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HOT DIP GALVANIZING PROCEDURE

MINA ABDULLAH REFINERY

A ~
• P et:r o f ac ~
APPROVED WITHOUT COMMENT ‐ WORK MAY PROCEED

B
APPROVED WITH MINOR COMMENTS– WORK MAY  _.......,~~- ~~ KNPC CFP Project DSN:
PROCEED ‐REVISE AND RESUBMIT teN~ -.:I!"
MAB 1 Package S20159
C
D
REVISE AND RESUBMIT – WORK MAY PROCEED SUBJECT 
TO INCORPORATION OF COMMENTS INDICATED
APPROVAL NOT REQUIRED. INFORMATION ONLY. WORK 
MAY PROCEED
REVIEW
CODE: 1 I BY:
DH
IDISCIPLINE: DATE :
19/10/15
F AS‐BUILT / ACCEPTED AS FINAL
REVIEW CODE:
REJECTED ‐ REVISE AND  RESUBMIT. WORK MAY NOT 
R PROCEED
1 ~Approvect\No Comments; 2-Minor Comments; 3-Comments as Noted;
4-Rejected:
V VOID (DOCUMENT HAS BEEN CANCELLED / DELETED)
Purchaser's review of this document does not relieve Supplier of the 
responsibility for correctness under the Purchase Order. Permission 
to proceed does not constitute acceptance of design, detail and 
calculations, test methods or material developed or selected by the 
Supplier and does not relieve the Supplier from full compliance with 
the Purchase Order or any other obligations, nor detract from any of 
the Purchaser's rights.

Signed
Ihab Elhawash r 106-10-15 I
By____________________________________Date ____________
~ "' ~

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·.::.
A~A~
~fROMAS"
05 03-10-2015 Issued for Approval
JOSEPH
I(·~
AMAN \ THOMAS
04 08-09-2015 Issued for Approval
JOSEPH
THOMAS
03 08-08-2015 Issued for Approval AMAN
JOSEPH
THOMAS
02 28-06-2015 Issued for Approval AMAN
JOSEPH
THOMAS
01 09-06-2015 Issued for Approval AMAN
JOSEPH
Rev. Date Description Originator Checked By Approved By

Kuwait National Petroleum Company (K.S.C.)


Clean Fuels Project
Kuwait
··-~·...,¢1J.,..,•. J""'' "'" II
_,.._ .. -... ,·--··--
·-...,\., ..,... 1........... KNPC ~

Petrofac I Samsung I CB&I


PSCJ Job No. Jl-2025 Petrofac & .-111Ui UI• 1 SAMSUNG
ENGINEERING A m!I•l
ABJ Engineering & Contracting Co.KSC Subcontractor Doc. No.
(Closed)
P.O.Box 10331, Shuaiba-65454, Kuwait
002043200/MS/MB-WS/Galv-1 0 IMBTC
CONTRACT NO. CONTRACTOR JOB NO. DOCUMENT NO. REV

CFP/EPC/0054-MAB1 Jl-2025 P6012MAB.000.1 0.48.753 05


Kuwait National Petroleum Company (K.S.C)

·li . o:i. .¢Jiti. ob,JIJ~IA: o ·ll


(D._,...., .. .. - . JMI
Clean Fuels Project (CFP)
~ 440'1!1» A
~.:::;;;;;:::::.:z;;;; KNPC -.iii? KNPC Contract No. CFP/EPC/0054-MAB1
PSCJ Job No. Jl-2025
Petrofac - SAMSUHG
ENGINEERING

COMMENTS RESOLUTION SHEET


Discipline : Piping

Original DocumentTitle: P6012MAB.000.10.48.753


Hot Dip Galvanizing Procedure CONTRACTOR's Review Comments Transmittal No. :
Date: 28-SEP-2015
PS CJ-ABJ E-CFP-MAB1-TS-00050

Serial Document No., Rev,


Company~'sCOMMENT Action
CONTRACTOR RESPONSE(**)
COMPANY's Response
No. Page No. Code (*) (Open or Closed)
1 6 Change 61 Ogms/m2 to 707gm/m2 in clause 3.3 Comment Incorporated
Remove repetition: The Minimium Galvanizing Coating
2 6 weight shall be 61 Ogms/m2 surface in clause 3.3
Comment Incorporated

Action Code: A-Accepted, N-Not accepted (•) to be completed by Contractor (**) to be completed by Contractor if action code is "N".

SIGNED BY CONTRACTOR
SIGNED BY COMPANY
Prepared By (Name):
Date:
Signature:

Approved By (Name): Approved by (Name):


Signature: Date:
Signature: Date:

P6012MAB.000.1 0.03.QCF .003. Rev 01 Page 1 of 1


Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 2 of 13
PSCJ Job No. Jl-2025

Revision Record Sheet


NOTES

Revisions after Rev. OA are denoted by a vertical line in the right hand margin
against the revised text, with the revision number displayed next to the revision line
as shown on the right.

i) First submission OA, OB, OC ....


ii) Approved by PSCJ, then revision cycle will start from 01, 02, 03, 04 ....
iii) Approved document with Hold, then revision cycle will start from R1, R2, R3 .... .
iv) Approved by PSCJ/KNPC, then revision cycle will start from 81, 82, 83, 84 ... .

