ANNEXURE TO TENDER NO.

DPS/MRPU/1/1/238
Description of the ITEM: 10 kW Induction Heating System -1 Set
1.Description
Supply, installation and commissioning of INDUCTION HEATING SYSTEM and
demonstration by melting SS material at user’s site.
The Induction Heating System should consist of Converter, Inverter, Control, Protection &
Interlocks, Output Transformer and Working induction coil. The induction heater should be suitable
to prepare High Temperature Alloy Casts having melting point up to1800oC, using graphite crucible
as susceptor. The graphite size is 50 mm maximum OD to 30 mm minimum OD and wall thickness
is 4 to 8 mm.The charge for each heating batch will be about 250 grams.

2. Scope of supply, installation and commissioning

The assembly of various sub-systems, integration of induction coil, current feed-through with
the existing power source, installation and commissioning of the total system at site, shall be the
responsibility of the supplier.
2.1) 10 kW, Frequency6 kHz to 10 kHz inverter (IGBT based)– 1 No
2.2) Heat station consisting of transformers and capacitors for load matching - 1 No
2.3) DM water recirculation system for cooling the induction coil and generator components - 1 No
2.4) Induction CoilID 75 mm, height 75 to 85 mm, coil tube is 6.0 to 6.4 mm OD and wall thickness
is 1 to 1.2 mm- 1 No
2.5) Single and two color infrared pyrometer for measuring the temperature of the melt – 1No
2.6) Temperature controller – 1 No
2.7) Thermocouple – 1 No
3. Prequalification Criteria/ Evaluation criteria

3.1) Guaranteed Technical Particulars (GTP) of the induction heating system (MCCB, meters,
lamps
etc) shall be submitted with offer
3.2) Technical Leaflets for accessories in the induction heating system (MCCB, meters, lamps etc)
must be enclosed with the quotations.
3.3) Quotation without annexure sheets & technical leaflets will not be considered
3.4) The supplier shall have a minimum of 5 years experience in fabrication, installation, testing &
commissioning ofinduction heating systems of similar nature and the proof of the same shall be
attached.
3.6) OEM certificate shall be submitted.
3.7) Suppliers quoting for all the items only will be considered for evaluation as a single item.
3.8) Schematic diagram, drawing and sketch of the equipment shall be submitted alongwith the
quotation
 Biddersshall meet all the above criteria. Bidders shall furnish documentary proof for the criteria
specified, without which the offer will not be considered for further processing.

4. Specifications for Induction Heating System.

a) Inverter type : IGBT based inverter

b) Input Voltage : 415V, +/- 5%, 50 Hz (3 phase)

c) Output frequency : 6 kHz to10 kHz

d) AC Output Power : 10 kW (1 – 10)

e) Type of cooling : Water cooling

f) Control panel : Compact design. The dimensions shall be finalized based on

site requirement in consultation with purchaser.

