INNOVATIVE SOLUTIONS FOR DIFFERENTIAL PROTECTION OF

ELECTRIC ARC FURNACE TRANSFORMERS

Presented to: The Iron & Steel Technology (AIST) Conference and Exposition
May 7-10, 2007, Indianapolis, Indiana

Ljubomir Kojovic Martin T. Bishop Dharam Sharma

Cooper Power Systems Cooper Power Systems Nucor-Yamato Steel Company
T. A. Edison Technical Center T. A. Edison Technical Center Highway 18 East
11131 Adams Rd. 11131 Adams Rd. Armorel, Arkansas 72310
PO Box 100 PO Box 100 Tel: 870-762-7131
Franksville, WI 53126-0100 Franksville, WI 53126-0100 Fax: 870-762-5822
Tel: 262-835-1511 Tel: 262-835-1541 Dsharma@Nucor-yamato.com
Fax: 262-835-1544 Fax: 262-835-1544
lkojovic@cooperpower.com mbishop@cooperpower.com

Abstract
Current transformer (CT) saturation has been a recognized industry problem for reliable
protective relay operation. If the CT characteristics are not properly selected for fault conditions,
saturation will occur, and relays can misoperate. Though some protection schemes have been
designed to tolerate a certain amount of CT errors, the majority of applications need to faithfully
reproduce primary currents.
This paper presents high precision printed circuit board (PCB) Rogowski Coil (RC)
characteristics, designs, and applications for advanced protection, control, and metering
systems with new multifunction relays.
PCB Rogowski Coils can be designed with different shapes to adjust for the application.
Besides circular, they have been designed in an oval shape to encircle all three-phase
conductors (for measurement of residual currents) or parallel phase conductors that carry heavy
currents. PCB RC current sensors can also be designed in a “split-core” style for installation
without the need to disconnect primary conductors. High power laboratory tests of the influence
from nearby conductors on the coil performance confirmed the superb rejection of the external
electromagnetic field effect (less than 0.01% recorded).
A novel differential protection system has been developed and deployed on four scrap metal
electric arc furnaces (EAFs) at the Nucor-Yamato Steel, Blytheville, Arkansas facility and the
Nucor Steel, Crawfordsville, Indiana facility. For each 90 MVA arc furnace transformer, the
protection system consists of six RC current sensors and a multifunction relay that accepts the
signals from the RC sensors. Differential protection systems for EAF transformers have not
been applied in the past due to the lack of commercially available CTs for the secondary bus
tubes and the CT saturation problems due to the high current magnitudes, which often approach
100 kARMS.
This paper reviews performance of this first differential protection scheme for EAF transformers
implemented in the USA. The PCB RC sensors have also been applied for differential
protection of a mobile substation power transformer discussed in the paper. This technology
would also be useful in the differential protection systems applied on substation transformers,
substation bus protection, large motors and generators.

Key words: Rogowski Coil, Relay Protection, Electric Arc Furnace Transformer

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I. Introduction
The printed circuit board (PCB) Rogowski Coil design presented in this paper operates on the
same principle as coils that were first introduced in 1912 for magnetic field measurements. At
that time, the coils could not be used for relay protection because their output power was not
sufficient enough to drive electro-mechanical relays. However, with today’s microprocessor-
based equipment, RC current sensors are more suitable for such applications. Current
transformers (CTs) have traditionally been used for protection and measurement applications in
part because of their ability to produce the high power output needed by electromechanical
equipment. Microprocessor-based equipment makes high power output unnecessary and
opens the door for other measurement techniques, such as RC current sensor technology,
which have many advantages over conventional CTs.
Papers [1-2] explain the theory of RC operation and describe traditional designs and
applications. Papers [3-9] present an innovative and patented design of RC current sensors
that use PCBs. This paper presents novel solutions for differential protection of EAF
transformers, which are the first such applications in the U.S. and probably in the world. The
PCB RC sensors have also been applied for differential protection of utility power transformers,
and using the same principle may be applied for differential protection of large motors and
generators.