Record of Revisions

Rev. No. Page/Section Description

01 ALL Issued for comments

02 4 Issued for comments

3, 4, 5,6 ,7,
03 Issued for comments
11,12 & 13

3,5,6,8, 11 &
04 Issued for comments
13

05 6 Issued for comments

List of Holds

Page/Section Description

MS/MB-WS/Galv-10

•• Petrofac tJ SAMSUNG
ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 3 of 13
PSCJ Job No. Jl-2025

TABLE OF CONTENTS

1.0 GENERAL 4

1.1 PURPOSE 4

1.2 ABBREVIATIONS 4

1.3 DETAILS OF THE PROJECT 4

1.4 DEFINITION 4

1.5 REFERENCE 5

2.0 PROCEDURE 5

3.0 COATING REQUIREMENTS 6

4.0 GALVANIZING PROCESS 7

5.0 TOUCH UP AND REPAIR 11


6.0 HANDLING, TRANSPORT AND STORAGE 12

7.0 OUTPUT 12
8.0 INSPECTION 12
9.0 QUALITY ASSSURANCE 12

10.0 SAFETY 133


11.0 ATTACHMENTS 133
Attachment A. Form No MBTC-FO/WS04 Galvanizing Certificate
Attachment B. ZINGA Technical Data Sheet
Attachment C. Form No MBTC-FO/QC-39/Rev.OO Release Note
Attachment D. P6012MAB.000.10.03.002.QCF.003-VX, Rev 02

~
MS/MB-WS/Galv-1 0 SAMSUNG
Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 4 of 13
PSCJ Job No. Jl-2025

1.0 GENERAL
This procedure applies to project - KNPC Clean Fuels Project (CFP) Package
MAB1, for the Galvanizing Piping Spools in compliance with project specifications
carried out by Mohammed N.M. AI-Baddah & Partner General Trading &
Contracting Company W.L.L.
1.1 PURPOSE
The purpose of this procedure is to cover the requirements for Zinc Coating
(galvanizing) by the hot- dip process on for the Pre-Fabricated spools to meet the
P6000CFP.000.1 0.48.002_8 -Galvanized specification of the project- KNPC Clean
Fuels Project (CFP) Package MAB1.
This procedure covers both fabricated and non-fabricated spools, and fittings
(Flanges, reducer, Tee, Elbows etc).

1.2 ABBREVIATIONS
COMPANY Kuwait National Petroleum Company ( K.S.C) (KNPC)
MAB-1 Min a Abdullah Refinery- Package 1
EPC CONTRACTOR Petrofac International Ltd, Samsung Engg, CB&I ( PSCJ)
FEED Front end engineering design
PMC Foster Wheeler Energy Limited, UK
SUB-CONTRACTOR ABJ Engineering & Contracting Co. KSC I
Mohammed N.M. AI-Baddah & Partner General Trading
& Contracting Company W.L.L.
cs Carbon Steel
ITP Inspection Test Plan
1.3 DETAILS OF THE PROJECT
• Name of the Project : Clean Fuels Project (CFP)

• Company Project Number :CFP/EPC/0054/MAB-1

• Commencement Date: 13th April, 2014

1.4 DEFINITION
• COMPANY TEAM is the integrated Project Management Team comprising of
KNPC and Foster Wheeler employees.
• Contractor Project Team is the "Petrofac Samsung Engineering CB&I JV
(PSCJ) entrusted with execution of the PROJECT.

~
MS/MB-WS/Galv-10 SAMSUNG
Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 5 of 13
PSCJ Job No. Jl-2025

