Document No.
:
2007
Revision No. 00
Date Prepared: 9th May
Page 1 of 5
Date Revised:
PVC WELDING, JOINTING AND FRP
COATING PROCEDURE
Prepared by:
TSK
MQ
Reviewed by:
Unit Manager Maintenance
Approved by:
Technical Manager
Document No.:
2007
Revision No. 00
Date Prepared: 9th May
Page 2 of 5
Date Revised:
PVC WELDING AND JOINTING PROCEDURE
To ensure efficient welding of the fittings to avoid any failure, the following
welding and jointing procedure is to be followed:
1.
Roughen the surfaces for better adherence. Do this by rubbing the
surfaces with coarse emery paper.
2.
Thoroughly apply jointing solution to wet both surfaces that will
mate.
3.
After applying the solution, wait for about 30 seconds so that the
solution is partially dry. This will ensure a tight joint. Now slide the
surfaces onto each other. When fittings have mated, prepare for
welding.
4.
For welding, first turn on the PVC welding machine. This will turn on
the integrated blower on the machine, which will send high velocity
air to the welding gun.
5.
Turn open the air valve at the base of the welding gun to set the
desired airflow.
6.
Next, set the voltage according to the schedule of the fittings that
are to be welded. Use the following voltage ranges for common
fitting schedules:
7.
a.
SCH 10:
40-50 V
b.
SCH 40:
60-80 V
c.
SCH 80:
80-100V
Once the required voltage level has been set, wait for the air heater
to raise the temperature of the discharge air to an appropriate level.
This takes up about 30 seconds.
8.
Check that the discharge air is adequately hot by directing air onto a
naked hand. Keep a safe distance (about 10) as the air is hot and
may cause a burn.
Document No.:
Page 3 of 5
Date Prepared: 9th May
2007
Revision No. 00
Date Revised:
9. Once the welding equipment has been set up, pick up the filler wire
and prepare for welding. The filler wire must be the same material
as the base metals.
10. Before welding, preheat the base metals using the hot air from the
welding gun.
11. After preheating, start welding by melting the filler wire to fill in the
welding groove. Keep a smooth pace; making sure that the base
metal is also melted along with the filler wire. This will ensure a
strong joint.
12. Continue around the circumference of the fitting, making sure that
enough passes are applied so that the weld deposit forms a rightangled triangle.
Fitting A
Fitting B
REINFORCING PROCEDURE FOR WELDED JOINTS
Use the below described reinforcing procedure to add strength to the
joints earlier welded. This will ensure that the joints do not fail when
exposed to pressures while in service.
1.
Pour polyester resin (Cabasol powder) in a container.
Document No.:
Page 4 of 5
Date Prepared: 9th May
2007
Revision No. 00
Date Revised:
2. Then pour in an adequate amount of epoxy resin. Stir vigorously to
form a paste.
3.
Pour in 4-5 drops of accelerator (Cobalt). Continue stirring to
thoroughly mix.
4.
Now pour 4-5 drops of hardener (MEKP Methyl Ethyl Ketone
Peroxide). This will harden the paste so that it sets quickly.
5.
Now apply the thick paste thus produced onto welded joints.
6.
Form a tapered profile to prepare a flat inclined surface where FRP
will be later applied.
7.
Leave the paste to dry out. This process normally takes about an
hour.
8.
Now grind off any protrusions and make a smooth surface on which
FRP will be applied.
FRP COATING PROCEDURE
Use the following procedure to apply Fiber Reinforced Polyester (FRP)
coating to piping. This coating is meant to provide strength to PVC piping.
1.
Pour epoxy resin in container.
2.
Add 4-5 drops of accelerator (Cobalt) and mix.
3.
Pour 4-5 drops of hardener (MEKP Methyl Ethyl Ketone Peroxide)
and mix.
4.
Now place a woven fiberglass mat on a cardboard / wooden plank.
5.
Using a paintbrush, apply the solution made in step 3 to the mat on
both its top and bottom side.
6.
Place the wet fiberglass mat on the pipe / fitting where it is to be
applied.
7.
Using a roller set the mat into place.
8.
Continue circumferentially and cover the length of the pipe or fitting
with these mats.
Document No.:
Page 5 of 5
2007
Revision No. 00
9. Apply a second coat to add further strength.
Date Prepared: 9th May
Date Revised:
10. Now leave the FRP coating to dry out. The drying step can take up
to 24 hours depending upon the amount of hardener used.
