Dgs Mx 002 r1 Galvanizing

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Abu Dhabi Oil Refining Company

GALVANIZINGDGS-MX-002

Rev-1 Mar 2009

Takreer DGS-MX-002-Rev-1 Mar 2009 Printed 14-May-09 10:27:24 Initials Page 1 of 17

GALVANIZING

Amendment History

1 Mar 2009 AMD-MX-002-BECHTEL Clauses 2, 9 & Table 1 HAS/DDC QAM Mar 2009

No Date Amendment Description Proposed Approved Incorporated

DGS History

1 Mar 2009 DGS-MX-002-Rev-1 AMD-MX-002-BECHTEL HAS/DDC QAM / MAY

0 Mar 2006 DGS-MX-002-Rev-0 Previous Project / LessonsLearnt Incorporated

HAS/DDC ETSDM / EPDM

No Date Description Source Reviewed Approved

DGS-MX-002 Rev-1


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1.0 GENERAL

1.1 INTRODUCTION

This specification covers the requirements for Hot-Dip and Mechanical Galvanizing. Theitems to be galvanized include, but are not limited to the following:

1.1.1 Electrical

Conduit, Cable trays & covers including fasteners, and Light standards

1.1.2 Piping

Anchors, Cradles, Guides, Hangers, Shoes, Miscellaneous supports, Instrument Pipe and

Fittings, Non Fireproofed shop fabricated carbon steel pipe supports. Hot shoe supportsthat are not welded to the Pipe shall not be galvanized as significant damage to thegalvanizing will occur when these supports are welded to piping. These areas shall becoated with an appropriate protective coating as per DGS-MX-001

1.1.3 Structural Steel

Beams, Bolts, Bumper posts, Checker plate, Columns, Floor plate Grating, GuardrailHandrail, Ladders & cages, Miscellaneous fasteners, Nuts, Platforms, Stair treads, Stairstringers, Toeplate and Washers

1.1.4 Miscellaneous Items

Anchor bolts, Safety and Guard chain, Chain link fence & accessories, Concrete embedplates, Hardware (per ASTM A153), and Sheet metal

When an item is required to be galvanized the requirement shall be noted on the applicabledesign drawings.

The operating temperature for items that have been galvanized shall not exceed 400 C.

All exposed galvanized surfaces including structural beams, columns, ladders, laddercages, handrails, etc to be coated as per DGS-MX-001, using coating system 13.

1.2 PURPOSE

The materials, procedures, and requirements specified herein are provided to protect plantequipment from corrosion. Generally these requirements are common for all galvanizeditems to be used in the construction of the PROJECT.

1.3 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

CONCESSION REQUEST - A deviation requested by the SUBCONTRACTOR orVENDOR, usually after receiving the contract package or purchase order. Often, it refers


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to an authorization to use, repair, recondition, reclaim, or release materials, components or

equipment already in progress or completely manufactured but which does not meet orcomply with Takreer requirements. A CONCESSION REQUEST is subject to COMPANYapproval.

SHALL Denotes mandatory action or requirement.

SHOULD Denotes an action or requirement which isnot mandatory but which is stronglyrecommended.

DOCUMENT Any form, letter, facsimile, contract, specification, requisition, drawing, orrecord of any kind required to transmit information from one party to another. It alsoincludes computer generated drawings list, charts, etc. and other data used to form apermanent record of the Project progress.

2.0 CODES AND STANDARDS

The following codes and standards shall, to the extent specified herein, form a part of thisspecification. The latest edition (including addenda) in effect shall apply.

The publications listed below form a part of this specification to the extent referenced. Thepublications are referred to, in the text, by the basic designations only.

