Technical Specification of Induction Heating Power Source

Scope:Supply, Installation, Testing Training of Induction Heating system.

Functional Requirement of Induction Heating System:The induction heating system is intended to heat Graphite/Carbon-Carboncylinder centrally positioned inside a quartz tube as shown in Figure-(1). The heater rod will initially have diameterØ 20 mm which during the process will get increased to Ø 50-100 mm. The function of the Induction heating system is to magnetically couple with the graphite tube and generate power upto 50 KW. The frequency of the induction system shall be designed to take care of the changing requirements of the power with respect to the change in diameter of the heater cylinder with time.

The functional requirements for the process with time is shown in Fig- (2). The induction coil of the heating system shall be positioned outside the quartz tube.

Operating Parameters:

Heater Size: / The heater dimension will be changing during the process and will vary from:Initial - 20 mm dia x 350 mm height.
Final - 50 - 100 mm dia x 350 mm height.
Power / 50 KW
Frequency / The power source shall have capability to deliver power density as mentioned below
Feature / Tuning Facility with Bar Graphs display for Power, Voltage and Current to understand proper load matching
Power Density / The process demands a power density of 1.5 MW/m2on the heater surface. The power density will vary depending upon the heater dimension.
Heater Material / Graphite/ Carbon-Carbon Composite
Temperature Measuring / Temperature measuring two colour Pyrometer ranging to maximum 13000C

Physical Configuration & Design:

1)The system shall be vertical and modular in construction, with provision for cooling.

2)The system shall ensure proper coupling between the heater and the induction coil to provide a closed loop controlled heating. The Induction coil and the power source shall be supplied by the party and other parts as shown in figure 2 will be the under the scope of VSSC.

3)The induction coil of the heating system shall be positioned outside the quartz tube, having Outer Diameter of 100 mm. The coil shall have support system to maintain the position during the process.

4)The coil shall be designed for proper coupling between the coil and the heater surface. The design of the induction coil shall ensure that there isnegligible magnetic coupling with the SS- flange of the Quartz tube to avoid heating of the SS flange.

System Features: The system shall comply with the following features –

  • Output regulation –Voltage ,power and current
  • Limit Settings –Current, DC volts,Output Volts, Power, Frequency
  • Separate heat station with Coil which can be positioned over table
  • User-friendly operation front panel touch screen with controls
  • Flexible with wide range impedance matching by utilising multiple transformer ratios and configurable tank capacities
  • Tuning Facility with bar graphs displayed on monitor display for Power, Current and Voltage for Load matching
  • The front panel shall be touch screen and shall have provision to adjust key operating parameters and read system diagnostics
  • Minimum 5 programs with 9 programmable parameters
  • Provision for0-10 V or 4-20 mA external control and remote start/stop operation
  • Overload-tolerant output management
  • Command display in English (EN)
  • System diagnostics displayed on front panel
  • Air Cooled Chiller as Cooling system for induction coil and power panel with a capacity of 10 TR and additional features of Digital Temperature Controller, Alarm System , Fluid level sight glass, Hermetic compressor to deliver cooling water at a height of 5 m, Fluid bypass line with working of coolant at Max. Temperature difference of 100C
  • Facility forSerial Communication (RS232/485) with software for logging,monitoring of parameters during operations
  • Provision to record process parameters
  • Minimum two Remote inputs shall be provided to record additional process parameters like temperature, flow rate of cooling water etc other than generator parameters.
  • Customised Coil as per the dimension of the quartz reactor.

Technical Specification of the Induction System:

Features / Specification
RF Terminal Power (max-continuous) / 50 kW
Output Frequency / Controlled Frequency shall be to provide power density as per the process demands. The induction power source shall operate with a frequency of 50-150 Khz to meet the depth of penetration.
Line Voltage / 380/480 Vac, 3Ø AC
Display / LCD Monochrome, 240w x 128h Pixels
Compliance / CE EN 61010 EN 55011
Ingress Protection / IP54, NEMA 12
Features to enable cooling of the coil and power panel through water circulation. / To be designed by the supplier.
Abbility to add power / The system shall have provision to augment the power capability later by adding another system

Accessories:

  • Start-up assistance
  • Redundant safety relays
  • Footswitch
  • Extended workhead cable lengths
  • Front e-stop with retransmission
  • Complete spare parts kits -
  • Safety Features to aid safe working of the system

Transportation:

The party shall be responsible to transport the item at VSSC, Vattiyoorkavu, Trivandrum-695013, Kerala, India.

Installation:

The system has to be installed at VSSC, Vattiyoorkavu, Trivandrum-695013, Kerala, India.

All plumping works connected with the cooling system shall be done by the party.

Testing

Two heating trials will be performed to demonstrate the functional requirements:

  • Trial 1- Heating of Graphite/C-C Rod having Ø 25 mm X 350 mm Height. Trial-2- Heating of Graphite/C-C Rod having Ø 80 mm X 350 mm Height
  • During these trials the changing requirements of power shall be demonstrated.

The trial runs will be performed to verify the capacity of delivering the required power density to the system. During the trial, temperature of the heater will be monitoredto verify the uniformity of the temperature along the length of the heater. Also party has to design the induction heating such that there is minimum coupling because of the magnetic field with the SS flange of the Quartz reactor. This has to be demonstrated during the installation.Apart from the heating trials the system shall be demonstrated for the other technical requirements as will be specified in offer.

Training

Training shall be provided by the supplier after installation and testing at VSSC.

General

  • The offer from the party shall be in two parts: (1) Techno-Commercial Bid without price and (2) Commercial Bid. (Both shall be in separate sealed covers)
  • Party shall prepare a compliance matrix indicating the compliance to each points of the enquiry and attach the same in the technical offer.
  • The party shall include the cooling system and its accessories separately for the Induction Heating System in the technical bid as an option and the price for the same shall be mentioned in the commercial bid separately.
  • The party shall include details BOM &spares that will be supplied with the system separately in the offer. The price for the spares shall be mentioned separately in the commercial offer.
  • After placement of order, the party shall arrive at the configuration of the Induction Coil and its position after discussing with VSSC to optimise heating efficiency and minimise stray heating in undesired areas.
  • The party shall provide a layout drawing of the Induction power source, heater coil and cooling system after placement of offer.

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