Professional Documents
Culture Documents
(7 TANK PROCESS).
1. After visual inspection of black material lift the material with the help of crane.
2. Dip the material in degreasing bath. Lift after 10-15 minutes & drain out the
entire chemical & again dip for 5 min.
3. Lift the material from degreasing bath & dip in water bath for flush dipping. Then
send for pickling.
4. After degreasing dip the material in pickling bath for 10-15 min. Lift the material
& drain out the chemical & dip again for 5 min. & remove the black scale from
the upper layer of HCL bath with the help of strainer.
5. Remove the material from pickling bath & dip in two water rinsing tanks for flush
cleaning.
6. Remove the material from two water rinsing tanks & dip in flux bath at 60 to 80
0
C for material surface free from oxide.
7. Remove the material from flux bath & spread on hot plate for drying.
8. After material is dried completely then dip the material in molten zinc bath as
per required zinc coating & check the temperature & record. (i. e. bath temp. is
440 to 460 0C )
9. Remove the material from zinc bath & drain out the full molten zinc from the
material & dip in quenching bath.
11. Send the material for finishing i.e. to removing lumps, black spots, pimples etc
12. The chemical bath shall be monitored / discard as per instruction & record in
bath history sheet.
8. Take 10ml solution in conical flask. Add 2-4 drops of Methyl Orange indicator.
9. Titrate with 1 N H2SO4 solution to get end point yellow to pink. Note Burette
reading.
8. Take 25 ml bath solution in 250 ml standard flask & make up with distilled.
Water up to 250 ml.
9. Take 25 ml allocate solution in flask. Titrate with 0.5N Na2CO3 solution using
methyl orange indicator to get yellow end point. Note Burette reading.
4. Add 200 to 400 g/lit Zinc Ammonium Chloride chemical in Flux bath slowly
with continuous mixing.
5. Add additive Flag-500 20 lit. Chemical in Flux bath slowly with continuous
mixing.
8. Take 10 ml Sample dilute with 50ml water. Add 2-4 drops of Phenolphthalein
indicator.
9. Titrate with 1NNaOH solution to get dark wine red end point. Note Burette
reading.
3. Take raw water up to the overflow level if required in cleaned Acid Rinse
Tank No.1.
3. Take raw water up to the overflow level if required in cleaned Acid Rinse
Tank No.2.
1. Corolin MHX:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots & goggles & mask)
Caution: - If chemical comes in contact with Skin / eye wash with large
amount of Water & obtain medical attention if required.
2. Hydrochloric Acid:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots & goggles & mask)
Caution: - If chemical comes in contact with Skin / eye wash with large
amount of water & obtain medical attention if required.
3. Zinc Chloride:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots & goggles & mask)
Caution :- Chemicals are zinc base dont take internally & If chemical
comes in contact
With Skin / eye wash with large amount of water & obtain medical
attention if required.
4. Ammonium Chloride:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots &goggles & mask)
Caution: - If chemical comes in contact with Skin / eye wash with large
amount of Water & obtain medical attention if required.
5. Sodium Dichromate:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots & goggles & mask)
Caution: Chemicals are alkaline .Dont take internally. Avoid contact with
eye. If required obtain medical attention if required.
6. Caustic:
Precautions :- During handling chemicals (use rubber hand gloves, gum
boots & goggles & mask)
Caution: - If chemical comes in contact with Skin / eye wash with large
amount of Water & obtain medical attention if required.
5. Titrate this solution against N/10 KMnO4 solution. To get pink end point
(persist for 10 - 20 second). Note burette reading.
7. Take 20ml of Flux solution in 250ml Conical Flask. Add 100ml distilled water;
add 3 to 4 drops of Methyl Orange indicator solution mix well.
1) Measure 200 ml of Sodium Dichromate bath solution into a 500ml beaker and add 50ml
distilled water.
2) Transfer 25ml of this solution to a 250ml glass stoppered flask, add 10ml of 20% Potassium
Iodide and 10ml Hydrochloric Acid 30 to 32% and allow to stand in dark for 10mins.
3) Add about 200ml distilled water and titrate with N/10 Sodium Thiosulphate using two three
drops of Starch Mucilage or Starch Indicator, added towards the end of titrations indicator.
The end point will be color disappear.
4) Calculations:
2) 20% of Potassium Iodide Take 40 grams of Potassium Iodide powder and add 200ml
distilled water.
3) Starch Mucilage Indicator Take 0.5 gram Starch Mucilage powder and add 100 ml of
distilled water.
2. 0.1 N NaOH: - TAKE 2gm SOLID NaOH IN 500ml VOLUMETRIC FLASK. ADD
DISTILED WATER UP TO THE 500ml MARK. STOPPER THE FLASK & MIX
THOROUGHLY.
BY USING AMPOULES;
1. 1 N NaOH: CUT THE N/1 AMPOULE ON THE TOP TO PREVENT IT FROM FALLI
NG. POUR THE CONTENTS OF AMPOULE IN TO 500ml VOLUMETRIC FLASK.
RINSE THE AMPOULE & CAP CAREFULLY WITH DISTILLED WATER & AAD THE
RINSINGS TO THE FLASK. MAKE UP WITH DISTILLED WATER TO 500ml.
STOPPER THE FLASK & MIX THOROUGHLY.
2. 0.1 N NaOH: CUT THE N/10 AMPOULE ON THE TOP TO PREVENT IT FROM
FALLI NG. POUR THE CONTENTS OF AMPOULE IN TO 500ml VOLUMETRIC FLASK.