A. Principle of Operation
Traditional RCs consist of a wire wound on a non-magnetic core. The coil is then placed around
conductors whose currents are to be measured. The output voltage is proportional to the rate of
change of measured current (Equation 1).

d d
v (t ) = − μ 0nS [ ∑ ij (t )] = − M [ ∑ ij (t )] (1)
dt j dt j

where: μ0 is the magnetic permeability of air,

n is the winding density (turns per unit length),
S is the core cross-section, and
M is the mutual coupling.

A Rogowski coil signal is a scaled time derivative di/dt of the primary current. To use such
signals with phasor-based protective relays, signal processing is required to extract the power
frequency signal. This may be achieved using one of the following methods: (a)-integrating the
Rogowski coil output signal, or (b)-using a non-integrated signal and perform signal processing
to adjust magnitudes and phase shift signals 90°. For an ideal RC, measurement accuracy is
independent of conductor location inside the coil loop.
To prevent the unwanted influence of nearby conductors carrying high currents, RCs are
designed with two wire loops connected in electrically opposite directions. This cancels all
electromagnetic fields coming from outside the coil loop. One or both loops can consist of
wound wire. If only one loop is constructed as a winding on a non-magnetic core, then the
second wire loop can be constructed by returning the wire through the center of this winding. If
both loops are constructed as windings, then they must be wound in opposite directions. In this
way, the RC output voltage induced by currents from the inside conductor(s) will be doubled.
Rogowski coils can also be connected in series to increase the output signal. The traditional

2
method of designing RCs was to use flexible cores such as coaxial cables. The cable shield
was removed and the wire wound over the plastic cable core. The existing conductor through
the cable core center served as the return (second) loop. High precision Rogowski coils may be
designed using printed circuit boards.

B. PCB Rogowski Coil Designs

The high precision Rogowski Coil design presented in this paper consists of two printed circuit
boards (PCBs) located next to each other (Figure 1 and Figure 2). Each PCB contains one
imprinted coil wound in opposite directions (clockwise and counter-clockwise). The top and
bottom sides of each PCB are imprinted to form a coil around the center of the board. The
conductive imprints on the upper and lower sides of the PCB are interconnected by conductive-
plated holes. High precision is obtained because the manufacturing process is computer
controlled, providing accurate geometry of the coils. New RC designs use multi-layer PCBs,
which provides higher accuracy and more efficient manufacturing.
PCB Rogowski Coils can be designed with different shapes to adjust for the application and in
“split-core” styles for installation without the need to disconnect the primary conductors. Figure
3 shows non-encapsulated and encapsulated circular shape RC current sensors implemented
on multi-layer PCBs. Figure 4 shows an oval shape split-core style RC current sensor,
designed to enclose all three-phase conductors (for measurement of residual currents) or to
enclose parallel conductors that carry heavy currents. The “split-core” style RC consists of four
half loops. The first two half loops are constructed with two PCBs with imprinted windings
wound in opposite directions, but located next to each other. The remaining two half loops are
constructed in the same way, but wound in opposite directions. Figure 4 shows the principle of
the PCB “split-core” style RC design and a completed coil.

The PCB Rogowski Coil current sensor has the following characteristics:

- Metering class accuracy - the same sensor is used for both for protection and metering
- High short-circuit current withstand ratings
- Galvanic isolation from the primary conductor
- No environmental problems (oil and SF6 free)
- Safe for personnel (no open secondary high voltage hazard, no violent failures such as
with oil-insulated CTs)
- Immune to EMI (shielded)
- Small profile and light weight - can be installed around bushings or cables, avoiding the
need for high insulation

3
 PCB #1 PCB #2

i(t)
i(t)

PCB #2 wound
in opposite direction
to PCB #1

v(t)

