27 Nov 2010 RAJCO METAL INDUSTRIES P LTD. Minimum Requirements for Copper Tubes related to AC&R and Plumbing RAJCO METAL INDUSTRIES PVT.LTD. Mumbai

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper tubes – straight length & coils

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper Pipes – DHP Grade Chemical Composition Impurities – their effect on quality Physical Properties Manufacturing Processes On Line Testing Lab Equipment & Tests

Nov 27 2010 Rajco Metal Industries (P) Ltd. Chemical Composition – DHP Grade Minimum Copper - 99.9% Why 99.9% ??? If not 99.9% then impurities will be present in the copper tube – Lead - toxic Iron – leads to pin holes due to rusting & galvanic action Cadmium, Tin, Cobalt, Nickel

Nov 27 2010 Rajco Metal Industries (P) Ltd. Raw Material Selection Types of raw materials: Cathode Single wire Armature (motor winding scrap) Use of armature (4 - 4.5% cheaper) is bad for quality Armature has hydrocarbons stuck to it

Nov 27 2010 Rajco Metal Industries (P) Ltd. Raw Material Selection Copper melts at 1083 oC At this temp. during melting, varnish on armature wire turns to gas which gets trapped in the copper cast This is called Hydrogen Embrittlement During drawing – this gas bubbles expand into blow holes

Nov 27 2010 Rajco Metal Industries (P) Ltd. Induction Furnace No O2 / H2 pickup during melting

Nov 27 2010 Rajco Metal Industries (P) Ltd. Annealing Process & Impurities Impurities above certain ppm increases softening temp. Silver, iron cadmium, tin etc. all effect softening temp. Atomic radius & crystal structure of elements also have an effect on softening temp

Nov 27 2010 Rajco Metal Industries (P) Ltd. Iron Impurity – softening temp.

Nov 27 2010 Rajco Metal Industries (P) Ltd. TC – Chemical Comp.

Nov 27 2010 Rajco Metal Industries (P) Ltd. Chemical Composition - Phosphorus What is DHP Grade? Deoxidised High Residual Phosphorised P - Deoxidising agent P content - .015 % to .04% Lower P  oxidation when brazing Higher P  work hardening occurs & cracks appear over time

Nov 27 2010 Rajco Metal Industries (P) Ltd. Rajco TC – Chem Composition

Nov 27 2010 Rajco Metal Industries (P) Ltd. DHP Grade - lower P % With lower P in copper you need silver brazing rods – else joints crack after some time Lack of P results in oxidation of tube and joint while brazing / soldering leading to weak joints & leaks in future

Nov 27 2010 Rajco Metal Industries (P) Ltd. DHP Grade - higher P % Higher P %  tube is brittle Tube has high tensile strength & LOW elongation Such a copper tube will crack on bending or expanding

Nov 27 2010 Rajco Metal Industries (P) Ltd. DHP Grade - higher P % A component like a pig tail above a gas cylinder or the discharge tube above the compressor will mostly leak as high P means brittle copper tubes Vibration from the compressor (on / Off) will work harden the tube and tube will crack after some time

Nov 27 2010 Rajco Metal Industries (P) Ltd. Physical properties – Soft Annealed Hardness Max. 60 HV5 UTS Min. 21.42 kg / mm2 Elongation Min. 40% Higher the UTS  lower the elongation & vice-versa For soft tubes – aim is to achieve High UTS & HIGH elongation

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper Tubes – tempers – EN 1057

Nov 27 2010 Rajco Metal Industries (P) Ltd. Bendable tubes for Plumbing Essentially half hard tubes Important that no wrinkles are caused when tubes are bent – surface must be Wrinkle Free Wrinkles  incorrect physical properties

Nov 27 2010 Rajco Metal Industries (P) Ltd. BS 2871 – Table ‘X’

Nov 27 2010 Rajco Metal Industries (P) Ltd. Burst pipe – tested @ 215 bar pressure

Nov 27 2010 Rajco Metal Industries (P) Ltd. Burst pipe – 215 bar pressure Joints do not burst even at this pressure 22 mm pipe bursts @ 215 bar 15 mm pipe does not burst as bursting pressure is 240 bar

Nov 27 2010 Rajco Metal Industries (P) Ltd. Rajco TC – Physical Properties

Nov 27 2010 Rajco Metal Industries (P) Ltd. UTS Machine

Nov 27 2010 Rajco Metal Industries (P) Ltd.