5. Front panel display

The following minimum panel display and trip indications shall be provided to monitor the
healthiness of instrument during starting and running period
a) Ready Indication
b) Heater ON Indication
c) Input Voltage/Current ; power/voltage/current: Separate display
d) Water temperature trip indication
e) Water flow trip indication
f) 3 phase Power ON indicator
g) DC overcurrent
h) Over load trip
i) Cooling circuit ON indication and
j) Out Put : power/voltage/current/frequency: Separate display
6. Controls
The following parameters should be controlled from the front panel
a) Induction Heater ON / OFF. Control can be based on temperature controller
b) Mode of heating viz., Auto / Manual Selection. There must be provision to control the
heating in AUTO mode through temperature controller based on input from thermo-couple as
well as pyrometer. There must also be provision to increase the power to the induction coil in
manual mode with the help of potentiometer.
c) Emergency STOP - push type switch (To switch OFF the instrument immediately by the
operator incase of any abnormality/emergency condition with the instrument)
7. Functional tolerance: The system should be capable of tolerating abrupt discontinuities in the
coil circuitcaused due to sudden insertion, removal, or geometric changes of the work
 pieces. Inverter should have protection against short circuit faults on coil side and provision
need to be provided to indicate on panel with reset option. The system should go to safe
shutdown in case of failure of power components without a severe service outage. A reset
switch need to be provided.
8. Converter: Converter should be a 3 phase full wave rectifier bridge circuit. Filter choke and
adequate filter capacitors should be used for achieving steady and smooth DC output.
9. Inverter:The inverter circuit should consist of IGBT assembly, high frequency capacitors and
inductors, control & protection circuit. The power device provided should be suitable for
high frequency switching, liberally rated with a good margin.
10.Transformer, Inductor& Capacitor:Output circuits should be provided with one number of
high frequency matching output transformers in order to facilitate impedance matching with
graphite susceptors. The charge (materials to be melted) would be kept in a graphite
susceptor with ceramic lining. High frequency transformer should be provided with a
cooling facility and the induction coil should be connected to the output of the transformer.
Inductor (induction heating coil) should bespecifically designed and manufactured for
achieving the melt temperature up to 1800oC. The output transformer shall betapping at
primary side to vary the turn’s ratio. High frequency capacitor at transformer output shall be
optimallychosen to match the coil rating. The load matching transformer shall be inside the
power panel.
11. Operational interlocks
1. Power incrementing & decrementing shall be achieved through temperature controller in
both the modes (Auto & Manual).
2. The equipment shall have Safety interlocks as follow:
a) Interlocks on doors: Mains incoming MCCB shall be tripped if the door is opened
during heating. (i.e.) Heating should be stopped if the door opens.
b) Single phasing& under voltage: If there is failure in any one of 3 phases or reduce the
dropout coil voltage, the front panel display shall indicate ‘single phasing or under
voltage’ and the heating shall not start or the heating shallbe stopped during the
operation.
c) If sufficient water cooling/flow/temperature is not available to the electrical circuit
and/or to the induction heating coil, heating shall not start.
12. Induction Coil
The induction heating coil is kept at a maximum distance of 4 m from the matching
transformer. Hence, the instrument should work without any problem if the induction heating
coil is kept at varying distances upto a maximum distance of 6m from the matching
 transformer. The size of the induction coil should be preferably in the range of ID 75 mm,
height 75 to 85 mmand size of the inductor coil tube is 6 to 6.4 mm OD and wall thickness is 1
to 1.2 mm.

13.Electrical power
The electrical power requirement for the induction heater shall be approximately 20 A (max)
and 12 kVA.
14. Temperature controller
Type : PID

Input : 18 types, includes Thermocouple B & S/ 2 types of

RTD, 2 types of DC current and 4 types of DC voltage. User
selectable.
Output : 4-20 mA DC as control output suitable to drive thyristor power
controller. RS 485 MODBUS RTU serial communication for higher
end hookup lPC / SCADA.
Display

PV Display : 4 digit 7 segment, easily readable character size

Set value : 4 digit 7 segment, easily readable character size
Pattern : 1 digit 7 segment easily readable character size
Step : digit 7 segment easily readable character size
Alarm indication : By LED.
Run Display : By LED.
Accuracy : +/- 0.2% of display +1digit.
No. of Patterns : 9 patterns.
No. of steps : 9 steps per pattern. Possible to link Max. 81 steps. PID value for
each
step can be selectable.
Auto tuning : Multi zone auto tunable

Communication : RS485 Modbus protocol for connectivity. For communication with

PC or high end control.
Wait & Hold function: During program run, move to next step can be settable using this
function.
Parameter setting : By front panel keys & values shall be non volatile- stored in
semiconductor memory.
Parameter locking : User settable for different level.
Isolation switches : Between input, output & power.
Program selection : Program can be selectable and executable by the user.
Step time : Step time unit selectable for Hours: Minute or Minute: Seconds.
0 to 99Hrs. 59 minutes or 0 to 99 minutes 59 seconds.
Aux. supply : 1 phase, 230V, ± 10 %, 50 Hz
Size : 100 L X 100 W mm (Approximately) or lower

15. Thermocouple
1. Type : S or B type (Grounded)

2. Temperature range : 0 to 2000°C

 3. Thermocouple OD : 3 to 6 mm
4. Junction type : Grounded junction

16. Pyro meter (IGAR 6 Advanced) IMPAC make or equivalent

Description of the item: Non-Contact Infrared Pyrometer

1) Temperature measurement range : 100 to 2000 °C

2) Sub Range : Any range adjustable within the temperature range,
minimum span 50 °C
3) Spectral Ranges :Channel 1: 1.5 ... 1.6 μm; Channel 2: 2.0 ... 2.5 μm

