"Building Blocks of Experience: My Journey Through the World of Engineering Internships" - 3

 Mission Bhagiratha Site Visit – 28th January 2020

On 28th January 2020, we visited an e-colony where the Mission Bhagiratha works were in full swing. As part of the Telangana government’s ambitious project to provide clean drinking water to areas, this site visit gave me a firsthand experience of the construction and installation processes involved.

I observed a large-diameter black polyethylene (PE) pipe. This material is commonly used for underground pipelines due to its flexibility, durability, and resistance to corrosion. Below are the specific details of the pipe found at the site:

Pipe Details:

• Type: HDPE (High-Density Polyethylene) pipe
• Nominal Diameter (DN): 110 mm (approximately 4.3 inches)
• Length: 194 cm (76.4 inches)
• Batch Number: 5300011579
• Markings: "SHGAND HOPE PIPE" and "PETOO" (likely manufacturer or product identifiers)

Additionally, I noticed a hydraulic jack machine being used to install the pipe. The clamp attached to the pipe is likely part of the hydraulic jack system, which aids in pushing or pulling the pipe into place.

The hydraulic pipe ram was another key piece of equipment in use at the site. It's a specialized tool designed for pushing or pulling pipes into position, especially in confined spaces or underground installations. The system consists of a hydraulic cylinder that exerts pressure on a ram, which in turn moves the pipe into place. The yellow and black stripes on the machine are likely safety markings.

This information was shared by the site incharge, who provided a detailed explanation of the ongoing process.

Ritmo Electrofusion Machine in action. This machine is essential for joining plastic pipes through a combination of heat and pressure, ensuring a seamless connection.

The Electrofusion Process:

1. Preparation: The ends of the pipes to be joined are first cleaned and prepared. An electrofusion fitting is then placed over the pipe ends.
2. Connection: The electrofusion machine is connected to the fitting. When activated, it generates an electric current, which heats a resistance wire embedded in the fitting.
3. Fusion: The heat causes the plastic material of both the pipes and the fitting to melt and fuse together.
4. Cooling: Once the process is complete, the machine is turned off, and the joint is allowed to cool, forming a strong, durable, and leak-proof connection.

Electrofusion is a highly reliable and efficient method for joining plastic pipes, providing a connection that is resistant to corrosion, chemicals, and other environmental factors. This process is commonly used in applications requiring high-quality, leak-free connections, such as water supply systems, gas pipelines, and industrial processes.

We also came across a Butt Fusion Machine at the site, which is another crucial tool for joining plastic pipes. This method involves melting and fusing the ends of the pipes together, ensuring a seamless connection.

The Butt Fusion Process:

1. Preparation: The ends of the pipes are cut and chamfered, creating a beveled edge. The pipes are then heated using a heating element in the butt fusion machine.
2. Fusion: Once the pipes reach the desired temperature, they are pressed together and held in place for a specific amount of time. The heat and pressure cause the plastic to melt and fuse.
3. Cooling: After the fusion is complete, the pipes are allowed to cool gradually, ensuring the joint remains strong and durable.

Why is Butt Fusion Used in Pipe Installation?

Butt fusion is a reliable and efficient method for joining plastic pipes, offering a strong and durable connection. It is highly resistant to corrosion, chemicals, and other environmental factors, making it ideal for applications where leak-free, high-quality connections are essential—such as water supply systems, gas pipelines, and industrial processes.

During the installation process, the following specifications were noted:

• Fusion Time: 80 seconds
• Cooling Time: 4 minutes
• Product Identifier: 941114302398407554080758
• Component: Saddle 90
• Specification: 500L AMIN

The fusion time indicates the duration required for the pipes to melt and fuse, while the cooling time represents the period allowed for the joint to solidify and strengthen.

The term “Saddle 90” likely refers to a specific type of fitting used in the installation, allowing a branch connection to be made to the main pipe. The long numerical code may serve as a product identifier or batch number, and “500L AMIN” could pertain to a specification or quantity related to the material or process.

In conjunction with this, a threaded metal rod with a grooved end is used in the process. The saddle is positioned on the main pipe at the desired location and is typically secured temporarily using clamps or straps to hold it in place during the installation.

In conclusion, our visit to Ecolony on January 28th, 2020, provided valuable insights into the ongoing efforts of Mission Bhagiratha. Observing the installation processes involving advanced technologies such as hydraulic pipe rams, electrofusion machines, and butt fusion machines showcased the commitment to ensuring efficient and reliable water supply systems. The attention to detail, from the preparation of pipes to the fusion and cooling processes, highlights the importance of quality in construction practices. I look forward to sharing more experiences and insights from this project in future posts.

To be continued..

Pooja Mattapalli