work instruction gal

8/20/2019 Work Instruction Gal

1/31

WORK INSTRUCTION FOR GALVANIZING PLANT

(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 theentire chemical again dip for 5 min.

!. Lift the material from degreasing bath dip in water bath for flush dipping. "hensend for pickling.

#. 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 la$er of %&L bath with the help of strainer.

5. 'emove the material from pickling bath dip in two water rinsing tanks for flushcleaning.

(. 'emove the material from two water rinsing tanks dip in flu) bath at (0 to *00& for material surface free from o)ide.

+. 'emove the material from flu) bath spread on hot plate for dr$ing.

*. After material is dried completel$ then dip the material in molten ,inc bath as

per reuired ,inc coating check the temperature record. i. e. bath temp. is

##0 to #(0 0& /

. 'emove the material from ,inc bath drain out the full molten ,inc from thematerial dip in uenching bath.

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

11. end the material for finishing i.e. to removing lumps black spots pimples etc

12. "he chemical bath shall be monitored 3 discard as per instruction record in

bath histor$ sheet.

4'4A'D 678 9A :;'. A44':&%A';


2/31

WORK INSTRUCTION FOR DEGREASING BATH PREPARATION.

1. "ransfer all the old solution in "4 for further treatment.

2. &lean the tank carefull$ with fresh water.

!. "ake *000 Liter 'aw ?ater in cleaned degreasing tank.

#. %eat the water up to 50- +0@c.

5. Add !20-#00 kg Corolin-MHX in degreasing bath slowl$ with continues

mi)ing.

(. i) solution manuall$ to dissolve solids if remaining.

+. "ake 6ath ample Bor Anal$sis.

*. "ake 10ml solution in conical flask. Add 2-# drops of eth$l E>:; 4'E>:; 4'


3/31

WORK INSTRUCTION FOR

ACID BATH PREPARATION.

1."ransfer all the old solution in "4 for further treatment.

2.&lean the tank carefull$ with fresh water.

3."ake *000 Ltr 'aw ?ater in cleaned pickling tank.

4. Add *000 Liter !0 - !5 F commercial %&L in pickling bath.

5. Add ! - 5 Liter of Acid >nhibitor >n Above 6ath.

6.i) solution manuall$ to mi) the chemicals.

7."ake 6ath ample Bor Anal$sis.

8."ake 25 ml bath solution in 250 ml standard flask make up with distilled.

?ater up to 250 ml.

9. "ake 25 ml allocate solution in flask. "itrate with 0.5: :a2&

meth$l orange indicator to get $ellow end point. :ote 6urette reading.

10.

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

2.5

11.Do bath anal$sis as per ;AL=A:>E>:; 4'


4/31

WORK INSTRUCTION FOR FLUX BATH PREPARATION.



!. "ake *000 Ltr. 'aw ?ater in cleaned Blu) tank.

#. Add 200 to #00 g3lit Einc Ammonium &hloride chemical in Blu) bath slowl$

with continuous mi)ing.

5. Add additive Blag-500 20 lit. &hemical in Blu) bath slowl$ with continuous

mi)ing.

(. i) solution manuall$ to dissolve the solids if remaining.


*. "o check the specific gravit$. >t should be 1.11 to 1.1( g3ml.

. aintain the bath temperature (0 to *0 0&.

10. aintain the bath parameters as per ;AL=A:>E>:; 4'E>:; 4'


5/31

WORK INSTRUCTION FOR DI-CHROMATE BATH PREPARATION.



!. "ake 1(000 Ltr 'aw ?ater in cleaned Di-chromating bath.

#. Add 150 kg 1F odium di-chromate in Di-chromating bath slowl$ with

continues mi)ing.

5. Add 5 lit GF of ulfuric Acid in Di-chromating bath.

(. i) solution manuall$ to dissolved solids if remaining.


*. "ake 10 ml ample dilute with 50ml water. Add 2-# drops of 4henolphthalein

indicator.

. "itrate with 1::a


6/31

WORK INSTRUCTION FOR DEGREASING RINSE PREPARATION.


2. &lean the tank with fresh water.

!. "ake raw water in cleaned tank up to the overflow level.

4. &heck the p% of water.

5. tart using water for washing.

6. aintain the bath parameters as per ;AL=A:>E>:; 4'


7/31

WORK INSTRUCTION FOR ACID RINSE No. PREPARATION.



