SPECIFICATION SHEET FOR POWDER, PRETREATMENT & POWDER COATING Scope: Specification & process check for Powder,

Pretreatment & powder coating of mild steel & sheet metal parts. 1. 1.1 POWDER DETAILS Powder Type: Epoxy Polyester nternal parts of !ocal & Export P"mps. P"re Polyester External parts of !ocal P"mps. Shade: $ef.%omponent &rg. (loss: as per S: 1')*1+1,,'. .inish: $efer %omponent &rawing. Powder storage: 0s recommended 1y Powder 2an"fact"rer3 at '45 % Powder shelf life: 0s recommended 1y Powder 2an"fact"rer /Six months. PRETREATMENT PROCESS The mild steel 3sheet metal components are to 1e pretreated 1y Hot 7inc phosphate process, "sing chemicals of rep"ted man"fact"red. Ens"re that the %omponents are free from 8ea9y $"st & Pit 2arks. .ollow the instr"ctions of chemical man"fact"rer to maintain Parameters pertaining to Temperat"re, %oncentration, Pointage, dipping time & for testing, control, and replenishment of pretreatment 1aths. #.1.1 &egreasing: :ath %omposition: 0s recommended 1y chemical man"fact"rer. ;perating temp: *45 % to )45 % Testing 2ethods: 0s recommended 1y chemical man"fact"rer. Tests: Pointage: 0s recommended 1y chemical man"fact"rer. Testing .re<"ency+ &aily Note - Maintain Reco !" in Anne#$ e A%

1.# 1.' 1.1./ 1.6 2 #.1

;il contain: 0s recommended 1y chemical man"fact"rer.

Testing .re<"ency+ ;nce in a 2onth Note - Maintain Reco !" in Anne#$ e &%

$eplenishment: 0s per the recommendation of chemical man"fact"rer.

#.1.#

&er"sting =P"re Phosphoric acid 1ased> ' :ath %omposition: 0s recommended 1y chemical man"fact"rer. ;perating temp: 0m1ient Testing 2ethods: 0s recommended 1y chemical man"fact"rer. Tests: Pointage: as per the recommendation of chemical man"fact"rer. Testing .re<"ency+ &aily. Note - Maintain Reco !" in Anne#$ e A% rons contain: 0s per the recommendation of chemical man"fact"rer. Testing .re<"ency+ ;nce in a 2onth Note - Maintain Reco !" in Anne#$ e &% $eplenishment: 0s recommended 1y chemical man"fact"rer.

#.1.'

?inc phosphate: :ath %omposition: 0s recommended 1y chemical man"fact"rer. ;perating temp: *45% to */5% Testing 2ethods: 0s recommended 1y chemical man"fact"rer. Tests: Total 0cid' 0s recommended 1y chemical man"fact"rer. Testing .re<"ency+ ;nce in a shift Note - Maintain Reco !" in Anne#$ e A%

.ree 0cid: 0s recommended 1y chemical man"fact"rer. Testing .re<"ency+ ;nce in a shift Note - Maintain Reco !" in Anne#$ e A%

0ccelerator' 0s recommended 1y chemical man"fact"rer.

Testing .re<"ency+ ;nce in a shift Note - Maintain Reco !" in Anne#$ e A%

$eplenishment & %ompensating of %hemical: 0s recommended 1y chemical man"fact"rer.

#.1.-

Passi9ation: :ath %omposition: 0s recommended 1y chemical man"fact"rer. ;perating temp: 6/5% to */5% Testing 2ethods: 0s recommended 1y chemical man"fact"rer. Tests: %hecking of p 8 p 8 9al"e as recommended 1y chemical man"fact"rer.

Testing .re<"ency: Per shift. $eplenishment: 0s recommended 1y chemical man"fact"rer. Note - Maintain Reco !" in Anne#$ e A Note' Pa""i(ation )at* "*o$+! !i"ca ! in a ,ee-.

#.1./

8ot air drying: Temp. 64 to )45%.

#.1.6

.low chart for process of pretreatment

INP0T

ACTI.IT/

O0TP0T

!oading at 0m1ient

&egreasing at *44 to )44 %

2aintain record in 0nnex"re 0 & :

&egreasing

@ater $insing at 0m1ient

2aintain record in 0nnex"re 0

@ater $inse

&er"sting at 0m1ient

2aintain record in 0nnex"re 0 & :

&er"sting

@ater $insing 0t 0m1ient Phosphating *44 to */4 %

2aintain record in 0nnex"re 0 2aintain record in 0nnex"re 0 & :

@ater $inse

Phosphating

@ater $insing 0t 0m1ient

2aintain record in 0nnex"re 0

@ater $inse

Passi9ation 0t 644 to *44 %

2aintain record in 0nnex"re 0

Passi9ation

8ot air drying 0t 6/4 to */4 %

2aintain record in 0nnex"re 0

Anloading

#.1.* #.1.*. 1

%8E%B P; CTS .;$ P$ET$E0T2ECT P$;%ESS

Phosphate %oating weight to 1e achie9ed 1etween #.' g3mD to -.' g3mDas per S: '61)-1,66 =$eaffirmed #44#> %la"se Co.6.' Testing .re<"ency: ;nce in a week. Note - Maintain Reco !" in Anne#$ e &

#.1.*. #

'E C0%! Test F mmersed sample panel for 1# hrs in 'E C0%! =!$ (rade> sol"tionG as per S:'61)+1,66 =$eaffirmed #44#>%la"se Co.6.# Testing .re<"ency+ ;nce in a week Note - Maintain Reco !" in Anne#$ e &%

#.1.*. ' 1 '.1

His"al nspection ?ink Phosphated components sho"ld 1e free of $"st, Patchy Phosphate, yellow stain & other s"rface defects.

