Catalogue 2015 Since 1962
CONTENT Welding automation: PKTBA-US-1...PKTBA-US-4 4 PKTBA-USF-1800-2500-12000-KPNV 6 PKTBA-UN-1...PKTBA-UN-3 7 PKTBA-UN-6PM 8 PKTBA-UNG-750-400-400-KNV-А 9 Welding mechanization: PKTBA-RMS-1 10 Contact 11 3
PKTBA-US-1...PKTBA-US-4 WELDING UNIT FOR GIRTH SEAM WELDING OF PIPELINE PARTS PURPOSE: girth seam welding of pipeline parts with diameter from 15 up to 1400 mm ( ½..56") with MIG/MAG process. PKTBA-USG-1 EQUIPMENT ADVANTAGES: Simultaneous operation of two welding heads provides high performance of the unit. Standard set of the unit includes: rotator, gantry, two welding heads and two welders. Tilting rotator face-plate. Continuous adjustment of welding speed. Control system of the unit is based on industrial controller, thus allowing operator to set welding parameters (welding speed, number of faceplate revolutions etc.) while using touch sensitive control panel. The welding unit can be optionally completed with the following accessories:* - flux recovery system (for F version); - seam tracking system; - electrode oscillating mechanism; - water recycling station (PKTBA-SOV); - video control system; - idle roller bed. Simplicity and ease of operation. 4
PKTBA-US-1...PKTBA-US-4 WELDING UNIT FOR GIRTH SEAM WELDING OF PIPELINE PARTS PKTBA-USF-4 SPECIFICATIONS: Parameter PKTBA-USG-1 PKTBA-USG(F)-2 PKTBA-USG(F)-3 PKTBA-USF-4 Nominal internal diameter of welded valves (DN), mm ( ) Load capacity including the device, kg (lbs) 15...125 (½...5) 1000 (2205) 100...300 (4...12) 2000 (4410) 300...700 (12...28) 6300 (13890) 700...1400 (28...56) 30000 (66139) Welding head number, pcs 2 Arc protection gas gas (flux) flux Diameter of electrode wire, mm ( ) 1,0; 1,2; 1,6 (0,039; 0.047; 0,069) 1,0; 1,2; 1,6; 2,0 (0,039; 0.047; 0,069; 0,079) 1,6; 2,0 (0,069; 0,079) 2...5 (0,079...0,197 ) Rated welding current, at 100% duty cycle, A 350 550(600) 550(1000) 1000 Overall dimensions (LxWxH), mm ( ) * Upon customer request. 2150х2000х2600 (85х79х102) 2500х2200х2800 (98х86х110) 3000х2500х3100 (118х98х122) 8150х7000х6000 (321х275х236) 5
PKTBA-USF-1800-2500-12000-KPNV UNIT FOR EXTERNAL AND INTERNAL GIRTH AND LONGITUDINAL SUBMERGED ARC WELDING PURPOSE: automatic submerged arc welding of external and internal girth and longitudinal seams of cylindrical workpieces. EQUIPMENT ADVANTAGES: The unit allows to weld internal and external girth and longitudinal seams of workpieces with diameter from 500 mm (20''). Rigid design of the column. Longitudinal weld seams are done by horizontal console movement. Mechanical screw feed allows to use all types of flux. System of sensors for the flux monitoring controls the operation of the screw mechanism in automatic mode and prevents welding without flux. The presence of video control system with two video cameras and two monitors provides a visual control of the welding head movement during the machine adjustment and welding of girth and longitudinal seams. The idle section of a roller bed moves along the rail track that allows to place workpieces of various length on the unit. SPECIFICATIONS: Parameter PKTBA-USF-1800-2500-12000-KPNV Maximum weight of a unit, kg (lbs) 12000 (26448)* External workpiece diameter, mm ( ) 400 1800 (15...71)* Internal workpiece diameter, mm ( ) 500...1800 (20...71)* Maximum length of the longitudinal seam, mm ( ) 2500 (98)* Vertical travel of the console, mm ( ) 2000 (79)* Horizontal travel of the console, mm ( ) 3000 (118)* Horizontal travel of welding head, mm ( ) 105 (4) Continuously adjustable welding speed, m / h (in/h) 5,5...110 (216...4331) Electrode-wire diameter, mm ( ) 2,0; 3,0 (0,079; 0,118) Rated welding current, at 100% duty cycle, A 600* Maximum power consumption, kw 40 Compressed air pressure, bar (psi) 4...7 (58...102) Overall dimensions (LxWxH), mm ( ): Roller bed (actuated/idle section); 2000 1296 928/1934 1000 830 (79x51x37/76x39x33) Welding column with welding head, flux feed mechanism and separator FH-100 6200 1271 5000 (244x50x196) Weight (roller bed/welding column/welding head (without wire)), kg (lbs) 2104/2990/52 (4629/6578/114) 6 * Can be modified in accordance with customer request.
