Australian Welding June 2018 (Q2)

AUSTRALIAN 1

WELDING

Q2 | June 2018 Official Journal of Weld Australia www.weldaustralia.com.au

2

Australian Welding: June 2018

Weld Australia’s Value Proposition

Weld Australia is the peak industry body, representing the welding profession in Australia.

Our members include individuals and companies in almost every facet of Australian industry, making a significant contribution to the economy.

Weld Australia is the Australian representative member of the International Institute of Welding (IIW).

Our mission is to represent the interests of our members and safeguard the public.

We do this by ensuring the integrity of in-service welds, and promoting the use of best practice technology and quality systems.

HowWeld WeldAustralia AustraliaDelivers DeliversValues Value to How to Members Members Network

Learning

We provide a network for the exchange of ideas and the sharing of resources.

Technology Transfer

We facilitate technology transfer from research institutions and overseas markets.

We deliver pathways for learning.

Technical Solutions

We offer specialist technical solutions on all welding and materials related issues.

Voice

We are the voice of industry to promote awareness of welding to decision makers.

Certification We are an internationally accredited certification body.

Weld Australia Contacts National Office

Qualification & Certification

Editorial Submissions

Building 3, Level 3, Suite 5 20 Bridge Street Pymble, NSW 2073 (PO Box 197 Macquarie Park BC NSW 1670) T: +61 (0)2 8748 0100 E: info@weldaustralia.com.au

Paolo Corronca T: +61 (0)438 012 099 E: p.corronca@weldaustralia.com.au

Sally Wood T: +61 (0)434 442 687 E: sally@wordly.com.au

Chief Executive Officer

Marketing & Advertising

Geoff Crittenden T: +61 (0)2 8748 0100 E: g.crittenden@weldaustralia.com.au

Donna South T: +61 (0)2 8748 0130 E: d.south@weldaustralia.com.au

Training Paul James T: +61 (0)2 8748 0150 E: p.james@weldaustralia.com.au

Subscription to Australian Welding is a Weld Australia member benefit included in annual membership fees. All rights reserved. No part of this publication may be reproduced or copied in any form without the written permission of the Weld Australia.

Weld Australia and its agents are not responsible for statements or opinions expressed by contributors in this publication, which are not necessarily those of the Weld Australia. Publication of any advertisement does not constitute endorsement by the Weld Australia of any product, nor warrant its suitability.

3

Contents: June 2018

Contents 24

National Manufacturing Summit

From Weld Australia’s CEO

4

Inside the Industry Breaking News Skills Show & WorldSkills National Manufacturing Week Pipeline Repair Health & Safety Australian Standards

6 12 14 16 18 20

Feature & Technical Articles

32

Bombardier Australia Certified to EN 15085

38

Case Study: AGL Loy Yang Shut Down

Facility for Intelligent Fabrication National Manufacturing Summit Manufacturing Paradigm Bombardier Certified to EN 15085 Wynyard Station AGL Loy Yang Shut Down Joint Couplings’ Failure Precision Metal Group Austedan Fabrication

22 24 30 32 34 38 40 42 44

Inside Weld Australia Hotline Report Member Directory Upcoming Events

46 48 51

34

Cover Story: Wynyard Station Welcomes Interloop

Photo by Josh Raymond.

About Weld Australia A membership-based organisation, Weld Australia represents Australia’s welding profession. Our primary goal is to ensure that the Australian welding industry remains locally and globally competitive, now and into the future. Weld Australia is the Australian representative of the International Institute of Welding (IIW). For further information, please visit: www.weldaustralia.com.au.

4

Australian Welding: June 2018

A Message from Weld Australia’s CEO “

Weld Australia looks set to double the number of Australian companies that are certified to AS/NZS ISO 3834 this year. I believe this uptick in certification rates is absolutely fundamental to the future of welding in Australia.”

Geoff Crittenden Chief Executive Officer, Weld Australia

Until recently, many Australian asset managers were satisfied with simply asking contractors and suppliers to confirm their compliance to the relevant welding factory code: AS/NZS ISO 3834 - Quality requirements for fusion welding of metallic materials.

requirement for any company wishing to join their global supply chains.

Unfortunately, the problem with compliance is that there are an enormous number of grey areas, many of which would not be accepted by a qualified Weld Australia auditor. As a result, the quality of welding output often varies dramatically between a Weld Australia verified company and a company that has self-certified compliance.

Furthermore, state-owned infrastructure managers (such as Roads and Maritime Services in New South Wales and VicRoads in Victoria) will soon require similar levels of certification. The new Austroads Steel Fabrication Specification requires certification to AS/NZS ISO 3834 by an International Institute of Welding (IIW) accredited certifier which, in Australia, is Weld Australia.

