sop of testing

MANAKSIA STEELSLIMITED
HALDIA PLANT
INCOMING/INPROCESS/FINISH MATERIAL
DOC. NO.-An/8.2/02
DESCRIPTION DESIGNATION SIGNATURE DATE
APPROVED BY QUALITY HEAD
ISSUED BY MANAGEMENT REPRESENTATIVE
1.DETERMINATION OF pH
INSTRUMENT/CHEMICAL:-
pH meter
Standard Buffer solution (pH 4, pH 7, and pH 9)
Take one tablet of each pH and dissolve them in 100ml distilled water in
separately
PROCEDURE:-
Calibrate the pH meter by std. Buffer solution.
Standardization is done by dipping pH cathode, and then meter can be used for
other solution.
If the reading of pH meter matching with Std. pH, then meter can be used for
other solution.
PH of any solution can be finding by dipping bulb of standardized pH meter
CALCULATION:-
pH of sample = Reading of meter
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HALDIA PLANT
DOC. NO.-An/8.2/02
2.DETERMINATION OF CONDUCTIVITY
INSTRUMENT/CHEMICAL:-
Conductivity meter
Standard conductivity solution
PROCEDURE:-
Calibrate the conductivitymeterbystd.conductivitysolution.(Std. KCl are providedfor
Standardization)
Standardizationisdone bydippingconductivitycell in solution,and thenmetercanbe usedfor other
solution.
If the readingof conductivitymetermatchingwithStd. conductivity,then metercanbe usedfor other
solution.
Conductivityof anysolution canbe findingbydippingcell of standardizedconductivitymeter
CALCULATION:-
Conductivity of sample (micro S/cm) = Reading of meter
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HALDIA PLANT
DOC. NO.-An/8.2/02
3.DETERMINATION OF TOTAL HARDNESS OF
WATER
REAGENT:-
Std. CaCO3Solution:
Take 0.1gm. CalciumCarbonate anddissolve in1000 ml Distilledwater,thenHCl canbe added dropwise &
boil until all the all particlescool;thenaddedfew dropof methyl orange ,afterthataddedNH4OHto
neutralizedtill the colourchange ,nowmake upthe volume upto100ml . That is1mg/ml CaCO3.
Weight takenCaCO3 = 0.1019 gm. then, 0.1019 in 100ml
So, 1ml contains 1.019mg concentrationis1.019 mg/ml
0.1 N Na2 EDTA Solution:
Dissolve 3.7224 gm. Ethylene Di amine Tetra Aceticacid disodiumsalt (E.D.T.A) in1000ml Distilled water.
Ammonium Buffer : Take 6.76 gm. AmmoniumChloride (NH4Cl) anddissolvein57ml NH3 solutionand
makeupvolume 100 ml withDistilledwater.
EBT ( Eriochrome Black T):
PROCEDURE:-
Standardization: Take 5ml CaCO3 Sol in conical flask, add 1ml ammonium buffer pinch of EBT indicator,
titrate againstEDTA solutionuntil blueappeared
Let Titrate value is4.95,
We Know, V1S1=V2S2,
then,5x 1.1019 = 4.95 x S2[V1= Vol of CaCO3 ; V2= Vol ofEDTA;S1=Con. Of CaCO3}}
S2= 1.0129 (Factor ‘D’)
Testing: Take 100ml sample in a 250 ml conical flask. Add 2 ml Ammonium Buffer and a pinch of EBT
indicatorisaddedandpinkcolourappeared.
Thenit istitratedagainstNa2EDTA till colourchange PinktoBlue.
CALCULTION:-
Total Hardness (ppm) = V1 X D X 1000
V2
Where, V2 =Volume of EDTA;
V2=Sample volume;
D = Factor

HALDIA PLANT
DOC. NO.-An/8.2/02
Page No. 1 of 1
4.DETERMINATION OF OIL PERCENTAGE OF
COOLANT
REAGENT:-
Con. Nitric Acid (HNO3)
PROCEDURE:-
Take 90 ml Coolant sample transfer in 250ml boob bottle .Add 10 ml con. Nitric Acid.
Now heating with heater.
When all oil separated from water then cool it and fill the boob bottle with Water up to ‘0’ mark of boob
bottle and take Reading of oil volume.
CALCULTION:-
Oil percentage = Volume of Oil X 0.14
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HALDIA PLANT
DOC. NO.-An/8.2/02
5.DETERMINATION OF IRON CONTENT OF
COOLANT
REAGENT:-
Cons. Hydrochloric Acid:
40% Sodium Hydroxide Solution:
Take 40 gm. of SodiumHydroxide (GR) anddissolve in100 ml Distilledwater
5% Sulfosalicylic Acid:
Dissolve 50gm5-SulfosalicylicAcidDIhydrate (GR) in1000 ml Distilledwater.
0.1m EDTA Solution: Dissolve 3.72 gm. Ethylene Di amine TetraAceticaciddisodiumsalt(E.D.T.A)in
1000ml Distilledwater.
PROCEDURE:-
Take 50ml coolantsample ina 250 ml beaker.Add30ml cons.HCl to itand heatingit up to 1/3
volume of total volume.
Afterheatingcool itand Filter with44no Whatman Filterpaper.
Afterfiltration add40%NaOH solution (ornitricacid) forpH 2.
Add1ml SulfosalicylicAcidand Titrationagainst0.1m EDTA Solution till colorchange redtocolorless.