American Society for Test ing and Materials (ASTM)

A36 Standard specification for structural steel

A90 Standard test method for weight (mass) of coating on iron and steel articleswith zinc or zinc-alloy coatings

A123 Standard specification for zinc (hot-dip galvanized) coatings on iron andsteel products

A143 Standard practice for safeguarding against embrittlement of hot-dipgalvanized structural steel products and procedure for detectingembrittlement

A153 Standard specification for zinc coating (hot-dip) on iron and steel hardware

A307 Standard specification for carbon steel bolts and studs, 60,000 psi tensilestrength

A325 Standard specification for structural bolts, steel, heat treated, 120/150 ksiminimum tensile strength

A384 Standard practice for safeguarding against warpage and distortion duringhot-dip galvanizing of steel assemblies

A385 Standard practice for providing high quality zinc coating (hot dip)

A392 Standard specification for zinc-coated steel chain-link fence fabric


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A490 Standard specification for heat-treated steel structural bolts, 150 ksiminimum tensile strength

A653 Specification for steel sheet, zinc coated (Galvanized) or zinc-iron alloy-coated (Galvannealed) by the hot dip process.

A697 Specification for Chemical Passivation of SS Parts

A780 Standard practice for Repair of Damaged Hot-Dip Galvanized Coatings

B6 Standard specification for Zinc

B695 Standard specification for coatings of zinc mechanically deposited on ironand steel

E376 Standard practice for measuring coating thickness by magnetic-field oreddy-current (electromagnetic) test methods

Steel Structures Painting Council (SSPC)

SP 1 Solvent cleaning

SP 11 Power tool cleaning to bare metal

SP 10 Near white blast cleaning

International Organization for Standardization (ISO)

ISO 9001-2000 Quality Management System Requirements

ISO 9004-2000 Quality Management Guidelines for Performance Improvement System

ISO 19011 Guidelines for Quality and/or Environmental Management Systems Auditing

ISO 12944 Paints and Varnishes - Corrosion Protection of Steel Structures byProtective Paint Systems

3.0 REFERENCE DOCUMENTS

The following reference documents, to the extent specified herein, form a part of thisspecification. When an edition date is not indicated for a document, the latest edition in

force at the time of CONTRACTORS/VENDORS proposal or submittal shall apply.

Project Specifications

DGS-MX-001 Painting

DGS-MU-002 Preservation


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4.0 DOCUMENT PRECEDENCE

It shall be the SUBCONTRACTOR/VENDORS responsibility to be, or to become,knowledgeable of the requirements of the referenced codes and standards.

The SUBCONTRACTOR/VENDOR shall notify the CONTRACTOR of any apparent conflictbetween this specification, the related data sheets, the codes and standards, and any otherspecification noted herein. Resolution and/or interpretation precedence shall be obtainedfrom the CONTRACTOR/COMPANY in writing before proceeding with thedesign/manufacture.

In case of conflict, the order of precedence shall be stated in the AGREEMENT or otherPROJECT documents as applicable.

5.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviation to the Purchase order/Contract and its attachment including, butnot limited to, the data sheets and narrative specification shall be sought by the VENDORonly through the CONCESSION REQUEST format. CONCESSION REQUESTS requirethe CONTRACTORS and the COMPANYS review and approval, prior to the proposedtechnical changes being implemented. Technical changes implemented prior toCOMPANY approval are subject to rejection.

6.0 QUALITY ASSURANCE/QUALITY CONTROL

The SUBCONTRACTOR/VENDOR is solely responsible to implement a quality control

program to verify compliance with this specification.

The SUBCONTRACTOR/VENDOR shall have in effect at all times, an applicable ISO 9000series QA/QC program which clearly establishes the authority and responsibility of thoseresponsible for the quality system. Persons performing quality functions shall havesufficient and well defined authority to enforce quality requirements, initiate, identify,recommend and provide solutions to quality problems and verify the effectiveness of thecorrective action.

A copy of the SUBCONTRACTOR/VENDORS QA/QC program shall be submitted to theCONTRACTOR with its quotation for CONTRACTORS review and approval prior to award.If SUBCONTRACTOR/VENDORS QA/QC program and facility, where the work is to beperformed, is ISO 9000 certified, then only a copy of the SUBCONTRACTOR/VENDORS

ISO 9000 certificate is required. In addition, if SUBCONTRACTOR/VENDORS facility isISO certified, CONTRACTORS QA audit requirements will be waived in favor of ISO 9000registrar audits, unless the CONTRACTORS trend analysis program indicates areas ofconcern.

