Testing & Quality Control inPlastics Processing Industry With the advent of Science and Technology, the concept

of testingis an integral part of research and development, product designand manufacturing. Why we need testing? To prove design concepts To prove a basis for reliability Safety

 Protection against product liability suits Quality Control To meet Standards and Specifications To verify the manufacturing process To evaluate competitors products To establish a history for new materials QUALITY Degree to a set of inherent Characteristicfulfils Requirement TESTING Testing yields basic information about a Plastic, its propertiesrelative to another material and its quality in reference to astandard. TEST METHOD A definitive procedure for the identification, measurement andevaluation of one or more qualities, characteristics or propertiesof a material, product, system or service that produces a testresult. SPECIFICATIONS AND STANDARDS A specification for a plastic material involves definingparticular requirement in terms of density tensilestrength and other related properties . A standard is something established for use as abasis of comparison in measuring capacity, quantity,content, extent, value, quality etc. The ultimate purpose of the standards is to develop acommon language, so that there can be no confusionamong the developers, designers, fabricators, end-users and other concerned parties . BENEFITS OF STANDARDSIZATION Improved efficiency Mass production Superior quality goods through uniformity and newchallenges International trade Technical exchanges and establishment of commonmarkets INTERNATIONAL STANDARD ORGANISATION(ISO) ISO was established for the purpose of InternationalStandardization.

 It is a National Standard bodies of over 90 countries around theworld.Standard methods of test and evaluation commonly provide thebasis of measurement required in the specification for needed ordesired propertiesSpecification is intended to ensure batch-to-batch uniformity aswell as remove confusion between the purchaser and supplier CLASSIFICATION OF PROPERTIES Mechanical Properties Thermal Properties Electrical Properties Optical Properties Permanence Properties Product Testing TESTING OF UPVC PIPES FOR POTABLEWATER SUPPLIESIS: 4985 : 2000 Dimension Visual Appearance Opacity Effect on water Reversion Hydrostatic Pressure Test Impact at 0 o C Vicat Softening Temperature Density Sulphated ash content DIMENSION MEASUREMENT - OUTSIDE DIAMETER AIM:To determine the dimension of plastic pipe as per the standardsand to ensure the standard dimension.APPARATUS REQUIRED :Vernier Caliper, Pi-tapeSTANDARD :IS: 4985 - 2000TEST SPECIMEN :PVC PipeNO. OF SPECIMENS :Six specimens of each lot of the each gradePROCEDURE :Place the vernier caliper to theperpendicular axis of pipe andtake measurement from sixdifferent places and note the readings.EXPRESSION OFTEST RESULTS:Rounded off the readings obtained tonearest 0.1 mm. WALL THICKNESS - MEASUREMENT AIM :To ensure the wall thickness of the plastic pipe product asper the test standard.APPARATUS REQUIRED :Ball Ended Micrometre (RequiredPrecision 0.05 mm)NO. OF SPECIMEN :FiveTEST STANDARD :IS: 4985 - 2000TEST PROCEDURE :Place the Micrometre between the wallthickness

of the specimen and takemeasurement from six different places.EXPRESSION OFTHE RESULTS :Rounded off the readingobtained to the nearest 0.1mm REVERSION TEST SAMPLE :PVC PIPESAMPLE MANUFACTURING PROCESS: EXTRUSION METHOD AND SPECIFICATION Sample Specimen Size (Length mm) Oil Temperature o CPVC Pipe 200 150 +/- 2Specimen Placed (Position) Vertical Thickness (mm) Duration (min)1 to 8.5 60Over 8.6 up to 14.0 120Over 14.1 140GENERAL CONDITIONING: Condition the test specimen at 23 + 2 o C and 50 + 5 %relative humidity for not less than 40 hours prior to test in accordance withASTM 618 for these test. PROCEDURE SPECIMEN PREPARATION:A pipe shall be cut according tospecified length as per above chart.CIRCUMFERENTIAL MARKS:Shall be scribed on thespecimen 100 mm and in such a way that one of these marks isapproximately 15 mm from one end of the specimen.MEASURING DEVICES:Vernier Caliper (0.02 mm accuracy)APPARATUS :Hot oil batch (150 + 2 o C) TEST CONDITION: The Oil bath has to be maintained the temperatureaccording to the specified requirement and then the test specimen shall beplaced in the Oil bath as specified position and duration.(as per above chart)After specified duration the specimen shall be removed from the bath andallowed to cool to room temperature. The distance between the scribed marksshall be measured along the surface of the pipe and the % of change in lengthto be calculated. CALCULATION: % Longitudinal Reversion = Change in length x100Original lengthChange in length = L I -L F L I = Initial LengthL F = Final LengthReversion (%) = L I -L F x 100L I REPORT : Express the results in % of Longitudinal Reversion HYDROSTATIC PRESSURE TEST AIM :To evaluate the time-to-failure of plastic pipe under constantinternal pressure.HOOP STRESS: Hoop stress is defined as the circumferential stress in amaterial of cylindrical form subjected to internal or externalpressure.EQUIPMENT:Constant temperature system, pressuring system,pressure gauges, time device, specimen and itsenclosure.SPECIMEN

