Objectives

The primary objective of this tender is to appoint a qualified and experienced service provider to conduct diagnostic testing, fault finding, and a technical assessment of an existing induction vacuum melting furnace at the CSIR. The assessment aims to determine the current technical condition, identify faults or missing/defective components, evaluate the feasibility of restoring the furnace to safe and reliable operation, and provide recommendations, cost estimates, and a way forward for refurbishment or re-commissioning.

Scope

The scope of work includes:

• Performing a comprehensive visual and mechanical inspection of the furnace and associated equipment, including refractory lining, induction coil, busbars, safety guards, ancillary systems, and structural components.
• Assessing the induction power supply, including rectifier, inverter, cooling arrangements, control boards, protection devices, and insulation.
• Inspecting the furnace coil, crucible, and melting zone for condition, compatibility, and potential refurbishment needs.
• Evaluating the vacuum system, including gauges, pipework, pumps, leak tightness, and performance.
• Assessing electrical, control, and instrumentation systems, including safety interlocks, alarms, and control logic.
• Conducting a feasibility assessment considering component availability, operational risks, costs, safety, and remaining service life.
• Providing a detailed technical diagnostic report with findings, faults, safety concerns, recommendations, repair/replacement plans, cost estimates, and an implementation plan.

Technical Requirements

The service provider must:

• Inspect and evaluate all relevant systems and components as outlined in the scope.
• Perform electrical diagnostic tests such as insulation resistance, continuity, earth checks, control circuit, and component tests where safe and appropriate.
• Identify whether existing coils and crucible arrangements are reusable, require refurbishment, or need replacement.
• Assess vacuum system integrity and recommend performance tests, including leak checks and drawdown tests.
• Determine the functionality and safety of electrical, control, and instrumentation systems, recommending upgrades if necessary.
• Provide a cost estimate broken down into categories such as repairs, upgrades, consumables, labor, testing, and third-party services.
• Develop a site assessment plan, inspection records, and a comprehensive final diagnostic report.

Skills Requirements

The service provider must demonstrate:

• Proven experience and competence in inspecting, fault finding, maintaining, refurbishing, or commissioning induction and vacuum furnaces or similar high-power electrical thermal processing equipment.
• Ability to identify safety-critical defects and provide practical refurbishment recommendations with associated costs.
• Availability of calibrated testing equipment suitable for electrical and mechanical diagnostics.
• Qualified personnel skilled in electrical and mechanical inspection work.
• Capability to work safely within operational research or laboratory environments.
• Experience with projects of similar scope and complexity, supported by references and project records.