Wednesday, September 19, 2012

Flattening Test for Extruded uPVC Pipes

When you test by the given method, the specimen shall be free from any Cracks and Crazing.

First of all you must get 50mm length of specimen from the pipe. Then hold it between the two plates of smooth surface and compress under a losd at the rate of 10mm per minute until the outside diameter of of the test specimen is depress to half the original diameter. Specially you can use Tensile strength Measuring Test Machine with special plates to supply that load.






Sunday, September 2, 2012

Longitudinal Reversion Test ( For Extruded uPVC Pipes )

Introduction


When you test by the given method, approximately 300mm length of pipe shall not alter in length by more than 5%.


Test Sample


  • After extrude the pipe you must keep the pipe at 23±2 °C for at least 2 hours.
  • Then you can get a 300±20mm length of sample from above pipe.
  • Then you must trace (mark) two circumferential marks apart 100mm (L0) on the test specimen (One of the marks must be at least 10mm from one end of the sample).
  • Repeat above trace three times at the same sample as given image.
  • After that, drill or cut two holes at least 15mm from other end of sample to insert Metal Wire ( Two holes must be on diameter and parallel  to mouth of pipe).

Longitudinal Reversion Test ( For Extruded uPVC Pipes )



Preparing Apparatus


The apparatus shall consist of Thermostatically Controlled bath at 150±2°C. And it shall be made for effective agitation to ensure that the temperature tolerance is maintained throughout the heating medium. You can use Glycerine, Glycol, Silicone Oil, Vaseline Oil ( Free from aromatic hydrocarbons ) or a solution of calcium chloride.

When you choose the heat transfer medium, it must be stable at the temperatures required and it does not affect the sample.


Procedure


  • First of all you must measure the two marks to within 0.2mm ( Using vernier Caliper ) at 23±2 °C.
  • Then control the temperature of the heating medium at 150±2 °C.
  • Then suspend the test piece vertically using inserted metal wire in the heating medium by the end furthest from the marks, so that immersed portion of the test piece is at least 20mm long.
  • Make sure the sample is not touch wall or base of the bath.
  • After that  leave the test piece immersed for,

15min
for pipes of maximum specified thickness equal to less than 8mm.

30min
for pipes of maximum specified thickness more than 8mm.

  • After that remove the test piece from the bath and suspend them vertically.
  • Then allow them to cool by exposure to the air at 23±2 °C.
  • After complete cooling, get four measures of the distance between the marks at 23±2 °C within 0.2mm.

Test Results


For each distance between two marks, calculate the Longitudinal reversion as a percentage by following the formula.


Longitudinal Reversion Test Formula


Lo is the distance between the marks in millimeters before test.
L is the distance between the marks in millimeters after the test.

Choose the measurement of  L which gives the greatest value of |ΔL| where ΔL could be positive or negative.







Tuesday, August 21, 2012

Test for Resistance to Acetone ( For Extruded Pipes )

Procedure


  1. First of all you must get 25mm length sample of pipe.
  2. Then clean the surface of sample using cotton waste or any thing like that.
  3. Then get a beaker and put the sample into the beaker.
  4. Then fill the Analytical Reagent Acetone up to sample level ( add acetone at room temperature ).
  5. After 2 hours you can note the effect of Acetone on the pipe surface.

When you test by the given method, pipe shall not show Delamination or Disintegration. Flattening  or Swelling of the pipe is not to deem as a contribute failure.








Monday, August 20, 2012

Determination of Effect of Material on Water Quality ( Method of Extraction )

Test Specimen


You must get three test specimens of pipe. Each test specimen must taken from different pipes randomly. Each test specimen must contain approximately 500mm in length.


Procedure


  • First of all you must wash every test specimen using tap water for a period of 6 hours. 
  • The pH value of water must be 7-8. 
  • Fit a stopper at one end of the each test specimen. 
  • Each stopper must contain with a Glass Stop-cock. 
  • Then stand the specimen in a vertical position and stop-cock at the bottom opened to give  the desired flow of the water through the specimen. 
  • Make sure stoppers and other materials used for sealing are not contain materials which may cause contamination. 
  • The water shall be passed through the specimen at approximately 50mm/s. 
  • Because the specimen must kept fully filled with water. 
  • You must add sufficient water to overflow at all times.


  • After washing, you must fill each specimen with the fresh solution of the distilled water acidified to a pH value of  4.5 - 4.6 by bubbling a current of CO2 through it. 
  • To fill that solution seal a one end with a material that doesn't contain any toxic substances. 
  • After fill the solution, seal other end using above material.

  • After that you have to maintaining the specimen at room temperature for 48 hours.
  • The solution should decant into a suitable container for analysis as the First Extraction.
  • Then you must repeat the procedure for second and third time.
  • Then retain these sample for the determinations of the amounts of metal and other toxic substances as second and third extractions.


After all of that you can analyse First and Third Extraction for Lead.

And also you can analyse The Third Extraction for Dialkyl Tin as Tin ( C4 and above ).