POWDER COATING

Powder Type: $efer cla"se 1.1

'.#

Ens"re that Powder coating Process sho"ld start within ) 8rs from completion of Phosphating process.

'.'

Powder %oating Thickness =&ry .ilm Thickness> .or External %omponents &.T+ min )4 micron on o"ter s"rface &.T+ min /4 micron on inner s"rface .or nternal %omponents. &.T +0ll o9er min /4 micron

'.'./

Pro9ide 2asking on Threaded portion. ;9en to 1e cali1rated for TT$=To 1e %ali1rated e9ery Six 2onth>

'.6

Sto9ing Time & Temp. : Typical sto9ing sched"le is 14+1/ min. at 1)45 % 8owe9er follow the instr"ction gi9en 1y Powder 2an"fact"rer.

2 -.1 -.1.1 -.1.#

Te"tin3 o4 Po,!e Coatin3 Co56onent"7Re4% IS 181 & IS 119:1; His"al nspection .inish: Powder coated s"rface sho"ld not show any scratch, crack marks, l"mps deposits, d"st, pin holes, cissing. (loss & shade: (loss as recommended 1y Powder man"fact"rer =as per 1')*1:1,,'.> and shade sho"ld 1e as per respecti9e drawing re<"irement% Threaded portion sho"ld 1e free from powder deposits S:

-.1.' -.#

Test Panel &etails+Powder %oated Panels Si7e /4 x 144 x4.634.) mm are to 1e "sed for test.

-.' -.'.1

2echanical Tests

&.T =&ry .ilm thickness>: $ef '.' for coating Thickness F$efer S 141 =Part ' 3 sec #.>:1,),G 8ardness test

-.'.# -.'.#.1 -.'.#.# -.'.' -.'.'.1 -.'.'.# -.'.'.'

%ross 8atch test+%oating sho"ld not peel off =(TI 4> F$efer S 141 part / 3 sec #.> :1,))G Scratch hardness test Sho"ld pass ' Bg !oad, F$efer S 141 =Part / Sec.1> : 1,))G

.lexi1ility and 0dhesion4 2andrel 1ending test: J 6. #/ mm as per S 141 =Part / sec #>:1,)) Erichsen c"pping test: 0s per S 141 =Part / 3 sec# cla"se Co.->:1,))

mpact test: = $ef. S 1')*1 :1,,'> (rade 0 =(lossy (rade+: =Semi+ .inish> (lossy .inish> mpact $esistance #/4 1/4 kg3cm &"ra1ility Test

(rade % =2att .inish> 1/4

-.-.-.1

$esistance to h"midity "nder condition of condensation: The painted sample shall 1e s"1Kect to expos"re "nder condition of condensation for se9en days as per S 141 =part 63 Sec+1 %la"se no.+#>:1,)). t shall not show r"sting marks no 1listers or loss of adhesion Salt spray test: The painted sample when s"1Kect to this test for 1444 8o"rs as per S 141 part 63 Sec+1 %la"se no.+':1,)). t shall show no r"st .ormation

-.-.#

-./

En9ironmental tests Li<$i! Met*o! P"t one drop of 2EB on Powder coated s"rface &ipping D$ ation 1 min L am1ient =$eco9ery Period I M hrs.> -) hrsL am1ient Re"$+t" Co change in hardness. =0fter r"11ing with cloth powder film sho"ld not comes o"t> Co change in gloss or colo"r.

-./.1

2EB

-./.# -./.' -./.-././ -./.6 -./.* -./.) -.6 -.6.1 -.6.# -.*

Petrol

$esistance to 1oiling water 13# hr at 144 deg.%.=$ef. S:141 Part *3Sec.1 +1,),> $esistance to l"1ricating oil, S0E '4. *# 8rs at *4 deg. % =$ef. S:141 Part *3Sec.# +1,,4> $esistance to heat do"1le 1ake sched"le.+1)4 deg. % for '4 min"tes =$ef. S:141 Part *3Sec.' +1,,4> $esistance to 1leeding. =$ef. S:141 Part *3Sec.- +1,,4> $esistance to detergent+/E Sol"tion for 1/4 ho"rs. 0t *- N3+1 deg. % =$ef. S 1')*1 :1,,'+0nnex :> $esistance to acid3alkali.=$ef. S 1')*1 :1,,'+0nnex %> ;ptical Test (loss: To 1e meas"re with gloss meter. =$ef.+ S: 141 part - 3 Sec- +1,))> $esistance to AH: To pass /4 8rs test as per 0ST2 & -/)*+,1, light ='1' mm> test method &. Co significant change in shade, loss of gloss 64E expected Cote: Tracea1ility sticker indicating: 9endorOs name, item code no, inspected 1y & date =$ef. (!+,-6 for sticker detail> to 1e affixed on each component 1y 9endor.