However, this situation is currently undergoing a dramatic change.

The prime contractors involved in the defence shipbuilding and land systems projects—valued at over $150 billion—require AS/NZS ISO 3834 certification as a minimum

In addition, all welders working for aspiring defence industry welding companies will need to be certified to ISO 9606 - Qualification testing of welders - Fusion welding.

The certification requirements set out by both defence industry prime contractors and state-owned infrastructure managers has created a surge in demand for both individual and company welding certification.

As a result, Weld Australia looks set to double the number of Australian companies that are certified to AS/NZS ISO 3834 this year.

After years of hard work, with only a modicum of success, we now find ourselves in an industry that is embracing change.

I believe this uptick in certification rates is absolutely fundamental to the future of welding in Australia.

Until the quality of work produced

by Australian welders matches that of welders in Europe and America, Australia will always lag behind and struggle to compete.

Weld Australia’s policy has always been that we welcome competition from overseas fabricators and suppliers, as long as they comply to the same Australian and International Standards as Australian welders and fabrication companies.

Lasting Connections

5 Don’t forget: Always put on protective clothing before starting to weld!

A Message from the CEO

THE BEST FOR THE BEST.

Wherever and whatever you have to weld, Böhler Welding has the best stick electrode for the job. We supply any type you may need and our electrodes are always easy to handle, with fine arc ignition and stability.

Scan for more information

voestalpine Böhler Welding www.voestalpine.com/welding

6

Australian Welding: June 2018

Breaking News Weld Australia’s Weld Fume Position Statement The International Agency for Research on Cancer (IARC) has reportedly reclassified welding fume from being ‘Possibly carcinogenic to humans’ to ‘Carcinogenic to humans’. The nomograms and information available to IARC have yet to be published.

Until such time as the data can be independently verified and endorsed by suitably qualified experts, Weld Australia will continue to monitor the situation.

Weld Australia is aware that welding fume can be injurious to health and therefore continues to recommend prudent avoidance to weld fume exposure.

Please refer to the recommendations of Weld Australia’s Technical Note Seven: Health and Safety in Welding, and to our Fume Minimisation Guidelines.

The latter is available as a free download from Weld Australia’s website: www.weldaustralia.com.au.

New Lithium Refinery Planned at Kiwana WA Lithium, a 50/50 joint venture between Sociedad Química y Minera de Chile and Kidman Resources, recently signed an agreement to enter into an ‘Option to Lease’ with LandCorp for a new lithium refinery in Kwinana, Western Australia. Almost 400 jobs will potentially be created during the construction of the refinery, which is expected to start in mid2019. Additionally, the company’s lithium mine and concentrator will create about 300 jobs during construction and 150 jobs during the operational phase.

The refinery will produce approximately 40,000 tonnes per annum of lithium carbonate and lithium hydroxide, which will be processed at the proposed mine and concentrator at Mt Holland.

BOC Celebrates $35 Million Upgrade to Western Sydney Manufacturing Site BOC Australia recently unveiled a new $20 million specialty gases production facility and $15 million robot cylinder automation system at its Sydney Operations Centre in Wetherill Park. The new investments were officially opened by Minister for Resources and Northern Australia, the Hon Matthew Canavan MP and Minister for Western Sydney, the Hon Stuart Ayres MP. John Evans, BOC South Pacific Managing Director, said the new specialty gases facility will increase BOC’s capacity to locally produce and supply over 8,000 high purity and specialty gases to many high value industries in Australia – from science and medical research, to manufacturing and energy exports.

Embracing the new era of advanced manufacturing and digital technology, BOC also revealed a robot cylinder automation system that has transformed the way cylinders are sorted, picked and moved around the busy production site. The system is a world-first application of a six-axis robot combined with four turntables that can see, pickup and handle cylinders.

“The launch of this cylinder automation system is a landmark moment for BOC, driving a competitive advantage, and representing a significant safety investment for the Sydney Operations Centre, which produces more than 1.3 million cylinders each year.

Designed with global experts and local engineers, the system integrates advanced laser vision technologies, automated guide vehicles, robots and 3D cameras – which has successfully automated manual handling processes and introduced new skills of the future into BOC’s workforce,” said Evans.

Image: BOC’s $35 million upgrade to its Sydney Operations Centre in Wetherill Park.

Inside the Industry: Breaking News

7

Bisalloy to Supply First Trial Order for SEA1000 Future Submarine Project Bisalloy Steels has confirmed receipt of an initial order for 250 tonnes of its specialised high performance steel plate from Naval Group Australia (NGA) as part of the ongoing collaboration on the Commonwealth of Australia’s SEA1000 Future Submarines Project.