PKTBA-UN-1...PKTBA-UN-3 MACHINES FOR HARDFACING / OVERLAYING OF PIPELINE VALVES PARTS PURPOSE: automated hardfacing / overlaying of pipeline parts and elements with diameter from 50 up to 1200 mm (2...48") with or without electrode oscillation with submerged arc process or in an atmosphere of shielding gases (MIG/MAG processes) with full wire. Weld pad EQUIPMENT ADVANTAGES: The machine is fitted out with forced cooling of the welding unit and a set of water-cooled welding heads. The electrode oscillating mechanism allows to increase the width of the overlayed seam up to 60 mm (2⅜"). Advanced construction of rotator allows to fix overlaid workpiece in three coordinates (tilt angle and position along the x and y axes). Machine control system is based on industrial controller thus allowing operator to set hardfacing / overlaying parameters (oscillation amplitude, amplitude velocity, number of faceplate revolutions, and length of welding seam) through a touch screen control panel. The unit is equipped with remote controller. Time for readjustment from "gas" to flux" not more than 10 min. The set of spare parts includes a set of tools, wearing parts kit and first aid kit. Welding zone backlighting. The machine allows hardfacing / overlaying of internal cylindrical surfaces and perform welding of girth welding seams located in the horizontal plane (overlaying of sealing rings, welding of flanges).* The machine allows to reach a hardness of surfacing of 60 HRC and above.** SPECIFICATIONS: Parameter PKTBA-UN-1 PKTBA-UN-2 PKTBA-UN-3 G F G F G F Valve range, DN, mm ( ) 50 300 (2...12) 50 600 (2...24) 300 1200 (12...48) Faceplate rotation speed, rpm 0,08...4,5 0,0125...1,25 Arc protection method gas (flux) Power supply, V/Hz 400/50 (480/60*) Welding current, А up to 600 Electrode-wire diameter, mm ( ) 1 1,6 (0,039...0,063) 2 4 (0,079...0,157) 1 1,6 (0,039...0,063) 2 4 (0,079...0,157) 1 1,6 (0,039...0,063) 2 4 (0,079...0,157) Wire feed rate, m/h (in/h) 100 1500 (3937...59055) 50 400 (1969...15748) 100 1500 (3937...59055) 50 400 (1969...15748) Capacity, kg/h (lbs/h) up to 5 (11) up to 10 (22) Overall dimensions, mm ( ) 1732x900x3190 1735x922x3580 (69x36x128) (69x37x143) Weight (machine/power source/ control panel), kg (lbs) 1120/240/70 (2470/529/154) 1300/240/70 (2866/529/154) 100 1500 (3937...59055) 50 400 (1969...15748) 3900х1800х5112 (156x72x204) 4800/240/70 (10582/529/154) * Upon customer request. ** While using appropriate welding materials. 7
PKTBA-UN-6PM MACHINE FOR HARDFACING / OVERLAYING OF ROTATING BODIES PURPOSE: automated hardfacing / overlaying of shafts, spindles and rods with diameter of up to 400 mm (16") with consumable electrode in an atmosphere of shielding gases (MIG / MAG / TIG* processes). EQUIPMENT ADVANTAGES: The machine is completed with forced cooling welding head and bended water-cooled burner for welding of fillet welds. The machine allows hardfacing / overlaying of cylindrical workpieces with length up to 1300 mm (51"). The control system of the machine is implemented on the basis of industrial controller, which allows the operator to set the parameters of welding (range of oscillations, velocity of the oscillations, number of the faceplate revolutions, length of overlaying etc.) on the touch screen of control panel and to perform welding process in automatic mode. Electrode oscillating mechanism provides greater performance of the hardfacing / overlaying process. The machine allows to perform hardfacing / overlaying of cylindrical surfaces and welding of girth seams with automatic filling of the cutting edge. The machine can be equipped with an additional (second) welding head to provide its greater performance. SPECIFICATIONS: Parameter PKTBA-UN-6PM Range of workpiece diameters, mm ( ) 25...400 (1...16) Maximum weight of welded workpiece, kg (lbs) 800 (1760) Maximum length of welded workpiece, mm ( ) 1300 (51) Vertical travel of welding head, mm ( ) 300 (12)* Horizontal travel of welding head, mm ( ) 1500 (59) Welded workpiece rotation speed, rpm (continuously adjustable) 0,05...3 Horizontal travel of welding head along welding seam, mm ( ) ±50 (±2) Tailstock displacement, mm ( ) 1300 (51) Amount of the quill movement, mm ( ) 40 (1,6) Arc protection method gas Core wire diameter, mm ( ) 1,0; 1,2; 1,6 (0,039; 0.047; 0,069) Rated welding current at 100% duty cycle (40 C), A 350 Power supply, V / Hz 400 / 50 Overall dimensions (machine / power supply unit) (LxWxH), mm ( ) 2400х1150х2000 / 1100х455х1000 (94x45x79/44x18x40) Weight (machine / power supply unit), kg (lbs) 850 /129 (1870/284) 8 * Upon customer request.