Effect of Materials on Water Quality ( Extruded uPVC Pipe )

Introduction


When we made pipes for contact with or likely to come in to contact with drinking water shall not,
  • constitute a toxic hazard
  • support microbial growth
  • give rise to any unpleasant taste or odor
  • Cloudiness or discoloration
of the water.

May be chemicals, Biological Agents or Other Substances leached from the Pipe. But relevant parameters shall not exceed the maximum values.



The values of Toxic substance

Lead

  • First Extraction : 1.0 mg/Kg
  • Third Extraction : 0.3 mg/Kg


Dialkyl Tin as Tin ( C4 and above )


  • First Extraction :  - 
  • Third Extraction : 0.02 mg/Kg








Tuesday, August 14, 2012

Bulk Density Test for Blended PVC Compound

Introduction


Bulk Density is one of the easiest measured and most practical physical properties of PVC resins and compounds. Therefore, temperature of polymerization, and the thermal history of the PVC affects the density. After Dry Blending process, blended compound must test for Bulk Density. If this test doesn't pass, it will be reason to many defects.

Instruments


  • Bulk Density Measuring apparatus
  • Sample of Blended Compound
  • Measuring Flask
  • Scale ( Min. 0.1g)

Bulk Density Measuring apparatus


Bulk Density Measuring apparatus


Procedure


  1. Measure 120 ml of Blended Compound sample in to measuring flask. Make sure it doesn't contain air gaps.
  2. Add Measured sample in to the funnel of Bulk Density Measuring Apparatus. Make sure valve of funnel closed.
  3. Measure the weight of empty cup.  (M1)
  4. Setup empty cup with  Bulk Density Measuring Apparatus. Make sure is it center with funnel outlet.
  5. Open the valve to free flow the PVC compound.
  6. After completely flow, remove extra compound using flat plate ( C ) smoothly. Don't touch or hit the cup before removing extra compound.
  7. After that clean the surface of cup and get it's weight.  (M2)
  8. Then calculate Bulk Density using the formula given below.

Bulk Density formula









 V = 100ml






Thursday, August 9, 2012

Thermal Stability of Dry Blended PVC Compound

Test Method for Thermal Stability test of Dry Blended PVC Compound.


Instruments


Sample of Blended Compound
Glycerin Bath ( Heated to 200°C )
Test Tube
Glass Stopper
Glass rods
Piece of Congo Red
Test Tube Stand
Stop watch


Procedure


Setup all instruments following given image.

Test Method for Thermal Stability test of Dry Blended PVC Compound


The temperature of Glycerin Bath must be Constant. When you put sample added test tube in to the glycerin bath, immediately start the stop watch. Then wait until colour change of Congo red. When start colour changing, stop the stop watch and get the time. That's the time for Decomposition of PVC Compound.

Colour range of Congo Red






Colour range of Congo Red






Approximate pH range for color change : 3.0-5.0
Color of acid form : Blue
Color of base form : Red


So when PVC  Compound decomposed pH value will decrease (HCl gas content will increase). Then colour of Congo Red will change Red to Blue.






Monday, August 6, 2012

Identification of Polymers ( Simple Method )

Introduction


In our everyday life, we encounter many polymeric materials, many of which are in the form of disposable containers used for many household products. As our natural resources are diminished and our landfills become filled1, we are finding that it is better to recycle much of our waste materials than to dispose of them or burn them.

Most of the polymers we encounter in our daily lives are the six polymers listed in Table 1. To make recycling of these polymers easier, the plastics industry has adopted the codes shown. Since compliance in labeling is voluntary, not all plastics are labeled for identification. Identification, simply by appearance, is  difficult, however, there are a few types that are readily identifiable. Clear, colorless containers that are used for soft drinks are most often polyethylene terephthlate (PETE). Opaque, translucent (and often white in color) plastics used for containers such as milk cartons are usually high-density polyethylene (HDPE). Bottles used for shampoos or cleaning materials are usually made from polyvinyl chloride (V or PVC). Plastic bags and some plastic wrap is often made from low-density polyethylene (LPDE).

In this experiment, we will examine some common plastics and perform several tests to identify them. A flow chart for the tests is given below:






Materials Needed



  • Samples of resin pellets in vials labeled 1 through 6
  • 2 Unknown samples of plastics (These are in vials labeled 7 through 12)
  • Isopropyl alcohol solution, CH3CHOHCH3 , 45.5% by volume. This solution is made by diluting 45.5 ml isopropyl alcohol to 100 ml with water. (Also, by diluting 65 ml 70% isopropyl rubbing alcohol to 100 ml with water.)
  • Mazola corn oil
  • Copper wire
  • Corks to fit 18 mm test tubes
  • Acetone
  • Test tubes, 18 x 150 mm
  • Stirring rod, glass
  • Bunsen burner
  • Beaker, 50 ml
  • Beaker , 250 ml
  • Tongs or forceps
  • Ring stand and ring with wire gauze


Safety Precautions


Isopropyl alcohol is flammable and the vapors are considered to be toxic. Keep containers closed and cover any open containers, such as a beaker, with a watch glass. Avoid flames. Acetone is flammable and the vapors are considered toxic. Keep containers closed and cover any beakers of acetone with a watch glass. Work in a well ventilated area. Avoid flames. The copper wire will get hot when heated in a flame. Hold the wire with tongs or forceps to avoid burns.


