The document summarizes an upgrade project to replace two aging copper boil pots at a nickel plant. The 40+ year old vessels were replaced with new duplex stainless steel pots to improve material, design, and access. The project was completed safely on time in November 2011 through extensive planning and offsite fabrication, with a total cost of over $3.6 million. Lessons from the project highlighted benefits of modular offsite fabrication and dedicated planning. The project reduced reliability risks and improved plant integrity and access.

1. NKW Cu-Boil Pots
Upgrade
Brandon Smith
Senior Project Engineer – NKW Projects
28th February 2012

2. Overview
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 2

3. Project Brief
• Replace the existing vessels during November 2011 Cu-
Boil shutdown:
– D2C-17 (#1 Pot);
– D2C-18 (#2 Pot);
– Existing vessels 40+ years old – asset at end of
serviceable life.
• Basic Scope:
– Improve Material (Duplex SS Grade SAF2205);
– Improve design;
– Improve sparger/ring main fabrication;
– Improve access to area (Confined space
access/Platforms/Stairs).
• Risk Reduction project. (CURA = 90)
• Complex replacement methodology – Brownfield
installation
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 3

4. Project Team
Page 4NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade
Project Manager
Brandon Smith
Project Team
Snr Mechnical Project
Engineer
Frederik Mollentze
Electrical Project
Engineer
Katie Singh
Planner/Scheduler
Joe Kopilovic
Mechanical Project
Officer
Allen Terry
Electrical Project
Officer
Tom McClements
Drafting Coordinator
Dean Alexander
EPCM
PROTEUS
Snr Mech Engineer
Tony Balloch
Access Petrotec
Vinod Gupta
GHD
Peeyush Mathur
Fabrication
Specialised Welding
Services
Phil Bell
QA/QC - Welding
Inspector
Jason Buchanan
Mixtec Australia
Parag Dharkar
Crisp Engineering
Alan Crisp
Installation
Installation
Management
GRS
Installation Contractor
(Mech)
Downer
Installation Contractor
(Structural)
Cape
Installation Contractor
(Elec)
Downer
Scaffolding
ATIVO
Freo Cranes
Michael Viachi
Project Sponsor
Jacques du Toit
Stakeholders
Manager -
Maintenance NKW
Johan Snyman
Reliability
Superintendent
Brent Johndahl
Plant Integrity
Marcus Bredenhann
Snr Asset
Improvement
Engineer
Stefan Depre
Snr Integrity Engineer
Leon Mascini
Permit Coordinator -
North
Andrew Garforth
Permits
Lance O'Connor
Production
Coordinator - North
Dragan Supljelav

5. Zero Harm
TOTAL MAN-HOURS (DIRECT): >18,300hrs (~18 people for 3.5 mths)
• Fabrication Man-hours: >7,000hrs
• Pre-Outage Man-hours: >5,600hrs
• Installation Man-hours: >4,700hrs
• Post-Outage Man-hours: >1,000hrs
First Aid Cases (FAC): 3
• Nickel Rash – repeat FAC from other work
• Scalp Rash – poor hygiene
• Bruised Knee – inexperienced personnel
Incidents: 2
• DMS# 1039441 – Dropped object from height (~4m) within controlled area
• DMS# 1039429 – Contractors Sprayed with process liquor while removing valve
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 5

6. Schedule
Definition: ~6 mths
• Approved – 28 Feb 2011
• Target Completion – 29 July 2011
• Actual Completion - 15 July 2011
Execution: ~3.5 mths
• Approved –15 July 2011
• Fabrication: 3 mths (Included material
procurement, fabrication, NDT, lagging, delivery)
• Installation Window: 10 days (31st Oct 2011- 9th
Nov 2011)
• Target Practical Completion – 30 Nov 2011
• Actual Practical Completion - 28 Nov 2011
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 6

7. Cost
D2C-17 – No.1 Cu-boil Pot
Actual Total Cost (AUD$ YTD) = 1,835,375
D2C-18 – No.2 Cu-boil Pot
Actual Total Cost (AUD$ YTD) = 1,859,305
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 7
Phase USD Ex Rate Stretch Target Threshold
Definition 97.19 211,500 235,000 258,200
Execution 103.6 1,534,096 1,704,551 1,875,006
TOTAL
(AUD$)
103.6 1,663,119 1,925,011 2,032,701
Phase USD Ex Rate Stretch Target Threshold
Definition 97.19 211,500 235,000 258,200
Execution 103.6 1,534,096 1,704,551 1,875,006
TOTAL
(AUD$)
103.6 1,663,119 1,925,011 2,032,701

8. Lessons Learnt - Δ’s
• Aggressive target dates
• Supply/HR issues – verification of contract
information not correct
• Welding (onsite) – workload underestimated / poor
quality of workforce
• Materials – problems with correct identification
and delivery of all materials required (i.e. 7 TPI vs
8 TPI studs)
• Poor workforce interaction –
Maintenance/Operations/Projects
• Scope creep - interaction with surrounding pipe
work & pipe stresses
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 8

9. Lessons Learnt - +ve’s
• Zero Harm
• Maximised offsite Fabrication (Modular
approach)
• Dedicated planner/scheduler
• QA/QC – Excellent utilisation of third
party expert
• ITP – Fabrication/Installation
• Identification of quality manufacturer
• Precision Engineering and Installation
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 9

10. Outcomes
• Replacement of vessels within aggressive
target dates
• Improved plant reliability
• Increased plant integrity
• Reduced risk: 90 to 3 (No longer a
material risk to NKW)
• Reduced MFL (Maximum Foreseeable
Loss) = $22M to $1M
• Improved maintenance & operational
access to area
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 10

11. Overall Outcomes
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 11

12. Ongoing Commitment
NKW Projects – FY12 – NKW Cu-Boil Pots Upgrade Page 12