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: CLIENT: P.O NO.: LOCATION: SUPPLIER: DOCUMENT NUMBER:

EPC CPF Phase-1 al BADRA OIL FIELD Unger Steel Middle East FZE / PETROFAC 2013030011 UAE G.K.Wire Industries LLC LME- FCP-199-004

REV.

ISSUE DATE

PURPOSE OF ISSUE

PREPARED

APPROVED

01 02

05-09-2012 05-09-2012

Customer Specific Customer Specific

N.B.Joshi N.B.Joshi

Dhananjay Joshi Dhananjay Joshi

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]

REVISION HISTORY: REV 00 DATE 05.09.2012 DESCRIPTION PREPARED BY APPROVED BY Dhananjay Joshi

Customer Specific

N.B.Joshi

DEFINITIONS :

Project: Contractor: Galvanizer:

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

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]

TABLE OF CONTENTS

1. 2. 3. 4.

SCOPE REFERENCE DOCUMENTS RESPONSIBILITIES PROCEDURE a. b. c. d. e. f. g. h. i. j. k. l. m. Blasting & Cleaning the surface of steel articles Degreasing Water Rinse Pickling ( HCL Acid cleaning process ) Water Rinsing Process Flux coating process :( Zinc Ammonium Chloride Triple Salt) Drying of Articles Zinc coating ( Hot dip Galvanizing ) of steel items Water Quenching process Cleaning & Grinding of galvanized Items Inspection Adhesion Repair

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]

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 Industries LLC.

2.

REFERENCE DOCUMENTS 1. BS EN ISO 1461:2009 Hot Dip galvanized coatings on fabricated iron & steel articlesSpecification & test method. 2. ISO8501-1 - Preparation of steel substrates before application of paints and related Rust grades and products preparation grades of uncoated substrates and of steel substrates after overall removal of previous coatings. 3. ASTM A 123-Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products 4. GB088-2013-200-CS-SP-002 Engineering Specification to structural steel work

3.

RESPONSIBILITIES Production Engineer / QC Inspector

4.

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 ) Availability of tying points b. Vent holes & drainage holes (As per ASTM A385, FIG-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. c. Pre-weighing - Articles are weighed on the calibrated balance & weight of items recorded in logbook. 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. 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 rounds required according to surface condition of articles. c. Blasted articles are inspected visually by the Quality control engineer & items shall be shot blasted to a surface cleanliness of Near White Blast Metal.( SA 2-1/2 grade blasting surface finish (as per d. Any incomplete blasted areas are assessed by QC Inspector to determine whether the contaminant can be removed during the pickling process. e. After blasting each article is tilted & shot particles shall be removed from inside portion of each article by shaking each other.

SSPC,SP10)

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]

f.

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. g. The frames are attached to cranes & the wired articles are checked for uniform distribution, venting & drainage. 2) Degreasing Articles are dipped in batches in degreasing tank to remove organic contaminants including dirt, water based paint markings, grease and oil. Degreased objects are visual inspected for removal of impurities on the surface. Articles are lifted and tilted to drain all solution from articles. 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 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 during fresh start of acid bath. c. In regular use the shift foreman / QC Inspector visually inspects the articles for cleanliness after 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 achieved. Quality 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 obtained & submitted to local Authority for approval. After approval from 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 galvanized surface, Black surface, Black spots, pH value 2-3, Iron content (Fe) 150gms/lit. max., HCL concentration % > Complete replacement of old acid from bath. i. 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. j. 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 loaded materials.

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]

5) Water Rinsing Process : a. Pickled articles are dipped into the rinsing bath completely & suspended over the bath until water no longer pours off. 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 (pH <3). 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 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 fresh start of Flux bath. c. Density of flux is maintained 22 30 Baume & flux bath temperature is maintained 70 80 C. d. In regular use, the 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 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 flux bath until the required relative density of min. 22 30 Baume is achieved. e. Depending upon the quality 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 off through Local Authority Environmental department. 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. 110C to max. 120C. 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 445C 5C 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 wetting. d. The zinc bath surface is skimmed & zinc ash removed by scrapers. e. After complete 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. f. In regular use, the level of zinc (max. 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. These fresh zinc slabs are preheated by keeping near the molten zinc before adding into the molten bath.

