Sample Galvanizing Procedure +ITP

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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

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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

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

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 Nea

SSPC,SP10)

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

e. After blasting article by

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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 to

w

impurities 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 ac

of 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 obta

Local 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.

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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 <3).

b. Samples from rinsing water bath checked with pH paper every 7 days for determining the pH value, results are recorded. Fresh water shall be added when water becomes too acidic

6) Flux coating process :( Zinc Ammonium Chloride – Triple Salt)

a. Rinsed articles immersed in the flux bath for a minimum of two minutes, withdrawn & suspended above the bath until flux is no longer runs off. Flux coating is performed to remove / dissolve oxides of iron, which had formed after pickling also flux coating acts as anti oxidation coating on

esh start of Flux bath.

. Density of flux is maintained 22 – 30 Baume & flux bath temperature is maintained 70 – 80 °C. e Flux bath solution density is measured with Hydrometer at every 4 Hrs. intervals & decided how much flux concentration or water is needed to restore the flux to the required

ux bath until the required relative density of ality of Galvanized materials, every six month flux bath solution is checked visually for flux bath solution quality, strength & if the solution is found weaker then it is disposed

t. the surface.

b. Flux solution comprising of Galva flux - STC-III + Flux additives - STC prepared at 2 : 1 ratio respectively mixed with fresh water in flux bath during fr

c

d. In regular use, th

density in the bath. Accordingly fresh solution of flux (100 kg. Galva flux – STC-III + 30 kg. Flux additives – STC) is added with water directly into the fl

min. 22 – 30 Baume is achieved. e. Depending upon the qu

off through Local Authority Environmental departmen 7) Drying of Articles :

a. The fluxed article frames are suspended in the oven & preheated to assist flux drying. The oven temperature is maintained min. 110°C to max. 120°C.

b. The suspended article frames are detached from the 1st_{crane & attached to the 2nd crane for next}

galvanizing operation.

8) Zinc coating ( Hot dip Galvanizing ) of steel items :

a. During fresh start of Zinc bath, 99.995% pure Zinc is added in the tank. An average molten zinc bath temperature of 445°C ± 5°C is maintained.

b. Suspended articles are slowly dipped at an inclined position until fully immersed in the molten zinc bath.

c. Depending upon the size, type & thickness of the section, the articles remains immersed until violent reaction have ceased & white smoke disappears. The articles are swung & agitated to assist

disappearing of white smoke the articles are slowly withdrawn from bath at inclined position to allow the free drainage of excess zinc & avoid lumps. Un-solidified excess zinc is removed by scrapers from the surface of suspended articles.

6’’ from top) is maintained by adding fresh 99.995% pure zinc slabs (24-26kg. each), depending upon the size & quantity of galvanized articles every day. wetting.

d. The zinc bath surface is skimmed & zinc ash removed by scrapers. e. After complete

f. In regular use, the level of zinc (max.

These fresh zinc slabs are preheated by keeping near the molten zinc before adding into the molten bath.

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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 running 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 lowerin

is determined by the Supervisor by assessing the article shape & size. b. Cooled & quenched articles are removed from the suspended

operation.

10) Cleaning & Grinding of galvanized Items :

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

department for removing with hydraulic jacking system.

e. Each batch of galvanized materials is inspected as per sampling plan for Coating thickne (Magnetic method), the mean

shall be minimum 70m to 100m. f. Finished materials are weighed aga

calculated. 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

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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

notedthe 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 ma

remove a portion of the coating , otherwise a cross-hatch test (according to ISO 16276 followed.

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

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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.

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July 2012 Revision 1 Page 1of 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 D’sa

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TABLE OF CONTENTS

1. SCOPE ... 3

2. DEFINITION... 3

3. REFERENCE CODE ... 3

4. INSPECTION AND TEST PLAN... 3

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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. DEFI NITIO N

Contractor - : Unger Steel Middle East FZE/Petrofac

Supplier : G.K Wire Industries

3. REFERENCE CODE

ASTM A123 : ISO BS EN 1461

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Document NoGKWI-ITP-001 : July 2012 Revision 0 Page 4of 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 IV IT Y №

WORK ACTIVITY QUALITY CHARACTERISTIC TO BE VERIFIED PROCEDURE REFERENCE/CODE/ STANDARD ACCEPTANCE CRITERIA / VALUE PERFORMED BY _GK W I U S M E P IL 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 - ½ grade blasting finish) Clean Surface with flux coat

Quality Control Engineer

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Document NoGKWI-ITP-001 : July 2012 Revision 0 Page 5of 5 Review Point - Documents relevant to inspection shall be reviewed, QC – Quality Control Inspector,USME – Unger Steel Middle east, PIL- Petrofac

A C T IV IT Y №

WORK ACTIVITY QUALITY CHARACTERISTIC TO BE VERIFIED PROCEDURE REFERENCE/CODE/ STANDARD ACCEPTANCE CRITERIA / VALUE PERFORMED BY _GK W I U S M E P IL 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