Inspection report for structural steel modules in Philippines

Order No. GCT 20044 AGP
Report No. BVMNL09090776-013
INSPECTION REPORT
GENERAL
(MODULES IN PHILIPPINES) • Sheet No. 1 of 8
Main Client : GORO NICKEL SA
Immeuble Malawi, Centre Ville, 52 Avenue
Foch BP.218-98845 Noumea
Cedex, France
Vendor and Project Management : INCO LIMITED
c/o INCO AUSTRALIA MANAGEMENT PTY. LTD.
Brisbane QLD 4000, Australia GPO Box 3282,
Brisbane QLD Australia
Project Title : GORO NICKEL PROJECT
GCT 01-000-8320-SP-003(D) : SPECIFICATION
FOR STRUCTURAL STEEL SUPPLY, FABRICATION
& ERECTION OF MODULES
Sub-Vendor: GORO NICKEL MODULARIZATION PROJECT
c/o ATLANTIC GULP & PACIFIC CO.OF MANILA INC.
San Roque Bauan, Batangas, 4201 PHILIPPINES
Tel No. (6343) 485-0437 Fax No. (6343) 485-0438
Contract No. : GCT 20044
Location : AG&P BATANGAS HEAVY FABRICATION YARD
San Roque, Bauan, Batangas, Philippines
P.O No. : GCT 2495 AG&P Job No. : 80051001
Supplier Job No. : 800061001 to 12 FABRICATION : STRUCTURAL PANNELS & MODULES
Client Reference : GCT01-XXX Date of Visit: 15-20 October 2007 Next Visit: DAILY
MATERIAL INSPECTED THIS VISIT : VARIOUS MODULE FABRICATION Inspection Status : ( 4 ) Acceptable/On-Progress
Item No. Quantity Description
Modules 19 units Various modules under Surveillance Inspection for Final Shipment
PANELS 8 units Various panels inspection at AG&P main fabrication release for painting
RESULTS OF INSPECTION: Accepted Release Note Issued: Non-compliance NCR Issued
ORDER STATUS: Complete Incomplete On-Production
COMMENTS (If applicable):
On-PROCESS daily inspection herein has been closely monitored as per client acceptance criteria from the
reference plan and drawings include witnessing, checking, reporting and review of document endorse/request by
Supplier during final Workshop fabrication on each panel or module including at yard erection for final verifications
on structural workmanship on supplier.
The inspection remarks listed below in our daily intervention, monitoring & surveillance works during ON-PROCESS at
Workshop Fabrication & Erection Yard on all structural units are still under confirmation at this stage others are
directly rectified on erection inspections, some found without remarks to their full welding & NDT examination, final
dimensional verification on each drawing approval reference, final conformance on panels, blocking & modules
structure were thoroughly inspected. Rectification & repair beyond the limits of Code using standard were mark NC
and verified accordingly to GORO Specs & GCT01-000-8321-39-1300 STRUCTURAL DESIGN.
TYPE OF VISIT : On-Process Fabrication
Pre-Inspection Meeting
Intermediate Inspection
Final Inspection
Review all Certs.
Witness NDT (Random)
Witness Performance Tests:
Witness Pressure Tests:
Dimensions & Workmanship:
Coating & Painting:
Next Schedule Visit :
Daily On-Process Inspection
Engr. Grandeo F. Cerilles
For GCT/VELOSI-Manila
VELOSI Inspector :
20 OCTOBER 2007
This Front Sheet to be returned to Inspection Group by due date
Dist: Manila, Philippines
Approved by MEI Date
INSPECTION STATUS:
1 Acceptable – Final
2 Not Acceptable
3 Not Ready
4 Acceptable – Initial/ On Progress

INSPECTION REPORT
GENERAL
Supplier INSPECTION PLANT:
AG&P BATANGAS HEAVY FABRICATION YARD
Production : GORO MODULARIZATION PROJECT
Structural Steels Fabrication & Erection Include
Parts & Accessories into Blocking MODULES.