1.5 REFERENCE
• P6000CFP.000.10.48.002_B- Galvanized specification
• Surface Preparation SSPC-SP-10 (Near White Metal Blasting)
• ASTM A123 Edition 2010/ BS 729(BS EN ISO 1461): Specification For Zinc
Coatings On Iron & Steel Product
• ASTM A 153 Edition 2010: Specification For Zinc Coatings On Iron & Steel
Hardware
• ASTM A 143 Standard Practice for Safeguarding against embrittlement of hot
Dip galvanized structural steel products and procedure for detecting
embrittlement.
• ASTM A 780 Edition 2010: Specification For Repair Of Damaged &
Uncoated Areas
Of Hot Dip Galvanized Coatings.
• ASTM 86 Edition 2010: Specification for Zinc
• ASTM A385 Edition 2010: Practice for Providing High Quality Zinc Coatings
• ASTM 8499: Standard Test Method for measurement of coating thickness by
the magnetic method.
• ASTM A384: Standard practice for safeguarding against warp-age and
distortion during HOG of steel assemblies
• AGA- (AMERICAN GALVANIZERS ASSOCIATION) Design of Products to
be hot dip galvanized after Fabrication.
2.0 PROCEDURE
2.1 General
Pipes or fabricated spools, serration protection and threads has to be made with
suitable chemical agents shall be processed for Hot Dip Galvanizing in line with the
following sequence:
2.2 Surface Preparation:
Surface preparation of all structural steel to be carried out as per SSPC-SP-1 0 or Sa
2 1/2, prior to acid pickling, to remove mill scale, slag, weld spatter, sharp surfaces.
2.2 Acid Pickling:
The hot water rinsed items are processed with Hydrochloric Acid at a concentration
of 10- 15% to remove the scales and rust of the steel surface as per SSPC-SP8.
2.3 Water Rinsing:

~
MS/MB-WS/Galv-1 0
SAMSUNG

B• Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.10.48.753
Clean Fuels Project REV. O5, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 6 of 13
PSCJ Job No. JI-2025

The acid pickled steels are washed with water to neutralize the acidic surface of the
steel. Use only clean water & supply the tank continuously with new water.
2.4 Chemical Fluxing:
The rinsed articles, which are free of rust and scale, shall be immersed in chemical
flux solutions ((ZnNH4Cl3) with a specific gravity of 1.53 at 17ºC, which acts as a
wetting agent and protects steel from atmospheric oxidation prior to galvanizing.
2.5 Drying chamber:
The fluxed steel members are dried at a temperature of 1200C before immersing in
the molten zinc batch.
2.6 Zinc coating (Galvanizing)
Galvanizer shall not damage the material by over pickling each aspects of the
process shall comply with ASTM A143. The dried flux articles are immersed in to the
molten zinc at a temperature of 4500C for a specific time depending upon the
chemistry of the steel.

2.7 Quenching:
The steel members after galvanization in the zinc bath shall be cooled in atmosphere
temperature.
3.0 COATING REQUIREMENTS
3.1 General requirement for galvanizing shall be as per P6000CFP.000.10.48.002 B
clause – 5
3.2 Calibration of temperature recorder & measuring instruments shall be ensured.
3.3 Thickness / Weight
The thickness or weight of the galvanized coatings shall conform to ASTM A 123 -
Coating Grade 100 , BS 729(BS EN ISO 1461).The Minimum Galvanizing Coating
weight shall be 707 gm / m2 surface. Coating thickness shall meet section 6 of ISO O5
O4
1461.

MS/MB-WS/Galv-10
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48. 753
Clean Fuels Project REV. 05,03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 7 of 13
PSCJ Job No. Jl-2025

<0 A123/A123M -13


TABLE 1 Minimum Average Coaling Thickness Grade by Material category
All Specimens Tostoo
stelll ll!icl<noss Ranga (Moasuroo), in. [mm]
Malolial Category
<:Y1-e I'•• to <'4 Yo to :y,, >¥1t to<1f, ~ 1/&tO< o/e >%
[<1.6] [1.6 to <3.2] [3.2 to 4.8] [>4.8 to <6.4] ["6.4 to <16.0] [>16.0]
Strucluml Shapes 45 ss 75 75 100 100
strip and Bar 45 ss 75 75 75 100
Plato 45 ss 75 75 75 100
Pipund Tubing 45 45 75 75 75 75
Wire 35 50 60 65 so so
Reinforcing Bar 100 100

3.4 Surface Finish


The galvanized 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.
Coating appearance shall meet the requirements of section 6 of ISO 1461.
Integrity of coating shall be determined by visual inspection, coating thickness
measurements and adhesion testing, Where slip factors are required to enable
friction grip bolting, these shall be obtained after galvanizing by suitable treatment of
the faying surfaces in accordance with the latest edition of the Specification for
Structural Joints. Using ASTM A325 or A490 bolts as approved by the Research
Council on Structural Connections of the Engineering Foundation
3.5 Adhesion
The galvanized coating shall be sufficiently adhesive to withstand normal handling
during transport and erection.
4.0 GALVANIZING PROCESS
4.1 Venti Drain hole shall be provided to avoid high internal pressure & air locks.