Disposal


Dispose of alcohol waste and acetone waste according to local regulations. Mazola corn oil can be reused if it is not dirty or contaminated. Dispose of any waste oil according to local regulations. Waste pieces of plastic can be disposed in the trash. Copper wire can be reused.


Experimental Procedure


Obtain a set of vials containing the six kinds of recycled plastic resin pellets. Note that each type of resin is a different color. This allows for visual identification in this experiment. Actual resins may be almost any color depending on colorants added during its initial formulation.
.

The Water Test


Place approximately 5 ml of water in a test tube. Start with one of the six plastic resin pellets. Place two of the pellets of the resin in the test tube containing water. Poke the each of the pellets with a stirring rod to remove any air bubbles adhering to the surface of the resin pellet and try to make it sink. Note whether the pellets sink or float. If both pellets do not behave in the same manner, test a third pellet of the same type and
use the results of two that behaved the same way. Remove the pellets, dry them and save them for later use.
Repeat the water test with each of the remaining resin samples and with small pieces of the two unknown samples. Save the samples that sank in the water for the copper wire test. Use the samples that floated for
the isopropyl alcohol test.

The Isopropyl Alcohol Test


Place 5 ml of isopropyl alcohol solution in a test tube. Using one of the resins that floated in the water, add two pellets to the test tube containing the alcohol solution. Poke each pellet with a stirring rod to remove any air bubbles adhering to the surface of the resin pellet and try to make it sink. Note whether the pellets sink or float. If both pellets do not behave in the same manner, test a third pellet of the same type and use the results of two that behaved the same way. Remove the pellets, dry them and save them for later use. Repeat the isopropyl alcohol test with each of the remaining resin samples and unknowns that floated in the water.

The Oil Test


Place 5 ml of Mazola corn oil in a test tube. Using one of the resins that floated in the isoproply alcohol solution, add two pellets to the test tube containing the alcohol solution. Poke the pellets with a stirring rod to remove any air bubbles adhering to the surface of the resin pellets and try to make them sink. Note whether the pellets sink or float. If both pellets do not behave in the same manner, test a third pellet of the same type
and use the results of two that behaved the same way. Remove the pellets, dry them and save them for later use. Repeat the oil test with each of the remaining resin samples and unknowns that floated in the isopropyl alcohol.

Copper Wire Test


This test uses the plastic samples that sank in the water. (They were more dense than water.) Obtain a piece of copper wire about 5 cm long. Push one end of the wire into a small cork. (The cork is used as a handle so you are not touching a hot wire.) Place one pellet or plastic sample near your Bunsen burner. This is the sample you will be testing. Hold the free end of the copper wire in the burner flame until it is red hot and the flame no longer has a green color. Remove the wire from the flame and touch the hot wire to the plastic pellet or sample you will be testing. A small amount of the plastic should melt onto the wire. If the wire sticks to the plastic sample, use a pair of tongs to remove it. (You do not want to burn a large piece of plastic.) Place the end of the wire, with the small amount of plastic on it, into the flame. You should see a slight flash of a  luminous flame (a yellow-orange color). If the flame turns green in color, then the sample contains chlorine.
Repeat this test for each of the remaining plastic samples that sank in the water.

The Acetone Test


There should be a beaker of acetone located under the hood. If not, place about 10 ml of acetone in a 50 ml beaker. Work under a fume hood to minimize vapors in the room. For this test, use samples of plastics that did not give a green colored flame. Using tongs, place a pellet of the plastic in the acetone for 20 seconds. Remove the pellet and press firmly between your fingers. A positive reaction has occurred if the polymer sample is soft and sticky. Scrape the sample with your fingernail to see if the outer layer has softened. If the sample has a positive reaction, discard it in the trash as the conclusion of this test. Repeat this test for each of the remaining plastic samples that did not give a green colored flame.

The Heat Test


Place approximately 100 ml of water in a 250-mL beaker and heat to boiling. For this test, use the samples of plastics that did not have a positive acetone test. Using tongs, place a pellet of the plastic in the boiling water for 30 seconds. Remove the pellet and press it between your fingers to see if it has softened. A  positive reaction has occurred if the polymer sample is softened. If the sample has a positive reaction, discard it in the trash as the conclusion of this test. Repeat this test for each of the remaining plastic samples that did not have a positive acetone test.






Sunday, August 5, 2012

First Step to uPVC Industries

Welcome to our Extrusion Tutorial Website.


This is a most useful website for beginners of self employment in PVC manufacturing.In this site, you can get various information about processing and manufacturing.

You can get small idea about PVC product manufacturing process from following image.





If you wish to improve your manufacturing process to Industrial manufacturing process, you must follow some standard like ISO or any standard that using to PVC manufacturing.

Every department must have Quality Controlling System. Quality Control Department must verify the product and issue a QC Certificate before it store.

After that, Quality Assurance Department must get samples of product and test the product. Then give Quality Assurance Certificate and product is ready to market.