Harmonic measurements, analysis, and power factor correction in a modern steel manufacturing facility

Maximizing electric power transfer directly affects the productivity of an electric arc furnace operation. Arc furnaces and rolling mill loads operate at power factors that result in penalty charges and lower bus voltages. In addition, the nonlinear characteristics of the furnace arcs and rolling mill drives generate significant harmonic currents that flow through the plant and utility power system. These harmonic currents cause system voltage distortion and power loss in the system, and can interact with power factor correction capacitor banks leading to equipment failures. This paper presents the analytical technique used to correct power factor in a modern steel manufacturing facility. The study included field measurements, harmonic analysis, and filter design work to reduce the amount of harmonic distortion in the plant. The modeling of arc furnaces and rolling mills for a harmonic analysis study is also discussed. The solutions recommended in this paper to increase power factor and reduce harmonics can be applied to other steel manufacturing facilities to improve power quality and therefore plant productivity.