4.2 Defects in substrate such as cracks, lamination, lap & folds shall be removed prior to
galvanizing.

4.3 All drilling, welding, cutting & final fabrication shall be completed prior to galvanizing.

4.4 Rough spots & burns shall be removed.

4.5 All materials shall be visually inspected prior to taking up for galvanizing

MS/MB-WS/Galv-1 0
Petrofac iJ SAMSUNG
ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05,03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 8 of 13
PSCJ Job No. Jl-2025

4.6 At the beginning of the process, all products are batched into the bundles, trays, or
racks to be handled in the most effective manner through the cleaning line. At this
stage, each product is examined to determine the presence of adequate details for
venting and draining of fluids during cleaning and galvanizing, and to assure that,
when necessary, the product is provided with holes or lugs for lifting. If additional
venting details or lifting holes I lugs are required, the customer is notified and
arrangements made to install them.
4. 7 After batching, the products are passed through the stages of the cleaning and
galvanizing line illustrated in Figure 1. This schematic applies to products whose
coating must meet the requirements of ASTM Specifications BS 729(BS EN
IS01461).
4.8 When parts are required to have excess zinc removed by centrifuging or brushing,
the stages shown in Figure 2 are applicable. Products are galvanized in this manner
to conform to the requirements of ASTM Specification BS 729(BS EN ISO 1461).
4.9 Re-fixturing
Depending upon the product and/or type of batching used during cleaning, some
products are re-fixtured or re-batched for better processing through the molten zinc
bath.
4.10 Galvanizing
Zinc used should be at least of grade (Prime Western) contain minirnum
98.0% Zinc as defined in ASTM 86. The fluxed, possibly re-fixtured, product
Is taken to the zinc kettles. The zinc kettle is provided with a foamy, black
blanket of zinc ammonium chloride flux, which floats on the surface of the
molten zinc. The products are lowered through the flux blanket en route to
the molten zinc below and, in so doing, receive one final cleaning. Products
rernain in the molten zinc until reaching the approximately +830°F molten zinc
temperature. Material distorted or wrapped shall be rejected.
4.11 Centrifuging or Brushing (ASTM 153/BS 729/BS EN ISO 1461)
When the perforated basket containing the product is rernoved frorn the molten zinc,
it is transferred immediately to the centrifuge where excess zinc is spun away.
Products that are too large to be centrifuged, but are still in need of removal of
excess zinc, are subjected to brushing of the critical areas before the zinc solidifies.

~
MS/MB-WS/Galv-1 0 SAMSUNG


Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 9 of 13
PSCJ Job No. Jl-2025

Rgure 1
Hot Dip Galvanizing Process for
ASTMA123

PICKLE RINSE

FLUX SOLUTION ZINC BATH QUENCH INSPECTION

MS/MB-WS/Galv-10

•• Petrofac tJ ••·I!Miiii» SAMSUNG


ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MA8.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page10of13
PSCJ Job No. Jl-2025

Fig\.!~-~
Hot Dip Galvanizing Process for
ASTMA153

PICKLE RINSE

FLUX SOLUTION ZINC BATH

QUENCH INSPECTION

•· ~ -tMWW»
MS/MB-WS/Galv-1 0 SAMSUNG
Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 11 of 13
PSCJ Job No. Jl-2025

5.0 TOUCH UP AND REPAIR


5.1 Repair of damaged zinc coating shall be as per P6000CFP.000.10.48.002 B
clause -9. The total uncoated areas for renovation by the galvanizer shall not
exceed 0.5% of the total surface area of the component. Each uncoated area
for renovation shall not exceed 1Ocm square. If uncoated areas are larger, the
article containing such area shall be re-galvanized as per ISO 1461-2009.
5.2 Mechanical Damage
Areas damaged by welding, flame cutting, or during handling, transport or erection
shall be repaired by one of the following methods whenever the damage exceeds
3/16"(5mm) in width on flat surfaces or 1/1 0"(2.5mm) on cut ends.
5.3 Cold Galvanizing Compound.
Surfaces to be reconditioned with zinc- rich paint shall be clean, dry, and free of oil,
grease, and corrosion products.
5.4 Areas to be repaired shall be sanded or with a power disc tool cleaning as per
SSPC-SP11 to bright metal. To ensure a smooth reconditioned coating, surface
preparation shall extend into the damaged galvanized coating.
5.5 Touch-up paint shall be an organic galvanizing compound having minimum of 65%
zinc dust in the dry film.
5.6 The paint shall be sprayed or brush applied in multiple coats until a dry film thickness
of 4 mils minimum has been achieved. A finish coat of aluminum paint shall be
applied to provide a color blend with the surrounding galvanizing.
5.7 Coating thickness shall be verified by measurements with a magnetic or
electromagnetic gauge
5.8 The colour of the finish coat shall be similar to the hot -dip galvanizing.
5.9 Localized over thickness area shall be buffed without damaging the zinc coating and
the required thickness shall be maintained uniformly.
5.10 Wet Storage Stain
Wet storage stain, if any, shall be removed prior to giving delivery from the
galvanizing plant to prevent premature failure of the coating.
5.11 Wet storage stain shall be removed as follows:
• The objects shall be arranged so that their surfaces dry rapidly.
• Remove light deposits with a stiff bristle (not wire) brush. Heavier deposits are