CALCULTION:-
Iron of Coolant (ppm) = A X B X 55.8 X 1000
C
Where, A =Titrate Value
B=Morality of EDTA Solution
C =Sample volume
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HALDIA PLANT
DOC. NO.-An/8.2/02
6.DETERMINATION OF CHLORIDE CONTENT
OF COOLANT
PRINCIPAL: -If the productorganic itis clarified.The solutionisacidifiedandthe chlorides
precipitatedinthe formof silverchloridebymeansof a solutionof silvernitrate.The excesssilvernitrate is
titratedwitha solutionof ammoniumthiocyanate,byVolhard’smethod
REAGENT:-
Cons. Nitric Acid:
0.0564N Silver Nitrate Solution:
Take 19.176 gm. of SilverNitrate (GR) anddissolvein 2000 ml Distilled water.And store ita black
bottle.
Nitrobenzene:
0.0564N Ammonium thyocyanate Solution:
Dissolve 4.1gm.Ammoniumthyocyanate (GR) in1000ml Distilledwater.
Ferric Alum Indicator: Dissolve 40gm Ammonium iron (111) Sulfate [Fe2 (SO4)3,(NH4)2 SO4] in
50ml Distill water .Add 3ml HNO3 and dilute in 100ml.
PROCEDURE:-
Take 50ml coolantsample ina 250 ml beaker.Add30ml cons. HNO3 to itand heatingitup to1/3
volume of total volume.
Afterheatingcool itand Filter with44no Whatman Filterpaper.
Afterfiltration take the sample in250ml conical flax (A) andadd 25ml AgNO3solution,1ml
Nitrobenzene andfew dropFerricAlumIndicator.
And another250ml conical flux (B) take 25ml AgNO3solution,1ml Nitrobenzeneandfew dropFerric
AlumIndicator.
NowTitrate the both (A & B) Solutionagainst 0.0564 N Ammoniumthyocyanatesolution tillthe
yellowishwhitepptcoming.
CALCULTION:-
Chloride of Coolant (ppm)= 5.845 x (v1t1- v2t2) X1000 X 1000
M X100
Where,
T1 = the normalityonthe silvernitrate solution
T2 = the normalityonthe thiocyanate solution
V1= Volume of addedsilvernitrate solutioninml
V2= Volume of addedthiocyanatesolutioninml usedfortitration
m= the weightinml of the coolant
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HALDIA PLANT
DOC. NO.-An/8.2/02
7.DETERMINATION OF SAP VALUE & TRAMP
OF COOLANT
REAGENT:-
Ethanolic KOH:
Dissolve 35gm.PotassiumHydroxide (GR) in1000ml Ethanol.
2-Propanol:
0.5N Hydrochloric Acid:
Dissolve 41.6ml 12N HydrochloricAcid (GR) in 1000ml Distilledwater.
Phenolphthalein (1% Solution)Indicator:
Sodium Chloride Salt
PROCEDURE:-
At fasttake 1000ml coolantsample ina 1000 ml beakerandheatingitup to 30min withsodium
chloride saltfor separate the oil.
Afterseparatingthe oil fromwater filteritwithaseparatingfunnel.
Afterfiltrationtake 1.5gmoil sample in250ml Roundflax (A) andadd 25ml EthanolicKOHsolution,
some 2-propanol & glass bit.
And another250ml round flux (B) take 25ml EthanolicKOH solution,some 2-propanol &glass bit
.Andheating& Reflux withCondenserthe both(A &B) solutionfor1hr.
After1hr openthe both flux &condenserandwashwith20ml 2-propanol.AndTitrate the both(A & B)
Solutionagainst 0.5N HCl solution usingphenolphthaleinindicatortillcolorchange pinktocolorless.
CALCULTION:-
Sap Value of Coolant (mg KOH/gm.) = (B-A) X 0.5 X 56.11
C
Where, A =Titrate Value of Sample, B=Titrate value of blank, C =Sample volume
Tramp of coolant (%) = (F- Sap value) X 100
F
Where, F= Sap value of Raw coolantOil
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HALDIA PLANT
DOC. NO.-An/8.2/02
8.DETERMINATION OF ACID CONTENT OF
HYDROCHLORIC ACID
REAGENT:-
1N Sodium Hydroxide Solution:
Take 40 gm. of SodiumHydroxide (GR) anddissolve in1000 ml Distilledwater
Methyl Orange indicator
PROCEDURE:-
Take 5 ml acid samples (forRawAcidtake 1ml sample) ina 250 ml conical flask .Add100ml distilled
water& fewdrop of methyl orange indicator(phenolphthaleinindicatorforraw Acid).
Titrate the solutionagainst1N NaOH solutiontill the colorchange redto greenish(forraw acid
colorless topink).
CALCULTION:-
% of HCl (for pickling acid) = Titrate value X36.5 X Normality of NaOH X100
By volume 5 X 1000
Concentration of HCl (for Raw acid) = Titrate value X36.5 X normality of NaOH X100
By mass 1 X 1000 X Specific gravity of acid
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HALDIA PLANT
DOC. NO.-An/8.2/02
9.DETERMINATION OF IRON CONTENT OF
HYDROCHLORIC ACID
REAGENT:-
N/10Potassium Permanganate (KMnO4) Solution:
Take 15.8gm. of potassiumpermanganate(GR) anddissolve in1000 ml Distilledwater
Methyl Orange indicator
Cons. Sulphuric Acid
.PROCEDURE:-
Take 5ml acidsample ina 250 ml conical flask.Add100ml distill water,5ml Cons. Sulphuricacid &
fewdropof methyl orange indicator.