Figure 1 Principle of the PCB Rogowski Coil Design

Figure 2 Principle of the PCB Rogowski Coil Design (Imprinted Windings)

Figure 3 Non-Encapsulated and Encapsulated PCB Rogowski Coils (Non Split-Core Design)

4
 Split-Core Type “Water-Cooled”
Rogowski Coil Conductors

nt
rre nt
Cu rre
Cu

Relay
Figure 4 Split-Core PCB Rogowski Coil Design and Application

C. Performance Tests
The RC output voltage is proportional to the rate of change of measured current (di/dt) enclosed
by the coil. Therefore, the RC non-integrated signal can be significantly different than the
waveform of the measured current since the fault current DC offset will be attenuated and
higher frequency components amplified by the RC sensor. The sensor output waveform will
also be shifted in phase by 90° relative to the measured current waveform. Figure 5 shows non-
integrated and integrated RC output signals, which are obviously different. However, the
integrated signal is almost identical to the waveform recorded by a precision laboratory current
sensor (Figure 6).

Figure 5 PCB Rogowski Coil Non-Integrated and Integrated Signals

5
 Figure 6 Test Current recorded by a Precision Laboratory Current Sensor
and by PCB Rogowski Coil (Integrated Signal)

Influence from nearby conductors is one of the most important tests to determine the RC
current sensor accuracy. The test was performed in a high power laboratory at a test current
magnitude of 60 kARMS (Figure 7). Two RC current sensors were tested, RC1 was installed to
measure the test current and RC2 was located 5 cm next to the primary conductor to test the
influence from the primary conductor. Since the induced signal in RC2 was very small, a x100
amplifier was used to increase the signal to the level acceptable by the recorder. The results
are shown in Figure 8. The influence from the primary conductor was below 0.01%, verifying
very good coil immunity to the external magnetic fields. In most applications, RC current
sensors will be installed at a distance from nearby conductors. Since the magnetic field from a
current carrying conductor declines proportional to the distance squared, the influence will be
nearly zero.

6
 Transient
Recorder

O/E
Circuit Fiber
Breaker R, X Optic
G Cables
Making
Switch E/O
Laboratory CT

RC1

RC2
Amplifier

5 cm
Figure 7 High Power Test Setup

Figure 8 Influence from the Nearby Conductor

7
II. Differential Protection of Power Transformers and Generators

The projects that use Rogowski Coils current sensors for relay protection presented in this
paper include differential protection of electric arc furnace (EAF) transformers; differential
protection of power transformers in mobile substations; and differential protection of generators.

A. Differential Protection of EAF Transformers

In steel facilities that use EAFs (Figure 9) to manufacture steel from scrap, the EAF transformer
is one of the most critical pieces of electric power equipment in the plant. Failures in the EAF
transformer or its buswork interrupt production and require costly and time-consuming repairs.
Traditional overcurrent protection is often applied at the circuit breaker that supplies the cable
serving the furnace transformer. This protection is normally set to reach into the furnace
transformer primary winding for faults in the winding, but may not have sufficient sensitivity to
reach through the transformer into the secondary winding or into the secondary leads. Faults
that occur in the secondary buswork, water cooled leads, or in the conducting arms above the
furnace are not detected by the upstream overcurrent protection and are normally interrupted
only after personnel manually open the circuit breaker. The damage due to the extended fault
duration can result in long or costly outages.