The VENDOR shall identify in purchase documents to itsSUBCONTRACTOR/SUBVENDOR all applicable QA/QC requirements imposed by theCONTRACTOR, and shall ensure compliance thereto. On request, VENDOR shall provideobjective evidence of its QA/QC surveillance of its SUBCONTRACTOR/SUBVENDORSactivities.


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The VENDOR shall submit certified reports of production tests as soon as the tests are

completed satisfactorily.

The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanshipat all stages of manufacture and to witness any or all tests. TheSUBCONTRACTOR/VENDOR, 30 days after award but prior to the pre-inspection meeting,shall provide the CONTRACTOR with a copy of its manufacturing and inspection plan forreview and inclusion of any mandatory COMPANY/ CONTRACTOR witness points.

7.0 DOCUMENTATION

VENDOR shall submit the type and quantity of drawings and documentation forCONTRACTORS authorization or information as listed in the individual material

requisitions and purchase orders.

Mutual agreement on scheduled submittal of drawings and engineering data shall be anintegral part of any formal purchase order.

Comments made by CONTRACTOR on drawing submittal shall not relieve VENDOR orSUBCONTRACTOR/SUBVENDORS of any responsibility in meeting the requirements ofthe specifications. Such comments shall not be construed as permission to deviate fromrequirements of the purchase order unless specific and mutual agreement is reached andconfirmed in writing.

Each drawing shall be provided with a title block in the bottom right-hand cornerincorporating the following information:

Official trade name of the COMPANY

VENDOR/SUBCONTRACTORS drawing number

Drawing title giving the description of contents whereby the drawing can be identified

A symbol or letter indicating the latest issue or revision

PO number and item tag numbers

Revisions to drawing shall be identified with symbols adjacent to the alterations, a briefdescription in tabular form of each revision shall be given, and if applicable, the authorityand date of the revision shall be listed. The term Latest Revision shall not be used.

8.0 HANDLING

8.1 PACKAGING AND SHIPPING

8.1.1 Preparation for shipment shall be in accordance with the VENDORS standards and asnoted herein. VENDOR shall be solely responsible for the adequacy of the preparation forshipment provisions with respect to materials and application, and to provide equipment atthe destination in ex-works condition when handled by commercial carriers.


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8.1.2 Adequate protection shall be provided to prevent mechanical damage and atmospheric

corrosion in transit and at the jobsite.

8.1.3 Preparation for shipment and packing will be subject to inspection and rejection by theCOMPANYS/CONTRACTORS inspectors. All costs occasioned by such rejection shall beto the account of the VENDOR.

8.1.4 After inspection and test, equipment shall be completely free of water and dry before startof preparation for shipment.

8.1.5 Equipment shall be packed, securely anchored, and skid mounted when required. Bracing,supports, and rigging connections shall be provided to prevent damage during transit,lifting, or unloading. All temporary bracing/supports shall be marked, REMOVE BEFOREEQUIPMENT COMMISSIONING AND STARTUP.

8.1.6 Flanged openings shall be protected with metal coverplates to prevent damage duringshipment. Covers shall be a minimum of 6 mm thick and shall be installed with a full-sizegasket using a minimum of 4 full diameter bolts. Large diameter flanges will requireenough full diameter bolts to seat the cover all around. The cover and flange shall betaped for waterproof protection.

8.1.7 Open ends of tubes and pipe shall be capped for protection. Female threaded connectionsshall be plugged with solid metal pipe plugs, and male threaded connections shall beprotected with full metal pipe caps.

8.1.8 Separate, loose, and spare parts shall be completely boxed. Pieces of equipment andspare parts shall be identified by item number and service and marked with

CONTRACTORS order number, tag number, and weight, both inside and outside of eachindividual package or container. A bill of material shall be enclosed in each package orcontainer of parts.

8.1.9 Exposed finished and machined surfaces, including bolting, shall be given a coating of rustinhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rustpreventative prior to shipment. Openings shall be suitably tagged to indicate the rustpreventative applied.

8.1.10 Mechanical seal assemblies shall be fully protected from rusting and entry of moisture anddirt.

8.1.11 One complete set of the installation, operation, and maintenance instructions shall be

packed in the boxes or crates with equipment. This is in addition to the number called for inthe Purchase Order.