PERSONNEL : GCT-Goro Nickel Project @ Philippines
1. VELOSI AMERICA LLC …………… Engr. Grandeo F. Cerilles
2. AG&P QA Manager ………..........Engr. Greg A. Coronel
3. AG&P Project Manager ………… Engr. F.O Pamfilo
4. GCT-GORO Yard Manager …….. Mr. Allen MYLES
5. GORO QA Engineer ……. ……… Mr. Danny COOMBE
Report Detail:
1.0 Summary:
Witness On-Process Fabrication, Inspection & Monitoring as a Workshop Inspector supplied on behalf to
VELOSI America as a GORO CONSTRUCTION TEAM on at the Vendor facilities which the schedule visits are
by daily basis to examine Fit-up, Edge preparation, Welding Workmanship, NDT works, Plan & Drawing
orientation & dimensional checkings, Documents review on suppliers procedures, & their records of report
specially on each priority components, assembly & accessories describe herein and supplied by the
supplier/manufacturer.
2.0 DOCUMENTS OF REFERENCE : (Endorse by Supplier & Vendors)
Title Reference n° Rev. Approved by Date
Specification for STRUCTURAL STEEL
SUPPLY, FABRICATION & ERECTION
GCT 01-000-8320-SP-003(D) F5 P. Krepoid 03-03-2006
Structural Design Standard List GCT01-000-8321-39-1300 S1 J. Green 29-09-2005
Project Specs. Material Requirement GCT01-000-8440-SP-0012 (D) A2 S. Bullock 17-05-05
Protective Coating GCT01-000-8440-SP-0010 A2 S. Bullock 28-06-2005
Positive Material Identification GCT01-000-8440-SP-0030-(D)
Welding and Fabrication of Duplex
Stainless Steel
GCT01-000-8440-SP-0009 A2 T. French 28-Nov. 2005
Piping Fabrication & Installation GCT01-000-8440-SP-0011 F1 G. Shand 25-05-2005
Duplex Site Piping Material GCT01-000-8230-RP-0009 F1 G. Shand 25-05-2005
Stainless Steel Site Piping Material GCT01-000-8230-RP-0009 F1 G. Shand 07-July 2005
Structural Steel Welding Part 1 :
Welding of steel Structure
AS/NZS 1554.1:2004 Ed. 7 AUSTRALIAN
STANDARD
January 2005
Structural Welding Code - Steel AWS D1.1/D1.1M:2002 Ed. 18 AWS STD. August 2001
Qualified Welders GCT-Goro Project 80051001-LL-001 18 F.O.Pamfilo 17 July 2007
AG&P ITP for Structural Fabrication 80051001-VS-01 Type : Q40 3 F.O.Pamfilo 02 June 2006
AG&P ITP for Piping Fabrication 80051001-VS-01 Type : Q50 3 F.O.Pamfilo 02 June 2006
Welding Procedure Index
Fabrication & Erection of Structure
80051001-KS-031 (Ref.F75105)
Total = 36 WPS Approved
0 F.O.Pamfilo 23 Feb. 2007
AG&P Qualified Welders List
On Structural Fabrication & Erection
80051001 (Ref.F62205)
Total = 51 Welders Approved
18 F.O.Pamfilo 17 July 2007
Welding Procedure Index
Piping Fabrication & Erection
80051001-KX-024 (Ref.F75105)
Total = 48 WPS Approved
AG&P Qualified Welders List
On Piping Fabrication & Erection
80051001 (Ref.F62205)
Total = 224 Welders Approved
AG&P Engineering Drawings Dwg. No. 80061012ESXXXX - AG&P Control Per inspection
AG&P Inspection Request F75131A(per Panels & Modules) - QC Form Per inspection
AG&P Visual Examination Report F82406 (Std. AS4100:1990 ) Rev.1 QC Form Per inspection
Welding Inspection Checklist F82405 (per Panels & Modules) Rev. 3 QC Form Per inspection
AG&P NDT Report for UT Examination F82411 (per Buttwelds @10% ) - QC Form Per inspection
AG&P NDT Report- MPI Examination F82410 (per Lifting Lugs ) - QC Form Per inspection
AG&P NDT Report for PT Examination F82412 (crack test checking ) - QC Form Per inspection
AG&P Bolt Tightening Report F75113 (Final module deliveries) - QC Form Per inspection
3.0 Activities carried out

INSPECTION REPORT
GENERAL
3.1 Vendor’s Procedure/Document Status: FABRICATION & ERECTION OF STRUCTURAL STEEL
A ) WPS/PQR
WPS Number Used for
