electrodes and the reduction of the voltage flicker.

Focusing on the second one, this is mainly obtained

through control of the DC arc current, which is
Design Tools of DC EAF Power Supply maintained almost at a constant value even when short-
Systems for Optimum Reduction of Flicker circuits of the arc occur, while for AC arc furnaces this
and Interharmonic Disturbances current is limited only by the transformers, the supply
impedance and possibly the anti-flicker inductances. For
this reason, the flicker generated by a DC arc furnace is,
at least during the melting down phase at maximum
P. Bordignon, M. Perna power, typically much less than that generated by an
Ansaldo Sistemi Industriali S.p.A. AC arc furnace of identical nominal power.
Power Electronic Operation
V. le Sarca 336, 20126 Milano, Italy On the other hand, the current-controlled high power
39-02-6445-4256 rectification used in such systems may potentially
produce a wide spectrum of current harmonics and
P. Mattavelli interharmonics. Therefore, a proper design of the whole
Q. Department of Electrical Engineering plant is generally needed in order to minimize the
Q. University of Padova amount of non-characteristic harmonics and
V. Gradenigo 6/a 35131 Padova, Italy interharmonics, which may strongly deteriorate the
39-04-9827-7525 quality of the power supply voltage. Indeed, the high
level of interharmonic currents may arise mainly due to
F. D’Amico the AC/DC harmonic interaction caused by the
IPSCO Steel Inc. resonances between the supply impedance, TCRs, and
1770 Zachary Avenue the harmonic and reactive compensation system. The
Muscatine, IA 52761 current-control regulator and the synchronization
319-381-5400 scheme also play a key role in the amplification of such
disturbances.

Methods to effectively analyze the aforementioned

interaction primarily come from HVDC system studies 1-
10
. Some techniques use a frequency domain approach
SUMMARY and solve a set of steady-state equations with the aid of
an iterative procedure for each frequency 8. We feel that
Ansaldo utilizes simulation and analytical tools for these techniques are not useful from the industrial point
analysis and system design to prevent harmonic of view, since cumbersome calculations are usually
interaction and to optimize the design of the entire required. Others use time domain simulations
power supply system in terms of cost, losses and (employing, for example, the Alternative Transient
performance. The results and measurements taken in a Program (ATP), practically the PC version of EMTP),
DC EAF installation in the U.S. show that the whole where a set of differential equations, related to a detailed
system, through adopted provisions, is able to match representation of the entire system, are solved using
the desired specification in terms of flicker, harmonics, numerical integration. We feel, instead, that this tool is
interharmonics, voltage unbalances and power factor. quite useful for design purposes since it enables even
complex industrial systems to be represented. In fact,
using a detailed modeling of each single part of an
INTRODUCTION industrial plant, behavior (close to reality) can be
achieved. With this approach, it is possible to obtain a
The application of thyristor controlled rectifiers to comprehensive calculation of the harmonics in the
supply DC arc furnaces has been rapidly growing practical converter operation including firing angle
thanks to some fundamental advantages, which DC arc errors, influence of commutation overlap and DC ripple,
furnaces feature compared to traditional AC furnaces, saturation of converter transformer, characteristic AC
among which are lower consumption of carbon and DC system impedances, negative unbalance

