3.15 MVA Furnace Transformer for Arc Furnace — Cement Plant, Karnataka
A mid-sized cement plant in Karnataka was experiencing repeated failures of their 3 MVA arc furnace transformer — two units replaced in three years. The root cause: standard distribution transformers specified in place of a purpose-built furnace unit.
The Challenge
Arc furnace applications subject transformers to extreme duty cycles — high inrush currents at every heat cycle, low power factor loads, voltage fluctuation from the arc, and thermal stress from frequent off-load conditions. A standard distribution transformer has none of the design tolerances needed to survive this environment. The plant was spending ₹12–15 lakh per replacement and losing 2–3 weeks of production per event.
The Actaan Solution
Actaan Electric designed and supplied a 3.15 MVA furnace-duty transformer with on-load tap changer (OLTC), reinforced copper windings rated for repetitive short-circuit events, Class H insulation, and delta-delta connection to block third-harmonic currents. The unit was tested to IS 2026 including a temperature rise test at 110% rated current. The transformer was commissioned with a comprehensive AMC from day one.
Scope of Supply & Work
- ·3.15 MVA furnace-duty transformer, IS 2026 compliant
- ·On-load tap changer for voltage regulation under arc load
- ·Class H insulation for high thermal cycling tolerance
- ·Delta–delta connection to block 3rd harmonic
- ·Reinforced copper windings rated for short-circuit withstand
- ·Full factory acceptance test including temperature rise
- ·Transformer AMC with quarterly BDV and thermographic inspection
Results
Other projects by Actaan Electric.
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