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At present we are having 100 dedicated professionals and qualified managers. Light and sophisticated machines and equipment are used in the production process, are efficiently automatic & computerised. As a result whole manufacturing process is fully automated with definite meticulous attention to each and every detail, with its automatically manufacturing process under the directorship of four competent directors.
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BUTT WELDING TECHNOLOGY
BUTT WELDING MACHINE
Butt welding machine designed to fabricate fittings like bends, wyes (Y), tees and crosses (up to Ø 630 mm) by joining pipe segments, with the help of special clamps. All clamps opening / closing and locking movements are controlled hydraulically.
Butt welding machine is composed of:
- A machine body with two hydraulically controlled carriages.
- A control panel on which we find the hydraulic controls (lever for opening and closing the carriages, clamps opening/closing and locking, milling cutter and heating plate movements), the electric and electronic controls (switches for the milling cutter and heating plate, the automatic electronic temperature control device, timer for the heating and welding phases, acoustic and visual indicator).
- A heating plate that slides on recirculating ball slideways.
- A milling cutter that slides on recirculating ball slideways, electrically controlled for levelling the ends of pipes and/or fittings.
- An upper cylinder, to be positioned on the clamps, for welding extra thick pipes and/or whenever it’s necessary to use high pressures.
BUTT WELDING TECHNOLOGY
KPT is having advanced Italian make Ritmo Butt welding machine to do butt welding joints 110 mm and 160 mm pipes. KPT has a complete range of butt-welding machines available. Butt welding is the process of bringing together two piece of metals together along a unmarried edge in a single plane. This appendage can be used on many types of materials, though metal and thermoplastics resin are the most common. When two sails of steel are reposed side by side and linked up together along a single joint,
Butt-welding Technology is an economical and reliable way of jointing without using additional components. A butt-welding joint is made by gradually heating up the two weld ends with a weld plate and then joining them under a specific pressure. This process is very suitable for prefabrication and producing special fittings. Internationally Butt welding is acceptable for the size above 110 mm to join PPR-C pipes instead 0f coupling joints, to adhere to international quality standards.
BUTT WELDING EXPLAINED
Butt-welding is a reliable way of jointing when a proper weld has been made. The butt-weld process consists of the following 6 steps
- Preparations: Good preparation consist of making sure the butt-weld machine is clean and works properly. The products that are to be joined using the butt-weld machine need to be cut on a straight angle, properly aligned in the machine and clean as well.
- Machining the surface: Machining the surface makes sure that both sides run parallel and join up correctly. All shavings should be removed and the weld end remain clean.
- Preheating under pressure: Press the two ends to be jointed gradually to the heating element until a bead is created. The size of the bead is a good indication that the appropriate pressure and time is used.
- Heating up with less pressure: HDPE is a good insulator, therefore at this stage it is necessary that the correct heating depth of the pipe ends is obtained. Only a small amount of pressure is required to maintain the contact of the ends with the heating element. The heat will gradually spread through the pipe/fitting end. The size of the bead will increase a little.
- Change over: Remove the heating element from the jointing areas and immediately join the two ends. Do not push the ends abruptly onto each other. The removal of the heating element needs to be done quickly to prevent the ends from cooling down.
- Welding and cooling: After the jointing areas have made contact they should be joined with a gradual increase in pressure up.
APPLICATIONS OF BUTT WELDING TECHNOLOGY
- RO Line
- Injection Moulding
- Chiller Line
- Cooling Tower Line
The process of joining PPR-C pipes and fittings is very simple and results and inseparable water tight joints. lt is carried out using a simple welding machine that melts the internal surface 0f the fitting and the external surface of the pipe, so that the material of the pipe and the fitting will be melted together.
The following steps describe the steps of the welding process
- Prepare the welding machine by fitting it with the welding dies of the diameters to be welded.
- Connect the plug to the 220V power supply socket and wait until the green light on the machine goes out indicating the welding machine has reached the working temperature.
- Cut the pipe at right angles to the pipe axis using suitable pipe cutter.
- Remove any burrs or cutting chips by deburring the cutting area.
- Mark the welding depth 0n the pipe using suitable marker.
- Insert the end of the pipe without turning into the heating sleeve up to the marked welding depth and at the same time slide the litting without turning into the other side of the heating tool up to the stop. lt is essential to observe the mentioned heating times Leave the pipe and getting into the heating tool until the heating time is elapsed.
- At the end of the heating time, remove the pipe and fitting from the heating tool and push them immediately against each other up to the mark indicating the welding depth. At this stage the depth mark will be covered with the welding bead.
- During this process, do not rotate the pipe and fitting relative to each other.
FUSION TECHNIQUE II : WELD-IN SADDLE TECHNIQUE
Branches can easily be made by weld-in saddles, even at a later stage of installation. By using weld-in saddles you save material and time. Whereas in case of tees three joints have to be welded, installation of saddle is restricted to mounting the saddle and branch pipe only.
The following steps describe the steps of the technique
- Drill the pipe
- Warm up the saddle
- Pipe wall and outside pipe
- Connect the elements
lf a hole is accidentally made in the pipe (with a drill bit or screws) and if the hole is in only one side of the pipe, it can be repaired using the hole repairing die, bearing in mind that the pipe size must be compatible with the die diameter.
The repairing procedure are as follows:
- Clean and dry the part to be repaired.
- Fit the male part 0f the Hole repairing die into the hole; it must melt the surface to be adjusted by the operator to suit the pipe thickness, to ensure that the die cannot be inserted too far and melt the other side of the pipe. To make this adjustment, undo the screw which fixes the bush and then move it along the die.
- At same time as the male part of the die melts the area around the hole, the female part melts the repair bar usually supplied with die.once the heating time has passed (5sec.) the repair bar must be inserted in the hole. When this operation is complete, wait for everything to cool and then cut 0f the excess part of the repair bar.
- lf the diameter of the hole to be repaired is greater that of the die, or both sides of the pipe are punctured, the piece of pipe must be cut out and the repair made using normal pipe fittings.