Vacuum Arc Remelting Furnace Power Supply System Engineered for Rapid On-Site Commissioning
On March 19th TET ESTEL has completed the shipment of the ARV-40000-40 rectifier system designed for powering a vacuum arc remelting (VAR) furnace.
From the initial concept to the final shipment, this project represents 9 months of meticulous engineering, precision manufacturing, and rigorous testing. We are proud to see this unit head out to the field, ready to set a new standard for reliability in metal refining.
This fully containerized rectifier system is not just a piece of equipment; it is a turnkey solution designed to operate under the most demanding industrial conditions, specifically engineered to provide stable, high-capacity power for a VAR furnace.
The rectifier was manufactured by order of a well-known engineering company for operation at a metallurgical plant in the United Kingdom.
Main technical parameters:
Rated DC current: 40 kA
Rated DC voltage : 40 V
No-load DC voltage : 70 V
Supply voltage : 11 kV
Current regulation range : 1 to 40 kA
DC current ripple: less than 3%
The rectifier is designed as a 12-pulse system with parallel connection of thyristor-based three-phase bridge circuits.
Cooling is provided by a closed-loop water system using deionized (distilled) water via an integrated heat exchanger. This ensures efficient thermal management of the rectifier components at a maximum technical water temperature of 38°C and ambient air temperature of up to 40°C.
The rectifier is equipped with a power factor correction (PFC) system, enabling power factor up to 0.94.
Control is implemented via a SIMATIC S7-1200 PLC and an operator control panel (display, indicators, and push buttons). Communication between the control cabinet and the operator panel is carried out via PROFINET through an Ethernet switch.
All rectifier components, including busbar connections, comply with enclosure protection class IP52. To meet this requirement, the rectifier is installed in a containerized solution (with the exception of the 11 kV / 690 V power transformer, which is installed in the plant’s switchgear).
The container is equipped with integrated utility and safety systems, including a chiller and heat exchanger for air cooling, lighting, smoke and heat detectors, and a fire alarm system.
This solution significantly simplifies on-site installation. The rectifier system includes 16 units of power equipment, as well as a substantial amount of power busbars, power cables, and control wiring.
On-site installation is limited to positioning the container, connecting AC power cables, DC busbars, and the technical water supply.
The rectifier has been tested under equivalent operating loads to confirm compliance with all specified parameters. As a result, installation and commissioning can be completed within a very short timeframe.