4) Measuring Mode : Single color and Smart mode: 100 to 2000 °C

Two color (ratio) mode: 250 to 2000 °C
(Single and Two colour ratio.)
5) Accuracy :+/- 0.5% FS
4) Repeatability : 0.1% of FS
5) Response time : 7.5ms adjustable to 1 sec.
6)Temp. Resolution :0.1 °C at interface; < 0.0015% of selected sub range
at analog output, min. 0.1 °C, 16 bit;1 °C on display
7) Spectral Response : One or Two narrow bands near IR region
8) Field of view ratio : 60: 1
9) Analog output : 4-20 mA isolated and scalable.
10) Temperature display : Bright alpha numeric LED, 4 digits.
11) Digital interface : Bi-directional RS485 communications

12) Operating temperature : 0 to 50 °C

13) Target size : Unaffected by target size (provide accurate reading

with only 5% of target area within field of view)
14)Slope adjust : 0.800 to 1.200 in 0.001 steps (Two colour)
15) Emissivity adjust : 0.050 to 1.000 in steps of 1/1000 (1-color mode)
0.600 to 2.000 in steps of 1/1000 (2-color mode)
16) Protection Class : IP 65 IEC 60529 (value in mated condition)
17) Operating Position : Any
18) Ambient Temperature : 0 to 65 °C at housing
19) Storage Temperature : -20 to +80 °C
20) Relative Humidity : Non condensating conditions
21) Housing : Stainless steel
16.1Accessories to pyrometer
1) Adopter power supply:
a. Input : 90 -250 VAC,
b. Output : 24V at 0.7 Amps
c. Frequency : 47 to 63 Hz.
 2) Adjustable mounting stand (tripod stand)
3) Connection cable : 5 meters long cable (Supply & Signal).
3) Driver software : Suitable driver software.
4) Protective jacket with window end cap
17. Spares
The quotation shall include the cost of following essential spares for 10kW induction heater
Sl. No. Item Name Quantity
1 IGBT 2 Nos
2 Semiconductor Fuses 6 Nos
3 Water flow switches 2 Nos
4 Thermal switches 2 Nos

18. Safety features

i. Flow monitoring switches shall be provided to trip the MCCB incase of low flow/no flow of
cooling water in the cooling circuit.
ii. Colour coded PVC braided pipes for inlet and outlet water connections shall be provided.
iii. Adequately rated Electrolytic Tough Pitch (ETP) copper bus bars with tinning at the contact
points shall be used to keep the losses minimum.
iv. Circuit breaker for control circuit, semiconductor fuses for power circuit, door interlock for
MCCB etc. should be provided.
v. Power controls should be present.
vi. Single push button switch shall be provided to put OFF the equipment in emergency.
vii. Thermal switches shall be provided to trip the MCCB in case of crosses the set temperature
19. Pre-Dispatch Inspection and Testing

The complete functioning of the induction heating system including its components and
assemblies shall be made available for inspection to the purchaser or his representative at vendor
works prior to dispatch. The induction heating system should be completely pre-assembled at the
factory for cold and hot tests. The cold tests shall include:
∗ HLT test shall be done under vacuum, and maintain the leak rate less than 10-7Std. cc/secfor
induction coil and coaxial power feed-through
∗ Verification of electrical system and process control
∗ The hot test: Coupling test of power supply to induction heating coil
∗ Cold test: component modules and the operation of the entire system

20. Cold Tests/Supervision

Cold testing of the system shall be conducted following the conclusion of the respective
Installationworks.Cold testing procedures shall be extended to components, component
modules and the operationof the entire system. The respective test data achieved shall be
collected and certified by both parties (supplier and the purchaser).
21. Hot Tests
The hot tests to be carried out to optimize settings of various system parameters at the supplier
premises.The test data shall be collected and certified byboth supplier and purchaser.

22. Acceptance criteria

The following final performance test shall be carried out minimum five cycle operation at the
supplier’s premises for full satisfaction of the purchaser.
a. The charge (SS) shall be heated (in ambient)up to the maximum temperature of 1800 °C.
b. The induction heating system shall meet the complete indent specifications.
c. Only after successful demonstration of system performance and training imparted to two
engineers of the user department, final acceptance will be issued.
d. Two sets of system manual and necessary circuit diagram shall be supplied.
e. After installation, final performance test shall be carried out with five to six cycles of heating
operation at the IGCARpremises for full satisfaction of the user.

23. Guarantee
The supplier shall guarantee the induction heating system with accessories for trouble free operation
for a minimum period of 12 months from the date of commissioning, after successful installation,
integration and performance demonstration of the system at purchaser’s site or 18 months from the
date of supply.