Figure 9 Electric Arc Furnace Operation

Differential protection schemes are not typically applied on EAF transformers due to the
difficulty in providing current transformers (CTs) of sufficient rating for the secondary leads
carrying currents of 60 kA or more. Some modern EAF transformers are rated to deliver a
steady state secondary current of 80 kA. In some cases, a CT is built into the transformer that
monitors the current in only one secondary winding (there are typically multiple secondary
windings per phase group). This current signal might be used for metering or regulator control

8
purposes, and the magnitude is calculated externally with a scale factor assuming the current in
each winding is the same. The accuracy of this technique is not sufficient for a reliable
differential protection system.
The differential protection system presented in this paper uses Rogowski Coil current sensors,
and multifunction relays designed to accept the RC secondary signals, making differential
protection of EAF transformers possible (Figure 10). This novel protection system was
implemented for two 90 MVA, 34.5/1 kV EAF transformers equipped with 33-tap load tap
changer (LTC). The vault equipment at the transformer primary side includes the following main
equipment: a three-phase motor-operated disconnect switch, a three-phase vacuum circuit
breaker used as a switching device, three resistor-capacitor surge suppression networks, EAF
transformer-mounted surge arresters (line-to-ground and line-to-line connected), and potential
transformers used for protection and metering purposes (line-to-ground and line-to-line
connected).
The differential protection system creates a zone of protection that is defined by the location of
the RC sensors. Both the primary and secondary RC sensors were located in the EAF vault.
The secondary system voltage can have different magnitudes, depending on the furnace
regulator program, with a maximum magnitude of approximately 1 kV line-to-line. The nominal
secondary current at rated MVA and 1 kV line-to-line is approximately 52 kARMS. This requires
large secondary busbars at the terminals of the transformer. The interconnection assembly,
called a delta closure, collects the current from multiple secondary windings into 9-inch water-
cooled bus tubes. The delta connection is closed external to the vault, so there are six of these
bus tubes leaving the vault through an insulating wall assembly (Figure 11). The bus tube
spacing for four outside tubes is the same (10-inch spacing between tube centers) and the
middle two tubes are on 26-inch spacing. Because the RC can be designed for the application,
the secondary RC sensors were designed with two different sizes (instead of one larger size),
which optimizes the installation design. Since the secondary tubes cannot be opened, split RC
current sensor designs were required for the secondary sensors for installation in the vault.

EAF Transformer Vault

Arc Furnace
RC1 Transformer RC2
I1P I2P

I1S Tap
Position I2S

“Water-Cooled”
Conductors

Multifunction Relay EAF

Figure 10 Principle of Arc Furnace Transformer Differential Protection

9
 High Voltage Side Arc Furnace Side

A
B to
Primary C EAF
Rogowski
Coils
(RC1) Primary Secondary
Terminals Secondary
Terminals Rogowski
A
B Coils
(RC2)
C

Figure 11 Installation of PCB RCs for Arc Furnace Transformer Differential Protection

The primary RC current sensors were designed as solid-core style (Figure 12). To provide the
required dielectric strength and the BIL at 34.5 kV voltage level, the RC current sensors were
mounted around air-air bushings. A cycloaliphatic epoxy air-air bushing was selected for
mounting the sensor. A complete installation of three primary RC current sensors in one of the
EAF vaults is shown in Figure 13. The sensors were installed on the load side of the motor-
operated switch in the vault, so all work could be completed on the sensors with a visible break
on the source side of the sensor location.
Secondary RC Current Sensors were designed as split-core style (Figure 14). The secondary
delta closure connection in the EAF vault interconnects the multiple secondary winding bus bars
that make up the EAF transformer secondary, with the large plates external to the vault that are
the connection point for the water-cooled leads to the furnace arms. The secondary sensors
were mounted on the wall at the point where the secondary bus leaves the vault. As mentioned
in the previous text, the secondary RC current sensors were made in two sizes to enclose the
two sets of nine-inch tubes on 10-inch spacing between centers, and the one set mounted on
26-inch spacing. Figure 14 shows both designs of secondary sensors (one large and two
smaller RC current sensors). This protection scheme was tested in the high power laboratory at
Cooper Power Systems using the actual RC current sensors and the multifunction relay that
was built for installation at the site. Figure 15 and Figure 16 show the test results. Figure 17
verifies that the relay operated at only 5% fault current. Figure 16 shows that the relay did not
operate during transformer energizing at voltage zero, producing high inrush currents (4,000
Apeak in this test), verifying the protection scheme stability.
Figure 17 shows the relay’s event recorder (manually triggered) capturing user-programmable
data during operation of the EAF. The data shown is during a relatively flat bath point in the
heating cycle. The waveforms in the top two panels are the primary and secondary EAF
transformer currents. The next two panels are the operating and restraining currents in the
transformer differential algorithm. The bottom panel in Figure 17 is the status of the trip signals.
The scale on the secondary current panel is ±300 kApeak. At the point of the cursor in Figure 17,

