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(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.
9.
10.
HCL gm/lit
B. R. x 0.5 x 36.5
2.5
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.
10.
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:
1ml of N/10 Sodium Thiosulphate = 0.004367 gm of Sodium Thiosulphate
Result :
% of Sodium Dichromate =
10 x X x 0.004367
2
% of Sodium Dichromate = xml X 0.021835
1) Purity of Potassium Iodide (KI) = 99 to 100 %
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.
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.
3. 0.1 N POTASSIUM PERMANGNATE: 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.
3. Dip the material in degreasing tank.
4. After dipping complete material spreading.
5. Immediate lift the material from degreasing tank in tilt condition.
6. Hold the material in tilt condition for complete removal of degreasing solution.
7. Once again dip the material in degreasing tank for 10 20 min.
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.
10. Ensure material surface is free from grease & oil.
11. If material found ok then proceed further.
(Further process is degreasing rinse).
1. Remove the black carbon soot from pickling tank. (On the surface of
acid layer).
2. Lift the degreasing material with the help of crane.
3. Dip the material in acid.
4. After dipping check the complete material spreading.
5. Immediate lift the material from pickling tank.
6. Once again dip the material in acid tank for 10 20 min.
7. After completion of dip time lift the material.
8. Hold the material in tilt condition for complete removal of acid from
surface.
9. Ensure material surface is free from rust.
10. If material found ok then proceed further.
(Further process is Acid rinse 1).
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.
3. After dipping check the complete material spreading.
4. Lift the material from acid rinse no. 1tank in tilt condition from one end.
5. Once again dip the material in acid rinse 1 tank.
6. After dipping check the complete material spreading.
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.
2. After dipping check the complete material spreading.
3. Lift the material from acid rinse 2 tank in tilt condition.
4. Once again dip the material in acid rinse no.2 tank.
5. After dipping check the complete material spreading.
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.
2. After dipping check the complete material spreading.
3. Lift the material from flux tank in tilt condition.
4. After fluxing process transfer the lot for further process.
(Further process is drying).
1. After completion of fluxing then place the material for proper drying.
2. After complete drying the material.
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).
2. After dipping check the complete material dipping.
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.
5. Hold the material in tilt condition for complete removal zinc.
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.
2. After completion of Galvanizing process dip the lot in quenching tank.
3. After dipping check the complete lot dips in quenching tank.
4. Lift the lot from quenching tank in tilt condition from one end for removal of
water.
5. After quenching process transfer the lot for further process.
(Further process is Di-chromating).
Burette Calibration:
1. Take 0.1N NaOH in Calibrated burette.
2. Take 10ml 0.1N H2So4 solution in conical flask.
3. Add 2 3 drops of phenolphthalein indicator.
OR
12. If calibrated burette reading & uncalibrated burette reading are same then
the
burette is calibrated.
Pipette Calibration:
1. Take water in calibrated pipette up to the marking level.
2. Transfer calibrated pipette water in uncalibrated pipette.
3. See the water level of uncalibrated pipette.
4. If calibrated pipette reading & uncalibrated pipette reading are same then the
pipette is calibrated.
Mass (M)
Surface area
i.e.
16
0.01034
= 1547 gram/m2
SR
No.
STANDARD TIME
MAX TIME
(FOR 86
MIC)
MIN
MAX
MAX TIME
(FOR 120 MIC)
PROCESS
LOADING POINT TO PICKLING
TANK
10
20
15
15
10
20
15
15
10
20
15
15
10
10
10
10
10
11
12
13
14
38
52
45
43