4hrs
ELECTRODE REGULATION SYSTEM

The Electrode Movement is through Hydraulic Regulation


System
The Electrode speed control is achieved by comparing the
electrode arc voltage and arc current.
Balance point is created to establish proper Arc.
The circuit has been divided into two groups-
• Voltage
• Current
The Arc Voltage Feedback is taken from the Voltage
Transducers which are connected to the Bus bars of
Transformer Secondary.
The Arc Current Feedback is taken from the Current
Transd uc ers whic h are c onnec ted to the CTs of
Transformer Secondary.
The Arc Voltage and Arc Current analog signals are fed
into the PLC. The difference in signals is compared and
error is generated through PLC Logic.
Depending upon the sign and magnitude of the error
signal, the PLC will generate the proportional output
voltage.
This output voltage is fed to the Proportional Valves
which drive the furnace columns up/down.
In turn the power input to the scrap is controlled
automatically.
Whenever voltage signal is more compared to the
current signal the Proportional Valve will drive the
column downwards.
Whenever current signal is more comparing to the
voltage signal the Proportional Valve will drive the
column upwards.
The f ie ld voltages to these motors are kept at preset
levels which is varied during calibration of the column
speeds.
CAUSES FOR HIGHER ENERGY CONSUMPTION
AND REMEDIES

• Selection of Scrap
• Heat Loss
• Electrode Regulation
• Power Supply
• Operating Practice
SELECTION OF SCRAP

• Furnace should be loaded with approx. 22 Tonnes of scrap


• The proper mixture of heavy (Wheel cuts), medium, and
light scrap to be ensured
• Charge shall be full
• Avoid back charge
• Avoid charging Wheels
HEAT LOSS

• Maintenance Problems
• Keep roof open for minimum time
• Maintain water cooled panel temperature
• Maintain the furnace lining
• Apply required power
• Minimize Tap to Tap time
• Avoid holding the heat
POWER SUPPLY

• Incoming supply
• Selection of Tap
OPERATING PRACTICE

• Starting of Furnace.
• Power Input
• Oxygen Lancing
• Chemical Analysis
• Ladle Capacity and Condition
• Tapping at Over Temperature
REMEDIES FOR HIGH POWER CONSUMPTION

• Minimize operator interference


• Use Auto Melt Controller
• Proper Electrode Regulation
• Regular training / Brain storming sessions
• Adopt advanced controllers / equipment
• Faster heats
EAF-C HYDRAULIC REGULATION UPGRADATION
• Existing Impedance Control Module system (Obsolete)
was changed to PLC Control System through available
spares
• The wo rk was ac c o mplishe d in ho use with the
available spares and existing software
• The programming for Electrode Regulation was done
by RWF Team
• Approximately 500 Units per Heat Energy is saved
• The Approximate Saving in Energy is 11,40,000 Unit Per
Year. (500 Units x 8 Heats x 285 Days)
• The Cost saving is approximately 10,260,000 Rs. per
Year. (11,40,000 Units x 9 Rs.)
MODIFICATIONS AND PRACTICES

• The VCB normal switching operation was modif ie d to


improve the performance of VCB
• After pressing the VCB Off Push Button, the VCB will get
off when the Current becomes zero. So that the load on
the I nte rrupte rs will be le ss. This inc re ase d the
Interrupters Life
• The VCB tripping was modif ie d such that during High
Current the Electrodes will move in upwards direction
with full speed, thus reducing the current and avoiding
un necessary tripping of VCB.
• The VCB Maintenance schedule was modif ie d so that
the spares replacement was done as per schedule. This
reduced the premature failure of VCBs and improved the
performance
Q&A

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