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Manufacturing Pipe Galvanizing Plant

CAPACITY 4 M.T. PER HOURS FOR PIPE GALVANISING (1/2” TO 6”)
SPECIFICATION AS PER API/IS/ASTMBS STANDARD
FUEL FURNACE OIL WITH A NET CALORIFIC VALUE OF 10000 K. CAL./KG OR GAS
ZINC CONSUMPTION AVERAGE 6 TO 7% DEPENDING UPON PIPE SIZE
ZINC EFFICIENCY AVERAGE 6 M FROM FLOOR LEVEL
BY PRODUCT ZINC DROSS : 8 TO 10%
ZINC DUST :10 TO 16%
ZINC ASH : 16 TO 18%
OF THE ZINC USED
Manufacturing Pipe Galvanizing Plant
PRE – TREATMENT PROCESS

1. PICKLING UNIT
ACID FUME SUCTION ARRANGEMENT
THE SECTION OF FUME FROM THE PICKLING TANKS WILL BE THROUGH A CENTRAL DUCT TO OUTSIDE THROUGH A FRP LINED CENTRIFUGAL FAN, THE CHIMNEY WILL BE FIBRE LINED. AIR BLOWING IS PROVIDED AT THE TOP OF TANKS.

2. ROCKING ARM ARRANGEMENT

ROCKING ARM IS TO BE FITTED FOR ACID FUME TANKS. ALL THE ARRANGEMENT TO BE MADE FOR FINE ACCURACY & CLEANING OF THE PIPES. WHEN THE PIPE BUNDLE IS TO BE FEED IN ACID TANK AT THAT TIME LINER MOVEMENT IS REQUIRE FOR THE PIPES. SO THAT ACID IS TO BE CIRCULATED IN ALL DIRECTION OF PIPE INSIDE & OUTSIDE SURFACE OF THE PIPE. THE ARRANGEMENT IS MADE TO ROTATE THE PIPE IN HIGH DIRECTION & CLEANING IS MADE FOR THE EFFECTIVE GALVANISING.

3. WATER RINSE TANK

THERE WILL BE 2 WATER RINSING TANK ONE TO WORK AS COLD WASH AND OTHER HOT WASHING. THESE TANKS ALSO MADE OF STEEL WITH GLASS FIBRE LINING.

6. DRIP TRAY

THE FLUX PIPE WILL BE PUT ON THIS DRIP TRAY SO THAT INTO SMALL DROPLS OF FLUX IN THE PIPE ARE DRAINED THE FLUX TANK. (ALL THESE TANKS WILL BE PROVIDED WITH SUITABLE DRAINS, OVERFLOW CONNECTION ETC)

7. GALVANIZING
SINCE WE ARE FOLLOWING DRY GALVANIZING PROCESS THEREFORE, THE HOT GASSES FROM THE MAIN FURNANCE ARE DRIVERTED INTO THE DRYING CHAMBER FOR HEATING THE PIPES THEREBY HAVING BETTER UTILIZATION OF THE HEAT FROM FUEL GASSES BEFORE BEING DISCHARGED INTO THE MAIN CHIMNEY. THE COMPLELTE ARRANGEMENT CONSISTS OF THE FOLLOWING ITEMS.

1) SUPPORT SKIDS AND PIPE FEEDING CONVEYOR

THIS WILL BE AN MS FABRICATED SKID ON WHICH PIPES WILL BE KEPT. FROM THESE SKIDS THE PIPES WILL BE FED TO THE DRYING CAMBER THROUGH CHAIN CONVEYOR.

2) DRYING CHAMBER


THIS CHAMBER IS MADE OUT OF STEEL (MILD) PLATES DULY REINFORCED AND LAID WITH FIRE PROOF BRICKS. THE PIPE WILL BE PUT ON A CRADLE IS PASSED OVER 3 DRIVEN CHAINS INTO THE HOT CHAMER. THE DRIVE HAS VARIABLE SPEED SO THAT FOR PIPES OF DIFFERENT THICKNESS THE TIMES FOR HEATING CAN BE ADJUSTED AN ADDITIONAL BURKER IS PROVIDED FOR BETTER HEATING REQUIRED.