Testing & Fabrication
Approval Code Process POSITION Base Material
(A36 or SS )
Remarks
Status Used
AG&P WPS INDEX 80051001-KS-031 MMAW &
FCAW
- - Ref : F75105
date: 05July’07
AS:05:013 ( Testing ) AS 2980 ( F62205 ) MMAW 3G & 4G Steel Plate Last July 2005
AS:05:014 ( Testing ) AS 2980 ( F62205 ) FCAW 3G Steel Plate Last July 2005
ASME:05:058(Testing ) ASME IX GTAW+SMAW 6G SA106 Pipe Last Sept. 2006
ASME:98:01 (Testing ) ASME IX SMAW 6G SA106 SS Pipe Last Jan. 2006
ASME:99:09 (Testing ) ASME IX GTAW+SMAW 6G SA312 SS Pipe Last Sept. 2006
ASME:06:004 (Testing) ASME IX FCAW 1G SA312 SS Plate Last Jan. 2006
ASME:06:026 (Testing) ASME IX GTAW 6G SA790 SS Pipe Last Mar. 2007
AS:05:001(Fabrication) AS/NZS 1554.1 MMAW 3G & 4G AS3679.2/ A36 With approve PQR
AS:05:002(Fabrication) AS/NZS 1554.1 FCAW 3G & 4G AS3679.2/ A36 With approve PQR
AS:05:025(Fabrication) AS/NZS 1554.1 MMAW 3F & 4F AS3679.2/ A36 With approve PQR
AS:05:026(Fabrication) AS/NZS 1554.1 FCAW 3G & 4G AS3679.2/ A36 With approve PQR
• Supplier ITP of AG&P has been approved by GORO last 21 June 2006 No. 80051001-VS-01
• Total of 36 & 48 Approved WPS issued for the project including attached qualified PQR’s.
• Total of 51 & 224 Approved Personnel of AG&P are listed on the Qualification Index on Welders
• Total of 16 NDT Personnel : 8 are qualified Cert. of AG&P Qualification list Level II ASNT Supplied.
• The total numbers of calibrated machines & equipment used by Supplier are still on process check
• Approved receiving materials are identified by Heat No., Piece Mark, Certificates & Stamp ID’s.
• Paint Coating Procedure – for AG&P are still on review verification without intervention
• Approve Workshop Procedure by GORO Fabrication are on review during used by AG&P reports
• AG&P PQR/WPS & WQT – on progress review verification on welders code used on visual reporting
• Those immediate rectification found on final inspections has been monitored & randomly check
• The GORO NCR will ISSUE only upon without given an action to immediate repair found on panels
• Carryover works & punch listed items on panels, modules & stick built items has been reviewed
• Production Data Book for structural panels, modules & stick built assemblies has been Sign check
3.2 Material Supplied Status:
• Actual Fabrication & Inspection (Scheduled) Status in Percent @ AG&P Supplier only
3.3 Fabrication Status:
The above modules at erection yard & workshops fabrication has been monitored by On-Process fabrication
by weekly summary of our daily reporting, All Workshops & Erection Yard inspection herein has been closely
monitored/surveillance as per client procedure & the supplier inspection test planning acceptance criteria from the
reference approval plan and drawings include witnessing, checking, reporting and review of document that been
endorse or requested by Supplier to GCT during final Workshop fabrication on each panels or module, Those items
listed below are still on progress and others are for final shipment which has been satisfied during thorough
inspections by vendors priority scheduled, the intervention herein shall inspect fit-up & edge preparation, full
welding & NDT examination, final dimensional verification on each drawing reference during final conformance by
random basis. Those immediate rectification & carryover works are subject for acceptance by GCT other that are
repair beyond limits to reference Code standard has been mark non-conformance and monitored on our daily
workshop intervention.
