Work Instruction For Galvanizing Plant (7 Tank Process) .: WI No.: HY/WI/01 Rev. No Eff. Date

WI No.
: HY/WI/01
WORK INSTRUCTION FOR
GALVANIZING PLANT Rev. No
(7 TANK PROCESS). Eff. Date :
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
0C 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.
10. After quenching then dip the material in chromating 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.
PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

WI No.: HY/WI/02
DEGREASING BATH Rev. No :
PREPARATION. Eff. Date :
1. Transfer all the old solution in ETP for further treatment.
2. Clean the tank carefully with fresh water.
3. Take 15000 Liter Raw Water in cleaned degreasing tank.
4. Add 3000 lit METACLIN-GP in degreasing bath slowly with continues

mixing.
5. Mix solution manually to dissolve all liquid if remaining.
6. Take Bath Sample For Analysis.
7. Take 10ml solution in 100ml measuring cylinder & to add 90 ml distilled water
to make 100 ml.
8. To take 10 ml allocate solution in conical flask & add 5-46drops of Methyl

Orange indicator.
9. Titrate with 0.1 N NaOH solution to get end point pink to yellow. Note Burette
reading.
10. Burette reading = Total acidity.( 17 – 18 ml)
11.Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

(Format No- HY/QA/01)
12.Do bath analysis as per GALVANIZING PROCESS PARAMETERS

(Format No- HY/QA/01) i.e. once a day.

WI No.: HY/WI/03
WORK INSTRUCTION FOR Rev. No :
ACID BATH PREPARATION.
Eff. Date :
3. Take 7000 Ltr Raw Water in cleaned pickling tank.
4. Add 8000 Liter 30 - 35 % commercial HCL in pickling bath.
5. Add 3 - 5 Liter of Acid Inhibitor In Above Bath.
6. Mix solution manually to mix the chemicals.
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.
10. HCL gm/lit B. R. x 0.5 x 36.5

=
2.5


WI No.: HY/WI/04
FLUX BATH PREPARATION.
Eff. Date :
3. Take 8,000 Ltr. Raw Water in cleaned Flux tank.
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.
6. Mix solution manually to dissolve the solids if remaining.
8. To check the specific gravity. It should be 1.11 to 1.16 g/ml.
9. Maintain the bath temperature 60 to 80 0C.
10. Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

11. Do bath analysis as per GALVANIZING PROCESS PARAMETERS


WI No.: HY/WI/05
ZINC BATH PREPARATION.
Eff. Date :
1. Take 8000 Kg Lead (Zn-Pb) to spread at the bottom of the Zinc bath.
2. Now spread 108 MT Zinc (not less than 99.99% mass of zinc) on Lead.
3. Now start heating up to Zinc melt i.e. 4400C to 4600C.



WI No.: HY/WI/06
DI-CHROMATE BATH Rev. No :
3. Take 16,000 Ltr Raw Water in cleaned Di-chromating bath.
4. Add 150 kg 1% Sodium di-chromate in Di-chromating bath slowly with

continues mixing.
5. Add 5 lit ½% of Sulfuric Acid in Di-chromating bath.
6. Mix solution manually to dissolved solids if remaining.
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.
10. Burette reading = Total alkalinity.



WI No.: HY/WI/07
DEGREASING RINSE Rev. No :
2. Clean the tank with fresh water.
3. Take raw water in cleaned tank up to the overflow level.
4. Check the pH of water.
5. Start using water for washing.


WI No.: HY/WI/08
ACID RINSE No.1 Rev. No :
3. Take raw water up to the overflow level if required in cleaned Acid Rinse
Tank No.1.


WI No.: HY/WI/09
WORK INSTRUCTION FOR ACID Rev. No :
RINSE No.2 PREPARATION.
Eff. Date :
3. Take raw water up to the overflow level if required in cleaned Acid Rinse
Tank No.2.


WI No.: HY/WI/10
QUENCHING PREPARATION.
Eff. Date :
1. Transfer all the old water from quenching tank to ETP.
3. Add raw water up to the overflow level in quenching tank.
4. Start using water for Quenching.