Titrate the solutionagainstN/10KMnO4 solutiontill the colorchange redtocolor lesstopink.
CALCULTION:-
Iron content of HCl (gm. /l) =Titrate value X 5.6
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HALDIA PLANT
DOC. NO.-An/8.2/02
10. DETERMINATION OF SPECIFIC GRAVITY
INSTRUMENT:-
Specific Gravity Bottle
Digital balance
.PROCEDURE:-
At fasttake the weightof empty sp. gravity bottle (W1)
Thentake the weightof sp. gravitybottle +DM water(W2)
Afterthistake the weightof sp. gravitybottle +sample (W3)
CALCULTION:-
Sp. gravity of Sample (gm. /cc) = W3 –W1
W2 –W1
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HALDIA PLANT
DOC. NO.-An/8.2/02
11. DETERMINATION OF STRENGTH IN
DEGREASING BATH OF CGL
REAGENT:-
1NHydrochloric Acid Solution:
Take 88mm Conc. HydrochloricAcid (AR) &make it in1000 ml.By addingdistilledwater.
Phenolphthalein indicator
PROCEDURE:-
Take 25 ml degreasingsolutioninaconical flask.
Nowadd 50 ml distilledwater&3-4 dropsof Phenolphthaleinindicator.Solutionbecomespinkcolour.
Titrate the solutionagainst1N HCLslowly till the colourchange pink tocolourless.
CALCULATION:
Strength of Degreasing sample (gm. /lit) = Titrate value x 9.8
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HALDIA PLANT
DOC. NO.-An/8.2/02
CHROMATING BATH OF CGL
REAGENTS:
0.15N Sodium thio - Sulphate Solution:
Take 37.5gms sodiumthio- sulphate anddissolveitin1000-ml distilledwater.
Potassium Iodide Solution:
Weight50gms potassiumiodide crystal (AR) anddissolveitin1000-ml distilledwater.
Starch Solution:
Take 5gms of soluble starch(AR) anddissolve itin500ml water, and heatingit.
Afterheatingcoolingthe Solution.
Now weight5gmsof NaOHand dissolve itin500ml Coldwater.
After cooling the starch solution up to room temperature mix both the solution in one 1000-ml bottle.
Shake well forhomogenization
Cons. Sulphuric Acid
PROCEDURE:
Take 5ml chromic acidsample in500ml conical flask.
Add 100ml distilled water and 2-3ml conc. Sulphuric acid and 20ml potassium iodide solution, the solution
changesto redbrown.
Titrate with0.15N Sodiumthio- Sulphateuntil colourchange toyellowbrown.
At this moment add 1-2 drops starch solution and Continue titrate with sodium thio- sulphate till colour
change to pale green.
CALCULATION:
Strength of Chromic Acid (gm. /lit) = Titrate value
[Take 02 gm. chromium trioxide (AR) and dissolve in 100-ml. volumetric flasks. Now take 0.5 ml solution and
proceed according above method. Result should be 20 gm. /lit, with 01% tolerance that procedures as well
as reagentare correct.]
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HALDIA PLANT
DOC. NO.-An/8.2/02
13. DETERMINATION OF ALUMINIUM ZINC
BATH STANDARD
REAGENT:-
Buffer Solution (pH-5.65): -
Take 55 gm. of Ammonium acetate dissolve it in 100ml of Distilled water. On the other hand take 13.2
gm. of Sodium acetate in 100 ml distilled water up to 1000ml. Adjust the PH
of the final solution at 5.65
PH
byaddingsome glacial aceticacid.
Ascorbic Acid:
Take 1.00 - gm. of Ascorbicacidand dissolve itin200-ml.(0.5% w/v) distilledwater.
Ascorbic Acid Buffer Mixture:
Mix 30ml ascorbicacid and 30ml of buffersolution of pH5.65 in a beaker.
Chromozurol-s:
Weigh 0.290gms of chromozurol –s in a volumetric flask of 100ml and 7.0ml of HNO3 of (6N), shake it
now add 500ml of ethyl alcohol (pure) and 200ml-distilled water. Add0.75gms urea mixes all these
togetherandmake up withdistilledwaterupto 1000ml
Nitric Acid (6N):
Take 3.8ml Nitric acid in a 10ml measuring cylinder. Add distilled water and make volume to 10ml mix
well.
Zinc Solution (Z1) (100mg/ml soln.):
Weigh 100 gm. pure zinc into one liter volumetric flask addin it 500ml conc. Nitric acid and boil it for few
minutes,cool anddilute torequiredvolume.Perml of thissolutionhaving100 mg zinc.
Aluminum Solution (A) (1mg/ml soln.):
Weigh 1.00 gm. pure Aluminum in volumetric flask, add 20 ml conc. HNO3 heat up to the moment when
nitrogenperoxide isgivenoff.Cool down,dilute uptothe markand homogenize.
Standard Zinc Solution (Z2) (0% Al.):
Take 20 ml of Zincsolution(Z1) anddilute into1000 ml volumetric flaskdistilledwater.
Standard (Zn/Al) Solution (0.1% Al.):
Take 20 ml of zinc (Z1) and 2.0 ml of Aluminum solution (A) in 1000 ml volumetric flask and dilute with
distilledwateruptothe mark.