REQUIRED:10 times of its dia of pipe (or) 750 mm max.CONDITIONING:Test specimens are pre-conditioned at 23 + 2 o C and50 + 5 % relative humidity for not less than 40 hours.Prior to test in accordance with ASTM D 618 for thesetests, where conditioning is required. In case ofdisagreements, the tolerance shall + 1 o C and + 2% relativehumidity. PROCEDURE Connect end closures to the pipe ends and fill each specimen completelywith the test fluid conditioned to the test temperature.Connect the specimens to the pressure device, ensuring no gas isentrapped when using liquids.Immerse the test specimens in the conditioned medium then apply thepressure to the specimen.Record the time-to-failure of each specimens.T e s tT e s tT e s tT e s t temperature duration pressure o C (Hours) MPaType Test 60 1000 1.16 * PN(MPa)Acceptance Test 27 1 4.19 * PN(MPa)Where: PN WORKING PRESSURE EFFECT ON WATER AIM :To determine the effect on water test for rigid PVCPipes.SIGNIFICANCE:The test is used to find out the determental effect onthe composition of the water flowing through the PVCPipes.STANDARD:IS: 4985 - 2000TEST EQUIPMENTS:Water circulating system,Atomic Absorption Spectrometer (AAS)Inductively Coupled Plasma Spectrometer (ICP)SPECIMEN PREPARATION:Cut the UPVC Pipe of 300 mm lengthTEST CONDITION:Lab atmosphere of 23 + 2 o C & 50 + 5 %relative humidity.NO. OF SPECIMEN:Three PROCEDURE (1 st Extration) The test pipe samples are to be connected with a circulated water tank whichwill pass water through pipe continuously for 6 hours. By circulating the water,inner surface of the pipe will be changed. After cleaning, the test pipes has to be filled with distilled water for 48 hours.After the completion of 48 hours, the extracted water has to be analyzed byAAS / ICP as evaluated the results as per IS: 4985 - 2000 and the maximum limitshall be noted. The maximum permissible limit shall be as follows: Extraction shall be repeated II & III timeI. Lead (1 st extraction) :1.000 ppmThe experiment should be repeated for II & III extraction andresults should be with in the following limits :II. Lead (Third Extraction) :0.300 ppmIII. Dialkyl / tin C 4 and higher homologues measured for third extractions0.020 ppmIV. Cadmium for all three extracts:0.001 ppmV. Mercury for all three extracts :0.001 ppm OPACITY OF PLASTIC PIPES & FITTINGS STANDARD:IS: 4985/IS: 12235 (Part - 3) 1986SAMPLE:PVC PipesPRINCIPLE:Measurement of the light flux passing through atest piece, cut from a pipe & fittingTEST APPARATUS: Opacity Tester, Adjustable Power Arc,Diaphragm and Optical Lenses and Sample HolderTEST PIECE:Take

