Visit Report Nam Trieu Shipyard NASICO
Visit report no.
Project number:
Purchase order:
Item (s)
Yard:
Location:
Purpose of visit:
001
YN1318 - Magdalena
N.A.
Visit report rev.
Date of visit:
Attendees IHC:
1
From 15-04-2025 to 18-04-2025
S.L.C. White – Quality Engineer
Bryan Irion - Site Manager
Thuy Thi Thanh Nguyen – Site Secretary
Anh Nguyen Trong – Site QC Lead
Sections, Plate assemblies
Attendees Yard: Phong Vu Hong – Manager Project
Management & Production Department
Nam Trieu Shipyard ( NASICO )
Coung Pham Tien – QC Team Leader
Tam Hưng, Thủy Nguyên, Hai
Duc Anh – Welding Engineer
Phong 180000, Vietnam
Audit the quality delivered by the yard against project specifications. Identify subjects that
need attention. Focus is on fabrication by welding. IACS Z23 used for guidance.
Remarks/Observations:
1. Welding Procedures WPQR / WPS
1.1 Project specific welding procedure specifications have not been prepared. Welding procedures currently
implemented are general WPS’s and have been approved by NK on 10 oct 2023. NK is a member of IACS.
1.2 Welding procedures specifications are written in English only. The WPS’s do not serve their purpose as an
instruction to the welders and fitters. Due to the fact that most of the yards workforce doesn’t have English reading
comprehension.
1.3 Welding procedure specifications are not available where sections and plate assemblies are being fabricated. Did
not observe WPS’s posted on notice boards or in the form of booklets.
1.4 Observed inconsistency in welding procedures used. Similar assemblies are welded by different methods. for
example butt-welds in plate fields in the PA position with a thickness of 10mm are welded either with a combination of
FCAW and SAW, SAW or FCAW only. With various bevel details. ( See Photo’s 1 and 2 )
1.5 There is no supporting WPS for butt-welds in plate thicknesses under 14 mm.
1.6 Welding procedures for tack welds are not available. Only the remark “Root gap alignment of the joint shall be fixed
properly with fit-up pieces” is mentioned on WPS’s.
1.7 ( for improvement ) The yards standard is to back gouge/grind all SAW welds. Technically this is not incorrect.
However it is possible to complete SAW welds without back gouging. Given that the yard prepares welding procedures
that supports this operation. There is an opportunity to save time and costs. ( See photo’s 3 and 4 )
1.8 ( Positive remark ) Scope of testing of current welding procedure qualification records complies with the ISO
15614-1.
1.9 Essential information is missing on welding procedure qualification records. Pre-heat temperature and material
certificates.
1.10 ( Positive remark ) Noted welding consumable’s used in fabrications ( K-71T Kiswel, SF-71 Hyundai, M-12K + S-717
Hyundai ) These are BV approved and have supporting WPS’s.
1.11 Non BV approved welding consumables are noted on WPS’s ( A38 UTP, ST.50.6 Hyundai, NA70S Nawelco, NA70C1
Nawelco ) These have not been observed in fabrication.
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1.12 Noted BV approved welding consumables noted on WPS’s but not used in fabrication. ( Supercord-71H Hyundai, T316L Kiswel, K-316LT kiswel, KD-42 + EF-200K Kiswel )
1.13 ( for improvement ) Welding Procedures could be combined to be applicable for multiple positions instead of only
a single position. For example WPQR’s NT73 and NT72 could be combined in a single WPS.
2. Traceability of Materials
2.1 ( Positive Remark ) Requested the material certificates of 4 part ( plates ). Certificates could be traced back to the
parts via cutting plans.
2.2 ( for improvement ) Prepare list divided in the sections that links part numbers to certificate, Heat and plate
numbers.
3. Fit-up of weld joints
3.1 Section construction drawings do not define welding joint details. ( Bevel Type, Bevel angle, Root gap and Chamfer )
On WPS’s there is the remark “ See attached welding application plan” This plan has not been prepared.