3. "ake raw water up to the overflow level if reuired in cleaned Acid 'inse"ank :o.1.

#. tart using water for washing.



8/31

WORK INSTRUCTION FOR ACID RINSE No.! PREPARATION.



!. "ake raw water up to the overflow level if reuired in cleaned Acid 'inse

"ank :o.2.

#. tart using water for washing.



9/31

WORK INSTRUCTION FOR QUENCHING PREPARATION.

1. "ransfer all the old water from uenching tank to "4.


!. Add raw water up to the overflow level in uenching tank.

#. tart using water for 9uenching.

4'4A'D 678 9A :;'. A44':&%A';


10/31

WORK INSTRUCTION FOR HANDELING OF CHEMICALS.

1. Corolin MHX

4recautions 8- During handling chemicals use rubber hand gloves gum

boots goggles mask/ &aution8 - >f chemical comes in contact with kin 3 e$e wash with large

amount of ?ater obtain medical attention if reuired.

2. H!"ro#$lori# %#i" 4recautions 8- During handling chemicals use rubber hand gloves gum

boots goggles mask/ &aution8 - >f chemical comes in contact with kin 3 e$e wash with large

amount of water obtain medical attention if reuired.

!. &in# C$lori"' 4recautions 8- During handling chemicals use rubber hand gloves gum

boots goggles mask/

&aution 8- &hemicals are ,inc base donHt take internall$ >f chemicalcomes in contact

?ith kin 3 e$e wash with large amount of water obtain medical

attention if reuired.

#. %mmoni(m C$lori"' 4recautions 8- During handling chemicals use rubber hand gloves gum

boots goggles mask/

&aution8 - >f chemical comes in contact with kin 3 e$e wash with largeamount of ?ater obtain medical attention if reuired.

5. )o"i(m *i#$rom+t'

4recautions 8- During handling chemicals use rubber hand gloves gum

boots goggles mask/ &aution8 &hemicals are alkaline .DonHt take internall$. Avoid contact with

e$e. >f reuired obtain medical attention if reuired.

6. C+(,ti#

4recautions 8- During handling chemicals use rubber hand gloves gumboots goggles mask/

&aution8 - >f chemical comes in contact with kin 3 e$e wash with largeamount of ?ater obtain medical attention if reuired.

4'4A'D 678 9A :;'. A44':&%A';


11/31

WORK INSTRUCTION FOR DEGREASING BATH ANALYSIS.

1. ?ash reuired apparatus with fresh water.

2. &ollect bath sample in beaker.

3. "ake 1: %2E>:; 4'


12/31

WORK INSTRUCTION FOR ACID BATH ANALYSIS.



or HCL gm,/lit.!. "ake 0.5: odium carbonate solution in burette.

#. "ake 25 ml previousl$ filtered sample in 250 ml measuring c$linder make up to

250ml with D3 water mi) thoroughl$.

5. "ake 25ml allocate solution in conical flask. Add few drops of meth$l orangeindicator.

(. "itrate this solution against 0.5: odium carbonate solution. "o get $ellow end

point. :ote burette reading.

+. HCL gm/lit HCL gm/lit == B. R. x 0.5 x 36.5 )'#ii#+tion = 100 150 gm,/lit. 2.5

R

*. "AI 1 : :aLLD ?A"' 2-!

D'


13/31

WORK INSTRUCTION FOR FLUX BATH ANALYSIS.



or iron #ont'nt

3. "ake :310 In


14/31

WORK INSTRUCTION FOR DI-CHROMATING BATH ANALYSIS.

1) Measure 200 ml of Sodium Dichromate bath solution into a 500ml beaker and add 50ml

distilled water.2) ransfer 25ml of this solution to a 250ml !lass sto""ered flask# add 10ml of 20$ %otassium

&odide and 10ml '(drochloric cid 30 to 32$ and allow to stand in dark for 10mins.

3) dd about 200ml distilled water and titrate with *+10 Sodium hiosul"hate usin! two three

dro"s of Starch Mucila!e or Starch &ndicator# added towards the end of titrations indicator.

he end "oint will be color disa""ear.

4) ,alculations-

1ml of *+10 Sodium hiosul"hate 0.00436/ !m of Sodium hiosul"hateResult :

$ of Sodium Dichromate

$ of Sodium Dichromate ml 0.02135

1) %urit( of %otassium &odide &) to 100 $

2) 20$ of %otassium &odide ake 40 !rams of %otassium &odide "owder and add 200ml

distilled water.