10
the C-phase secondary current magnitude is approximately 67 kARMS (95 kApeak). The relay
operating signal at that point shows a mismatch between the transformer primary and the
secondary currents of less than 1% of rated current. Figure 18 shows Rogowski coil signals of
the EAF transformer primary and secondary currents that were recorded during the furnace
operation. Even though the currents are heavily distorted, the primary and secondary current
waveforms are accurately reproduced.

Figure 12 Primary Side EAF Transformer Rogowski Coil

Figure 13 Installed Primary Side EAF Transformer Rogowski Coils

11
Figure 14 Secondary Side EAF Transformer Rogowski Coils Mounted on Secondary Bus Tubes

12
Figure 15 High Power Tests of EAF Transformer Differential Protection System
(5% fault current inside the zone)

Figure 16 High Power Tests of EAF Transformer Differential Protection System

(transformer energizing)

13
 Figure 17 Multifunction Relay’s Event Recording

Figure 18 Rogowski Coil Signals of an EAF Transformer Primary and

Secondary Currents

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B. Differential Protection of Power Transformers
The same principle applied to EAF transformer differential protection may be used to protect all
power transformers. The initial projects included differential protection of mobile substation
power transformers, which require that the equipment tolerate the motion and vibration
associated with movement over the road on a trailer. The Rogowski coil approach offered much
less weight and size in the sensor when compared to conventional CT along with improved
protection system performance.

C. Differential Protection of Generators and Motors

The primary system time constant near generators is large. Unless physically impractical CT
designs are applied, CT saturation for close-up through-fault conditions and some other external
disturbances cannot be avoided. Even where CT are of similar design and the leads between
each set of CT and the differential relay are balanced, the CT will not saturate to the same
degree at the same time because of remanent flux. Traditional differential protection schemes
require stabilization for external faults or disturbances that cause CT saturation, since it is not
feasible to avoid CT saturation under all circumstances.
Rogowski Coils provide superior differential protection of large motors and generators since
they are linear (do not saturate), reject external electromagnetic fields, and are accurate,
providing simpler and more reliable protection. Rogowski Coil physical dimensions and weight
are much smaller than conventional current transformers.

III. Conclusions

This paper presented novel relay protection systems that include:

The first differential protection systems in the USA that have been successfully designed, built,
and installed for electric arc furnace (EAF) transformers that provide power for scrap metal
electric arc furnaces. The protection systems consist of novel RC current sensors and
multifunction relays. High power tests and data captured by the relay’s event recorder during
EAF operations confirmed that the current sensors are accurate, allowing applications for large
transformer differential protection systems that had not been feasible using conventional CT-
based technology. One fault event captured during the testing period revealed relay operation
within 2 cycles of fault initiation. The two systems at the Blytheville, Arkansas facility have been
in operation for over two years. The Crawfordsville, Indiana systems have been in operation for
over one year.
Rogowski coil based differential protection has been also applied for mobile substation
transformer differential protection (instead of conventional CTs) because they provide better
accuracy, smaller size, and easier installation. Rogowski coils avoid BIL and design constraints
of conventional CTs.
Rogowski Coils can provide superior differential protection for substation busbars, large motors,
and generators, since they are linear (do not saturate), reject external electromagnetic fields,
and are accurate. The Rogowski Coil physical dimensions and weight are much smaller than
conventional current transformers, while providing simpler and more reliable protection.