3.2 Observed buttwelds in plates that generally have to be full penetration. Have been fitted with root gaps of 0-2 mm.
Back gouging required to make the welds Full-penetration. ( see Photo’s 5, 6, 7, 8 )
3.3 Bevel edges are crudely cut. ( See Photo 9 )
3.4 There is no standard for auxiliary materials to be used for fit-up. Generally scraps are used that don’t provide
sufficient strength. ( See Photo’s 10 and 11 )
3.5 Observed temporary lifting eye plates of various designs and dimensions. There does not seem to be a standard
design.
3.6 Observed run-off/on plates that are too short. The run-on and run-off plates should be of sufficient length to ensure
that start/stop imperfections are contained within them. ( See photo’s 12 and 13 )
3.7 ( Positive remark ) Generally fit-ups of filet welds are acceptable. Gaps are within limits tacks have been grinded
smooth and sufficient length. ( See Photo 14 )
3.8 ( Positive remark ) Generally alignment of butt-welds are acceptable.
4. Welding execution
4.1 Due to the fact that welding joint details are not defined on the construction drawing and welding application plan
is not available. It is unclear which WPS should be applied as the WPS’s available give multiple options for each
thickness and bevel detail.
4.2 Observed a SAW weld that has excessive penetration in combination with lack of fusion on the sides. Was grinded
flush with the plate before the weld was back gouged. When the weld is grinded flush the exact location of the weld is
lost. When the back side is welded the back weld might not align with the front weld. This could cause a lack of
penetration. ( See Photo 15 )
4.3 ( Positive remark ) Generally good craftmanship and common practice are being applied. Such as cleaning between
weld passes, Feathering and grinding of start/stops.
4.4 ( Positive remark ) Generally welds are visually acceptable. ( See Photo’s 16, 17 and 18 )
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4.5 Observed temporary lifting eye plates that are poorly welded. The slag has not been removed this indicates that the
welds have not been inspected before lifting. ( See photo 19 )
5. Welder Performance Qualifications
5.1 Current WPQ’s are according to NK rules. According to the ITP WPQ’s are to be according to IS0 9606. Apposed to
NK rules in ISO 9606 a butt-weld does not qualify a fillet-weld. Current WPQ’s are all butt-welds.
5.2 WPQ’s don’t have 6 month prolongation stamps.
5.3 WPQ’s are of the type 9.3a and will expire in June 2025.
5.4 Operators certifications for operator of SAW and mechanized FCAW machines are not included in the WPQ’s shared
by the yard.
5.5 WPQ summary list does not contain: certificate numbers, range of qualification and prolongation dates.
5.6 ( For improvement ) Welder ID’s to be marked next to the welds they have welded.
5.7 ( Positive remark ) New welders are tested at the welding training workshop before they may weld production
welds.
5.8 ( For improvement ) No written procedure for testing of new welders is available that Specifies what type of tests
they most pass and how they will be examined.
6. Dimensional inspection of sections / plate assemblies
6.1 Sections and plate assemblies are build on 1 meter high grids made of various profiles. Leveling of sections is done
with transparent tubes filled with water. Proper level measuring equipment are not being used. This raises concerns if
the sections are build level. ( See Photo’s 20, 21 and 22 )
6.2 Dimensional inspections of section is done with tape measures and pendulums. Measurements with a theodolite or
3D are not done.
6.3 ( Positive remark )Dimensional inspection are done where the alignment and position of Decks, Bulkheads,
longitudinal/transverse stiffeners and brackets are checked.
7. Non destructive testing
7.1 Visual testing is done by the yard and IHC site team.
7.2 Yards QC inspector’s don’t have a formal visual testing certification.
7.3 Yard coordinates 3rd party NDT company NDT ( QMI ). According to NDT plan.
7.4 Yards NDT summary list is incomplete. Report numbers are not listed. Rejections and repairs have not been
registered. Statistics of NDT are not available.
7.5 Reviewed multiple NDT reports numerous errors and lack of traceability. Incorrect procedures and acceptance
criteria is noted, Incorrect details of weld. Exact location of defect is not registered. No reference is made to a NDT
request.
7.6 QMI’s NDT Procedures have been accepted by BV and Reviewed by an LVL 3 operator not employed by QMI.
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7.7 NDT operator certificates are acceptable. QMI has ten level 2 operators employed. Noted that QMI does not have a
level 3 operator employed. It is not required to have a level 3 operator employed as per ISO-9712. However a level 3
operator is an asset.