PROCEDURE
Take 1.0gm of bath sample in volumetric flask and 10 ml (50 % v/v) HNO3.Heat for few minutes till
complete dilutionandexpellingfumes.Cool the solutionandmake upwithdistilledwaterupto500 ml.
At leasttake three 100 ml volumetricflaskandeachone containingasunder.
i) 10 ml Std. Zinc solution (Z2) + 20 ml ASCORBIC BUFFER MIX wait for 10 –15 minutes now add 10
ml chromozurol – s make withdistilledwateruptothe mark (100ml).
ii) Now take again in second flask 10 ml standard (ZN/Al) solution + 20ml ASCORBIC BUFFER MIX
wait for 10 – 15 minutes now add 10 ml chromozurol –s. Then make up to the mark 100ml with
distilledwater.
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HALDIA PLANT
DOC. NO.-An/8.2/02
iii) Then in third volumetric flask take zinc bath solution 10ml Chromozurol-s and make up to the
mark withdistilledwater.
Just before you start testing make on photo calorimeter for at least 20 minutes. Now calibrate with (x)
solution and set at 00 then take solution (y) and measure (OD) is say absorbance – Ya. At last take (OD) of z
solutionsayZa.
CALCULATION:
Aluminum content in zinc bath (%) =Za /Ya x 0.1 %
OD – OPTICAL DENSITY
IMP.NOTE:
Before measuring the intensity of colour concentration i.e. Absorbance/
O.D ensures that the colour of the solution in three (VF) is matching. If the colour
concentration is high in any of the samples ten-tat sample should be previously
diluted. In case of Zn Al alloy dilute the sampleup to 100 times.
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HALDIA PLANT
DOC. NO.-An/8.2/02
14. DETERMINATION ZINC CHLORIDE IN
GALVANISING FLUX
REAGENTS:
Buffer Solution
55 gm. ammoniumchloride +350 ml ammoniumhydroxideandmake it1000 ml withDM water.
Eriochrome Black T indicator
Dissolve 1gm of Eriochrome Black T indicator and 10 gm. of Hydroxylamine Hydrochloride in
sufficientMethyl Alcoholtoproduce 2.50 ml solution.
EDTA solution 0.0575 M
21.74. G EDTA Dissolve in1000 ml DM water
Sulphuric Acid 1.0 (N)
Addwaterslowlywithstirring28 ml of SulphuricAcidandVolume make upto1000 ml.
PROCEDURE:
Weighoutnear about3.0 gm. sample.Dilute withwaterandmake upthe volume to250 ml.
If solutionturnshazy,Add25 ml buffersolutionandfew dropsof Eriochrome BlackT indicator.
Titrate with0.0575 (M) EDTA solutionstill colourchangesfromradishtoblue.
CALCULATION:
Zinc Chloride content in galvanizing Flux (%) = (Titrate value of EDTA X 7.837)
Weigh taken for the test x 4
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HALDIA PLANT
DOC. NO.-An/8.2/02
15. DETERMINATION OF MASS OF ZINC
COATING PER UNIT AREA
REAGENTS:
Antimony tri chloride Solution
Dissolve 32gm. AntimonyTri chloride (Sbcl3)andmake it1000 ml with con. HCl.
50 % HCL Solution -
Take 1.0-literconc. HCL and make the volume 2.0-literwithDMwater.
Stripping Solution –
Take 1.0 literof 50 % HCL solutioninabeaker,add50 ml Sbcl3 Solutionandshake well.
PROCEDURE:
Take (100 x 100)-mm sample from galvanized sheet,weightbefore (W1) andafterstripping(W2)
CALCULATION:
Zinc coating (gm. /m2) =(W1 - W2) x 100
For not measurable area
Zinc coating (gm. /m2)= (W1 - W2) x7860 x BMT
W2
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HALDIA PLANT
DOC. NO.-An/8.2/02
16. DETERMINES THE ADHESIVETY OF ZINC
COATING ON GALVANISIED SHEET.
OPERATING OF BENDING TESTER: -
a) One bendtestshell be conductedforeverycoil.
b) For bendtesttake a test piece cut across the directionof rolling.
c) Testpiece forbendtestshouldbe free fromburr.
d) Sample of galvanizing steel sheet shall withstand bending through 180O
around a mandrel
having diameter 2T for hard material and 0T for soft material (T indicates thickness of the
sample) without peeling or flaking of zinc coating. Crack or facture of base metal shall not be
permitted.
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HALDIA PLANT
DOC. NO.-An/8.2/02
DEGREASING BATH OF CCL
REAGENT:-
Sulphuric Acid 1.0 (N) stock solution
Add28 ml of SulphuricAcidinDM waterslowlywithstirringandVolume make upto1000 ml.
0.1N Sulphuric Acid Solution:
Take 100mlSulphuricAcidstocksolution&make itin1000 ml.By addingdistilledwater.
Methyl-orange indicator
PROCEDURE:-
Take 10 ml degreasingsolutioninaconical flask.
Now 3-4 dropsof Phenolphthalein indicator.Solutionbecomes Pink colour.
Titrate the solutionagainst 0.1N H2SO4 slowly till the colourchange pinktoorange.
CALCULATION:
Strength of Degreasing sample = Titrate value x 0.21 %
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HALDIA PLANT
DOC. NO.-An/8.2/02
CHROMATING BATH OF CCL
REAGENTS:
0.1N Sodium thio-Sulphate Solution:
Take 24.8 gm. sodiumthio-sulphate anddissolveitin1000-ml distilledwater.