••• ~
MS/MB-WS/Galv-1 0 SAMSUNG
Petrofac ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 12 of 13
PSCJ Job No. Jl-2025

to be removed by brushing with an acidic-based metal cleaner. The cleaned surfaces


shall be thoroughly rinsed with water.
5.12 Coating thickness shall be checked in the affected areas to ensure the remaining
zinc coating, after the removal of wet storage stain, is sufficient to meet or exceed
the requirements of the specification.
6.0 HANDLING, TRANSPORT AND STORAGE
6.1 The steel members after galvanization in the zinc bath shall be cooled in atmosphere
temperature.
6.2 Galvanized articles shall be loaded and stored as follows to prevent the formation of
wet storage stain
6.3 The material shall be loaded in such a manner that continuous drainage could occur.
6.4 During storage, the articles shall be raised from the ground and, if necessary,
separated with strip spacers to provide free access of air to most parts of the surface.
They shall also be inclined in a manner which will give continuous drainage. Under
no circumstances shall galvanized steel be allowed to rest on cinders or clinkers; nor
shall it be stored on wet soil or decaying vegetation.
7.0 OUTPUT
7.1 Output- Galvanized ferrous metals
8.0 INSPECTION
Products are visually checked for coating integrity and measured to verify that
coating thickness made or exceeds ASTM A 123 I BS 729(BS EN ISO 1461)
Standards.
9.0 QUALITY ASSURANCE
9.1 Quality control checks shall be as per P6000CFP.000.1 0.48.002- B clause -10

9.2 Relevant ASTM Standards


A 53 Pipe, Steel, Black and Hot-Dipped Zinc Coated Welded and Seamless.
A 123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
A 153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware.
A 385 Providing Quality Zinc Coatings (Hot-Dip).
A 780 Repair of Damaged Hot-Dip Galvanized Coatings
ASTM A 143 Standard Practice for Safeguarding against embrittlement of hot
Dip galvanized structural steel products and procedure for detecting embrittlement.
9.3 Certification

MS/MB-WS/Galv-10

•• Petrofac tJ SAMSUNG
ENGINEERING
Kuwait National Petroleum Company
(K.S.C) HOT DIP GALVANIZING P6012MAB.000.1 0.48.753
Clean Fuels Project REV. 05, 03-10-2015
KNPC Contract No. CFP/EPC/0054-MAB1 PROCEDURE Page 13 of 13
PSCJ Job No. Jl-2025

When requested by the purchaser, a Certificate of Compliance shall be provided


stating that the galvanizing complies with ASTM Specifications and Standards and all
other applicable requirements specified herein.
9.4 Inspection and Tests.
Inspections, tests, and sampling shall be as per A 123 ASTM Specifications and
Standards.A designated party shall carry out inspection at the galvanizing plant.
Inspection rights and privileges, procedures, and acceptance or rejection of
galvanized steel material shall conform to ASTM A 123 or A 153 as applicable.
Inspections and tests shall include the following:
• Visual examination of samples or finished products, as appropriate.
• Tests to determine coating thickness, Uniformity of zinc coating or weight of
zinc coating per square foot of metal surface.
• Adhesion, Coating thickness & Uniformity of zinc coating.
10.0 SAFETY
10.1 The safety aspects of the Hot Dip Galvanizing plant shall be the responsibility of
the safety supervisor, and shall be in accordance with Company Safety Manual.
10.2 Hot Dip Bath attainder shall wear protective helmet with mask, leather cover all the
time.
10.3 All employees involved in the HOG works shall wear safety helmets, safety goggles,
working gloves, safety shoes and mask all the time.
10.4 No smoking or naked flames shall be allowed on the Hot Dip Galvanized Plant.
10.5 Sufficient ventilation shall be provided for the fumes, acidic smell to vent away.
10.6 Sufficient number of the Fire Extinguishers shall always be kept in the Hot Dip
Galvanized Plant.
10.7 Acid manufacturer's safety recommendations and instructions provided in the
materials Safety Data Sheet shall be strictly observed.
10.8 Sign Boards shall be placed near all the tanks.
10.9 Waste acid shall be disposed as per the Ministry of Public Authority For Industry.
11.0 ATTACHMENTS
Attachment A. Form No MBTC-FO/WS04 Galvanizing Certificate
Attachment B. ZINGA Technical Data Sheet
Attachment C. Form No MBTC-FO/QC-39/Rev.OO Release Note
Attachment D. P6012MAB.000.10.03.002.QCF.003-VX, Rev 02

MS/MB-WS/Galv-10
Petrofac I:J SAMSUNG
ENGINEERING
MBTC-FO/WSO4 Rev.1
Mohammed N. M. Al-Baddah & Partner
General Trading & Contracting Company w.l.l.
P. O. Box 9088, Ahmadi-61001, Kuwait.
Tel: 1867777 (30 lines) Fax: 22284500 e-mail: galvanizing@nbtc-kuwait.com