7.8 A overview list of QMI’s NDT equipment shows that they have one UT set, Two MT yokes and one RT source
calibrated. This is not sufficient equipment for 10 operators.
8. Inspections by Yard
8.1 ( Positive remark ) Sections are inspected at multiple stages. Every plate assembly is inspected on fit-up and
alignment before its connected to the section. The alignment and fit-up of the plate assemblies added to the sections
are inspected before welding. After welding a final inspection of welding and dimensions is done. Inspectors have tools
such as tape measures, taper bore gauge, filet weld gauges and rulers.
8.2 Inspection reports prepared by the yard for visual, dimensional, Fit-up and leak-test. Don’t reference ITP points,
Procedures or acceptance criteria. On numerous reports its unclear what exactly has been inspected.
9. Drawing revisions
9.1 Drawings of sections in DMS that have the status “for internal use only” or are not available at all. Are currently in
production. ( Section 1470 and 1201 ) Raises concerns how or if drawing revisions are managed.
10. Fairing
10.1 Fairing is done consistently. Observed an occurrence where plates where heated red hot and then water was
poured on the heated area. This will cause hardened zones. ( see photo 23 )
11. Condition of facilities
11.1 Generally the condition of facilities is poor. Walls, roofs and doors are damaged. Floors are uneven. Concerns for
poor welding conditions due to draft and rain.
11.2 Facility for the fabrication of pipe spools needs a lot of attention to make it suitable for the fabrication of
hydraulic, Lube oil and fuel oil pipes that require cleanliness and precision ( See photo 24 and 25 )
12. Welding consumable storage
12.1 Two central welding consumable stores are present at the yard. Both are poorly organized. Different types of
welding consumables are mixed. Unclear which consumables can be used for each project. ( see photo’s 26, 27, 28 and
29)
12.2 In the central store located approximately in the center of the yard. Welding consumables are stored close to a
large bay door that opens and closes frequently. Environmental conditions can not be controlled.
12.3 There are no designated welding consumable stores where fabrication takes place. Concerns that workers will
create their own uncontrolled stores to avoid traveling to the central stores.
12.4 Noted that wire spools of SAW welding wire don’t have tags to identify the wire. Concerns that incorrect wire and
flux combinations might be used. As multiple saw wires and fluxes are present.
13. Welding Machines / Equipment
13.1 Visually inspecting the externals of power sources for MIG/MAG and SAW welding. There is wear and tear which
indicates these machines have been in service for a long period of time. No stickers for a yearly check and calibration
are present.
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13.2 Wire feed units for MIG/MAG welding manual and mechanized seem to be fairly new and in good condition. No
stickers for a yearly check and calibration are present.
13.3 Wire feed units for SAW have wear and tear. No stickers for a yearly check and calibration are present.
13.4 Requested the validation/Calibration certificates of two SAW machines. The yard could not provide the
certificates. Conform ISO 9001 the yard should be able to provide calibration certificates.
13.5 Observed a workpiece cable that was poorly crimped to a steel pipe and tacked to the section. This is not an
acceptable means to attach the workpiece cable. Due to this there will be a loss of current. ( See Photo 30 )
14. Communication
14.1 Generally the English comprehension reading/writing and speaking of the yards supervisors and managers is low.
When complex subjects are discussed a translator needs to be present. Concerns for qualities issues due to
miscommunication.
Conclusions:
1. The yards welding procedures need to be made project specific and cover the full scope of work. Written in language
and format that the welders and fitters can understand. Welding procedures need to be implemented to guarantee the
mechanical properties of the weld.
2. Plate materials are traceable to their material certificates. The traceability should be made more clear and convenient
by preparing an overview list.
3. Generally fit-ups of weld details are acceptable to IACS 47. Standardization and engineering is needed. Drawings do
not indicate what type if weld bevels are required and no other plans have been prepared. Generally scraps are used for
auxiliary materials. Bevel edges are crudely cut.
4. Generally welding execution is acceptable. Welders are missing instruction on which WPS is to be applied. Welds of
temporary lifting eye plates are in some cases unacceptable.
