Galvanizing Procedure(5400)

MarcusUn-Control Stamp

The Company with the Strength of Steel GGAALLVVAANNIIZZIINNGG

ProcedureRev / Date

: 5-4-00 : 2.0 / 01.02.2013

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Process Related Documents

TABLE OF CONTENTS

SECTION TITLE PAGE

5-1-00 (Manufacture)

5-2-00 (Produce Prototype & Test)

5-3-00 (Plan Production)

5-4-00 (Galvanizing)

5-5-00 (Manufacture Pressure Vessels)

7-11-00 (Control of Welding Consumables)

7-15-00 (Weld Repair)

Guidelines For: 5-1-G1

(Magnetic Particle Inspection) 5-1-G2

(Ultrasonic Testing) 5-1-G3

(Standard Approved Repairs [SS]) 5-1-G4

(Standard Approved Repairs [GP]) 5-1-G5

(Inspection Sampling & Tower Tolerance) 5-1-G6

(Galvanized for QC Inspection) 5-1-G7

(Dipping Time Control) 5-1-G8

(Repair of Damages & Un-Galva Areas) 5-1-G9

(Brinell Hardness Examination) 5-1-G10

(Penetrating Oil Test) 5-1-G11

(Painting) 5-1-G12

(Storage & Handling of S. Steel Material) 5-1-G13

(Outsourcing of Radiographic Testing) 5-1-G14

(Fab. Tolerance / Acceptance Criteria for Insp. & Test)5-1-G15

(Weld Visual Inspection {AWS D1.1} [SS]) 5-1-G16

(Liquid Penetrant Examination {AWS D1.1} [SS]) 5-1-G17

(Storage & Handling of Paints) 5-1-G18

(Vacuum Box Examination) 5-1-G19

(Weld Visual Inspection of Storage Tank) 5-1-G20

(Hydrostatic Test for Storage Tanks) 5-1-G21

(Positive Matl. Identification [PMI] Testing) 5-1-G22

(Holiday Testing (HT)) 5-1-G23

(Dim. Inspection Tolerance Shop Built ST)

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--- Table of Content............................................................1

1 Scope............................................................................ 2

2 Applicable Standard...................................................... 2

3 Galvanizing Process & Applicable In-House W. Ins......2

4 Test Method For Coated Thickness.............................. 3

5 Repair Of Damaged Galvanized Coating......................4

6 Inspection Of Galvanized Material................................ 4

7 Galvanizing Test Certificate.......................................... 4


ProcedureRev / Date

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1 SCOPE This procedure covers the galvanization of iron and steel materials / products.

2 APPLICABLE STANDARD

2.1 In accordance with the requirements laid down in ASTM A123 & A153 "Hot Dip Galvanized Coatings on Iron and Steel Articles", and BS EN1461 Hot Dip Galvanized Coatings on fabricated Iron and Steel Articles.

2.2 Other applicable document shall be ASTM A385, 384, B695 and A780.

3 GALVANIZING PROCESS AND APPLICABLE IN-HOUSE WORK INSTRUCTIONS 3.1 Degreasing

Remove oil, grease, lubricant and other dirts which exist on the surface of steel articles by dipping the articles into hydrochloric acid solution with additive of special degreasing agent in accordance with Work Instruction Pre-Galvanizing WI 5-1-61.

3.2 Pickling

Remove the scale and rust on steel articles by pickling them in hydrochloric acid solution with small quantity of inhibitor added in accordance with Work Instruction Pre-Galvanizing WI 5-1-61.

3.3 Rinse

When the pickling is finished, rinse all the iron salt left on the steel articles during pickling in a water bath where the water is overflowing continuously in accordance with Work Instruction Pre-Galvanizing WI 5-1-61.

3.4 Fluxing

When pickling and rinsing is finished, fluxing allows to remove any acid and iron salt still left over the surface of steel articles in pre-fluxing bath.

The fluxes prevent the iron of the articles from oxidation and help the galvanizing reaction to be more effective.

Flux solution is maintained at 60 5 degrees centigrade.

3.5 Drying

When the fluxing is finished, material is allowed to dry before dipping in zinc bath to avoid splashing.

3.6 Hot Dip Galvanizing

The hot-dip galvanizing process is through zinc-iron alloy reaction between iron and molten zinc at the temperature of 445-455 degrees centigrade in accordance with Work Instruction Galvanize WI 5-1-62 and Guideline Dipping Time Control WI 5-1-G7. Additive: Small amount of aluminum.

3.7 Water Quench

When galvanizing is finished, the steel articles are cooled in water bath of temperature at about 70 degrees centigrade.


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4 TEST METHOD FOR COATED THICKNESS 4.1 Measuring by magnetic thickness gauge.

Five location of a member in each lot shall be tested to determine the uniformity of coating.

Thickness readings by the use of magnetic thickness gauge shall be taken as per relevant standard and recorded.

The zinc coating shall have a thickness according to ASTM A123, A153, or BSEN-ISO 1461 as required by client specification.

4.2 Sampling 4.2.1 Sampling of each lot shall be performed for conformance with the requirements of Para 7 of ASTM

A123. 4.2.2 A lot is a unit of production or shipment from which a sample is taken for testing. Unless otherwise

agreed upon between the galvanizer and the purchaser, or established within ASTM A123 specification, the lot shall be as follows: For testing at a galvanizers facility, a lot is one or more articles of the same type and size comprising a single order or a single delivery load, whichever is smaller, or any number of articles identified as a lot by the galvanizer, when these have been galvanized within a single production shift and in the same bath. For test by the purchaser after delivery, the lot consists of the single order or the single delivery load, whichever is the smaller, unless the lot identity, established in accordance with the above, is maintained and clearly indicated in the shipment by the galvanizer.

4.2.3 The method of selection and number of test specimens shall be agreed upon between the

galvanizer and the purchaser. Otherwise, the test specimens shall be selected at random from each lot. In this case, the minimum number of specimens from each lot shall be as follows:

Number of Pieces in lot Number of Specimens

3 or less All 4 to 500 3 501 to 1200 5 1201 to 3200 8 3201 to 10,000 13 10,001 and over 20

4.3 Adhesion test shall be performed in each lot 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. The adhesion shall be considered inadequate if the coating flakes off in the form of a layer of the coating so as to expose the base metal in advance of the knife point. Do not use testing carried out at edges or corners (points of lowest coating adhesion) to determine adhesion of the coating. Likewise, do not use removal of small particles of the coating by paring or whiting to determine failure.

When required by project specifications, Strip Test and Preece Test shall be carried out in accordance with WI Preece Test WI 5-1-55 and Stripping Test WI 5-1-56.


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5. REPAIR OF DAMAGED GALVANIZED COATING Damaged galvanized coating shall be repaired in accordance with the requirements of ASTM A780 "Standard Practice for Repair of Damaged Hot-Dip Galvanized Coatings". Guideline Repair of Damages and un-galvanized Areas Doc. No. 5-1-G8 shall be followed.

6. INSPECTION OF GALVANIZED MATERIAL Inspection & Test for galvanized material shall be carried out in accordance with Work Instruction Quality Control Galvanizing WI 5-1-52 and Guideline Galvanized for Quality Control Inspection WI 5-1-G6.

7. GALVANIZING TEST CERTIFICATE Galvanizing Test Certificate (GTC) shall be issued to document inspected and accepted galvanized material using Form No. 5-1-FQ1.