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 1 of 10
voltages, effects of control action, etc… . Although the II. PLANT DESCRIPTION
results are accurate, this approach does not give a
complete insight into the mechanisms of harmonic The DC EAF installation being the object of this
amplification and flicker generation, as needed for the paper, is a part of a new steel plant, built by IPSCO and
optimization of the system design. located in Montpelier, Iowa. This location is served by
Central Iowa Power Cooperative.
To better understand the overall dynamic response
of the whole system, a transfer function approach can The whole plant can be supplied by two different
be used 10-14. In this way, it is possible, under different feeding networks, as shown in Fig. 1; when the plant is
degrees of approximation, to analytically derive all the fed by 345 kV power supply through a Walcott
transfer functions of interest like, for example, those substation (Point of Common Coupling, PCC), the short-
relating the firing angle and DC current, and the DC and circuit power, at the plant high voltage bus-bar, is about
the AC side impedances under open and closed loop 6400 MVA (7700 MVA at PCC); instead, when the
conditions. This approach, although less accurate than power system is supplied at 161 kV through Substation
the previous one, can be effectively applied for system 56 (PCC), the high voltage bus-bar short-circuit power is
design regarding both interharmonic and flicker about 2300 MVA (5600 at PCC). Indeed, the different
suppression when the calculation of all the transfer characteristics of the power supply system, strongly
functions of interest are performed including most of the determines the system performance in terms of flicker
aspects of the actual system operation. Among many and interharmonic disturbances.
interesting relations and focusing just on the
interharmonic issue, the transfer function between the For each feeding network there are two step-down
firing angle and the DC current, using different transformers with two different rated power and
synchronization schemes and filters, is highlighted in secondary voltage levels, which are 70 MVA, 13.8 kV
this paper, showing that the current-control parameters, and 170 MVA, 34.5 kV respectively. In fact, the
damping of harmonic filters, and the synchronization electrical system of the plant is composed of two
scheme must be properly designed to avoid different bus-bars; one of these, at 34.5 kV, feeds the
amplification of the interharmonic disturbances. These steel making facilities such as the DC furnace, ladle
results have been effectively applied to optimize the metallurgical furnace (LMF), and Steckel Mill with
design of the damping of the harmonic filters, the cycloconverter drives; the other one, at 13.8 kV, feeds
current regulator parameters and the filters for the various loads as the Rolling Mill and auxiliaries with
synchronization of the firing scheme in terms of squirrel cage motors, AC/DC and AC/AC (DC/AC)
interharmonics and flicker suppression, thyristor (voltage source inverter) drives.
stresses and system losses.
The DC arc furnace employs four AC/DC thyristor
The paper is organized as follows: In section II we converters fed by two MV/LV transformers (34.5 kV/766
describe the IPSCO Steel Inc.’s plant, where V) rated at 140 MVA; each of these transformers has
measurements reported in this paper were obtained; two secondary windings, in delta and star connection,
Section III describes the interaction between the providing 12-pulse operation for the thyristor
harmonic filters and the system impedance; Section IV converters.
deals with the use of the time domain simulations for
system representation, while Section V describes how Ansaldo supplied all HV and MV electrical
the frequency domain can be useful for the design of equipment, power converters and drives both for the
proper provisions. melt shop and rolling mill as well as the complete
automation of the plant. The whole system was
designed in order to have the best electrical and
production performances and to match the Central Iowa
Power Cooperative’s constraints in terms of power

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 2 of 10
 To Walcott To 56
345 kV Substation 161 kV Substation

6400MVA 2300MVA

70MVA 70MVA

13.8 kV

170MVA 170MVA

34.5 kV

60 Mvar
SVC system
2x70 MVA

180 Mvar
SVC system
LF

M
EAF 2 Cycloconverter
2x 10 MW

quality. In fact, the customer is responsible for the at 60 MVA. On each bus-bar, the whole installed
following contract specifications and demands, among reactive power is properly shared on different power
which the most important is reviewed in the following: filter circuits tuned to suitable frequencies; the
equipment performs harmonic current and fixed
n unity average power factor, which is measured capacitive reactive power compensation. Instead,
and monitored at the 345 kV and 161 kV variable reactive power compensation, voltage drop
dispatching substations on a 15 minute elimination, power factor and voltage fluctuation
interval; the compensation equipment has to improvement are performed by Thyrister Controlled
ensure a maximum reactive power fluctuation of Reactors (TCRs), which ensure, at any time, the sum of
± 4 Mvar at the boundary of the high voltage the reactive power of the connected loads and that of
lines the TCRs is equal to the total reactive power of the filter
n voltage fluctuation < 0.30 at substation 56 on circuits.
the 161 kV level and < 0.25 at the Walcott
Substation on a 345 kV level
n voltage imbalance III. INTERACTION BETWEEN THE HARMONIC
n total Current Harmonic Distortion according to FILTERS AND POWER SYSTEM IMPEDANCES
IEEE 519 (1992)
Harmonic filters perform harmonic current
In order to guarantee PCC performance criteria, two compensation providing a low impedance path for the
Static Var compensators have been considered by harmonics to which they are tuned. Complementary to
Ansaldo in the final design; one at the 34.5 kV bus, this desired effect, the total impedance seen by the
rated at 180 MVA and the other at the 13.8 kV bus rated power converters shows also some peak values, which

