Some Australian Pressure Equipment Innovation
- Details
- Category: General - Regulatory, Legal, Standards, E&T
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APEK |
SOME AUSTRALIAN PRESSURE EQUIPMENT INNOVATION |
APEK GN 225 Rev 1 Issued: 17/10/2014 |
Developed for: ACA, AICIP, AIES, AINDT, CAAA, Eng Aust, Met. Aust, NATA, Stds Aust, WTIA, & PE Industry & Regulators
1 Scope
This note provides some examples of Australian innovation by the Pressure Industry and Government.
2 Purpose to:
a) Illustrate the types of innovation that have occurred in Australia.
b) Provide encouragement for others to innovate.
c) Be a tribute to the many who have initiated the innovation or contributed to its success.
d) Make provision for additions of other significant innovation to PE.
3 Examples of Innovation See Table 1
1. For each outcome above there was new idea (start of innovation process), concept, discussion, R&D, tests and trials, initiative, find acceptance and issue in Standards, laws, technical and reports.
2. Period from idea to final document approximately 10 years mean (2 to 40 years).
3. Dates and details may not be exact but innovation is.
4 Improvement Corrections and additions to this note are welcome.
Table 1 Some Australian PE Innovation
|
Year |
Title |
By |
|
1926 |
SA-ME/1 Committee “Unification of Boiler Regulations” formed |
All Govts & Industry |
|
1931 |
AS CB1 SAA Boiler Code – completed by ME/1 and issued. Adopted by Governments and Industry – included qualification of welding procedures and personnel. |
All Govts & Industry |
|
1949 |
Low hydrogen welds with high Re and Gv proven good brittle fracture crack arrestors. |
Dept of Navy & DSL |
|
1956 |
New refinery permitted by government to use ASME (as well as AS CBI) |
NSW Govt and Caltex |
|
1958 |
Safety Factor = 4.2 required on Welded PE to cover “stress concentration” at weld toe. Later dropped for static PE and replaced by new “fatigue rules”. |
Reg. Authority and ME/1 |
|
1958 |
SA – ME/1 Meeting 1 negative vote by ME/1 beats 35 for – on sound technical basis. |
W Bernard – pioneer welding |
|
1964 |
AWRA formed for National Cooperative Research (following Kings Street Bridge collapse due to brittle fracture. |
Industry and Govt (CSIRO) |
|
1967 |
Australia wide R & D. Lead to major changes to rules for design pressure for liquified gas PV. (Appendix Q of AS 1210). Recognised importance of diameter. Later ICI work lead to AS ???? |
Shell, CIG, ICI and SA -ME/1 |
|
1967 |
SA Committee ME/1 Policy for participation in ISO/TC 11 meetings for international standards for boilers and PV. |
SA – ME/1 |
|
1969 |
Cold-stretched PV research for ME/1 accepted (based on Swedish Avesta work). |
SA – ME/1 |
|
1970 |
SA – ME/1 support at ISO/T11 meeting for new Wells Wide Plate based low temperature design (proposed by Shell/BP) design against brittle fracture (recognised important influence of thickness also). |
SA – ME/1 |
|
1971 |
Fracture mechanics used to accept HP power station boiler drum with serious non-conforming welding. Alternatively modified standards. |
AWRA, ICAL, SECWA |
|
1971 |
AS 1210 First issued – replaced some outdated requirements of AS CBI but added much more to align with world best practice. |
SA – ME/1 |
|
1975 |
Prequalified welding procedures concept agreed and recommended. |
AWRA Panel 1 |
|
1979 |
Higher design stress pressure vessels recognised with AS 1210 supplement 1. |
AWRA, ICI, SA – ME/1 |
|
1980 |
Self-checking boiler water level controls, adopted by SA – ME/1 – based on extension work initiated by Victorian Govt to avoid huge cost of continual boiler attendance. |
DLI-Vic (Don Robinson) Maxitherm (Ron Fletcher) |
|
1980? |
AS serially produced PV issued (1st full performance based PE Standard) |
SA – ME/1 |
|
1980 |
Adoption of Duplex Stainless Steel for pressure purposes initially low hazard and risk. Then not recognised in standards. Guidance note issued PEN - ?? |
QAL (Rex Tomlins) |
|
1981 |
WTIA formed – Joining AWI and AWRA (initiated for better service and reduce Govt findings. |
AWI, WTIA |
|
1981 |
FEA (Finile Element Analysis) Accepted by Regulator for PE not complying with AS 1210 – Dished ends. |
C & DLI-NSW |
|
1982 |
Fracture mechanics adopted for In-service Inspection of PE |
DLI-NSW |
|
1982 |
Ist Quality Assurance based PE manufacture accepted by Regulator to CSA 290 |
W E Smith (NSW) |
|
1983 |
Certified Quality System method accepted (not mandatory) as alternative to manufacture inspection. |
SA – ME/1 |
|
1984 |
Beer barrels – new USA design (higher design stress not to AS 1210) accepted after AU research. Safe use rules introduced. Now standard saved over 20 lives. |
Tooheys, DLI-NSW, UNSW (Hugh Stark) |
|
1984 |
First SS LPG Auto vessels developed and accepted (ultimately by SA-ME/1 |
Mytyons, DLI-Vic |
|
1984 |
Glass fibre wrapped HP aluminium gas cylinder design and manufacture researched and accepted in NSW |
CIG, DLI-NSW |
|
1985 |
Sustained Load Cracking (1st reported USA and Australia 1983) – Extensive AU R & D & Solutions developed and lead world. |
CIG, UNSW (Hugh Stark) |
|
1986 |
Heat Exchanger – tube plate design. R & D resulted generally in reduced thickness and resulted in AS ?????? |
ICI (Peter McGowan) and CD |
|
1990 |
AS 3??? Quenched & Temperence Steel Plate issued after huge R & D, assessment tests for Regulatory acceptance. Uniquely combines structural and pressure vessel grades. |
Bisaeloy SA – ME/01 |
|
1992? |
AS/NZS 3788 first issued (in-service inspection) |
SA – ME/1 and (Ron Read) |
|
1993 |
AS 3920.1 (PE Conformity assessment and Hazard levels). Issued to fill gap and industry commitment resulting from NSA. Producing a world first. |
SA – ME/1 |
|
1994 |
National Std for Plant issued – Major Reform with industry fully responsible. Major future impact on PE industry – good/not so good |
Govts & Regulators |
|
1995 |
AICIP formed to fill gap being created by NSP – for industry now to do in-service inspection. |
Industry, Govt & WTIA |
|
1999 |
Sub-arc welding of PE nozzles to shell. |
L&A (L Chouaifaity) |
|
2000 |
AS/NZS 1200 revision. Acceptance of overseas Standards , added comparison of standards and essential safety requirements |
SA – ME/1 |
|
2004 |
ISO Cryogenic PV standard developed (1st ISO PV Standard) |
ISO/TC 220, SA – ME/1 |
|
2004 |
Regulatory reform resumed to replace NSP and unify AU laws and Regulations on Work Health and Safety. 10 year review. |
Regulators |
|
2007 |
ISO 16528 – Boilers and Pressure Vessels – Basic general requirement only. Mainly a guide for various countries. |
ISO/TC11, SA – ME/1 |
|
2011 |
National WHS Act and Regulation adopted by most jurisdictions. |
Govts & Regulators |
|
2013 |
AU researched and development on weld toe treatment to improve fatigue – performance fix loads first recognition in AS1280 – 2010 and AWRA work 1975 by Ian Polmeau (Ref AWI Nov 2013). |
BV, CQV, Rio Tinto |
SA