Certificate No:
Galvanization Certificate
Date:
Consignor's Ref :
Consignee:
ABJ/PSCJ/KNPC Job Title:
KUWAIT

PROJECT :- JI-2025-Clean Fuel Project - MAB 1 Consignee's Ref :


END USER :- Kuwait National Petrolem Company (KNPC)
Delivery Note/Date:
CLIENT :- Petrofac, Samsung & CBI - JV (PSCJ) Contract No:
Zinc Bath Temperature
ZINC COATING THICKNESS IN MICRONS
S.No. DESCRIPTION Qty
+ SPECIMEN VALUES AVERAGE

1 AVERAGE WEIGHT OF ZINC COATING - gms/m2  


2 VISUAL CHECK : UNIFORM COATING YES NO
3 JOB APPEARANCE : SURFACE - SMOOTH & CONTINUOUS YES NO
: FREE OF NODULES YES NO
: FREE OF BLISTERS YES NO
: FREE FROM ROUGHNESS & SHARP EDGES YES NO
4 ADHESION : ZINC COATING LIFTING OFF IN LARGE
: FLAKES WHEN LIFTED WITH STOUT KNIFE YES NO
We hereby certify that the material described above are Hot Dip Galvanized
in accordance with or conforming to the specification
Standards as per ASTM A 123 / BS EN ISO 1461 : 2009 ( formerly BS 729, 1971 )

Calibration details of Temperature recorder & measuring Instruments :-

Place & Date of Issue

MBTC QA/QC SUB-CONTRACTOR QC CONTRACTOR COMPANY

Name

Signature

Date
MBTC-FO/QC-39/Rev.00
RELEASE NOTE

SRN NO : Rev No. : Date :

This is to certify that the material as described here under have been inspected and released.

Company :
Project :
Contract No :
Contractor :
Location :

The following material was released :

Inspection
Sl, No. Description QTY Drawing No Remarks

The goods specified have been inspected with good results in accordance with scope of inspections as
stated on the inspection Reports as attached.

MBTC CONTRACTOR / TPI CLIENT

NAME

DESIGNATION

SIGNATURE

DATE
Kuwait National Petroleum Company (K.S.C)
Clean Fuels Project (CFP)
KNPC Contract No. CFP/EPC/0054-MAB1
PSCJ Job No. JI-2025

Surface Preparation/ Priming Inspection Report


Client Name : Project Name :
Contractor : Project No :
Sub-contractor : Report No :
Tag No : Date :
Sub system No : Rev :
Drawing No : RFI # :

Ambient Condition during application Surface preparation details


Date Specified Visual std.:
Time Abrasive / Power tool:
Dry Bulb ºc: Dust Level Check :
Wet Bulb ºc Chloride test : Mg/cm2
Dew Point ºc Attach Press 'O' Film
R.Humidity %
Substrate Temp. ºc
Ave. Mil/µm Max. Mil/µm Min. Mil/µm
Profile Mesurment

Specified Painting System: Inspection Result:


A li d primer
Applied i T
Type:
Paint Manufacturer Name & Product Code:
Base & Curing Agent Batch nos.
Application Method: Signature & Date:

Substrate Details Primer Inspection Date:


DFT
S.No. Identification No. Size Heat no./Spool no. Quantity Remarks
Min(µm) Max (µm) Avg.(µm)

Witness Signatories Sub-Contractor QC Contractor QC Company


Name
Signature
Date
P6012MAB.000.10.03.002.QCF.003-VX, Rev O2
Ref.: Technische fiches/1

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ZINGA
ZM-RE-PRO-04-A (01/08/06)

The film galvanising system Zinga is a one pack coating that contains 96% zinc in the dry film
and provides cathodic protection to ferrous metals. It can be used as a unique system as an
alternative to hot-dip galvanisation or metallisation, as primer in a duplex system or as a
recharging system for hot-dip galvanisation or metallisation. It can be applied by brushing,
rolling or spraying on a clean and rough substrate in a wide range of atmospheric
circumstances. Zinga is also available as an aerosol and is sold as Zingaspray.

Physical data and technical information

• Wet product

Components - zinc powder


- aromatic hydrocarbons
- binder
Density 2,67 Kg/dm³ (± 0,06 Kg/dm³)
Solid content - 80% by weight (± 2%)
- 58% by volume (± 2%) according to ASTM D2697
Type of thinner Zingasolv
Flash point ≥ 40°C to < 60°C
VOC 474 gr/Lt (EPA method 24)