8.2 PRESERVATION AND STORAGE

8.2.1 Equipment and materials shall be protected to withstand ocean transit and extended periodof storage at the jobsite for a minimum period of 18 months. Equipment shall be protectedto safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt,sand, mud, salt air, salt spray, and seawater.


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8.2.2 All equipment and material shall be preserved and export packed in accordance with

Project Preservation Specification, DGS-MU-002.

8.2.3 Galvanized items, to be stored at site, shall be stacked so adequate ventilation of allsurfaces is maintained in order to avoid the formation of white rust.

9.0 DESIGN

9.1 FABRICATION

9.1.1 Potential problems that require a modification in design, in order to eliminate possibleembrittlement or warpage, shall be brought to the attention of the CONTRACTOR, by theVENDOR, before proceeding with fabrication. It shall be the VENDORS responsibility tosafeguard against embrittlement, bending, and warpage.

9.1.2 Cold working of carbon steel items to be galvanized shall not be permitted unless the itemsare heat treated in accordance with the recommendations of ASTM A143, paragraph 5, ortested for embrittlement in accordance with ASTM A143, paragraph 8.

9.1.3 Floor plates and shop assembled platforms shall be limited in size so that multiple dippingis avoided wherever possible.

9.1.4 The design and fabrication of structural shapes shall follow the guidelines given in ASTMpractices A143, A384, and A385. The following points shall be given special attentionduring design of the item and the associated galvanizing of that item:

Vent/drain holes shall be provided to avoid high internal pressures and air locks

Defects in the substrate such as cracks, laminations, laps, and folds shall beremoved prior to galvanizing

As appropriate drilling, cutting, welding, forming, and final fabrication of unitmembers and assemblies shall be done before galvanizing

Welds shall be continuous, Where laps can not be avoided all overlaps or contactedsurfaces shall be seal welded

Sharp edges, rough spots and burns shall be removed by grinding prior togalvanizing

Mouse holes shall be large enough to ensure that they are not blocked by zinc build

up during drainage.

9.1.5 Components of bolted assemblies shall be dipped separately, before assembly by bolting,with all bolts removed.

9.2 MECHANICAL GALVANIZING

9.2.1 High strength bolts, ASTM A325, and common bolts, ASTM A307, may be either hot-dip ormechanically galvanized. Hot-dip galvanizing shall comply with ASTM 153, Class C.


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9.2.2 Mechanically zinc-coated nuts for assembly with mechanically zinc-coated bolts shall be

tapped oversize prior to coating and need not be retapped again.

9.3 HOT-DIP GALVANIZING

9.3.1 The zinc used for galvanizing shall be at least equal to the grade designated as PrimeWestern (Z19001) containing a minimum of 98.0 percent zinc.

9.3.2 Surfaces shall be cleaned to remove oil, grease, mill scale, weld slag, and fabricationmarkings before galvanizing.

9.3.3 Nuts shall be tapped oversize, according to ASTM A563, prior to hot-dip galvanizing, andthen retapped again afterwards.

9.3.4 The cleaned steel shall be galvanized in a bath of molten zinc in conformance with thereferenced ASTM specifications to achieve the coating weights as stated in thisspecification.

9.3.5 After immersion in the molten zinc, the items shall not be subjected to any process ofscraping or wiping which may reduce the uniformity or the specified weight of the zinccoating, except in order to remove flux, dross, needlepoint, sharp edges etc.

9.4 COATING PROPERTIES

9.4.1 The zinc coating shall be free of voids, blisters, flux spots, inclusions, dross, acid or blackspots. The coating shall be adherent so it will not be removed by any reasonable process

of handling or erection. Lumps, globules, or heavy deposits of zinc, which could interferewith the intended use of the galvanized item, shall not be permitted.

9.4.2 Particular attention shall be taken to ensure that mouse holes are free from zinc and that nopooling of the zinc takes place adjacent to the mouse holes.

9.4.3 Runs, drips and tear drops along the edges of the flanges shall be carefully removedwithout compromising the coating thickness.