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 3 of 10
 50
[Ω]

Supply through Walcott Substation

40

30
Supply through
Substation 56

20

10

0
0 60 120 180 240 300 360 420 480 540 600
frequency [Hz]

Fig. 2 Upstream impedance seen by the thyristor converters referred to 34.5 kV (undamped filter conditions).
The dotted line and the continuous line represent the supply through Substation 56 and through the
Walcott Substation, respectively.

correspond to the parallel resonances between the only if special provisions are taken jointly with other
supply impedance and the filter impedances. The important parameters of the DC EAF supply system.
frequencies and the peak values of the anti-resonant
conditions are determined by the harmonic filter and the In the next sections we show some tools both in the
supply characteristics, as shown in Fig. 2, where the time-domain and in the frequency-domain, which help to
frequency response of the upstream impedance seen at understand such phenomenon and to optimize the
the 34.5 kV bus is highlighted in the two possible system design in terms of interharmonic and flicker
supply conditions of IPSCO’s DC EAF. attenuation.

The presence of parallel resonances potentially

gives some trouble in the DC EAF operation since a IV. TIME-DOMAIN SIMULATION AS A TOOL FOR
high level of interharmonic currents can possibly be DESIGN PURPOSES
generated due to AC/DC harmonic interaction between
the total supply impedance and rectifier converter In order to analyze the aforementioned problems and
operation arising due to the aforementioned resonances. to design suitable provisions, which can be used to
Indeed, even small currents injected at those prevent the harmonic interaction and to optimize the
frequencies produce large voltage distortion, which may design of the entire power supply system in terms of
cause firing angle errors and amplify the harmonic cost, losses, and performances, ATP time-domain
disturbances. It is worth noting that such phenomenon simulations seem to be the most viable tool since they
is strongly influenced by the harmonic filter and supply allow the most important part of the industrial plant to
characteristics, current regulator parameters and be modeled in detail. While power system components
synchronization scheme. Thus, the modification of are directly available in the ATP library, the control
harmonic filter design, using the straightforward scheme both for the thyristor converters and for the
solution of either adding damping resistors or changing TCRs are implemented via means of the TACS
the shape of the harmonic impedance, is not the (Transient Analysis of Control Systems) models. The
appropriate solution unless an oversizing of the level of detail of the ATP DC EAF model is, of course,
damping resistors is used at the cost of increased directly related to the purpose of the analysis and the
losses. Indeed, a proper optimization can be achieved design. For example, for flicker analysis, the control of

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 4 of 10
the electrode height can be disregarded, since it gives a Fig. 3 (a) and Fig. 4 (a) show that the line currents have,
minor effect at the relevant frequencies, while, for the beyond the fundamental value, a high level of
same purposes, all of the control details for the TCR interharmonics at about 30 Hz and 150 Hz, which
(reactive power transducer, TCR synchronization…) corresponds to one parallel resonance seen by the DC
have to be considered. EAF when supplied through the Walcott substation.

Fig. 3 shows the potential problem that may arise [dBA] 0

fundamental component (60Hz)
with an improper synchronization scheme or with an
improper design of the harmonic filters and/or of -10
≅ ( 150Hz)
interharmonic component
current regulator parameters.
-20 ≅ ( 30 Hz)
interharmonic component
[A]

1500 -30

1000
-40
500
-50
0

-500 -60
0 100 200 300 400

-1000 frequency [Hz]

(a)
-1500
[dbA] 0
dc component
1.40 1.42 1.44 1.46 1.48 1.50
-10
time [s]
(a) -20
characteristic harmonic ( 360 Hz)