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Biographies

Ljubomir A. Kojovic is a Chief Power Systems Engineer for Cooper Power Systems at the Thomas A.
Edison Technical Center. He has a Ph.D. in power systems with specialties that include protective
relaying, distributed generation, testing, digital modeling, and systems analysis. He is an adjunct assistant
professor at Michigan Technological University. He is included on the roster of experts for the United
Nations Development Organization (UNIDO) and is a registered professional engineer in Wisconsin. He is
an IEEE Senior Member, member of the main committee, and member of several working groups of the
IEEE Power System Relay Committee. He has earned eight U.S. patents and authored more than 140
technical papers.

Martin T. Bishop is a Chief Engineer in the Systems Integration Group of Cooper Power Systems, South
Milwaukee, Wisconsin. The section is responsible for projects related to power systems protection
system applications including system automation projects. Marty is responsible for the marketing and
engineering development of the AdPro™ line of protection systems offered by Cooper Power Systems.
Mr. Bishop has served as an instructor in the Cooper Power Systems' Overcurrent Protection Workshop,
the Fundamentals of Power Distribution Workshop, the Distribution System Reliability Workshop, and the
Transformer Application and Protection Workshop. He received a B.S.E.P.E. and M.S.E.P.E. from
Rensselaer Polytechnic Institute, Troy, New York, and an MBA from The Keller School of Management.

Dharam Sharma is a Staff Engineer in the electrical maintenance department at Nucor-Yamato Steel in
Blytheville, AR. Mr. Sharma’s primary responsibility is the optimization of the electric arc furnace
operation in the melt shop at Nucor-Yamato. As a part of that responsibility, he is involved in the
oversight of the electric power supply to the melt shop, including relay and protection of the apparatus in
the substation. Other substation equipment related to the furnace operation includes the series reactor,
vacuum switch and circuit breaker selection and maintenance, protective relay applications and setting,
capacitor filter and SVC operations, and transformer maintenance. Dharam is involved in the
management of the AMI electric arc furnace regulator systems.

REFERENCES
[1] K. Heumann, “Magnetischer Spannungsmesser hoher Prazision, ETZ-A, 1962.
[2] Lj. A. Kojovic, ”Rogowski Coils Suit Relay Protection and Measurement”, IEEE Computer
Applications in Power, July 1997.
[3] Lj. A. Kojovic, 2002, ”PCB Rogowski Coils Benefit Relay Protection”, IEEE Computer
Application in Power, July, pp. 50-53.
[4] Lj. A. Kojovic, 2003, “Novel Protection Systems for Arc Furnace Transformers”, CIRED 17th
International Conference on Electricity Distribution, Barcelona, Spain.
[5] D. Sharma, M. Bishop, Lj. Kojovic, S. E. Williams, 2004, “RC Current Sensors at Nucor-
Yamato Steel Provide Superior Protection”, The Line, Cooper Power Systems, October, pp.
9-11.
[6] Lj. A. Kojovic, M. T. Bishop, V. Skendzic, 2003, ”Advanced Protection for EAF Transformers
Prevents Steel Mill Downtime”, The Line, Cooper Power Systems, October, pp. 17-19.
[7] Lj. A. Kojovic, V. Skendzic, S. E. Williams, 2001, “High Precision Rogowski Coil”, U.S.
Patent Number: 6,313,623; Date of Patent: November 6.
[8] Lj. A. Kojovic, 2004, “Measuring Current Through An Electrical Conductor”, U.S. Patent
Number: 6,680,608 B2; Date of Patent: January 20.
[9] Lj. A. Kojovic, M. T. Bishop, S. E. Williams, D. Sharma, “Applications of Low-Energy
Sensors for Differential Protection of Large Power Transformers and Generators”, the North
American T&D Conference and Expo, Toronto, Canada, May 11-19, 2005.

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