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]

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 in a manner which will enable the steam to escape safely The articles which may suffer distortion during quenching are cooled naturally by lowering onto the concrete floor. The quenching suitability is determined by the Supervisor by assessing the article shape & size. b. Cooled & quenched articles are removed from the suspended frames / fixtures & moved to cleaning operation. 10) Cleaning & Grinding of galvanized Items : a. The tie wires (if any) are cut & removed from galvanized articles & surfaces are visually inspected. The good galvanized materials are further cleaned with smooth grinding & excess lumps / flow marks / excess zinc deposits are removed from the surface. b. Additional zinc deposits are removed from both ends of holes location by hammering the punch rod & all hole edges are to be removed by grinding. c. Tie wire markings & small pointed galvanized spots (if any observed) are cleaned & sprayed with zinc rich paint- As per BS 2569 minimum two coating layer. d. Distortion due to heat (warpages / bends) shall be removed by hammering or send to Fabrication department for removing with hydraulic jacking system. e. Each batch of galvanized materials is inspected as per sampling plan for Coating thickness (Magnetic method), the mean Zinc coating thickness for the steel thickness 3mm to above 6mm shall be minimum 70m to 100m. f. Finished materials are weighed again on calibrated balance & galvanized materials weight is calculated. Accordingly daily production report is prepared along with weighing records sheets. 11) Inspection: a. The integrity of the coating shall be determined by visual inspection and coating thickness measurement as per BS 1461:2009 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 standards of galvanizing. The final weight of galvanized coating shall be as per BS 1461:2009. Table-3,4 12. Adhesion : The test is to be carried out by the customer. G.K.Wire will provide test sample of the same material for his testing, if required. 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 manner tending to remove a portion of the coating , otherwise a cross-hatch test (according to ISO 16276) shell be 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 the coated article. c) The galvanized coating shall be sufficient by adherent to withstand normal handling during transport and erection.

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]

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

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]

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

INSPECTION AND TEST PLAN HOT DIP GALVANIZING

PROJECT:

EPC CPF Phase -1 al BADRA OIL FIELD Unger Steel Middle East FZE

CLIENT:
P.O NO.: LOCATION: SUPPLIER: Document No:

UAE LINK MIDDLE EAST LIMITED GKWI-ITP-001

Rev. 0

Issue date

Purpose of issue Issued for Review

Prepared Ronald Dsa

Approved

July 2012 Revision 1

Page 1 of 5

G. K. WIRE INDUSTRIES LLC

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

TABLE OF CONTENTS

1. 2. 3. 4.

SCOPE ............................................................................................................................................................. 3 DEFINITION...................................................................................................................................................... 3 REFERENCE CODE ......................................................................................................................................... 3 INSPECTION AND TEST PLAN........................................................................................................................ 3 4.1 INSPECTION & TEST PLAN- RECEIVING INSPECTION OF RAW MATERIALS FOR FENCE AND GATES... 4

July 2012 Revision 1

Page 2 of 5

G. K. WIRE INDUSTRIES LLC

P.O.Box - 32820 , RAS AL KHAIMAH , United Arab Emirates 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 Supplier : Unger Steel Middle East FZE/Petrofac : G.K Wire Industries

3.

REFERENCE CODE

ASTM A123 : ISO BS EN 1461

4.

INSPECTION AND TEST P L AN

July 2012 Revision 1

Page 3 of 5

G. K. WIRE INDUSTRIES LLC

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

4.1

INSPECTI ON & TEST PL AN- RECEIVING INSPECTI ON OF RAW M ATERI ALS FOR F ENCE AND GATES
R-

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, Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac
ACTIVITY

WORK ACTIVITY

QUALITY CHARACTERISTIC TO BE VERIFIED

PROCEDURE REFERENCE/CODE/ STANDARD

ACCEPTANCE CRITERIA / VALUE

PERFORMED BY

USME

GKWI

QUALITY VERIFICATION RECORD

Receiving of fabricated Structures, Pipes, accessories

Completion of fabrication Qty, Surface condition damages and defects

Internal Procedure, GB0882013030011-CV-J04-001

Operation completion as per drawing, specification Qty as per Order Free from damages and Any defects

Quality Control Engineer Production Engineer

PIL

Visual Inspection Report

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

Visual Inspection Report

Document No GKWI-ITP-001 : July 2012 Revision 0

Page 4 of 5

G. K. WIRE INDUSTRIES LLC

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

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, Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac
ACTIVITY

R-

WORK ACTIVITY

QUALITY CHARACTERISTIC TO BE VERIFIED

PROCEDURE REFERENCE/CODE/ STANDARD

ACCEPTANCE CRITERIA / VALUE

PERFORMED BY

USME

GKWI

QUALITY VERIFICATION RECORD

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

PIL

Hot Dip Galvanizing Certificate

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

Pre despatch Inspection Report

Document No GKWI-ITP-001 : July 2012 Revision 0

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