PKTBA-UNG-750-400-400-KNV-А MACHINE FOR HARDFACING / OVERLAYING OF CYLINDERS PURPOSE: automated hardfacing/overlaying of the external and internal surfaces of cylinders with consumable electrode in an atmosphere of shielding gas or by flux-cored wire (MIG/MAG). EQUIPMENT ADVANTAGES: Compact size. The control system of the machine allows to program the unit to perform hardfacing/overlaying of several types of parts. The hardfacing/overlaying process may consist of several passes with different overlaying rate, the presence of transverse oscillation, different oscillation parameters (range, speed etc.). Automation of hardfacing/overlaying process provides higher quality of the final result, excluding human factor. Availability of flat surfaces hardfacing/overlaying. Minimum internal diameter of overlayed workpiece is 16 mm (½ ). Water-cooled welding head. SPECIFICATIONS: Parameter PKTBA-UNG-750-400-400-KNV-А Horizontal travel of welding head, mm ( ) 550 (27) Travel of a welding head along zenith, mm ( ) 100 (4) Vertical travel of a welding head, mm ( ) 400 (16) Rotator load capacity, kg (lbs) 400 (880) Rotator faceplate rotation speed, rpm 0,05 7 Tilt angle of a rotator faceplate, deg. 0 50 Electrode-wire diameter, mm ( ) 1,6; 2,8 (0,069; 0,110) Rated welding current, at 100% duty cycle, A 350 Welding current adjustment range, А 5 380 Range of welding voltage, V 14 35 Arc protection method gas Maximum power consumption, kw 35 Power supply, V/Hz 400/50 Overall dimensions, (LxWxH), mm ( ): - machine; 2040х1000х3410 (80x40x134) - power source. 1100х455х950 (44x18x37) Weight (machine/power source), kg (lbs) 880/104 (1936/229) 9
PKTBA-RMS-1 WELDER S WORK STATION 1 PURPOSE: mechanization of semi-automatic welding machine. WELDING MECHANIZATION EQUIPMENT ADVANTAGES: Multi-purpose work station allows to optimize the process of welding and to clear the floor space. Flexible console of a column allows placing a wire feeding device into a convenient position in the service area. Large service area. The range of faceplate rotation speed allows to weld products with a big range of diameters. Faceplate rotation is switched on / off by a footswitch (pedal). SPECIFICATIONS: Parameter PKTBA-RMS-1 Maximum load capacity of the platform, mm ( ) 50 (2) Maximum diameter of service area, mm ( ) 5000 (197) Maximum lifting height, mm ( ) 2450 (96) Minimum lifting height, mm ( ) 950 (37) Maximum torque on the axis of rotation, Nm 6300 Maximum torque in relation to faceplate supporting plane, Nm 16000 Maximum load capacity, kg (lbs) 3150 (6930) Maximum diameter of girth welds, mm ( ) 1800 (71) Maximum faceplate tilt angle, deg. 135 Adjustment of faceplate rotation speed smooth The height from the floor to the axis of rotation of the spindle when the faceplate in a horizontal position, mm ( ) 950 (37) Overall dimensions (LхWхH), mm ( ): - column; 3150 501 2670 (124x20x105) - platform; 700 300 90 (28x12x4) - rotator. 1690х1500х1100 (67x59x43) Weight, kg (lbs): - column with platform; 265 (583) - rotator. 1400 (3080) 10
CONTACT: Export Department Tel.: +7 (8412) 200-201 E-mail: sales@revalve.com ADDRESS: 75 Prospekt Pobedy, Penza 440060, Russia. 11
«PKTBA» CJSC 75 Prospekt Pobedy, Penza, 440060, Russia. Tel./fax: +7 (8412)-200-201 e-mail: sales@revalve.com, web: www.revalve.com