9.4.4 The weight of the zinc coating shall be as given in Table 2, Coating Requirements forGalvanizing.

9.5 REPAIR OF DAMAGED ZINC COATINGS

The exact procedure used to repair damaged mechanically applied zinc coating(galvanizing) shall be submitted to the CONTRACTOR for approval. The repair methodcontained within this section and that which shall be proposed by the EPC CONTRACTORshall include the repair of on site damaged galvanizing.

Repairs to damaged surfaces, galvanized with the hot-dip process, shall be as follows:


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All oil, dirt, and foreign matter shall be removed by solvent or detergent cleaning,according to SSPC-SP 1.

Areas of spot rust, burn residue, weld spatter, and other solid adherent foreignmatter shall be blast cleaned in accordance with SSPC-SP 10. In the event blastcleaning is not practical mechanical cleaning in accordance with SSPC-SP-11 usingnon-woven abrasive discs (3M Company) may be used with the CONTRACTORSapproval. Welded joints of galvanized items shall be cleaned with a non-wovenabrasive cup wheel prior to feathering with a non-woven abrasive disc.

Cleaned and prepared surfaces shall be primed with the following materials in accordancewith the MANUFACTURERS instructions, recommendations, and guidelines.

When the operating temperature is 930C and below, organic zinc primer, having a minimum

of 80 percent zinc by weight in the dry film. Primer shall be applied to have a dry filmthickness of 75 microns.

Alternatively, a 90% zinc content epoxy mastic such as Metagard may be applied to thesame thickness as the original galvanizing. In this case unless for aesthetic reasons, it isnot necessary to apply a finish coat. Equivalent mastics may be considered for COMPANYapproval.

When the operating temperature is 940C through 4000C, inorganic zinc primer, having aminimum of 80 percent zinc by weight in the dry film. Primer shall be applied to have a dryfilm thickness of 75 microns.

Surfaces that have been primed with the organic zinc rich primer shall be finish coated with

one coat of polyamide epoxy, applied to a dry film thickness of 75 microns. The color ofthe finish paint shall closely match the color of the adjacent galvanized surface. Pleaserefer to specification DGS-MX-001, Painting, for the materials required in each of thepreceding paragraphs.

Metallizing with zinc is an acceptable alternative to the above coating repair procedures.

Connections between galvanized surfaces and copper/copper alloy/aluminum shall beprotected with a suitable tape wrap. Materials and procedure shall be approved byCONTRACTOR prior to application.

Galvanized contact surfaces, to be joined by high tensile friction grip bolts, shall beroughened before assembly so that the defined slip factor is achieved.

Galvanized steel surfaces shall not be subjected to underground service

Galvanized nuts and bolts shall be used for connecting other galvanized components only.A more durable coating shall be used for other bolts.

All atmospherically exposed galvanized surfaces shall be painted in accordance withProject Painting Specification DGS-MX-001. The CONTRACTOR may propose analternative to the use of galvanizing with a painting system, providing the alternative systemis designed for a C5-M environment as defined in ISO 12944.


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10.0 INSPECTION

The adherence of the zinc coating to the surface of the base metal shall be determined bycutting or prying with the point of a stout knife, applied with considerable pressure in amanner tending to remove a portion of the coating. The adherence shall be consideredinadequate if the coating flakes off in the form of a layer or skin so as to expose the basemetal in advance of the knife point. Testing carried out at edges or corners (points oflowest coating adherence) shall not be used to determine adherence of coating. Likewise,removal of small particles of the coating by paring or whittling shall not be used todetermine failure.

The distribution of the zinc coating shall be determined by visual inspection. Except forlocal excess coating thickness which would interfere with the use of the product, or make itinconvenient or dangerous to handle (edge tears or spikes), rejection for poor distribution

shall be made only for plainly visible excess coating not related to design factors such asholes, joints or special drainage problems. If, in the opinion of the CONTRACTOR, visualexamination is not conclusive, the distribution of zinc shall be determined by using amagnetic thickness gauge after a sufficient number of readings, not less than five andpreferably ten, are taken at each end and in the middle of the piece being examined.