3) Starch Mucila!e &ndicator ake 0.5 !ram Starch Mucila!e "owder and add 100 ml of

distilled water.

PREPARED BY: QA ENGR. APPROVED BY: QA INCHARGE

10 0.00436/

2


15/31

WORK INSTRUCTION FOR PREPARATION OF LABORATORY REAGENTS.

B ):; )L* )L:

1. 1 : :+H8 - "AI 20gm D :a: 500ml =LD ?A"' J4 "< "% 500ml A'I. "LD ?A"' J4 "< "%

1000ml A'I. "J : 500ml =LLD ?A"' J4 "< "% 500ml A'I. "& A&>D% 2& A&>D*5F meta-% !4LJ" >" >: "' D>">LLD ?A"'.

B ):; L@* )L:

+. 50 )L>HRC %C*8 "AI 250ml *F 4J' JL4%J'>& A&>D


16/31

WORK INSTRUCTION FOR PREPARATION OF LABORATORY REAGENTS.

B ):; %M>L)A

. 1 : :+H8 &J" "% :31 A4: "% A4">LLD ?A"' "< 500ml.

"">LLD ?A"' AAD"% '>:>:; "< "% BLAI. AI J4 ?>"% D>">LLD ?A"' "< 500ml.

"& BLAI. '>: "% A4">LLD ?A"'"< 500ml. ": "% A4">LLD ?A"'"< 500ml. "">LLD ?A"' AAD "%

'>:>:; "< "% BLAI. AI J4 ?>"% D>">LLD ?A"' "< 500ml."


17/31

WORK INSTRUCTION FOR DEGREASING.

1. 'emove the oil la$er from degreasing tank. mmediate lift the material from degreasing tank in tilt condition.

(. %old the material in tilt condition for complete removal of degreasing solution.

+. f material found ok then proceed further.

Burther process is degreasing rinse/.

4'4A'D 678 9A :;'. A44':&%A';


18/31

WORK INSTRUCTION FOR DEGREASING RINSE.

1. After completion of degreasing process dip the material in degreasingrinse tank.

2. After dipping check the air locking complete material spreading.

!. Lift the material from degreasing rinse tank.

#. f material found ok then proceed further. MBurther process is pickling.N



19/31

WORK INSTRUCTION FOR PICKLING.

1. 'emove the black carbon soot from pickling tank. mmediate lift the material from pickling tank.

(. f material found ok then proceed further.

Burther process is Acid rinse 1/.

4'4A'D 678 9A :;'. A44':&%A';


20/31

WORK INSTRUCTION FOR ACID RINSE No. .

1. &heck the water addition overflow in acid rinse no. 1 tank/ adOust water flow

to maintain p% within range.

2. After completion of pickling process dip the material in acid rinse 1 tank.

!. After dipping check the complete material spreading.

#. Lift the material from acid rinse no. 1tank in tilt condition from one end.

5.


21/31

WORK INSTRUCTION FOR ACID RINSE No. !.

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.

!. Lift the material from acid rinse 2 tank in tilt condition.

#.


22/31

WORK INSTRUCTION FOR

FLUXING.

1. After completion of acid rinse 2 process dip the material in flu) tank.

2. After dipping check the complete material spreading.

!. Lift the material from flu) tank in tilt condition.

#. After flu)ing process transfer the lot for further process.Burther process is dr$ing/.



23/31

WORK INSTRUCTION FOR HOT

DRYING PLATE.

1. After completion of flu)ing then place the material for proper dr$ing.

2. After complete dr$ing the material.

!. Lift the material from hot dr$ing plate for further process.

Burther process is ;alvani,ing/.



24/31

WORK INSTRUCTION FOR GALVANI%ING.

1. After completion of hot dr$ing process dip the material in ,inc bath;alvani,ing/.

2. After dipping check the complete material dipping.

!. Dip the lot in ,inc bath for 2 # minute or stop the boiling action/


25/31

WORK INSTRUCTION FOR QUENCHING.

1. &heck the water addition overflow in uenching tank/ adOust water flow tomaintain temperature within range.

2. After completion of ;alvani,ing process dip the lot in uenching tank.

!. After dipping check the complete lot dips in uenching tank.