RINSE THE AMPOULE & CAP CAREFULLY WITH DISTILLED WATER & AAD THE
RINSINGS TO THE FLASK. MAKE UP WITH DISTILLED WATER TO 500ml.
STOPPER THE FLASK & MIX THOROUGHLY.
4. 0.1 N SULPHURIC ACID: CUT THE N/10 AMPOULE ON THE TOP TO PREVENT IT
FROM FALLI NG. POUR THE CONTENTS OF AMPOULE IN TO 500ml VOLUMETRIC
FLASK. RINSE THE AMPOULE & CAP CAREFULLY WITH DISTILLED WATER & AAD
THE RINSINGS TO THE FLASK. MAKE UP WITH DISTILLED WATER TO 500ml.
STOPPER THE FLASK & MIX THOROUGHLY.
5. 0.1 N HCL: CUT THE N/10 AMPOULE ON THE TOP TO PREVENT IT FROM FALLI
NG. POUR THE CONTENTS OF AMPOULE IN TO 500ml VOLUMETRIC FLASK.
RINSE THE AMPOULE & CAP CAREFULLY WITH DISTILLED WATER & AAD THE
RINSINGS TO THE FLASK. MAKE UP WITH DISTILLED WATER TO 500ml.
STOPPER THE FLASK & MIX THOROUGHLY.
1. Remove the oil layer from degreasing tank. (On the surface of degreasing
solution).
2. Lift the material with the help of crane from material (Lots) storage.
6. Hold the material in tilt condition for complete removal of degreasing solution.
8. After completion of dip time lift the material from degreasing solution.
9. Hold the lot in tilt condition for complete removal of degreasing solution.
2. After dipping check the air locking & complete material spreading.
1. Remove the black carbon soot from pickling tank. (On the surface of
acid layer).
8. Hold the material in tilt condition for complete removal of acid from
surface.
1. Check the water addition overflow (in acid rinse no. 1 tank) & adjust water flow
to maintain pH within range.
2. After completion of pickling process dip the material in acid rinse 1 tank.
4. Lift the material from acid rinse no. 1tank in tilt condition from one end.
7. Lift the material from acid rinse 1 tank in tilt condition for removal of water.
8. After acid rinse 1 process transfer the material for further process.
(Further process is acid rinse no. 2).
1. After completion of acid rinse 1 process dip the material in acid rinse no.2 tank.
6. Lift the material from acid rinse no. 2 tank in tilt condition for removal of water.
7. After acid rinse 2 process transfer the material for further process.
1. After completion of acid rinse 2 process dip the material in flux tank.
1. After completion of fluxing then place the material for proper drying.
3. Lift the material from hot drying plate for further process.
(Further process is Galvanizing).
1. After completion of hot drying process dip the material in zinc bath
(Galvanizing).
3. Dip the lot in zinc bath for 2 4 minute (or stop the boiling action) OR as per
requirement of zinc coating.
4. After completion of dip time lift the material from zinc bath in tilt condition.
6. After Galvanizing (zinc bath) process transfer the material for further process.
(Further process is Quenching).
1. Check the water addition overflow (in quenching tank) & adjust water flow to
maintain temperature within range.
4. Lift the lot from quenching tank in tilt condition from one end for removal of
water.
3. Lift the lot from Di-chromating tank in tilt condition from one end for
removal of solution.
Burette Calibration:
10.Take water in calibrated burette up to the marking level & transfer in uncalibrated
burette.
12.If calibrated burette reading & uncalibrated burette reading are same then the
burette is calibrated.
Pipette Calibration:
4. If calibrated pipette reading & uncalibrated pipette reading are same then the
pipette is calibrated.
1. The hammer used shall conform as per drawing mention in IS 2629 (6.4.1).
2. The hammer blow shall be controlled by holding the pivoted base of the
handle on a horizontal surface.
3. Allow the hammer head to swing freely through an arc from vertical position
to strike the horizontal surface.
4. Repeat this test two or more times with 6mm spacing in a same angle
(i.e.90 deg.).
5. If zinc coating between 6mm distance is not removed then zinc coating is ok.
1. Take 36g of technical grade copper sulphate dissolve in 100ml distilled water.
2. Neutralize the free sulphuric acid in solution by shaking with copper carbonate OR
copper hydroxide (about 1gram/lit) & allow to stand for at least 24 hours.
3. The specific gravity of the test solution during the test shall be 1.186 at 18 (+/-
20C).
1. Check the specific gravity (1.186) & temperature (180C +/-20C) of the copper
sulphate solution.
2. Immerse the test pieces in copper sulphate solution without touch each other.
3. After each dip, withdraw the test pieces & rinse immediately in clean running water
(temperature of the rinse water should be 15 to 200C).
4. Wipe & dry the test pieces with a clean soft cloth & return immediately to solution.
6. When the test pieces is finally rinsed & wiped dry, it does not show any adherent
red deposit of copper upon the base metal.
2. To clean the test pieces by pickling (i.e. to remove zinc coating) after that rinsing
& drying.
4. Subtract the first mass from the second mass (i.e. M1- M2.).
5. Now dividing the result by the surface area of the test pieces.
FOR EXAMPLE
Take 162 X 25 X 6
Length = 162mm Galvanized weight=232 gram (M1)
Width = 25mm
Thickness = 6mm Black weight=216 gram (M2)
= 10344mm
=10344/1000000 = 0.010344 m2
= 16 gram.
= 1547 gram/m2