Nov 27 2010 Rajco Metal Industries (P) Ltd. Annealing Process Physical properties like UTS and elongation, hardness controlled in this process Critical that close control on time / temperature is kept to get properties that satisfy EN, ASTM, JIS standards / Client internal standards

Nov 27 2010 Rajco Metal Industries (P) Ltd. Annealing Rajco has a 5 metre vacuum furnace to achieve uniform annealing Uniform temperature maintained with internal circulation Anneal in inert gas with positive pressure Rajco uses Medical Gas high purity N2 – less than 1 ppm O2

Nov 27 2010 Rajco Metal Industries (P) Ltd. Hydrogen Embrittlement High purity nitrogen means less H2 Hydrogen diffuses into the copper and reaction with O2 to form steam which causes embrittlement

Nov 27 2010 Rajco Metal Industries (P) Ltd. Annealing Achieve Uniform grain size Achieve uniform coaxial microstructure A pattern like merged grain structure leads to cracks in a soft tube during expansion ‘Dead Soft’ term a misnomer used wrongly by clients – means you have heated/softened (?) the tube to death

Nov 27 2010 Rajco Metal Industries (P) Ltd. RAJCO Copper Tubes RAJCO copper tubes breath!!! They have uniform grain size They have correct grain structure & they give life to an installation…

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper tubes – Carbon Content Carbon film or C content in the ID of the copper tube is required to be max. 0.035 gm/m2. Presence of C films in copper tubes can lead to premature failure in copper cold water pipes carrying hard or moderately hard deep well waters.

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper tubes – Carbon Content Hence the EN 1057 now calls for a carbon film / content test A carbon film reacts violently with non CFC gases like R 134A / R 600 / R 410 Low C also a requirement for Medical Gas Pipes

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper tubes – Carbon Content Lubricants used for drawing of copper tubes Lubricants leave behind a residue of hydrocarbon – the C content is measured Essential that C is totally removed during drawing – a clean inside finish is CRITICAL for all applications!

Nov 27 2010 Rajco Metal Industries (P) Ltd. Copper tubes – Carbon Content Rajco eliminates C content by use of ‘Total Loss Lubricant’ A clean inside finish also means that there has to be no copper oxide in the ID of the tube R 134A / R 600 / R 410 reacts with either C or Copper Oxide

Nov 27 2010 Rajco Metal Industries (P) Ltd.

Nov 27 2010 Rajco Metal Industries (P) Ltd.

Nov 27 2010 Rajco Metal Industries (P) Ltd.

Nov 27 2010 Rajco Metal Industries (P) Ltd. Floating Plug ensures concentric tube & clean inside finish as required by EN 1057 Die

Nov 27 2010 Rajco Metal Industries (P) Ltd. Flux / Solder Wire Correct quality of solder wire & flux important Solder wire – Tin (99%) -lead free (<0.1%) Flux – water soluble / non-acidic / non corrosive / paste form Both ensure correct capillary action during soldering

Nov 27 2010 Rajco Metal Industries (P) Ltd. JOINING METHOD: Proper Technique & Joint Fill

Nov 27 2010 Rajco Metal Industries (P) Ltd. Eddy Current Testing Pneumatic test is not allowed as no water can touch the outside of the tube – it will oxidize No Hydro-static test is allowed as water cannot touch the inside of the tube – copper oxide formation is fatal for MGPS & VRF applications ALTERNATIVE – 100% Eddy Current testing as per ASTM E 243

Nov 27 2010 Rajco Metal Industries (P) Ltd. Eddy Current Testing All Pipes 100% Eddy Current Tested Re-Certification of Line Supervisor – Level 3 of Non Destructive Testing

Nov 27 2010 Rajco Metal Industries (P) Ltd. Eye Testing

Nov 27 2010 Rajco Metal Industries (P) Ltd. Regular Eye Tests

Nov 27 2010 Rajco Metal Industries (P) Ltd. Lab Equipment

Nov 27 2010 Rajco Metal Industries (P) Ltd. RoHS Compliance Our tubes are RoHS compliant as per Euro directives

Nov 27 2010 Rajco Metal Industries (P) Ltd. RoHS & Rajco Tubes

Nov 27 2010 Rajco Metal Industries (P) Ltd. Hitachi Award – Best Partner Award

Nov 27 2010 Rajco Metal Industries (P) Ltd. Indian Plumbing Association

Nov 27 2010 Rajco Metal Industries (P) Ltd.

Nov 27 2010 Rajco Metal Industries (P) Ltd. Hologram…Printing Sticking of Rajco hologram on tubes meant for traders to ensure supply of approved brand of copper tubes

Nov 27 2010 Rajco Metal Industries (P) Ltd. RAJCO Copper Tubes Manufacturers / Contractors / Consultants – our prices are based on our superior raw materials, technology & processes !!! However we sell at market prices… + we give free product & installation training anywhere in India