[kA] 36.5 -30

interharmonics≅( 90 Hz)
-40
36.0 ±
sideband interharmonic (360Hz 90Hz )
-50

3.55 -60

3.50 -70

-80
34.5 0 100 200 300 400
time [s]
34.0 (b)

Fig. 4. ATP Simulations Without Corrective Provisions

1.40 1.42 1.44 1.46 1.48 1.50 (a) line current spectrum [pu] at the secondary
time [s] of the 345/34.5kV transformer;
(b) (b) dc current spectrum [pu] of a thyristor
rectifier
Fig. 3 ATP Simulations Without Corrective Provisions
(a) Line current at the secondary of the Corresponding to these disturbances, the DC current
345/34.5 kV transformer has a non-negligible interharmonic component at about
(b) DC current of a thyristor rectifier 90 Hz, whose modulation through the thyristor rectifier
causes the 150 Hz (90 Hz + 60 Hz) and the 30 Hz (90 Hz -
60 Hz) AC current interharmonics.

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 5 of 10
 This system behavior is totally unacceptable and have completely disappeared and the spectra of the DC
immediate provisions have to be taken in advance to and AC currents, not reported here, shows that all of the
prevent such a problem; ATP simulations can be interharmonic components have a negligible value.
effectively used to design suitable provisions. Just as
an example, we show in Fig. 5, the same quantities More comprehensive studies can also be performed
reported in Fig. 3, but with some suitable modifications, in order to optimize system response in terms of flicker.
in current regulation parameters, synchronization This can be done, for example, by applying a sinusoidal
scheme and damping of harmonic filters. perturbation to the arc parameters at the typical flicker
frequencies (1-30 Hz) and analyzing the voltage drop
and/or the reactive power variation at the PCC. With
[A] this approach, the control parameters (reactive power
1500 transducers, open loop and closed loop reactive power
controls, current control parameters, etc…) of the TCRs
1000 and of the thyristor rectifiers, which feed the DC EAF,
can be tuned to the particular configuration of the
500
IPSCO Steel plant. As a simple example, Fig. 6 shows
0 the variation of the instantaneous reactive power,
directly related to the voltage fluctuation, due to a 10 Hz
-500 sinusoidal modulation of the arc voltage measured at
-1000 the primary of the MV/LV DC EAF transformer (trace a)
(i.e. variation of the reactive power of the load) and at
-1500 the primary of the HV/MV transformer of the plant (trace
b) (i.e. variation of the reactive power of the
1.40 1.42 1.44 1.46 1.48 1.50 compensated load). The effects of the TCR
time [s] compensation are clearly evident.
(a)
[MVAr]

a)
[kA] 36.5 20

36.0
10

3.55 b)
0

3.50
-10

34.5
-20
34.0
-30
1.2 1.25 1.3 1.35 1.4 1.45 1.5
1.4 1.42 1.44 1.46 1.48 1.50
time [s]
time [s]
(b) Fig. 6. Variation of the instantaneous reactive power
Fig. 5. ATP Simulations with Corrective Provisions due to a 10Hz sinusoidal modulation of the arc
(a) line current at the secondary of the voltage calculated with ATP at the primary of
345/34.5kV transformer the MV/LV DC EAF transformer (trace a) and
(b) dc current of a thyristor rectifier at the primary of the HV/MV transformer of the
plant (trace b).
V. FREQUENCY-DOMAIN ANALYSIS
It is worth noting, that the interharmonic disturbances

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 6 of 10
 One of the major problems when dealing with a time- frequencies corresponding to the resonance peaks of
domain problem, is that a complete insight of the system the AC system impedance. More importantly, Fig. 8
behavior is still missing and system optimization can shows that an improper conditioning of the
only be achieved based on experience without the synchronizing voltage is potentially able to strongly
support of an appropriate analytical tool. In order to amplify such problems given time, to a significant
better understand the dynamic DC EAF behavior, the increase to interharmonic disturbances, which may even
transfer function approach in the frequency-domain can cause the DC EAF to shut down. This analytical tool
be used 10-14. Using this approach, it is possible to has been effectively verified with the detailed time
analytically derive, under different degrees of domain ATP simulations under open-loop conditions
approximation, all of the transfer functions of interest referring a different DC EAF installation at 50 Hz; for
like, for example, that relating the firing angle and the DC that case, we have used a small perturbation of the firing
current, and the DC and the AC side impedances under angle around its working point at different frequencies
open and closed loop conditions, including most of the and calculated the corresponding modulation of the DC
aspects of the system’s actual operation, such as the current. Symbols “o” correspond to each ATP
firing angle modulation, converter control and simulation. Fig. 8 shows that the s-domain model is
commutation period variations, etc… . accurately verified.

