187262803 Sample Galvanizing Procedure ITP

G. K. WIRE INDUSTRIES LLC

P.O.Box - 32820 , RAS AL KHAIMAH , United Arab Emirates RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

Head Office, Dubai - Tel.(9714) 8872904 , Fax.(9714) 8816250 E-mail : [email protected]

PROCEDURE FOR SURFACE PREPARATION

AND HOT DIP GALVANIZING ON FABRICATED STEEL ITEMS

PROJECT: EPC CPF Phase-1 al BADRA OIL FIELD

CLIENT: Unger Steel Middle East FZE / PETROFAC

P.O NO.: 2013030011

LOCATION: UAE

SUPPLIER: G.K.Wire Industries LLC

DOCUMENT NUMBER: LME- FCP-199-004

REV. ISSUE DATE PURPOSE OF ISSUE PREPARED APPROVED

01 05-09-2012 Customer Specific N.B.Joshi Dhananjay Joshi

02 05-09-2012 Customer Specific N.B.Joshi Dhananjay Joshi




REVISION HISTORY:

REV DATE DESCRIPTION PREPARED BY APPROVED BY 00 05.09.2012 Customer Specific N.B.Joshi Dhananjay Joshi

.

DEFINITIONS : Project: EPC CPF Phase-1 al BADRA OIL FIELD Contractor: PETROFAC / Unger Steel Middle East FZE Galvanizer: G.K.Wire Industries LLC




TABLE OF CONTENTS

2. REFERENCE DOCUMENTS

articles

ple Salt)

( Hot dip Galvanizing ) of steel items nching process

& Grinding of galvanized Items k. Inspection l. Adhesion m. Repair

1. SCOPE

3. RESPONSIBILITIES 4. PROCEDURE

a. Blasting & Cleaning the surface of steelb. Degreasing c. Water Rinse d. Pickling ( HCL Acid cleaning process ) e. Water Rinsing Process f. Flux coating process :( Zinc Ammonium Chloride Trig. Drying of Articles h. Zinc coatingi. Water Quej. Cleaning




1. SCOPE This Process procedure intends to have the clear guidelines for Hot Dip Galvanizing of fabricated Steel products as per Order specification & Standard code specification requirements applicable to G.K.Wire

2.

on & test method. related Rust

grades and products preparation grades of uncoated substrates and of steel substrates after s coatings.

ification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

2013-200-CS-SP-002 Engineering Specification to structural steel work

4.

Industries LLC.

REFERENCE DOCUMENTS 1. BS EN ISO 1461:2009 Hot Dip galvanized coatings on fabricated iron & steel articles-

Specificati2. ISO8501-1 - Preparation of steel substrates before application of paints and

overall removal of previou3. ASTM A 123-Standard Spec

4. GB088-

3. RESPONSIBILITIES Production Engineer / QC Inspector

PROCEDURE Preparation for Galvanizing Materials:

a. The Production Engineer decides on the article suspension method either tying or placing them in

suitable fixture taking into consideration the following points, Articles shape, size, weight & Identification of member number. Position of venting & drainage holes ( if required )

IG-6.7) if required, shall be drilled as per Job material requirements. Dia 8 mm to 15 mm as required, if required depending upon shape and size.

rated balance & weight of items recorded in logbook.

Availability of tying points b. Vent holes & drainage holes (As per ASTM A385, F

c. Pre-weighing - Articles are weighed on the calib

d. All articles to be galvanized shall be handled in such a manner as to avoid any mechanical damage and to minimize distortion due to mechanical force.

1) Blasting & Cleaning the surface of steel articles :

a. Articles are blasted with Automatic shot blasting method by using steel shots S-170 grade or other

grades. Used steel shots / scales are collected in drums & refilled with new shots & used shots are disposed off to authorized dump yard.

ds required according to surface condition of articles.

r White Blast Metal.( SA 2-1/2 grade blasting surface finish (as per

r the contaminant

each article is tilted & shot particles shall be removed from inside portion of each shaking each other.

b. Articles are blasted to ensure that the surface is entirely free of rust and other visible contaminants. The shift foreman determines the no. of roun

c. Blasted articles are inspected visually by the Quality control engineer & items shall be shot blasted to a surface cleanliness of NeaSSPC,SP10)

d. Any incomplete blasted areas are assessed by QC Inspector to determine whethe can be removed during the pickling process.

e. After blastingarticle by




f.

g. ion, venting drainage.

2 Degreasing

2.2 to 2.5mm dia. Black annealed wire pieces are used for tying the articles to the frames. The batch articles are spaced along the frame to ensure no contact with each other. The frames are attached to cranes & the wired articles are checked for uniform distribut&

)

remove organic contaminants including dirt, ater based paint markings, grease and oil. Degreased objects are visual inspected for removal of

fted and tilted to drain all solution from articles.

Articles are dipped in batches in degreasing tank towimpurities on the surface. Articles are li

3) Water Rinse

After cleaning articles are rinsed in water by immersing in Water bath. Again articles are lifted and tilted to drain the water.