Potassium Iodide Salt:
Starch Solution:
Take 5gms of soluble starch(AR) anddissolve itin500ml water, and heatingit.
Afterheatingcoolingthe Solution.
Nowweight5gmsof NaOHand dissolve itin500ml Coldwater.
After cooling the starch solution up to room temperature mix both the solution in one 1000-ml bottle.
Shake well forhomogenization.
25%Sulphuric Acid
Take 50 ml DM water in beakers and add 25 ml Cons. H2SO4slowly and mix well. After mixing acid
cool it and fill up to 100 ml.
PROCEDURE:
Take 5ml chromic acid sample in250ml conical flask.
Add 50ml distilled water and 20ml of 25% Sulphuric acid solution and 2-3gm. potassium iodide salt, the
solutionchangesto brown.
Titrate with0.15 N Sodiumthio-Sulphateuntil colourchange frombrownto yellow.
At this moment add 1-2 drops starch solution and Continue titrate with sodium thio-sulphate till colour
change to blue-black.
CALCULATION:
Strength of Chromic Acid (granodine1402w)(ml) = Titrate value x 1.162
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HALDIA PLANT
DOC. NO.-An/8.2/02
19. STANDARD TESTING METHOD OF MEK
DOUBLE RUB
1. SCOPE :
Thisprocedure isto be usedto determinethe degree of cure of a Curedfilmbythe paintfilm’s
resistance toa specifiedsolvent.
2. EQUIPMENT and MATERIALS :
2.1 Good qualityplain cottonwool,un- medicatedshouldbe usedfor thistesting.
2.2 Testpanel at least5 inches (12.5cm) longby 3 inches (7.5cm) wide.
2.3 Solvent–Shouldbe chemicallypure ( L.Rgrade ),Methyl Ethyl Ketone (MEK)
3. PROCEDURE :
3.1 Wrap two thicknessof cottonwool aroundthe index fingerandimmerse insolventMEK.
Immediatelybeginrubbingthe testpanel inabackand forth motionina straightline witha
stroke at leastthree inches (8cm) longusingmoderate toheavypressure.
Approximate weightof pressureshouldbe between2000 & 2500gms. Rubat a rate of
approximately100 double rubsperminute.The rubsare counted( one forwardand one
backwardto be countedasone double rub) and continueduntil failureof the filmoruntil the
requirednumbertodouble rubsisreached.
4. EVALUATION :
4.1 The coating mustwithstand the requirednumberof rubs.Recordthe numberof rubs to pass
the specificationortofailure.
4.2 Failure shall consistof removal of the filmtoexposethe sub strateatanyspot alongthe center
of the stroke.
4.3 Duplicate the testtoconfirmresults.
5. COMMENTS / PRECAUTIONS :
5.1 Voids,scratches,dirtandduston the test panel,solidparticleson the clothorin the solventor
an irregularsurface underthe paintscanseriouslyaffectthe testresults.
5.2 Filmthicknessshouldbe carefullycontrolledtoensure reproducibility.
5.3 The cotton wool mustbe keptconstantlywetwhile rubbing.If the cottonwool dries,quickly
immerse insolvent&continue rubbing.
5.4 This testmaybe usedto evaluate cure onan object, whichdoesnothave a smooth,flat
surface.Inthiscase, selectthe flatted&smoothestareaforthe test,andrub thisarea as
consistentlyaspossible.
5.5 To protectskinfrom solvent,weararubberglove whenperformthistest.
6. REFERENCES:
ASTMD-7835 / D- 4752
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HALDIA PLANT
DOC. NO.-An/8.2/02
20. STADARD TESTING METHOD OF CROSS –
HATCH FOR COATED METAL SHEET
DESCRIPTION:
The cross-hatchtest isa simple meansof assessingthe adhesionorresistance toseparationof coatingsfrom
substrated.
INSTRUMENT:
AS PER ASTMD-3359 – ON METAL SUBSTRATES
1. Cross–HatchCutter: CUT SEPERATION – 1mm;
No.OF CUTS - 11
COATINGTHICKNESS – 0-50 micron
The cutter, whichhasof a numberof bladesat equal spacing,isusedtoscore throughthe coating
downto the substrate.
2. Cello Tape – 3M # 610 TYPE
PROCEDURE:
Withthe cuttertwo cutsare made at rightanglestoeach otherresultinginagridof small squares.Debrisis
removedfromthe surface of the sample andthenadhesive tape isappliedoverthe grid. Afterremoval of
the tape,the coating adhesionisassessed.
RESULTS:
If the paintsinthe square holes peel-off&reportas per observation.If there isnopot stuckto the cellotape
thenadditionismarkedasO.K.
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HALDIA PLANT
DOC. NO.-An/8.2/02
21. STANDARD TEST METHOD OF DRY FILM
THICKNESS OF ORGANIC COATING
DESCRIPTION:
Dry film thickness is a critical measurement in the coating application process. It provides vital information
as to the expected life of the substrate, the product’s fitness for purpose, its appearance and ensure
compliance withahostof internal standards.
Digital coating thickness gauge are the most widely used due to their high level of accuracy and they can be
usedto measure the coatingthicknessonalmostanysubstrate,whetherferrous ornon-ferrous.
INSTRUMENT MODEL:
ELCOMETER 456 INTEGRAL
STANDARS:
ASTM– D1005
PROCEDURE:
DFT is the thicknessof acoating measuredabove the substrate.Thiscanbe consistof a single layeror
multiple layer.
