Energypac Engineers Ltd

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  • Topic: Copper, Corrosion, Zinc
  • Pages : 17 (3994 words )
  • Download(s) : 52
  • Published : March 13, 2013
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Electroplating shop:
Electroplating is primarily used for depositing a layer of material to bestow a desired property to a surface that otherwise lacks that property. Mainly electroplating is used for the following purposes: * Abrasion

* Wear resistance
* Corrosion protection
* lubricity and
* Aesthetic qualities
The electroplating shop of Energypac Engineering Limited consists of three sections. i) Seven color section
ii) Nickel section
iii) Silver section
Seven color section:
Parts that are made with mild steel are taken in this shop. At first zinc coating is provided to the parts and then these parts are seven colored. There is a single room provided for this section. Parts are taken to the room after cleaning and then stored in the table. There are three zinc tanks inside the room although there is a tank for seven color it remains unused. It is done outside the room. Acid cleaning is also done outside the room because it harmful for the workers. It is difficult to use an effective sequence in this section because the parts are not homogenous. Besides some parts are rusted which makes it difficult to calculate an identical flow time of the parts. But the existing efficiency can be improved. That is why it is important check the existing process flow, layout and work procedure. Process flow of seven color section:

Current layout of seven color section:
H2SO4(Mild steel)
Tap
Zinc Tank
Zinc Tank
Filter

Zinc Barrel Tank
Water

H2SO4

Water

7 color

Heater
Water
H2SO4(Cu, Brass)
Water

Working table
Water

7 color

Store

Administrative table
DOOR

DOOR

Working manual for seven color section:
1. First of all the job which are going to be electroplated is sunk into an Acid container of H2SO4. The duration of sinking depends on the size shape and corrosion level of the job. Normally big sized and highly corroded jobs are sunk about 1hour and 30 minutes. Medium size needs about 40 minutes. Small size needs 20-25 minutes. 2. Then the job is taken to a water container to clean. Sometimes jobs are washed by jet of water through a pipe. 3. Then the job is taken into the bobbing section to eliminate the dust, scrap, debris and unnecessary particles which stacked on the job surface. It will take 3-10 minutes. It vary due to size shape and corrosion level. 4. Then the job is taken into acid container again for 2-4 minutes for removing the rest of dusts and scraps. 5. The job is washed by water.

6. The job is then taken to the Zinc tank. There are two types of tank. One is used for the small parts known as barrel tank which have the capacity of 10 kg and it generally takes 1.30-2 hour to complete one operation. Another tank is used for the medium and large sized jobs. It takes 40min – 2.5 hours. The jobs are tied to a copper wire and connected to the cathode and sunk to the Zinc solution of the tank. 7. The jobs are washed with water after taken out from the Zinc tank. 8. Then the jobs are taken to the seven colors container and sunk there about 2 minutes. 9. Then the jobs are taken to the heater to dry it up.

10. Finally the jobs are stored and ready to deliver.

Flow time for seven color section:

Time required in different steps | Large sized jobs(min)| Medium sized jobs(min)| Small sized jobs(min)| Steps| HighCorrosion| Low Corrosion| Highcorrosion| Low Corrosion| HighCorrosion(min)| Low Corrosion| Acid | 90| 65| 40| 25| 8| 3|

Water| 1| 1| 0.75| 0.75| 0.5| 0.5|
Bobbing| 20| 10| 10| 7| 5| 2|
Acid| 2| 2| 2| 2| 2| 2|
Water| 1| 1| 0.75| 0.75| 0.5| 0.5|
Zinc tank| 150| 100| 80| 50| 150| 110|
Water| 1| 1| 0.75| 0.75| 0.5| 0.5|
Seven color| 3| 3| 2| 2| 2| 2|
Water| 1| 1|...
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