The average weight of the coating, given as grams per square meter, shall be determinedby multiplying the coating thickness (microns) by 6.9. The thickness is found by using amagnetic thickness gauge. Where thickness measurement is not feasible, the coatingweight shall be determined as noted in the referenced ASTM standards for galvanizing.

The following, Table 1, Inspection Checklist for Galvanizing, is provided to assist with thecomplete inspection of items that will be galvanized. The information contained lists theminimum requirements to be completed before the item is to be galvanized, during theperiod it is being galvanized and after the galvanizing has been completed.

11.0 HANDLING

Protective slings shall be used for off-loading and erection of galvanized members.Extreme care shall be taken to minimize damage to the zinc coating during loading,shipping and handling, and unloading of all galvanized items.


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NO ITEMS METHODS EXTENT (Frequency) CRITERIA

5. Weight/Thickness ofZinc Coating

a. Magnetic thicknessmeasurements,

b Stripping method,

c. Weighing before andafter galvanizing

CONTRACTORapproved frequency

CONTRACTORapproved procedure

6. Adhesion a. Stout knife test(ASTM A90 & A153)

b .Hammer test (ASTMA153)

Minimum of one testper day for at leastone item

Minimum of one testper day for at leastone item

No peeling or flakingallowed

According to ASTM153


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TABLE 2

COATING REQUIREMENTS FOR GALVANIZING

Item to be galvanizedMin. weight of zinc

grams/m2

GALV.

5601-STD

Averageof

specimenstested

Anyindividual

specimen

Structural Steel Under 1.6 mm (1/16) thick A123 335.7 335.7

1.6 mm (1/16) to < 3.1 mm (1/8) thick A123 457.8 457.8

3.1 mm (1/8) to 6.3 mm (1/4) thick A123 610.3 610.3

> = 6.3 mm (1/4) thick A123 701.9 701.9

Pipe Pipe A123 518.8 518.8

Class A: Castings-Malleable iron, steel A153 610.3 549.4

Hardware Class B: Rolled, pressed and forged articles

(except those articles included in Classes Cand D)

A153

B1 - Thickness => 4.7 mm (3/16) & length >381 mm (15)

610.3 549.4

B2 - Thickness < 4.7 mm (3/16) & length >381 mm (15)

457.8 381.5

B3 - Any thickness & length


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ADDENDUMSHEET

All revisions to this DGS subsequent to the issue of Rev Zero shall be recorded in this addendumsheet and shall be incorporated into the DGS in the next revision.

Date Proposed Revision Remarks

Mar,2009 AMD-MX-002-BECHTEL Incorporated inRev-1

AMENDMENTS TO SECTION 2 CODES AND STANDARDS

Delete ISO 9011 Quality Management Guidelines forPerformance Improvement System

Replace with ISO 19011 Guidelines for quality and/orenvironmental management systems auditing

Add ASTM A697 Specification for Chemical Passivation ofSS Parts

Add ISO 12944 Paints and varnishes - Corrosion protectionof steel structures by protective paint systems

AMENDMENTS TO SECTION 9 DESIGN

9.3 Hot-Dip Galvanizing

9.3.5 After zinc coating Add , except in order to remove flux,dross, needlepoint, sharp edges etc.

9.5 Repair of Damaged Zinc Coatings

After first sentence for approval. Add - The repair methodcontained within this section and that which shall be proposed bythe EPC CONTRACTOR shall include the repair of on sitedamaged galvanizing

Fourth and sixth paragraphs

Replace weight shall be applied to a dry film thickness

With weight in the dry film. Primer shall be applied to have adry film thickness


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Remove last sentence All exposed galvanizing.

Replace with All atmospherically exposed galvanizes surfacesshall be painted in accordance with Project Painting SpecificationDGS-MX-001. The CONTRACTOR may propose an alternative tothe use of galvanizing with a painting system, providing thealternative system is designed for a C5-M environment as definedin ISO 12944.

TABLE 1

III Galvanizing, No. 4, Methods column

Replace (sample comparison) with prior to commencement ofany galvanizing work, a test piece shall be dipped and thefinished appearance agreed for the contract duration

Dgs Mx 002 r1 Galvanizing

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