DRT is measuredforcure coatings. Properthicknessshouldbe determinedbythe followingprocess.
At firstthe instrumentiscalibratedwiththe bare sheet.
Thenplace the instrumentpointatthree differentpointsonthe coatedsheet;namely1).Machine side, 2).
At the center& 3).operatorside andtake the average as the coating weight.
CALCULATION:
Average thicknessof coating (micron) = 1+2+3
3
REMARKS:
The value shouldbe withinthe specification.
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HALDIA PLANT
DOC. NO.-An/8.2/02
22. STANDARD TESTING METHOD OF
PAINT GLOSS AT 60 degree WITH GLOSS
METER
1. IDENTIFICATION OF TERMS :
GLOSS METER : An instrumentusedtomeasure the amountof lightreflectedina mirrorlike
fashion.60E glossmeteriscommonfor all – purpose measurements.
SHINY APPEARANCE :Thisis whena beamof lightis reflectedfrom asurface isbasicallyone
direction. (Mirror on highlypolished surface).
FLATor MATTE APPEARANCE: Thisiswhenabeamof lightisreflectedfromasurface inall
directions(the lightisdiffused/scattered).
2. PROCEDURE :
2.1 Inspectthe underside (bottomsurface) of the instrumenttobe sure thatit iscleanand free of
scratchesand rough particles. A roughsurface will damage the testpiece and/orcalibration
Standard.
2.2 Inspectthe lencesandtheirchannelsremovinganydustorstray material.A small camel’shair
brushshouldbe usedto cleanthe lensesandsurroundingarea.
2.3 VERIFY CALIBRATION :
a. Wipe the calibrationpiece (polished black glass) clean usingasoftlintfree cloth.DONOT
SCRATCHOR MAR THE SURFACE!Refertocalibrationstandardcleaningcare fordetails.
b. Place the glossmeteronthe standard.
c. Pressand holdthe Readbuttonuntil the displayreadingstabilizes.
d. Verifythe reading.
I).Acceptable range 92.9 – 93.5 glossunit
ii). withthe read bottomdepressedadjustthe calibration toreadwithinthe requiredparameters.
e. Take two readingtoverify.
NOTE: Once the glossmeterhas beencalibratedbe careful not to adjust the Calibrating dial as this will
affectthe calibration.
2.4 Performrequiredglossmeasurement:
A).Place the glossmeteronthe test specimen.Specimenmust be flatand smoothinorder
for properreadingstotake place.
b). periodically confirmthe calibrationof the meterduringthe testingdesired.
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HALDIA PLANT
DOC. NO.-An/8.2/02
MAINTENANCE:
1. BATTERY CHANGING :
a).Batteryisto be changedonlyafterthe “LP BAT “symbol isdisplayed.Thiswill ensure maximumbatter
pack life.
b). the unitwill be chargedinapproximately16hrs.
2. LAMP CHANGING : RefertoManual forInstrument.
3. CALIBRATION STANDARD CLEANING &CARE
A).Use onlydrylint- free clothtocleanthe standard.
b).Do not use detergents oranycleaningagentsthatmay leave aresidue.
c). Do notscratch or mar the surface of the standard!!
Page 2 of 2

HALDIA PLANT
DOC. NO.-An/8.2/02
23. STANDARD TESTING METHOD OF T –
BEND FLEXIBILITY
SCOPE
These testmethodscoverthe determinationof the resistance toacracking (flexibility)of attachedorganic
coatingson substratesof sheetmetal.
METHOD:
ASTM– D4145
SAMPLE PREPARATION:
Take 10 x 10 cm paintcoatedmetal sheet – 2 Numbers (Coatedfilmthickness –16-18 micron)
PROCEDURE:
Place the testpanel ina vise withthe paintedmetal atleast2 inch (50cm) extendedoutside the vise.Usinga
steadypressure of the fingers,bendthe panelapprox.110 degree roundthe edge of the vise in1.5 sec.
Remove &re-insertintovise &close tocrimpmetal againstitself withmoderate pressure.Repeatuntil
requiredT- bendisachieved.Remove &examineimmediatelyforcrackingvisibletobe unaidedeye &tape
with3M #610 tape.
RESULTS:
No tape removal of a standard2-coat of 1T bendforAluminum&2T for steel substrate.These resultsare
dependentonsubstrate composition&the coatingthickness.
Page no 1 of 1

HALDIA PLANT
DOC. NO.-An/8.2/02
24. STANDARD TESTING METHOD OF PENCIL
HARDNESS GAUGE
PRINCIPLE:
The pencil hardnesstesterisaneffectivemethodtotestcoatingsforhardnessandresistance toscratches
and wear.The bestmethodallowsthe use of pencilswhichhave aknownhardnessgrade to be movedover
the surface to be testedat a fixedangle andpressure.
These pencilswhenpassedforaspecifiednumberof timesonthe coatingwill alsoallow awearfactorto be
determinedwhichisrelatedtothe hardnessof the pencil used.
Usingthis pencil Tester,itispossible toevaluate coatingsona vertical plane.The pressure orweightapplied
relatestopencil leadcrushingandtherefore canbe usedforvertical coatingevaluationtorepeatable
results.
INSTRUMENT:
1. PENCIL HARDNESSTESTER: AS PER ASTMD 3363
2. PENCIL SHARPNER : (6H to 2B)
3. PENCIL SHARPNER : (3B to 6B)
4. SET OF 14 PENCILS : (6B to 6H)
e.g.,B to 6B, HB, F & H to 6H
These leadsare mechanical pencil types,notwoodpencils.Woodpencils
May be usedif absolutelynecessary.