4) Pickling ( HCL Acid cleaning process )

a. After degreasing, articles are immersed for approx. 2 to 5 minutes in the pickling solution

uring fresh start of acid bath. the articles for cleanliness after

hieved. Quality

ined & submitted to local Authority for approval. After approval from

ized surface, Black surface, Black spots, pH value 2-3, Iron content (Fe) 150gms/lit. max., HCL concentration % > Complete replacement of old acid from bath.

Acid strength shall be checked every 15 days interval at in-house laboratory & samples are analyzed for Acid concentration & Iron content. Acid pH shall be checked everyday with pH paper at the beginning of the shift.

The finished materials are bundled & packed as per job requirements & dispatch note is issued. If direct delivery is arranged for finished materials then loading requisition note is issued against the

depending upon the size, type, shape and surface condition of the articles. Pickling is performed to remove mill scales and /or surface rust.

b. Pickling solution comprising of commercial grade HCL acid (33%) diluted with water to approximately 15% strength d

c. In regular use the shift foreman / QC Inspector visually inspects pickling process.

d. On rejection articles are repeatedly pickled until the above conditions are achieved. e. In regular use depending upon the quality of pickled galvanized materials the fresh acid + water in

2: 1 ratio respectively is added directly into the acid bath until the required pH is acof Pickled galvanized materials > Heavy coating thickness, Zinc flaking or peeling / chipping of zinc > Replenished the acid bath.

f. HCL Concentration > Min.17 - 18% & Required pH Value > Min. 7 g. If the acid is found weaker for process then it is collected in containers which are neutralized to

7pH by adding caustic soda & samples are sent to an independent laboratory for analysis. Test analysis certificate to be obtaLocal Authority, this neutralized acid is disposed off to approve dump yard location.

h. Following Criteria is used for changing the complete acid from bath : Weaker Acid strength > Blisters on galvan

i.

j.

loaded materials.




5) Water Rinsing Process :

a. Pickled articles are dipped into the rinsing bath completely & suspended over the bath until water no longer pours off.

(pH




g. Zinc ash is removed from bath every day & collected into drums, Zinc dross is removed from bath on weekly basis. Both the wastages are weighed prior to dispose off to scrap dealers & records are maintained.

9) Water Quenching process :

a. The Hot dip Galvanized articles are quenched in cooled runni

ng water bath by immersing gradually

g onto the concrete floor. The quenching suitability

frames / fixtures & moved to cleaning

in a manner which will enable the steam to escape safely The articles which may suffer distortion during quenching are cooled naturally by lowerinis determined by the Supervisor by assessing the article shape & size.

b. Cooled & quenched articles are removed from the suspendedoperation.

10) Cleaning & Grinding of galvanized Items :

a. The tie wires (if any) are cut & rem

oved from galvanized articles & surfaces are visually inspected.

l zinc deposits are removed from both ends of holes location by hammering the punch rod

spots (if any observed) are cleaned & sprayed with

hall be removed by hammering or send to Fabrication

ss Zinc coating thickness for the steel thickness 3mm to above 6mm

in on calibrated balance & galvanized materials weight is

11)

The good galvanized materials are further cleaned with smooth grinding & excess lumps / flow marks / excess zinc deposits are removed from the surface.

b. Additiona& all hole edges are to be removed by grinding.

c. Tie wire markings & small pointed galvanized zinc rich paint- As per BS 2569 minimum two coating layer.

d. Distortion due to heat (warpages / bends) sdepartment for removing with hydraulic jacking system.

e. Each batch of galvanized materials is inspected as per sampling plan for Coating thickne(Magnetic method), the meanshall be minimum 70m to 100m.

f. Finished materials are weighed agacalculated. Accordingly daily production report is prepared along with weighing records sheets.

Inspection: a. The integrity of the coating shall be determined by visual inspection and coating

thickness measurement as per BS 1461:2009

ndards of galvanizing. The final weight of galvanized coating shall be as per BS 1461:2009. Table-3,4

12.

b. Inspection shall be witnessed at the galvanizer works by the customer QC Inspector and client designated third party Inspector if required.

c. Where coating thickness measurement is not feasible the coating weight shall be determined as noted the referenced sta

Adhesion : The test is to be carried out by the customer. G.K.Wire will provide test sample of the material for his testing, if required.

nner tending to ) shell be

he coated article. c) The galvanized coating shall be sufficient by adherent to withstand normal handling during

transport and erection.

same a) The adhesion of the zinc coating to the surface of the base metal shall be determined by cutting or

prying with the point of a stout knife, applied with considerable pressure in a maremove a portion of the coating , otherwise a cross-hatch test (according to ISO 16276followed.

b) The galvanizing coating shall be continuous adherent as smooth and evenly distributed as possible and free from any defect that is detrimental to the stated end use of t




13. Repair: a. If any black surface or blistered surface and peel off surface observed then these items are re-

galvanized by complete process and remedial action are recorded in log book. b. Renovation of damaged zinc coating shall be followed as per BS 1461:2009 Para 6.3 c. Renovation shall be by thermal zinc spraying as per ISO 2063, or by a suitable zinc- rich paint

as per BS 2569. Where the zinc dust pigment conforms to ISO 3549 within the practical limits of such systems, or by suitable zinc flake or zinc paste products.