Without dealing with the analytical derivation, which

is beyond the scope of this paper, we recall that the VI. CONCLUSIONS
harmonic transfer in AC/DC converters can be
calculated through the modulation theory; basically, as This paper has presented some simulation and
shown in 15,16, the converter can be seen as a modulator analytical tools, which Ansaldo has found useful for the
and the harmonic transfer can be obtained using the analysis and design of DC EAF power supply systems
relations between the AC voltage and the DC voltage, in order to achieve the optimum reduction of
and between the AC current and DC current can be interharmonic and flicker disturbances. One set of tools
derived using the switching functions 15,16, related to the regards the use of time-domain simulations (employing,
thyristor conduction state. Consequently, the three for example, the Alternative Transient Program (ATP)),
port network analysis, proposed by 12, shows that through which close to reality behavior can then be
among a multitude of non-characteristic frequencies, reproduced. The results are accurate, but without a
only three frequencies are the most significant, complete insight into the mechanisms of harmonic
consisting of a positive and a negative sequence amplification and flicker generation, as needed for the
frequency on the AC side, separated by twice the optimization of the system design. Instead, another
fundamental frequency and a single frequency on the useful tool, which is complementary to time-domain
DC side, centered between the two AC side frequencies. simulations, is the transfer function approach in the
As shown in Figs. 3 & 4, if the AC current is modulated frequency domain, which allows the analysis of the DC
at 150 Hz (parallel resonance for the IPSCO plant when EAF dynamic behavior and of the interharmonic
supplied by the (Walcott substation). There is also a amplification taking into account the line impedance,
modulation of the DC current at 90 Hz (150 Hz - 60 Hz) resonances introduced by harmonic filters, current
and a modulation of the AC current also at 30 Hz regulator parameters, and the thyristor synchronization.
(negative sequence), whose effects are less evident due Based on this analysis, suitable provisions have been
to the lower system impedance. tuned to the particular configuration of IPSCO’s plant.

As an example of the potential of this analysis, Fig. 7 The results and measurements taken at IPSCO’s
shows the module and the phase of the transfer plant site, not reported here, show the effectiveness of
function between the firing angle and the DC currents the adopted provisions.
obtained using the aforementioned analysis. It is worth
noting that both module and phase strongly differ from
the classical design approach especially at the

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 7 of 10
[dBA] Improper conditioning of the synchronizing voltage

90 Improved synchronizing scheme

85

80
Classical design

75

70

65

60

55
10 f [Hz] 100 180

[degree]
150
Classical design

100

50

Improved synchronizing scheme

-50
Improper conditioning of the synchronizing voltage

-100

-150

10 f [Hz] 100 180

Fig. 7. Bode diagram of the transfer function between firing angle and dc current; solid line refers to an improved
synchronization scheme, dotted line to an inappropriate conditioning of the synchronization voltage and dashed line to
the classical design approach. All diagrams refer to an undamped harmonic filter condition.

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 8 of 10
 module [dBA]

90

85

80

75

70

65

60

10 100 150
frequency [Hz]

phase [degree]

150

100

50

-50

10 100 150
frequency [Hz]

Fig. 8. Bode diagram of the transfer function between firing angle and dc current; solid line refers to the frequency domain
model, while each symbol “o” refers to results obtained with ATP simulations. Results obtained in a 50Hz DC EAF
installation.

Bordignon, Perna, Mattavelli, D’Amico

ISS Technical Paper, Page 9 of 10
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ISS Technical Paper, Page 10 of 10