Ajay Flowline Plus INSTALLATION GUIDELINES

  • Cut pipe straight (very important). This will allow pipe to bottom into the socket.
  • Remove burr (shaving), use clean dry cloth or knife. Do not use abrasive material.
  • Clean pipe and fitting & ensure no dirt, grease or any other foreign particle.
  • Check dry fit. Pipe should easily go into the socket 1/3 to 2/3 of the way before any resistance is felt. This is commonly referred to as interference fit. If pipe goes to the bottom of the fitting without any resistance (interference) ensure fitting is of correct size. In case fitting is loose, change fitting.
  • Mark the socket depth on the pipe with a marker.
  • Apply a thin coat of cement into the fittings socket and a full even coat on the pipe till the mark to the depth of socket bottom. Do not puddles cement in socket use brush & dauber atlaest 1/2 the OD of the pipe.
  • For sizes above 2 inch AJAY recommends jointing with purple primer & Heavy duty gray solvent cement.
  • Insert pipe into the socket quickly while cement is still fluid (wet), if cement has dried, re-coat pipe and fitting. Twist pipe turn, this will allow cement to cover any dry spot. Make sure pipe goes all the way to the bottom of the fitting.
  • Hold pipe and fitting together (30 second) to make sure pipe does not push out.
  • Wipe off excess cement with clean dry cloth.
  • Allow cement to cure before pressure testing. Cure time is dependent upon temperature, humidity etc. however under normal conditions, allow 24 hours curing time.
  • http://www.youtube.com/watch?v=CcvKfh7yttg

THREAD SEALANT

  • All the Ajay Flowline Plus (brass / plastic) threaded Fittings must be used with a suitable thread sealant to ensure leak proof joints. Over the years, PTFE (Teflon or equivalent) tape has been the preferred thread sealant is still the most widely accepted and approved sealant. Some paste sealant can also be used, therefore only sealants recommended for use with CPVC by threaded sealant manufacturer should only be used.
  • Don’t use strings or jute to seal threads
  • Do not over tighten plastic threaded fittings.
  • Ajay does not recommend use of plastic threaded fittings above 600 C.

Pressure Testing

  • Prior to testing, safety precautions should be instituted to protect personal & property in case of test failure.
  • Conduct pressure testing with water only.
  • The piping system should be adequately anchored to limit movement. Water under pressure exerts thrust forces in piping systems. Thrust blocking should be provided at changes in direction, change in size and at dead end.
  • The piping system should be slowly filled with water, taking care to prevent surge and air entrapment. The flow velocity should not exceed 1ft./sec.
  • All trapped air must be slowly released. Vent must be provided at all high points of the piping system. All valves and air relief mechanisms should be opened so that the air can be vented while system is being filled.
  • Once an installation is completed and cured the system should be filled with water and pressure tested in accordance with local code requirements. However, care must be taken to ensure the pressure does not exceed the working pressure of the lowest component in the system (valves, unions, flanges, threaded parts, etc.)
  • Any leaking joints or pipe must be cut out and replaced and the line recharged and retested using the same procedure.

INSTALLATION GUIDELINES FOR CPVC PIPE WITH SOLAR WATER HEATERS & GAS BOILERS

  • Certain precautions are recommended to be undertaken while installation of CPVC pipes with solar water heating systems and gas boilers.
  • Venting or Thermo-regulating valve: It is strongly recommended that Solar Water Heaters be installed with Thermo-regulating valves. However if no thermo-regulating valves are provided then providing proper air-venting on the hot water outlet side is a must.
  • SDR 11 Pipes only: Ajay recommends that only SDR 11 pipes be used with Solar Water Heater main lines.
  • Expansion and Contraction Loops: Based on the height of the building, it is necessary to provide expansion and contraction loops in case of exposed piping being used with solar water heater installations. The design calculations of loops are available on (p-14) of our product manual and depend upon the maximum estimated water temperature difference and the maximum length of run of the pipe. For detailed information on expansion and contraction loops. Kindly contact authorized Ajay representative.
  • Pipe Insulation: All exposed piping leading from Water Heaters including the down-takes (vertical risers) should be insulated. Even though CPVC has the lowest thermal conductivity amongst all alternate plastic plumbing systems, however to maintain thermal efficiency, it is recommended that the pipes be insulated. Nitrile rubber or PE foam may be spirally wound round the pipe to provide adequate insulation. For longevity, it is also advised to cover the insulation with aluminum tape for protection against water and sunlight.
  • (Note: The insulation cost of CPVC pipe will be far lower than any alternate plumbing system such as GI, Cu or PPR.)
  • Support Spacing: Ensure that proper support spacing (pipe clamp spacing) as specified in the Ajay Flowline Plus product manual (P- 12) is followed. At the roof level, in case at any point proper support is not available against the wall or the floor, bricks should be used to provide proper permanent support to the piping.
  • Brass Transition Fittings: Use only Brass insert type transition fittings for all connections with solar water heaters.

GAS FIRED BOILERS

  • Avoid direct exposure of plastic piping to fire or flue gases.
  • Ajay recommends that CPVC be used after 10 ft. from the boiler before which metallic piping be used.
  • Follow all other precautions as listed above.