HOT DIP GALVANIZNG COATING CERTIFICATE

G. K. WIRE INDUSTRIES LLC P.O.Box - 32820 , RAS AL KHAIMAH , United Arab Emirates

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

July 2012 Revision 1 Page 1 of 5

INSPECTION AND TEST PLAN

HOT DIP GALVANIZING

PROJECT: EPC CPF Phase -1 al BADRA OIL FIELD

CLIENT: Unger Steel Middle East FZE

P.O NO.:

LOCATION: UAE

SUPPLIER: LINK MIDDLE EAST LIMITED

Document No: GKWI-ITP-001

Rev. Issue date Purpose of issue Prepared Approved

0 Issued for Review Ronald Dsa

.


RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515


TABLE OF CONTENTS

1. SCOPE ............................................................................................................................................................. 3

2. DEFINITION...................................................................................................................................................... 3

3. REFERENCE CODE......................................................................................................................................... 3

4. INSPECTION AND TEST PLAN........................................................................................................................ 3

4.1 INSPECTION & TEST PLAN- RECEIVING INSPECTION OF RAW MATERIALS FOR FENCE AND GATES... 4


RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515


1. SCOPE

The scope of this Inspection and Test Plan is to establish the requirements of Fabricated Steel

Steel as per Specification and procedures.

2. DEFINITION

Contractor - : Unger Steel Middle East FZE/Petrofac

Supplier : G.K Wire Industries

3. REFERENCE CODE

ASTM A123 :

ISO BS EN 1461

4. INSPECTION AND TEST PLAN


RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

Document No GKWI-ITP-001 : July 2012 Revision 0 Page 4 of 5

4.1 INSPECTION & TEST PLAN- RECEIVING INSPECTION OF RAW MATERIALS FOR FENCE AND GATES

LEGEND C- Check Point Inspection by LME , H - Hold Point CLIENT must attend, W - Witness Point - CLIENT must be informed but if not in attendance work can proceed, R - Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac

A

C

T

I

V

I

T

Y

WORK ACTIVITY QUALITY CHARACTERISTIC

TO BE VERIFIED

PROCEDURE REFERENCE/CODE/

STANDARD

ACCEPTANCE CRITERIA / VALUE

PERFORMED BY

G

K

W

I

U

S

M

E

P

I

L

QUALITY VERIFICATION RECORD

1 Receiving of

fabricated

Structures, Pipes,

accessories

Completion of fabrication

Qty, Surface condition

damages and defects

Internal Procedure, GB088-

2013030011-CV-J04-001

Operation completion as

per drawing, specification

Qty as per Order

Free from damages and

Any defects

Quality

Control

Engineer

Production

Engineer

C R R Visual Inspection Report

2 Surface preparation

Blasting, Pickling,

Flux coating

Surface free from Rust, Mill

Scales and Loose Burrs, Oil,

paint, Corrosion Marks

2013030011-CV-J04-001 Blasting to a surface

cleanliness of near White

Blast Metal ( SA 2 -

grade blasting finish)

Clean Surface with flux

coat

Quality

Control

Engineer

C W R Visual Inspection Report


RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

Document No GKWI-ITP-001 : July 2012 Revision 0 Page 5 of 5

LEGEND C- Check Point Inspection by LME , H - Hold Point CLIENT must attend, W - Witness Point - CLIENT must be informed but if not in attendance work can proceed, R - Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac

A

C

T

I

V

I

T

Y

WORK ACTIVITY QUALITY CHARACTERISTIC

TO BE VERIFIED

PROCEDURE REFERENCE/CODE/

STANDARD

ACCEPTANCE CRITERIA / VALUE

PERFORMED BY

G

K

W

I

U

S

M

E

P

I

L

QUALITY VERIFICATION RECORD

3 Hot Dip Galvanizing Zinc coating thickness, Zinc

adhesion, visuals,

Instrument calibration

verification

2013030011-CV-J04-001

ASTM A 123

ISO BS EN 1461

Average Zinc Coating as

per specification

No Peel off.

No lumps

Quality

Control

Engineer

C H H Hot Dip Galvanizing

Certificate

4 Final Inspection,

Identification,

Packing

Zinc coating finish

Individual / Batch

Identifications marks

Packing as per

requirements

2013030011-CV-J04-001

Customer specifications

Zinc coating as per

specification, no defects

Identification as per Job

numbers

Rigid packing to avoid

damages

Quality

Control

Engineer

C H W Pre despatch Inspection

Report