• Dry film

Colour matt metallic grey (colour darkens after contact with humidity)
Zinc content 96% (±1%) by weight, with a purity of 99,995%
Zinga gives full cathodic protection and conforms to the standard
ISO 3549 in regard to its zinc purity of 99,995 % and to the standard
ASTM A780 in regard of its use as repair coating for hot-dip
galvanisation.
Special - atmospheric temperature resistance
characteristics - minimum : -40°C
- maximum : 120°C with peaks up to 150°C
- pH resistance in immersion: from 5,5 pH to 9,5 pH
- pH resistance in atmospheric circumstances: from 5,5 pH to 12,5 pH
- excellent UV resistance
Non-toxicity A dry layer of Zinga is not toxic and can be used in contact with
potable water, according to the standard BS 6920.
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• Packing

500 ml aerosol
1/4 Kg available as sample (on request)
1 Kg available, packed in undividable boxes of 12 x 1 Kg
2 Kg available, packed in undividable boxes of 6 x 2 Kg
5 Kg available
10 Kg available
25 Kg available

• Conservation

Storage store in a cool and dry place


Shelf life unlimited
In case of long time storage it is recommended to shake the
unopened tin in an automatic shaker at least once every 3 years.

Application data

• System recommendations

Unique system - Zinga is used as a stand-alone system, applied in 2 or 3 layers to


obtain a total maximum DFT ∗ of 120 to 180 µm.
- This system is strongly recommended because of the easy
maintenance. In time the layer will become thinner as the Zinga
sacrifices itself due to the cathodic protection. A new layer of Zinga
can be directly applied once the surface has been properly cleaned
and it will re-liquidise and recharge the previous Zinga layer. The
DFT of Zinga that should be applied depends upon the remaining
Zinga layer.
- The system Zinga 2 x 60 µm DFT conforms to the standards
NORSOK M-501 syst. 7 and ISO 12944 cat. Im2 and Im3.
Duplex system - In a duplex system, Zinga should be applied in one single
application, preferably by spraying, to obtain a maximum DFT of 60
to 80 µm.
- The surface of the Zinga should be free of zinc salts and other
contaminations prior to application of a topcoat.
- Zinga can be topcoated with a wide range of compatible sealers and
topcoats. To avoid pinholes when topcoated, use the mist coat &
full coat technique.
Stripe-coat It is recommended to apply a stripe-coat of Zinga by brush on all
sharp edges, nuts and bolts and weld areas before the application of
the first full layer of Zinga.
Recharging system Zinga can be applied on top of a hot-dip galvanising layer, a
metallisation layer or an old Zinga layer in order to renew or
enhance the cathodic protection. The DFT of Zinga that should be
applied depends upon the existing galvanising layer.


DFT & WFT : dry film thickness and wet film thickness ; to be measured above the peaks of the roughness profile
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• Coverage and consumption

Theoretical - for 60 µm DFT : 0,28 Kg/m² or 0,10 Lt/m²


consumption - for 120 µm DFT : 0,55 Kg/m² or 0,21 Lt/m²
Theoretical coverage - for 60 µm DFT : 3,62 m²/Kg or 9,67 m²/Lt
- for 120 µm DFT : 1,81 m²/Kg or 4,83 m²/Lt
Practical coverage depends upon the roughness profile of the substrate and the
application method

• Environmental conditions during application

Ambient temperature - minimum -15°C


- maximum 40°C
Relative humidity - maximum 95%
Surface temperature - minimum 3°C above the dew point
- no visual presence of water or ice
- maximum 60°C
Product temperature During application the temperature of the Zinga liquid must remain
between 15 and 25°C. A lower or higher temperature of the product
will influence the smoothness of the film when drying.

• Drying process and overcoating

Drying process Zinga dries by evaporation of the solvent. The drying process is
influenced by the total WFT, the number of coats applied, the
ambient air and surface temperatures and the air circulation.
Drying time for 40 µm DFT at 20°C in a well-ventilated environment:
- touch-dry: after 10 min.
- dry to handle: after 1 hour
- fully cured: after 48 hours
- ready for immersion: after 2 hours
Overcoating - with a new layer of Zinga :
- brush : 1 hour after touch dry
- spray gun : 1 hour after touch dry
- with a compatible paint : after 6 to 24 hours depending on the
drying conditions
Reliquidisation Each new layer of Zinga reliquidises the former Zinga layer so that
both layers form one homogeneous layer.
Ref.: Technische fiches/1