WI No.: HY/WI/11
HANDELING OF CHEMICALS.
Eff. Date :
1. Metaclin GP:
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:
amount of water & obtain medical attention if required.
3. Platinum Flux NI Base:

Caution :- Chemicals are zinc base don’t take internally & If chemical
comes in contact
With Skin / eye wash with large amount of water & obtain medical
attention if required.
4. Ammonium Chloride:
boots &goggles & mask)
5. Sodium Dichromate:
Caution: Chemicals are alkaline .Don’t take internally. Avoid contact with
eye. If required obtain medical attention if required.
6. Caustic:

WI No.: HY/WI/12
DEGREASING BATH Rev. No :
ANALYSIS. Eff. Date :
1. Wash required apparatus with fresh water.
2. Collect bath sample in beaker.
3. Take 0.1N NaOH solution in burette.
4. Take 10 ml bath sample in 100 ml measuring cylinder & add 90 ml distilled

water in it to male 100 ml solution.
5. Take the 10 ml allocate solution in 250 ml conical flask & add 4 - 5 drops of
methyl orange indicator.
6. Titrate this solution against 0.1N NaOH solution.
7. To get yellow end point. Note the burette reading.
8. Total Acidity = Burette Reading.
9. Maintain the parameters as per specification (Specification= 17 – 18 ml).


WI No.: HY/WI/13
ACID BATH ANALYSIS.
Eff. Date :

For HCL gms/lit.

3. Take 0.5N Sodium carbonate solution in burette.
4. Take 25 ml previously filtered sample in 250 ml measuring cylinder & make up to
250ml with DM/ water mix thoroughly.
5. Take 25ml allocate solution in conical flask. Add few drops of methyl orange
indicator.
6. Titrate this solution against 0.5N Sodium carbonate solution. To get yellow end
point. Note burette reading.
7. HCL gm/lit = B. R. x 0.5 x 36.5 (Specification = 100 – 150 gms/lit).
2.5
OR
8. TAKE 1 N NaOH SOLUTION IN BURRTTE.

9. TAKE 5ml BATH SAMPLE IN CONICAL FLASK. ADD 50ml DISTILLED WATER & 2-3
DROPS OF METHYL ORANGE INDICATOR.
10. TITRATE THE SOLUTION WITH 1N NaOH SOLUTION.
11. END POINT = RED TO YELLOW.
12. HCL % = (BURETTE READING) X (0.73). (Specification = 15 – 18%).
For iron content:
13. Take N/10 KMnO4 solution in burette.

14. Take 10 ml of allocate solution in conical flask. Add 50 ml water. Add 5 - 10 ml
conc. H2SO4 solution.
15. Titrate this solution against N/10 KMnO4 solution. To get pink end point (persist for
10 - 15 second). Note burette reading.
16. Iron % = Burette reading x 5.65.
17. Maintain parameters as per bath parameters. (Specification = Max 120%)
OR
18. TAKE 0.1 N POTASSIUM PARMANGNATE SOLUTIONS IN BURRTTE.

19. TAKE 10ml BATH SAMPLE IN CONICAL FLASK. ADD 50ml DISTILLED WATER & 5ml
OF 50% SULPHURIC ACID SOLUTIOM.
20. TITRATE THE SOLUTION WITH 0.1N POTASSIUM PERMANGNATE SOLUTION.
21. END POINT = COLOURLESS TO VOILET.
22.Fe % = (BURETTE READING) X (0.056). (Specification = Max 120%)
23.Do bath analysis as per schedule. (Format No- HY/QA/01) i.e. once a day.

WI No.: HY/WI/14
FLUX BATH ANALYSIS.
Eff. Date :
For iron content:
3. Take N/10 KMnO4 solution in burette.
4. Take 10 ml of allocate solution in 250ml Erlenmeyer flask. Add 25 ml distilled

water. Add 25 ml of Zimmerman-Reinhardt solution.
5. Titrate this solution against N/10 KMnO4 solution. To get pink end point
(persist for 10 - 20 second). Note burette reading.
6. Iron % = Burette reading x 0.005585 x 100 (Specification = Max 0.5%)

Ml sample x sample density
For Free Acid:
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.
8. Titrate with 0.408N Sodium carbonate solution.
9. END POINT=RED TO YELLOW
10. Acid conc. g/100ml= Burette reading (Sodium carbonate sol.)

