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Proven Track Record

Manufacturing kettles is a controlled process carried out by skilled operators with suitable equipment and incorporating inspection, testing and monitoring.

Quality product

Furphy Engineering has been operating galvanizing plants for nearly 20 years. Currently we operate four galvanizing plants in Australia (click here) and have continually drawn from this experience, as a galvanizer, in improving the design of our kettles.

Experienced Galvanizer

Furphy Engineering has a proven track record of building galvanizing kettles for over 18 years and is currently building about 18 kettles annually for both general and continuous galvanizers. Kettles have been supplied to Australia, New Zealand, Asia and the Middle East. Good transport links allows kettles to be supplied to Pacific and Indian Ocean Rim Countries as well.

Two Galvanizing Kettles by Furphy Engineering awaiting final transportation.

The kettles are fabricated from steel with the following properties:

• Low silicon fully killed steel
• Grade A1006 AS/NZS 3678
• Ultrasonically tested to level 2 AS1710

The welds, using proven consumables, are in accordance with:

• 100% ultrasonic inspection
• 100% magnetic particle examination

All welds are fully visually scanned and examined. Butt (groove) welds are then subjected to:

• AS/NZS 1554.1 category SP
• AS/NZS ISO 3834.2. - Quality Requirements for Welding

 A National Association of Testing Authorities Australia (NATA) approved laboratory independently tests all kettle butt (groove) welds. All these details are provided in the manufacturer's data report supplied with the kettle.A National Association of Testing Authorities Australia (NATA) approved laboratory independently tests all kettle butt (groove) welds. All these details are provided in the manufacturer's data report supplied with the kettle.

Galvanizing kettle being welded to Austrlian Standards AS1554

Macro sample of wall to wall butt weld

Design and support services

Advice is available on the design of kettle including flange size and propping arrangements. Other design and operational support can be provided to assist the galvanizer in the operation and maintenance of the plant. This includes thickness testing of the kettle and life assessment.

Ongoing Research and development

As the leading manufacturer of kettles in the region, we have a commitment to ongoing research and development. This information is shared with our customers to assist in achieving the maximum economical life from the kettle. A paper was presented at the 4th Asia Pacific General Galvanizing Conference on the Design and Construction of Galvanizing Kettles for Long Life. Work is currently being undertaken on improving the welding of galvanizing kettles.

Furnace / Kettle package

In association with Kingfield Equipment, a package can be put together including combustion chamber, burners, controls, kettle cover and environment controls. This pools the combined expertise in plant design of both organisations. Both companies also operate a total of seven galvanizing plants throughout Australia and this operational expertise is brought to bear.

40 tonne Galvanizing Kettle being delivered to port ready for export to Singapore

Additional Equipment

The following equipment can be designed and manufactured to your requirements.

• Caustic tanks including immersion tubes
• Acid tanks
• Flux tanks
• Pre heat oven
• Management and operator training

Training of management and staff is offered to assist in ensuring the design life of the kettle is met. This would be tailored to suit the needs of the people and organisation involved and could include:

• Dross removal
• Thickness testing
• Safe operation
• Installation and commissioning
• Operational parameters

Facilities

The following plant is specifically used in the fabrication of kettles:

• 20 tonne and 10 tonne overhead cranes
• Capable of handling up to 60 tonne with supplementary cranage
• 1200 tonne hydraulic press (see picture this page)
• FCAW - 8Lincoln power sources ranging in size from 400 amp to 1000 amp
• MMAW - 4 Lincoln 400 amp welders
• Lincoln 400 amp Air Arc Gouger

Radius bending of 50mm plate in 1200 tonne press