OPERATION:
For thistest,pencilsof increasinghardnessvaluesare movedoverthe surface inapreciselydefinedway
until one leaddamagesthe surface.
Surface Hardnessisdefinedbythe hardestpencil grade whichjustfailstodamage the surface.
The pencil hardnessTesterhasbeendesignedtoensure thatthe cylindrical pencil leadismaintainedata
constantangle of 45 degree andexerts aforce of 7.5N (1.68lbF)
The pencil lead,preparedbefore usingthe special sharpnerandabrasive paper,isinsertedintothe hardness
Tester& pushedoverthe smooth,flat coatedsurface.
The test mustbe conductedat ambienttemperature (25-30degree C) &
50 -60% relative humidity.
1. Place the coated panel tobe testedona level, firmhorizontalsurface.
2. Observe the pencil track.Sufficientpressure musthave beenapplied Eithertocutor damage the coating
or to crush the leadpencil point.
3. If neithercoatingdamage norpencil pointcrushingisobserved,repeatthe testuntil adefinite
observationismade.
4. If scratching or damage of the surface occurs,proceedwiththe nextsofterpencil grade andrepeat
the testingprocessuntil apencil leadgrade isfoundwhichcrushesanddoesnotdamage the
coating.
Page No. 1of 2

HALDIA PLANT
DOC. NO.-An/8.2/02
5. If crushingof the hardestleadshouldoccur,the coatingis therefore extremelyhardandbeyondthe
measuringrange of the test.
6. The lowesthardnessvalue of the pencil whichmarksthe coatingdetermines the coatingshardness
rating.
7. Reportany deviance fromthe standards methodusedsuchas
* Type&brandof leadsused
* Roughness/profileof coatingsurface.
DATA SHEET:
The gauge isequippedwith8leadslocatedinthe followingstandard positions(Extraleadsare storedinthe
middle tube of the gauge):
Position 1 2 3 4 5 6 7 8
Hardness 2B B HB F H 2H 3H 4H
Softest Hardest
The difference betweentwoadjacementleadsisconsideredone unitof hardness.Testingistoproceedfrom
the hardestleadto the softestlead.
Page No. 2 of 2

HALDIA PLANT
DOC. NO.-An/8.2/02
25. STANDARD METHOD OF SALT SPRAY
TEST FOR COLOUR COATED SHEET :
DEFINATION:
The salt spraytest isan acceleratedcorrosionrestusedtomeasure the comparative corrosionresistance of
materialsexposedtosaltsprayor salt fogat hightemperature.
The corrosiontestis intendedtoprovide corrosionresistance informationonmetal andcoatedmetalswith
visual inspection.Followingthistestthe suitabilityof coatings,paintsandmetalstoresistcorrosionor
exposure tomarine environmentscanbe determined.
EQUIPMENT:
ClosedsaltspraytestingequipmentasperASTMB 117 – 95
PROCEDURE:
In the saltspray test,samplesare placesinan enclosedsaltspraytestingcabinetorchamberbuilttoASTMB
117 specificationandsubjectedtouninterruptedindirectfogorspray of a saltwatersolution.This
environmentismaintained throughoutthe durationof test. The temp ismaintainedat35o
C (1.1 to 1.7oC)
witha pH range of 6.5 – 7.2and a salt atmosphere of 5 parts of sodiumchloride to95 parts D.M. water,
introducedintothe chamberatspecificairpressure.Thistestdoesnotindicate the lengthof exposure.
Thissalt sprayteststandard isextensivelyusedtomeasure normal corrosionresistance to oceanwatertype
environments.Testdurationdependsonthe specificationoncorrosionresistance of the material.
CORROSION RESISTANCE TEST RESULTS:
Numberof specimens =
Exposedinsaltspraycabinethrs.=
Evaluationrequirement= Observedat500hrs intervals
]Page No. 1 of 2

HALDIA PLANT
DOC. NO.-An/8.2/02
HOURS OBSERVATION TEST NOTE
0 hrs. Panels submitted for testing with
edges waxed
500 hrs.
1000 hrs.
1500 hrs.
2000 hrs.
2500 hrs.
3000 hrs.
3500 hrs.
4000 hrs.
4500 hrs.
5000 hrs.
TEST NOTES *- 1. SMALL RED RUST SPOT
2. BLISTERING AROUNDA HOLE IN THE PANEL
3. SMALL HOLES etc.
Page No. 2 of 2

HALDIA PLANT
DOC. NO.-An/8.2/02
26. STANDARD TESTING METHOD OF UV
ACCELERATED TEST
DESCRIPTION:
UV weathertestchambersimulates damagingeffectsof longtermoutdoorexposureof materials&coatings
by exposingtestsamplestovaryingconditionsof the mostaggressive componentsof weathering –UV
radiation, moisture &heat.A UV weatheringtestchamberusesfluorescentlampstoprovide aradiation
spectrumcenteredinthe UV wave lengths. Mostisprovided byforcedcondensation,&temp iscontrolled
by heaters.
PRINCIPLE OF OPERATION:
Whenplacedinside the radiationchamber,the samplesare exposedtolightof appropriate spectral
distribution.The Qsun can alsobe programmedto maintainadesiredhumiditylevelduringlightexposure.