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Instructions for use

• Surface preparation

Cleanliness - The most common method to obtain a clean (and at the same time
rough) surface for the application of Zinga is:
The metal substrate should first be degreased, preferably by
steam-cleaning at 140 bar at 80°C. After that it should be grit-
blasted or slurry-blasted to cleanliness degree SA 2,5 according to
the standard ISO 8501-1 or to the cleanliness degree described in
the standards SSPC-SP10 and NACE nr 2. This means that the
surface must be free from rust, grease, oil, paint, salt, dirt, mill scale
and other contaminants. Once the grit-blasting is completed the
surface should be de-dusted with non contaminated compressed air
according to the standard ISO 8502-3 (class 2) or in case of slurry-
blasting the surface should be dried with non-contaminated
compressed air.
- Another method to obtain a clean surface is UHP water-jetting to
cleanliness degree WJ2 according to the standards NACE nr 5 and
SSPC-SP12 level SC1. But keep in mind that this method does not
create surface roughness.
- This high degree of cleanliness is not needed when Zinga is applied
on a hot-dip galvanisation or a metallisation layer, or when it is
applied on top of an existing Zinga layer. Please consult with the
Zingametall representative.
- For substrates that will not be immersed Zinga can be applied on
mild flash rust (FWJ-2) occurring in the allowed time limit. For
applications that will be immersed Zinga can only be applied on an
SA 2,5 prepared surface with contaminants to NACE No5/SSPC SP-
12 level SC1 unless otherwise agreed with the Zingametall
representative.
- On small areas or on non-critical applications Zinga can be applied
on a surface that is manually prepared to degree St 3 according to
ISO 8501-1. Please consult with the Zingametall representative.
Roughness - Zinga should be applied on a metal substrate that has roughness
degree Rz 50 to 70 µm (for total DFT < 280 µm) or Rz 60 to 80 µm
(for total DFT > 280 µm) according to the standard ISO 8503-2. This
can be obtained by grit-blasting (with sharp particles) but not by
shot-blasting (with spherical particles). Make sure that the surface is
degreased before the grit-blasting.
- This high degree of roughness is not needed when Zinga is applied
on a hot-dip galvanisation or a metallisation layer, or when it is
applied on top of an existing Zinga layer. Please consult with the
Zingametall representative.
- On small areas or on non-critical applications Zinga can be applied
on a surface that is manually prepared e.g. with a needle gun or a
grinding disk, in order to obtain an adequate roughness for Zinga.
Please consult with the Zingametall representative.
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Maximum time to Apply the Zinga as soon as possible on the prepared surface.
application - in dry circumstances : depending on the location
- in case of water-cleaning or if the relative humidity is close to 80%:
max. 4 hours waiting time
If contamination occurs before coating, the surface must be cleaned
again as described above. Flash rust can be removed by means of
a wire brush.

• Special instructions

Stirring - Zinga must be thoroughly stirred to achieve a homogeneous liquid


before application. After a maximum of 20 min. re-mixing is
necessary.
- During the spraying application, the product must be stirred
continuously.

Dilution Zinga can be diluted with 0 to 5% (volume on volume) of Zingasolv


when using airless spray equipment and 0 to 25% for air supported
applications. The Zingasolv must be added whilst stirring.
Rinsing of tools and Before and after using the spraying equipment, it must be rinsed
equipment with Zingasolv. Brushes and rollers should also be cleaned with
Zingasolv. Never use White Spirit.
Special demands for - Pour the Zinga through a filter of 100 mesh (150 µm) into the drum.
spraying equipment - For the spraying of Zinga, it is better to remove all filters from the
pistol and from the drum to avoid blockage.
- The spray gun must be equipped with reinforced needle springs.

• Application by brush and roller

Viscosity Zinga is ready for use when applied by brush or roller. Do not dilute.
First layer The first layer must never be applied by roller, only by brush, in
order to fill the cavities of the roughness profile and to wet the
surface.
Type of brush and - short hair roller (mohair)
roller - industrial round brush

• Application by spraying with spray gun with gravity cup

Dilution 0 to 25% (volume on volume)


Spray viscosity 25 to 35 sec. Ford cup nr. 4 at 20°C
Pressure at the 2 to 4 bar
nozzle
Nozzle opening 1,7 to 2,5 mm

• Application by spraying with spray gun with pressure pot

Dilution 0 to 25% (volume on volume)


Spray viscosity 25 to 35 sec. Ford cup nr. 4 at 20°C
Pressure at the 3 to 4 bar
nozzle
Pot pressure 0,8 to 1,5 bar
Nozzle opening 1,7 to 2,5 mm
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• Application by airless spraying

Dilution 0 to 5% (volume on volume)


Pressure at the 112 to 280 bar
nozzle
Nozzle opening 0,017 to 0,031 inch (0,43 to 0,78 mm)

• Other application methods

Please consult with the Zingametall representative.

For more specific and detailed recommendations concerning the application of Zinga, please
contact the Zingametall representative. For detailed information about the health and safety
hazards and precautions for use, please refer to the Zinga safety data sheet.
Waiver ∗


The information on this sheet is merely indicative and is given to
the best of our knowledge based on practical experience and
testing. The conditions or methods of handling, storage, use or
disposal of the product cannot be controlled by us and are therefore
outside our responsibility. For these and other reasons we retain no
liability in case of loss, damage or costs that are caused by or that
are linked in any way to the handling, storage, use or disposal of the
product. Any claim concerning deficiencies must be made within 3
months upon reception of the goods quoting the relevant batch
number. We retain the right to change the formula if properties of
the raw material are changed. This data sheet replaces all former
specimens.