10
(Specification =free acid Max 2 g/lit.)
11. Do bath analysis as per schedule GALVANIZING PROCESS PARAMETERS

(Format No- HY/QA/01).

WI No.: HY/WI/15
DI-CHROMATING BATH Rev. No :
ANALYSIS. Eff. Date :
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 :
10 x X x 0.004367
% of Sodium Dichromate =
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.

WI No.: HY/WI/16
Rev. No :
EFFLUENT TREATMENT
PLANT. Eff. Date :
1. Collect effluent in effluent Storage tank.
2. Take the 1500 lit effluent in neutralization tank & add the1500 lit fresh water in
neutralization tank.
3. Start the blower & Check the pH of effluent by using pH paper.
4. Decide additions of chemicals (caustic & acid) after observation of pH.
5. If effluent acidic then add caustic & if effluent is basic then add acid for
neutralization.
6. Add chemical in neutralization tank for obtained pH of effluent between 6 - 8.
7. Start air blower for treated effluent mixing.
8. Check pH of treated water & ensure pH 6 - 8.
9. Transfer the neutralized effluent in lamina tank with sludge & transfer the water
in irritation tank & transfer the lower sludge in sludge drying bed.
10. Then transfer the water in the clarifier tank.
11. After sludge settling in clarifier tank transfer upper clear water in water storage
tank & transfer lower sludge in sludge drying bed.
12. Transfer clear water from water storage tank through sand filter & carbon filter
& then stored in water storage tank.
13. Use treated water in garden.

WI No.: HY/WI/17
EXHAUST & SCRUBBER.
Eff. Date :
1. Check the water level in scrubber tank.
2. Maintain the water level in scrubber tank as per level indicator.
3. Check the pH of water in scrubber tank.
4. If water is acidic (pH = 2 - 3) then discard it & fill fresh water in it.
5. Start exhaust fan to suck the acidic fumes.
6. Start the scrubber pump to lift the water & spray on acidic fumes.

WI No.: HY/WI/18
Rev. No :
PREPARATION OF
LABORATORY REAGENTS. Eff. Date :
BY USING SOLID SOLUTION:
1. 1 N NaOH: - TAKE 20gm SOLID NaOH IN 500ml VOLUMETRIC FLASK. ADD

DISTILED WATER UP TO THE 500ml MARK. STOPPER THE FLASK & MIX
THOROUGHLY.
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.
3. 0.1 N POTASSIUM PERMANGNATE KMnO4: TAKE 15.803gm OF SOLID

POTASSIUM PERMANGNATE IN 1000ml VOLUMETRIC FLASK. ADD DISTILED
WATER UP TO THE 1000ml MARK. STOPPER THE FLASK & MIX THOROUGHLY.
4. 0.5 N SODIUM CARBONATE: TAKE 53gm OF SOLID SODIUM CARBONATE

SOLUTION IN 1000ml VOLUMETRIC FLASK. ADD DISTILED WATER UP TO THE
1000ml MARK. STOPPER THE FLASK & MIX THOROUGHLY.
5. 30 % POTASSIUM OXALATE; TAKE 150gm OF POTASSIUM OXALATE

SOLUTION IN 500ml VOLUMETRIC FLASK. ADD DISTILLED WATER UP TO THE
6. ZIMMERMAN-REINHARDT SOLUTION; TAKE 67gm OF MANGANESE

SULPHATE (MnSO4.4H2O) IN 700ml DISTILLED WATER.ADD 56ml OF 1.83
S.G. SULPHURIC ACID(H2SO4) REAGENT.ADD 133ml OF PHOSPHORIC ACID
(85% meta-H3PO4). & DILUTE IT IN ONE LITER DISTILLED WATER.
BY USING LIQUID SOLUTION :
7. 50 % SULPHURIC ACID: TAKE 250ml 98% PURE SULPHURIC ACID

SOLUTION IN 500ml VOLUMETRIC FLASK. ADD DISTILED WATER UP TO THE

WI No.: HY/WI/19
PREPARATION OF LABORATORY Rev. No :
REAGENTS. Eff. Date :
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.
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.
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.