TYPICAL DATA OUTPUT EXAMPLE:
Thisis justan irradiationchamber&no data outputresultsdirectlyfromthe instrument.However,the
objectsthatare irradiatedare analyzedlaterforspecificphotoeffectchange.The equipmentcanalso
determine the retentionof aestheticpropertiessuchascolour, surface finish,gloss, susceptibilityto
cracking,crazing or hazing.
SAMPLE REQUIREMENT:
UV testingchambercan accommodate a wide range of sample shapes&sizes. A standardsample amount
has dimensions of 75x150 mmand givesanactual exposure areaof approx.70x100mm. These are designed
for thetestingof flatspecimenssothe ideal sample inthiscase isa tile of a few mmthickness.
As the UV degradationisasurface phenomenon the sampleshouldnotbe twothickor itmay maskany
effectof the UV. Equallyverythinsamplescanalsosufferpremature failurewhichmaynotbe
representative of the final product.Ideallysamplesshouldbe inthe range of 1-5 mm. thick
Page No. 1 of 3

HALDIA PLANT
DOC. NO.-An/8.2/02
TEST CONDITION & DURATION:
The majorityof test standardsdonot specifythe testduration&thisis often pacified,aspartof the relevant
productstandards. You shouldcheckyourproduct standardsfirstforpossible specifiedtestingdurations.In
the absence of any definedperiods, recommendedminimumexposure durationis500hrs.
Thisis normallysufficienttodistinguishpoorlyperformingmaterials.However,lowerdurationsmaybe
necessarytodetermine which the bestperformingmaterial.Typicallyare,we maytestfor
500,1000,1500,2000 & 2500has durationwith500 & 1000 beingthe mostcommon.
In mostcasesit is recommendedincludingacontrol sample i.e.,amaterial withsome historyorknoon
outdoorperformance thatcan alsobe usedas a reference.Thiswill helptojudge if yourtestmaterial is
betteror worse thanpreviousmaterials.
Ideallymaterialsshouldbe testeduntil afailure pointisachieved,onlythencan be the real improvementin
the material be observed.However,oftenthisisnotpractical.Inall casesit isrecommendedthata key
parametersuchas colour, glossor mechanical propertiesare measuredwithexposuredurationasthiswill
oftensignal the firstchangesinthe material asit degrades.
WEATHER TEST CHAMBER SPECIFICATION :
1. Temperature range - RT + 20 degree C
2. Temp.uniformity - + or – 1 degree C
3. Humidity - > or = 90% R.H.
4. Testcycle setting - Illumination,condensation& waterspraytestCycle isprogrammable.
5. Lamp power - 40 w /piece
6. Lamp. Numbers - 8 numbers( UVA – 340 or UVB – 313 )
7. Irradiance - 1.0 w/m2
8. Testingtimes - 0 to 999 H, adjustable
9. Power - 22v/50Hz/ + or – 10% 5kw
10. Standard - ASTM D 4329 /D 499
Page No. 2 of 3

HALDIA PLANT
DOC. NO.-An/8.2/02
RESULTS (TABLE):
Sl.
No.
Hrs. Colour Change
(Deeping in water
cracking Chalking Change
of Gloss
Remarks
1 100 hrs.
2 150 hrs.
3 200 hrs.
4 250 hrs.
5 300 hrs.
6 350 hrs.
7 400 hrs.
8 450 hrs.
9 500 hrs.
10 550 hrs.
11 600 hrs
12 650 hrs.
13 700hrs.
14 750 hrs.
15 800 hrs.
16 850 hrs.
17 900 hrs.
18 950 hrs.
19 Final
Page No. 3 of 3

HALDIA PLANT
DOC. NO.-An/8.2/02
27. ASSAY DETERMINATION OF AMMONIUM
CHLORIDE
REAGENT:-
0.1 N Hydrochloric Acid Solution:
Take 8.8 ml of HydrochloricAcid(GR) and dissolve in1000 ml Distilledwater
0.1 N Sodium Hydroxide Solution:
Take 4 gm. of SodiumHydroxide (GR) anddissolvein1000 ml Distilledwater
Methyl red indicator
PROCEDURE:-
Take 0.3- 0.4 gm. Sample to250 ml .Take 25ml from itadd 25ml SodiumHydroxideSolution.
Afterthis boil ituntil smell of Ammoniumgone completely.Aftercoolingadd4 to6 drops of
indicatorand titrate against0.1 N HCl.End pointwill be redcolour.
CALCULTION:-
1ml of 0.1 N HCl equivalentto0.00535 gm. ammoniumchloride.
Assay (%) = Strength of HCl X 0.00535 X TV X 1000
Sample Quantity
Page No. 1 of 1

HALDIA PLANT
DOC. NO.-An/8.2/02
28. ASSAY DETERMINATION OF ZINC
CHLORIDE
REAGENT:-
0.1 N Silver Nitrate Solution:
10% Potassium Cromate Solution:
Methyl red indicator
PROCEDURE:-
Take 0.3- 0.4 gm. Sample andmake up vol.Up to 250 ml .Take 25ml from itadd 1ml potassium
cromate Solution and10 ml water.
Titrate against0.1 N SilverNitrate solution. Endpointwill be redcolour. Note the titrate value (A).
Alsoperforma blankTest(B)
CALCULTION:-
Here, 1ml of 0.1 N silvernitrate isequivalentto0.00682 gm. Zinc chloride.
Assay (%) = Strength of silver nitrate X 0.00682 X (B-A) X 1000
Sample Quantity
Page No. 1 of 1

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