section of convenient length from the pipe ofsample of suitable dimensions and originalthickness of the product.NO. OF SPECIMENS:Minimum 3 cut pieces is required for testingGENERAL CONDITIONING:Condition the test specimen at 23 + 2 o C and50 + 5 % Relative humidity for not less than 40 hours prior to test inaccordance with ASTM D 618 for these tests PROCEDURE: Switch on the equipment Check that the equipment indicates at zero in the absence oflight. Ensure that the photoelectric cell is protected from incidentdaylight. Check that the indicators reach 100 % in the light emitted by theluminous sources in the absence of test peace. Check the precision of the reading using standards lenses thatgives an absorption percent of about 0.2 %. Check the alignment of installation. MEASUREMENT: Adjust the apparatus to obtain a maximum reading carefully arranging thelight sensor in such a way that it receives the maximum light flux. Place the test piece on the support and position. The whole ensuring thatthe test piece is centered and perpendicular to light beam. Reach the indicated maximum deviation produced by the light beam. Thisdeviation corresponds to the light flux which was passed through wall of thetest piece. CALCULATION: Calculate the % of light which has passed through thewall of the test piece using following formula:D x 100DmWhere D = Maximum deviation produced by the light flux from thesource which was passed through the wall of the test piece.Dm = Maximum deflection produced directly by the light from thesource. TEST REPORT: The test report shall indicate the % of light that passedthrough the wall of the test piece. IMPACT RESISTANCE SAMPLEPipeEQUIPMENTFalling Impact Test EquipmentClimatic Chamber - 40 to + 100 o CMEASURING DEVICESSteel RuleSTANDARDIS: 4985 - 2000/IS: 12235 (Part9) - 86IS: 12818GENERAL CONDITIONINGCondition the test specimen at23 + 2 o C & 50 + 5 % RelativeHumidity for not less than 40 hours.SPECIFIED TABLEMean outside diameter Total Mass of the striker Height of free fall(mm) (gm) (mm)Up to 25 250 500 + 1032 to 50 250 1000 + 1063 to 75 250 2000 + 1090 to 110 500 2000 + 10125 and above 1000 2000 + 10 SPECIMEN PREPARATIONPrepare Test Specimen by cutting its length shall be200 + 10 mmCONDITIONING Specimens are conditioned at 0 o C in a ClimaticChamber for the Impact Test.

 Set at 0 o C by adjusting the temperature controller. After stabilize the temp 0 o C keep the test specimen inthe Climatic Chamber for 1 hour. Then each testspecimens are subjected to impact resistance test. VICAT SOFTENING POINTWhen tested by the method prescribed in IS: 6307, the Vicat SofteningTemperature of the specimen shall not be less than 80 o CDENSITYWhen determined in accordance with IS: 1336 Part 3, the density ofpipe shall be between 1.40 to 1.46SULPHATED ASH CONTENTSTANDARD : IS: 4985 (ANNEX B)REAGENTS : SULPHURIC ACIDAPPARATUS : silica (or) platinum crucibleanalytical balance, Bunsenburner & muffle furnace PROCEDURE Prepare the cruicible by heating at 850 + 10 o C after cooling in a dessicatorweigh to the nearest 0.1 mg (M1) Take 2 to 5 g of the sample and reweigh to the nearest 0.1 mg (M2) Heat the sample till burned by using a burner. Then add concentration H 2 SO 4 slowlytill all the black sample get wet properly and haet it again slowly till became dry Place the crucible in the muffle furnace at 850 + 10 o C for 30 minutes. Remove the cruicible from the furnace, cool it for at least one hour and weigh it (M3)Expression of ResultsSulphated Ash Content(%) by Mass = M3 - M1 * 100M2 - M1M1 = Mass of crucibleM2 = Mass of crucible and test portion sample andM3 = Mass of crucible and residue The Sulphated Ash Content in the pipe shall not exceed 11 percent. UPVC SCREEN AND CASING PIPES FORBORE / TUBEWELL STANDARDIS: 12818 - 1992 (INCL. AMED 1995)TERMINOLOGYDesignation Ribbed Screen Pipes Plain Screen Pipes Casing PipeRibbed Screen PipesThe Pipe used with external longitudinal ribs and transverseslots. This shall be designated as "RS"Plain Screen PipePlain surface pipe with transverse slots. This shall bedesignated as "PS"Casing PipeCasing pipes Classified as:Casing shallowCasing Medium. These pipes are designated as "CS" & "CM