WI No.: HY/WI/20
DEGREASING.
Eff. Date :
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).

WI No.: HY/WI/21
DEGREASING RINSE.
Eff. Date :
1. After completion of degreasing process dip the material in degreasing

rinse tank.
2. After dipping check the air locking & complete material spreading.
3. Lift the material from degreasing rinse tank.
4. Once again dip the material in degreasing rinse tank.
5. After dipping check the complete material spreading.
6. Lift the material from degreasing rinse tank.
7. Hold the material in tilt condition for removal of water.
8. Ensure material surface is free from degreasing chemical.
9. If material found ok then proceed further. [Further process is pickling.]

WI No.: HY/WI/22
PICKLING.
Eff. Date :
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.
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).

WI No.: HY/WI/23
ACID RINSE No. 1.
Eff. Date :
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.
5. Once again dip the material in acid rinse 1 tank.
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).

WI No.: HY/WI/24
ACID RINSE No. 2.
Eff. Date :
1. After completion of acid rinse 1 process dip the material in acid rinse no.2 tank.
3. Lift the material from acid rinse 2 tank in tilt condition.
4. Once again 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.

WI No.: HY/WI/25
FLUXING.
Eff. Date :
1. After completion of acid rinse 2 process dip the material in flux tank.
3. Lift the material from flux tank in tilt condition.
4. After fluxing process transfer the lot for further process.

(Further process is drying).

WI No.: HY/WI/26
HOT Rev. No :
DRYING PLATE. Eff. Date :
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).

WI No.: HY/WI/27
GALVANIZING.
Eff. Date :
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 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).

WI No.: HY/WI/28
QUENCHING.
Eff. Date :
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).

WI No.: HY/WI/29
DI-CHROMATING.
Eff. Date :
1. After completion of quenching process dip the lot in Di-chromating tank.
2. After dipping check the complete lot dip in Di-chromating
3. Lift the lot from Di-chromating tank in tilt condition from one end for
removal of solution.
4. After Di-chromating process transfer the lot for further process.

(Further process is finishing).

WI No.: HY/WI/30
MATERIAL FINISHING.
Eff. Date :
1. After completion of Di-Chromating process send the material for

finishing process.
2. ASH DEPOSITS:- To remove the ash from material with the help of
finishing file.
3. DRAINAGE SPIKES:- To remove drainage spikes (lumps) with the help

of proper finishing file if at the time of filing material pileup do touchups
with zinc rich paint or zinc spray properly with two three times.
4. DROSS:- It remove with the help of grinder or finishing file if possible

otherwise regalvanized material.
5. PIMPLES OR BLISTERS:- It remove with the help of sander paper

(i.e.ziro number polish paper).
6.BAR SPOTS OR BLACK SPOTS:- It is repaired with the help of proper

touchup with zinc rich paint or zinc spray by applying two three times.

WI No.: HY/WI/31
BURETTE & PIPETTE Rev. No :
CALIBRATION. Eff. Date :
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.
4. Titrate with 0.1N NaOH from calibrated burette.
5. Also take 0.1N NaOH in uncalibrated burette.
6. Take 10ml 0.1N H2So4 solution in conical flask.
7. Add 2 – 3 drops of phenolphthalein indicator.
8. Titrate with 0.1N NaOH from uncalibrated burette.
9. Reading of Calibrated burette = Reading of uncalibrated burette (uncalibrated

burette is exactly same as calibrated burette i.e. calibrated) OR
10.Take water in calibrated burette up to the marking level & transfer in uncalibrated
burette.
11.See the water level of uncalibrated burette.
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.

WI No.: HY/WI/32
Rev. No :
ADHESION TESTS
Eff. Date :
HAMMER TEST (IS 2629-1985)
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.