3) DIPPING SYSTEM

BY PNEUMATIC CYLINDERS

4) MAIN FURNANCE

THE OUTER FRAME OF THE FURNANCE WILL BE MADE OF STEEL STRUCTURE DULY REINFORCED WITH CHANNELS AND THE FURNANCE WILL BE LINED WITH FIRE PROOF BRICKS OF SUITABLE GRADES TO WITHSTAND THE HIGH TEMPERATURE OF THE FIRE. THE FURNACE WILL HAVE FIRED BURNERS COMPLETE WITH BLOWERS AND CUT OFF VALVES, ONE ADDITIONAL BURNER WILL ALSO BE PROVIDED IN THE DRAWING CHAMBER SO THAT THE PENDING UPON THE LOAD THIS BURNER CAN BE OPERATED FOR PREHEATING THE PIPES TO THE DESIRED TEMPERATURE.

5) ZINC TANK

A ZINC TANK MADE OUT OF LOW CARBON LOW SILICON FABRICATED STEEL WELDED WITH SPECIAL ELECTRODES SO AS TO GIVEN RADIOGRAPHIC WELD FOR A LONG LIFE. THIS TANK WILL BE OF ROUND CORNER DULY STRESS RELIEVED.

6) EXTRACTION UNIT

THE PIPE WILL BE WITHDRAWN FROM THE ZINC TANK BY MAN AND PUT ON BIG MAGNETIC ROLLERS , THE COMPLELTE CHAIN OF MAGNETIC ROLLER CONVEYOR WILL CONSISTS OF 1 BIG MAGNET ROLL, 3 SMALL MAGNETS AND 4 IDLE ROLLERS SUITABLE PLACED SO THAT PIPES ARE TAKEN UPTO THE EXTREME END. THE DRIVE WILL BE THROUGH VARIABLE MOTOR. AIR BLOWING DIES ARE FIXED FOR WIPING MOUT THE EXTRA ZINC WITHOUT DAMAGING THE UNIFORMITY AND FINISH OF ZINC COATING ON PIPE. AFTER THE TUBES ARE FULLY WITHDRAWN THEY ARE EJECTED WITH THE HELP OF LEVE PNEUMATICALLY OPERATED WHERE PIPE WILL RESET ON THIS . THE BLOWING WITH AIR CLEAN THE PIPES FROM INSIDE BY WIPING OUT EXTRA ZINC INSIDE THE PIPE. AFTER THE TUBES ARE BLOWN THE MAGNETS ARE DE-MAGNET AND THE TUBES ARE TRANSFERRED QUENCHING TANK.

7) CYCLONE

THIS SYSTEM CONSISTS OF A BLOWING BOX IN WHICH THE PIPES ARE BLOWN AND SUCH FINE POWDER OF ZINC DUST IS COLLECTED IN THE CYCLONE CONSISTING OF DOUBLE VOLUTE CHAMBER WITH CONE CONNECTED TO TROLLEY WHERE THESE ARE COLLECTED.

8) QUENCHING TANK

THIS TANK IS MADE OF MS PLATE 8 MM THICK WITH 3 CHAINS DRIVEN THROUGH GEAR BOX AND MOTOR FOR CARRYING THE QUENCHING PIPE TO OUTSIDE FOR INSPECTION AND COLLECTING.

9) ACID STORAGE TANK AND SUPPLY


10) NEUTRALIZATION

SUITABLE NEUTRALIZATION SYSTEM ALONGWITH AGITATING DEVICE AND LIME DOSING DEVICE WILL BE SUPPLIED.

11) INSTRUMENTS

SUITABLE TEMPERATURE MEASURING DEVICE LIKE THERMO COUPLE AND PYROMETER WILL BE PROVIDED FOR ZINC BATH, FLUX GASSES AND DRYING CHAMBER.

CONSUMPTION DETAILS PER TON OF G.I. PIPE PRODUCTION

ACID CONSUMPTION 30 LTR. / TON
CHEMICAL CONSUMPTION 28 LTR. / TON
FUEL 5 KG / TON
( AS ZINC CHLORIDE + AMMONIUM CHLORIDE + SODIUM DICHROMATE + GLYCERINE + SAW DUST)
BY PRODUCT 500 LTR. / TON
ZINC EFFICIENCY
A) Zn DROSS : 8-10% (Zn USED SHOULD BE 99.9% PURE)
B) Zn ASH : 5 TO 10 %
C) Zn Blowing : 13 % (AVERAGE)

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