#. Lift the lot from uenching tank in tilt condition from one end for removal ofwater.

5. After uenching process transfer the lot for further process.

Burther process is Di-chromating/.

4'4A'D 678 9A :;'. A44':&%A';


26/31

WORK INSTRUCTION FOR DI-CHROMATING.

1. After completion of uenching process dip the lot in Di-chromating tank.

2. After dipping check the complete lot dip in Di-chromating

!. Lift the lot from Di-chromating tank in tilt condition from one end for

removal of solution.

#. After Di-chromating process transfer the lot for further process.Burther process is finishing/.

4'4A'D 678 9A :;'. A44':&%A';


27/31

WORK INSTRUCTION FOR BURETTE & PIPETTE CALIBRATION.

B(r'tt' C+lif calibrated burette reading uncalibrated burette reading are same then theburette is calibrated.

>i'tt' C+lif calibrated pipette reading uncalibrated pipette reading are same then the pipette is calibrated.

4'4A'D 678 9A :;'. A44':&%A';


28/31

WORK INSTRUCTION FOR ADHESION TESTS

H%MMR ) ) 2629-1985

1. "he hammer used shall conform as per drawing mention in > 2(2 (.#.1/.

2. "he hammer blow shall be controlled b$ holding the pivoted base of thehandle on a hori,ontal surface.

!. Allow the hammer head to swing freel$ through an arc from vertical positionto strike the hori,ontal surface.

#. 'epeat this test two or more times with (mm spacing in a same angle

i.e.0 deg./.

5. >f ,inc coating between (mm distance is not removed then ,inc coating is ok.



29/31

WORK INSTRUCTION FOR PREECE TEST.

>R>%R%: C>>R )L>H% )L:

1. "ake !(g of technical grade copper sulphate dissolve in 100ml distilled water.

2. :eutrali,e the free sulphuric acid in solution b$ shaking with copper carbonate


30/31

WORK INSTRUCTION FOR MASS OF %INC.

M%)) &:C C%:; ) 4759-1996

1. "ake weight of galvani,ed test pieces. 1Cmass of galvani,ed pieces/.

2. "o clean the test pieces b$ pickling i.e. to remove ,inc coating/ after that rinsing

dr$ing.

!. "ake weight of cleaned test pieces. 2Cmass of clean pieces/.

#. ubtract the first mass from the second mass i.e. 1- 2. /.

5. :ow dividing the result b$ the surface area of the test pieces.

R X%M>L

"ake 1(2 K 25 K (

Length C 1(2mm ;+l+ni'" D'ig$t=232 gr+m M 1

?idth C 25mm "hickness C (mm Bl+# D'ig$t=216 gr+m M 2

)(r+#' +r'+ o t$' t',t i'#' C1(2 K 25/P25 K (/P1(2 K (/ K 2

C 10!##mm

C10!##31000000 C 0.010!## m2

M+,, o t',t i'#' i, M C 1- 2 i.e. 2!2-21(

C 1( gram.

:oD m+,, o in# #o+tingC ass / i.e. 1(

urface area 0.010!#

C 15#+ gram3m2



31/31

WORK INSTRUCTION FOR STANDARD OPERATING CYCLE TIME

SR

No. PROCESS

STANDARD TIME MAX TIME

'FOR !( MIC)

MAX TIM'FOR *+

MIC)MIN MAX

LOADING POINT TO PICKLING

TANK ! " ! !

! DIP TIME IN PICKLING TANK No. ( !( $ $

" LIFT & TITLT TIME IN PICKLING ! ! ! !

# DIP TIME IN PICKLING TANK No.! ( !( $ $

$ LIFT & TITLT TIME IN PICKLING ! ! ! ! !

+ DIP TIME IN PICKLING TANK No." ( !( $ $

, LIFT & TITLT TIME IN PICKLING " ! ! ! !

* DIP TIME IN RINSE & !. # # # #

DIP TIME IN FLUX ! ! ! !

( DRYING TIME ON HOT PLATE ( ( ( (

DIP TIME IN %INC BATH ! $ # !

! LIFT & TILT TIME IN %INC BATH ! ! ! !

" DIP TIME IN QUENCHING ! ! ! !

# DIP TIME IN DI- CHROMATING ! ! ! !

TOTAL TIME (min.) 38 ! " "3


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