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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 1|11 Visit Report Nam Trieu Shipyard NASICO 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 ) Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 2|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 3|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 4|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 5|11 Visit Report Nam Trieu Shipyard NASICO 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: Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 Date 6|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 7|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 8|11 Visit Report Nam Trieu Shipyard NASICO 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. Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 9|11 Visit Report Nam Trieu Shipyard NASICO 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 Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 10 | 1 1 Visit Report Nam Trieu Shipyard NASICO 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 Visit report Nam Trieu Shipyard, NASICO 001 Rev. 1 11 | 1 1
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