5. Summary of welder certifications needs to be updated to create a clear overview what qualifications welders and
welder operators have so they can be deployed on jobs they are qualified for. Current welders certificates are not
conform project specifications. Welder operator certifications are not present. To aid in the requirement that welds are
made by qualified welders. Welders could mark their ID’s next to the weld. New welders are tested before they may
weld in production. A written procedure for testing of welders is not implemented.
6. Grave concerns regarding the overall dimensions of the sections due to the platforms they are build on and absence of
appropriate measuring tools such as a theodolite.
7. 3rd party NDT company QMI has approved procedures and certified operators. Summary of NDT results is incomplete.
Rejects and repairs are not registered and statistics are not available. Review of NDT reports is unsatisfactory, reports
contain numerous errors. Concerns if NDT is executed according to NDT procedures. Yards QC team does not have a
formal visual testing certification.
8. The yard inspects sections on Fit-up, dimensional and welding. The inspection reports prepared by the yard are
unsatisfactory. Standards, acceptance criteria are not stated. Scope of inspection unclear on numerous reports.
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9. Concerns regarding management of drawing revisions and release to production due to their status “for internal use
only” in DMS. Sections with this drawing status are under construction.
10. Where material is heated for fairing. Concerns regarding hardening of material due to water being applied after
heating.
11. Overall condition of facilities is poor. Concerns for quality issues caused by rain, draft, dust and dirt. Especially the
facility designated for the fabrication of pipe spools is a concern.
12. Welding consumable stores are poorly organized and environmental conditions are not controlled. Risk of incorrect
welding consumables being used and risk of increased hydrogen content of welding consumables.
13. Condition of welding equipment is unclear. Stickers and certificates of yearly checks and calibration are not provided.
14. Generally the English comprehension reading/writing and speaking of the yards supervisors and managers is low.
When complex subjects are discussed a translator needs to be present. Concerns for qualities issues due to
miscommunication.
Closing Statement
The Yard has sufficient craftmanship however is lacking in the way of standardization, procedures and documentation.
Investments are needed in facilities, tools and equipment. Personnel need to receive qualifications such as CSWIP, IWE
or equivalent.
Conclusions: 1, 3, 5, 6, 7, 9, 10 and 12 Are considered critical and need action as soon as possible.
Actions:
1. The Yard is to propose actions to improve conclusions 1 to 14 accompanied by a planning and submit to IHC for
Approval.
2. IHC is to monitor progress of the actions and give guidance where necessary.
3. The yard is to give weekly progress updates.
4. IHC is to audit once again after improvements have been made.
SIGN-OFF
IHC QE
S.L.C. White
Name
Nam Trieu Shipyard, NASICO
Name
QE Department
☒ Witnessed Name: slcwhite
☐ Reviewed Date: 28/4/25
☐ Approved Sign:
Date report
28-04-2025
QE Department
☐ Witnessed Name:
☒ Reviewed Date:
☐ Approved Sign:
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Supporting photo’s
2
Welding of plate fields SAW
1
Welding of plate fields mechanized FCAW
3
Back grinding of welds in plate fields.
4
Back grinding of welds in plate fields.
5
Fit-up of full penn. butt-weld.
6
Fit-up of full penn. butt-weld.
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Supporting photo’s
8
Fit-up of full penn. butt-weld.
7
Fit-up of full penn. butt-weld.
9
Crude bevel cut.
10
Scraps used for fit-up of butt-weld.
11
Scraps used for fit-up of butt-weld.
12
Run-off tab too Short.
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Supporting photo’s
14 Fit-up of filet weld.
13
Run-off tab too Short.
15
Back weld on plate field grinded flush.
16
Sample of visual welding quality.
17
Sample of visual welding quality.
18
Sample of visual welding quality.
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Supporting photo’s
20 Raised Grids for construction of sections.
19
Welds of temporary lifting eye plate.
21
Raised Grids for construction of sections.
22
Raised Grids for construction of sections.
23
Water applied after heating of plate.
24
Pipe shop
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Supporting photo’s
26 Welding consumable store.
25
Pipe shop.
27
Welding consumable store.
28
Welding consumable store.
29
Welding consumable store.
30
Work piece cable of SAW machine
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