Item No. Quantity Description of Inspections
GCT G15-
067342
Inspection
Records
On-Process review on AG&P documents, material certificates, welding inspections
checklist, visual examination report, shops drawing approval checking, dimensional
report, NDT Test Report (UT, MPI & PT) on all components Assembly of Modules
Fabrication by AG&P for GORO MODULARIZATION PROJECT STEEL STRUCTURES

INSPECTION REPORT
GENERAL
5GOW-CHUTE
545-CHU-012
1pc
Section
Final welding & dimensional inspection, their 10%NDT examinations on butt weld joints,
welders & their code checking, complete immediate rectification & weld cleaning.
5P3A 2450.05
Plate Hopper
2pcs
Section
5P3B 2450.05
Plate Hopper
9pcs
Section
PLATFORM Unit
Elev. 167420
1pc
panel
DB96-PIPERACK
Section A
1pc
panel
DB91/DB92 N-S
Grid D. Piperack
1pc
panel
KB85-PIPERACK
Elev. Section A
1pc
panel
Final welding & dimensional, 10%NDT examinations on butt welded joints, Lifting Lug,
Elev. Section B
1pc
panel
Final welding & dimensional, 10%NDT examinations on butt welded joints, Lifting Lug,
Remarks : Piece Marked STRUCTURAL items in BLUE COLOR assemblies has been conform as per approved AG&P
Inspection & Test Plan No. 80051001-VS-01 Rev.3, dated:01-06-06 and GORO Specification for structural steel supply,
fabrication & erection No. GCT01-000-8320-SP-0003(D),Section10 INSPECTION as 100%Visual Panel fabrication &
erection module INSPECTIONS include NDT works by witnessing & documents review on their Production Data Book
include QC Field reports, sign & stamping of documents only on conformity items, others are still on review process.
ERECTION MODULES
DB 93 DB 94 DB 95 DB 96 ShipmentAG&P
MODULES
PLANT 240R/S
4 UNITS
Yard
Erection
DB93 & DB94 For-Shipment On-Progress Structural Erection & Piping for
Supplement Q: NEUTRALIZATION & Cu ION Pipe Rack @ Yard status: 75%
24 Oct. 2007
(tentative)
• Final Panelling @ Shop Percentage complete welding & dimensional as per shop drawings 95 %
• Structural Verification On-progress Inspections fit-up, welding, painting, dimensional, etc. 75 %
• PIPING Attachment On-Progress erections on mechanical & piping works components 75 %
• Final Yard Status Work On-Progress monitoring & inspections @ erection yard activities 75 %
• Records of Visual & NDT On-progress Inspections, review & checking on structural erections On-process
KB 87 KB 88 KB 89 ShipmentAG&P
MODULES
PLANT 285
3 UNITS
Yard
Erection
KB 89 For-Shipment On-Progress Structural Erection & Piping for
Supplement T : E-W EFFLUENT TREATMENT PIPERACK-2 @Yard status: 75%
24 Oct. 2007
(tentative)
• PIPING Attachment On-Progress erections on mechanical & piping works components 75 %
• Records of Visual & NDT On-progress Inspections, review & checking on structural erections On-process
MG59 : SUPPLEMENT M ( TRESTLE SYSTEM STRUCTURE ) ShipmentAG&P
MODULES
PLANT 310
1 UNIT
Yard
Erection
For Shipment On-Progress Structural Erection& Mechanical Attachment
for Area 310 – TRESTLE SYSTEM STRUCTURE ITEM @ Yard status : 75 %
24 Oct. 2007
(tentative)
• Works Panelling @ Shop Percentage complete welding & dimensional as per shop drawings 95%
• Structural Verification On-progress Inspections fit-up, welding, painting, dimensional, etc. 75%
• Mechanical Attachment On-Progress erections on mechanical & piping works components 0 %