Casing Shallow Pipe suitable for well with up to 80m depth Casing Medium suitable for well with up to 250m depth. TESTING Colour The Pipe colour shall be blue through the length. Slightcolour deviation is permissible.DimensionsScreen Pipes with RibsOutside diameter (d)Outside diameterOver Connection (ds)Wall thicknessUnder (Ribs) (s)Length of PipesEffective lengthSegmental lengthRibsMinimum numbers of ribs per centimeter is "three" Segmental Length Spigot length Socket length Segmental length (Screen Portion) Dimensions of Casting Pipes (CM/CS)Outside diameter (d)Outer side diameter (ds)Over ConnectionWall thickness (s)Dimensions of Trapezoidal threadsDimensions of Sealing ElementVisual AppearancePipe surface (Internal, External) shall be inspected for itssmoothness.Test for Internal DiaTest Mandrel of diameter as specified and of 100 mmlength pass smoothly through the pipe.Dia of Mandrel will vary according to dia of pipe. Specific GravityThe limit of Material shall be 1.40 - 1.45 g/cm 3 (IS: 8543 pt 1)Impact Strength at 0 o CThe Pipe sample shall not fracture/Crack through its complete wallthickness. The mass of striker and height shall be as follows:Nominal diameter Mass of Striker Height of free fall(mm) (Kg) (mm)40 0.25 1000 + 1050 0.25 2000 + 1080 and 100 0.50 2000 + 10125 above 1.00 2000 + 10 Tensile Strength Tensile strength at break shall be determined as per the IS: 8543 (pt 4: 84)Minimum Tensile strength required - 45 MPa Vicat Softening Temperature The vicat softening temperature shall not be less than 76 o C as per IS: 6307- 85. Effect on water The Pipe shall not change effect of composition of water flowing through them. The testis carried out as per IS: 4985 - 2000. The Toxicity limit shall be as follows:Lead I (Ext)1.000 ppm Lead III (Ext)0.300 ppmCD (All three)0.020 ppmHG (All three)0.001 ppmSN (All three)0.001 ppm TESTING OF HDPE PIPESFOR WATER SUPPLY IS : 4984 - 1995 Designation Grade of Material Internal Pressure Rating Nominal Diameter (OD) Example .PE63PN10DN200 PE-63 - Min. Required Strength of the Material inMPa. At 20

C for 50 Years PN-10 - Max. Working Pressure 1.00 MPa DN-200 - Out Side Nominal Diameter 200 mm.OD - 16 to 1000 mm Material Grade & PressureRating Of Pipes Material GradeRequired Strength (MPa)PE - 63 6.30PE - 80 8.00PE - 100 10.00Pressure RatingMax. PermissibleWorking Pressure (MPa)PN 2.5 0.25PN 4.0 0.40PN 6.0 0.60PN 10.0 1.00PN 12.5 1.25PN 16.0 1.60 Colour The Colour of the pipe shall be Black Equi-spaced longitudinal strips of width (Min 3mm) anddepth (Max. 0.2 mm) Blue in colour of sameCompound Material Nature of MaterialMFI at 190 C/5.0 Kg Load:HDPE:0.2 to 1.1 gm/10 min. :2.50 0.50 % DensityCarbon Black ContentCarbon Black Dispersion:940.0 to 958.0 kg/m 3 : Satisfactory Product Testing OD, Ovality & Wall Thickness Vernier Calliper Up to 110 mm Dia Pi Tape more then 110mm Dia ODWall ThicknessBall Ended Micro meter Ovality Difference in Max. OD and Min. OD Visual Appearance External and Internal Surface shall be Smooth, Clean, Freefrom Grooving and Other defects. Cut edge - Cleaning cut andSquare with axis of the pipes Performance Requirements Hydraulics Characteristic : Ten times of OD not less then 250 and not greaterthen 750 mmSpecimen Size Pressure = ------------2

i sd-s Where : i = Induced Stress in MPas = Min. Wall Thickness in mmd = OD of the pipe in mm T e s t Temp( C) Induced Stress( i) Mpa PE - 63 PE - 80 PE - 100T y p eT e s t 80165 3.54.65.5Acceptance Test8048 3.8 4.95.7Induced Stress( i) MPaT e s t T e s t T e m p ( o C)T e s t Duration(Hrs) Reversion Test Specimen Size: 200 mm Length 3 cut PiecesMeasuring Length: 100 mm Distance between two marks equidistanceon the circumference of the PipeOven Temperature:1 1 0 2 C Over All Migration Test Specification - IS:10146 - 1987 - With in 60 ppm or 10 mg/dm 2 Test Method - IS:9845 - 1986 - With Water at 40 C for 240 HrsWall Thickness (mm)T e s tT e m p .( 0 C) Test Duration (min)Up to 8 110 +/- 260 +/- 1Over 8 up to 16 110 +/- 2120 +/- 2Over 16110 +/2240 +/- 5