WI No.: HY/WI/33
WORK INSTRUCTION
Rev. No :
FOR PREECE TEST.
Eff. Date :
PREPARATION OF COPPER SULPHATE SOLUTION
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).
PREECE TEST(IS 2633-1986)
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.
5. Take successive four dips in the solution for one minute.
6. When the test pieces is finally rinsed & wiped dry, it does not show any adherent
red deposit of copper upon the base metal.

WI No.: HY/WI/34
WORK INSTRUCTION Rev. No :
FOR MASS OF ZINC.
Eff. Date :
MASS OF ZINC COATING (IS 4759-1996)
1. Take weight of galvanized test pieces. (M1=mass of galvanized pieces).
2. To clean the test pieces by pickling (i.e. to remove zinc coating) after that rinsing
& drying.
3. Take weight of cleaned test pieces. (M2=mass of clean pieces).
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)
Surface area of the test piece =(162 X 25)+(25 X 6)+(162 X 6) X 2
= 10344mm
=10344/1000000 = 0.010344 m2
Mass of test piece is M = M1-M2 i.e. 232-216
= 16 gram.
Now mass of zinc coating= Mass (M) i.e. 16

Surface area 0.01034
= 1547 gram/m2

Work Instruction For Galvanizing Plant (7 Tank Process) .: WI No.: HY/WI/01 Rev. No Eff. Date

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Work Instruction For Galvanizing Plant (7 Tank Process) .: WI No.: HY/WI/01 Rev. No Eff. Date

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10. After quenching then dip the material in chromating bath.

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

PREPARATION. Eff. Date :

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank carefully with fresh water.

3. Take 15000 Liter Raw Water in cleaned degreasing tank.

4. Add 3000 lit METACLIN-GP in degreasing bath slowly with continues

5. Mix solution manually to dissolve all liquid if remaining.

6. Take Bath Sample For Analysis.

8. To take 10 ml allocate solution in conical flask & add 5-46drops of Methyl

10. Burette reading = Total acidity.( 17 – 18 ml)

11.Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

12.Do bath analysis as per GALVANIZING PROCESS PARAMETERS

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank carefully with fresh water.

3. Take 7000 Ltr Raw Water in cleaned pickling tank.

4. Add 8000 Liter 30 - 35 % commercial HCL in pickling bath.

5. Add 3 - 5 Liter of Acid Inhibitor In Above Bath.

6. Mix solution manually to mix the chemicals.

7. Take Bath Sample For Analysis.

10. HCL gm/lit B. R. x 0.5 x 36.5

11.Do bath analysis as per GALVANIZING PROCESS PARAMETERS

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank carefully with fresh water.

3. Take 8,000 Ltr. Raw Water in cleaned Flux tank.

6. Mix solution manually to dissolve the solids if remaining.

7. Take Bath Sample For Analysis.

8. To check the specific gravity. It should be 1.11 to 1.16 g/ml.

9. Maintain the bath temperature 60 to 80 0C.

10. Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

11. Do bath analysis as per GALVANIZING PROCESS PARAMETERS

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

3. Now start heating up to Zinc melt i.e. 4400C to 4600C.

4. Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

5. Do bath analysis as per GALVANIZING PROCESS PARAMETERS

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

PREPARATION. Eff. Date :

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank carefully with fresh water.

3. Take 16,000 Ltr Raw Water in cleaned Di-chromating bath.

4. Add 150 kg 1% Sodium di-chromate in Di-chromating bath slowly with

5. Add 5 lit ½% of Sulfuric Acid in Di-chromating bath.

6. Mix solution manually to dissolved solids if remaining.

7. Take Bath Sample For Analysis.

10. Burette reading = Total alkalinity.

11. Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

12. Do bath analysis as per GALVANIZING PROCESS PARAMETERS

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

PREPARATION. Eff. Date :

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank with fresh water.

3. Take raw water in cleaned tank up to the overflow level.

4. Check the pH of water.

5. Start using water for washing.

6. Maintain the bath parameters as per GALVANIZING PROCESS PARAMETERS.

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

PREPARATION. Eff. Date :

1. Transfer all the old solution in ETP for further treatment.

2. Clean the tank with fresh water.

4. Start using water for washing.