AJAY GREENLINE INSTALLATION GUIDE

  • 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 matter.
  • 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 correct size. If it is not correct sizes get another fitting.
  • Mark the socket depth on the pipe with the marker
  • Apply a thin coat of cement into the fittings socket and a full even coat on the pipe till the mark depth of socket bottom Do not puddle cement in socket.
  • 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 quarter turn, this will allow cement to cover any dry spot. Make sure pipegoes 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. Curing time is dependent upon temperature, humidity etc. For curing time kindly refer Table No-5.

THREAD SEALANT

  • Threaded UPVC Fittings (Plastic & Brass) with tapered pipe threads (e.g. male threaded adapters) must be used with a suitable thread sealant to insure leak proof joints. Over the years, PTFE (Teflon or equivalent) tape has been preferred thread sealant, it is still the most widely accepted and approved sealant. Some paste sealant can affect UPVC Fittings, therefore only sealants recommended for use with UPVC by threaded sealant should be used.
  • Don’t use cloth strings or jute to seal the threads.
  • Don’t over tighten.

Pressure Testing GUIDELINES

  • 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 1foot per second.
  • 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.)
  • 7. The pressure test should not exceed one hour. Any leaking joints or pipe must be cut out and replaced and the line recharged and retested using the same procedure.