-.)

Type Test $eport $ecords are to 1e maintained 1y processor Te"t $esistance to h"midity "nder condition of condensation Salt spray test $esistance to AH TT$ of ;9an Phosphate %oating weight 'E C0%! Test Petrol $esistance to 1oiling water 13# hr at 144 P % $esistance to l"1ricating oil, S0E '4. $esistance to heat do"1le 1ake sched"le $esistance to 1leeding. F e<$enc= E9ery six 2onth E9ery six 2onth ;nce in year E9ery six 2onth ;nce in week ;nce in week E9ery 2onth E9ery 2onth E9ery 2onth E9ery 2onth E9ery 2onth E9ery 2onth E9ery 2onth six six Re4% Doc$5ent S"ppliers report3TP S"ppliers report3TP S"ppliers report3TP TT$ $eport of TP S"ppliers report3TP S"ppliers report3TP S"ppliers report3TP Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report. Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report. Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report. Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report. Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report. Powder coater to get &;%3test certificate from powder man"fact"rer & s"1mit along with inspection report.

-.-.1 -.-.# -.6.# './ #.1.*.1 #.1.*.# -./.# -./.'

-./.-

six

-././

six

-./.6

six

-./.*

$esistance to detergent

six

-./.)

$esistance to acid3alkali.

six

-.,

$o"tine Test Test %ertificate & test panels sho"ld s"1mit with each lot Te"t His"al nspection &.T 2eas"rement =&ry .ilm thickness> %ross 8atch test Scratch hardness test 2andrel 1ending test Erichsen c"pping test mpact test 2EB (loss F e<$enc= Each s"pply Each s"pply Each s"pply Each s"pply Each s"pply Each s"pply Each s"pply Each s"pply Each s"pply Re4% Doc$5ent S"ppliers report S"ppliers report S"ppliers report S"ppliers report S"ppliers report S"ppliers report S"ppliers report S"ppliers report S"ppliers report

-.1 -.'.1 -.'.#.1 -.'.#.# -.'.'.1 -.'.'.# -.'.'.' -./.1 -.6.1 >

Pac-in3-Powder coated component to 1e packed with %orr"gated sheet & 1"11le sheet to a9oid damages d"ring 8andling & Transportation. = f two or more than two components are packed in one :ox, Thick %orr"gated sheet to 1e "se 1etween two components.> P oce"" S6eci4ication S*eet 4o Po,!e , P et eat5ent & Coatin3@ to 1e a"dited 1y Q0 on 2onthly :asis.

Prepared :y: RRRRR

0ppro9ed :y: RRRRRR

Anne#$ e A &aily Pretreatment $ecord : &ate:+

Time:+
Sr. Co. Process %hem ical Ased Pointage $e<. 0ct"al Temp Pc $e<. 0ct"al $e< &ip Time 0ct"al Ph Hal"e $e<. 0ct"al Total 0cid $e< 0ct"al $e< .ree 0cid 0ct"al $e< 0ccelator 0ct"al $emarks

41 4# 4' 44/ 46 4* 4) 4, 4* 4)

&egreasing @ater $inse+1

@ater $inse+# = f applica1le>

&er"sting
@ater $inse+1 @ater $inse+# = f applica1le>

?n Phosphating @ater $inse+1

@ater $inse+# = f applica1le>

Passi9ation 8ot 0ir &ry

nspected :y.:

Herified :y:

10

Anne#$ e &

%8E%B C( ;. ; ! %;CT0 C ;. &E($E0S C( :0T8 &ate $e<"ired 0ct"al ;il %ontain $emark

%8E%B C( ;. $;C %;CT0 C ;. &E$AST C( :0T8 &ate $e<"ired 0ct"al ron %ontain $emark

&ate

Testing Time .rom To

$es"lts

TEST $EP;$T .;$ ' E C0%! TEST $emark

&ate nspected :y+

TEST $EP;$T ;. P8;SP80TE %;0T C( @E (8T $e<. 0ct"al #.'+-.'gm3mD Herified :y+

11

Revision Details: Revision No. Date: 01 25.12.2009

Change Details:
2odified for addition of 0> .ollowing tests 1> $esistance to 1oiling water 13# hr. #> $esistance to l"1ricating oil, S0E '4 '> $esistance to heat do"1le 1ake sched"le. -> $esistance to 1leeding. /> $esistance to detergent 6> $esistance to acid3alkali :> Temp of pretreatment chemical is changed as per chemical man"fact"rer %> Testing .re<"ency of $esistance to h"midity "nder condition of condensation is changed from ;ne year to six month. &> Ase of &"ra1le P"re Polyester Powder for export p"mp is remo9ed.

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