• Records of Visual & NDT On-progress Inspections, review & checking on structural erections On-Process
MG57 : SUPPLEMENT M ( CONVEYOR GANTRY ITEM STRUCTURE ) ShipmentAG&P
MODULES
PLANT 310
1 UNIT
Yard
Erection
Area 310 – CONVEYOR GANTRY ITEM STRUCTURE @ Yard status : 75 %
24 Oct. 2007
(tentative)

INSPECTION REPORT
GENERAL
J A 66 : SUPPLEMENT N ( PRECIPATATION TANKS ) ShipmentAG&P
MODULES
PLANT 275A
1 UNIT
Yard
Erection
Area 275A – PRECIPATATION STRUCTION w/ TANKS @ Yard status : 90 %
24 Oct. 2007
(tentative)
• Works Panelling @ Shop Percentage complete welding & dimensional as per shop drawings 98 %
• Mechanical Attachment On-Progress erections on mechanical(Tanks)&piping works components 95 %
IC04 1C06 1C08 1C10 ShipmentAG&P
MODULES
PLANT 210
3 UNITS
Yard
Erection
1C04 For Shipment On-Progress Structural Erection & Mechanical
SAPROLITE & LIMONITE DUMP HOPPER SYSTEM @ Yard status: 85%
24 Oct. 2007
(tentative)
• Mechanical Attachment On-Progress erections on mechanical(HOPPER) works components 0 %
1A 1 R : SUPPLEMENT U ( LIMONITE HOPER SYSTEM STRUCTURE ) ShipmentAG&P
MODULES
PLANT 210
1 UNIT
Yard
Erection
On-Progress Structural Erection & Mechanical Attachment for
Area 210 – LIMONITE HOPER SYSTEM @ Yard status : 80 %
06 Nov. 2007
(tentative)
1A 1 S : SUPPLEMENT U ( SAPROLITE HOPPER SYSTEM STRUCTURE ) ShipmentAG&P
MODULES
PLANT 210
1 UNIT
Yard
Erection
On-Progress Structural Erection & Mechanical Attachment for
Area 210 – SAPROLITE HOPPER SYSTEM @ Yard status : 60 %
06 Nov. 2007
(tentative)
J B 1D : SUPPLEMENT N ( COBALT PIPERACK-2 ) ShipmentAG&P
MODULES
PLANT 275S
1 UNIT
Yard
Erection
On-Progress Structural Erection & Mechanical(PIPING) Attachment
Area 275S – N-S COBALT CARBONATE PIPERACK-2 @ Yard status : 60 %
06 Nov. 2007
(tentative)
NA 74 : SUPPLEMENT M ( LIME HAMER MILLS ) ShipmentAG&P
MODULES
PLANT 320
1 UNIT
Yard
Erection
No-Progress Structural Erection & Mechanical Works Attachment
Area 320 – LIME HAMMER MILLS UNIT SYSTEM @ Yard status : 0 %
No schedule
S A 13 : SUPPLEMENT A ( HPAL DIRTY STEAM EVAPORATORS ) ShipmentAG&P
MODULES
PLANT 350
1 UNIT
Yard
Erection
On-Progress Structural Erection & Mechanical Attachment for Area
350 – HPAL DIRTY STEAM EVAPORATOR @ Yard status : 87 %
06 Nov. 2007
(tentative)
Remarks : STRUCTURAL Modules works on welding, dimensional, plumbness, NDT, mechanical & electrical, pressure
vessels, instrumentation, piping, electrical cables & others assemblies has been inspected/monitored properly, any
mis-installed/missing works prior to their shipment dates has been taken to an immediate rectification or taken as
punchlisted/carryover works to be approved by GCT, as per AG&P Inspection & Test Plan No. 80051001-VS-01 and
GORO Specification for structural steel supply, fabrication & erection No. GCT01-000-8320-SP-0003(D),Section10
INSPECTION as 100%Visual Panel fabrication & erection module INSPECTIONS include documents review on their
PDB & QC Field reports, sign & stamping of documents only on conformity items, others are still on review process.

INSPECTION REPORT
GENERAL

Inspection report for structural steel modules in Philippines

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Inspection report for structural steel modules in Philippines