A key component of the development program for Bisalloy has been refining its technical and production capability to assure NGA it could produce the particular grade of steel required to meet the design demands of the project.

“Bisalloy Steels and NGA have been collaborating extensively on this project for over 18 months,” said Greg Albert, Managing Director of Bisalloy Steels.

“This grade of steel has never been manufactured outside of France before so this first order is an important step in confirming Bisalloy’s manufacturing processes and capabilities in producing the very high specification steel required.”

“At Bisalloy we’re excited to be supplying 100% Australian-made and processed armour plate for this important defence project. Knowing our armour plate will be used to protect Australian defence personnel is an immense source of pride for everybody at Bisalloy.”

The SEA1000 Future Submarines Project is Australia’s largest ever defence procurement project involving the construction of 12 ‘future class’ submarines with an estimated budget of $50 billion. Construction of the submarines will be undertaken in Adelaide by NGA and is expected to continue to the 2040s.

Civmec Wins Offshore Patrol Vessels Contract Civmec was awarded a contract from Luerssen Australia for the SEA1180 Offshore Patrol Vessel (OPV) project.

Civmec will supply and processing steel for all twelve vessels. Following the build of the first two vessels in South Australia, Civmec will undertake specific fabrication and construction activities for the following ten vessels. Final consolidation of the ten vessels will be undertaken at Civmec’s new shipbuilding facility, which is currently under construction adjacent to its existing water-front facilities and head office at Henderson, Western Australia.

The Company has begun mobilising personnel and equipment to ensure steel for the project is cut in time to meet the Q4 2018 commencement for the construction of the first vessel in South Australia. With this award, Civmec’s order book stands in excess of A$800 million.

Image: Calan Giarrusso, Corey Marchioni and Ross George with newly fabricated cane bins at Wilmar Sugar’s Kalamia Mill in the Burdekin.

A Steel Deal as Sweet as Sugar Australian-made BlueScope and Orrcon steel products are being used in a multi-million dollar cane bin manufacturing project by Australia’s biggest sugar producer, Wilmar Sugar Australia.

As the owner and operator of eight sugar mills in north and central Queensland, Wilmar employs more than 2,000 local people and produces approximately 60% of Australia’s raw sugar exports. It is also the country’s largest producer of renewable energy from biomass.

Wilmar crushes about 16 million tonnes of Queenslandgrown sugarcane annually, and relies on a fleet of more than 20,000 cane bins to transport the harvested cane from paddocks to its mills. Cane trains are used to tow the bins along Wilmar’s extensive cane rail network, hauling about 200 units at a time. The bins have a lifespan of approximately 40 years, so Wilmar has to replace its cane bins at a rate of 500 per year to maintain the fleet.

After deciding to bring manufacturing of its cane bins back in-house in 2016, Wilmar sought out a steel supplier that could keep up with the mass supply and tight deadlines the project would demand. BlueScope Distribution was the successful tender coming out on top due to the company’s safety procedures, employee capability, and its ability to deliver quality products on time and within budget.

Wilmar’s Works Program Manager, Vito Giarrusso, said varied sizes of cane bins were required for use at the company’s eight mills.

“Our cane bins range in size from four-tonne capacity to 11-tonne capacity units,” Giarusso said. “They’re all manufactured at Wilmar’s on-site workshops by teams of qualified and apprentice boilermakers. This is important because it allows us to maintain and expand our skilled workforce. We’re proud to be able to keep jobs local, and support the economy by using Australian-made Orrcon Steel,” said Giarusso.

Australian Welding: June 2018

8

Breaking News CAMS 2018

– Wollongong University 27-29 November 2018

Steel: Essential to Shipbuilding Infrastructure According to Liberty OneSteel, the Federal Government is committed to strengthening its naval shipbuilding infrastructure at Osborne Naval Shipyard in South Australia, with the steel sector set to play a key role.

Australia’s Future Submarine Program to

from Research Collaboration Advancing Materials and Benefit Manufacturing

The Government’s plan marks the largest-ever infrastructure investment of its type in Australian history. Among its aims is the construction of stateof-the-art shipbuilding and sustainment infrastructure at Osborne Naval Shipyard in South Australia and the Henderson Maritime Precinct in Western Australia.

Upgrades at both sites will help modernise ship construction systems and processes in Australia, an important step in improving shipyard productivity and reducing the cost of Australian build programs.

The Government has founded a new body, Australian Naval Infrastructure Pty Ltd (ANI), to oversee the development and construction of the Osborne shipbuilding facility in line with the Naval Shipbuilding Plan, which was released in May 2017.

Lendlease was selected as the managing contractor for the construction of the new Osborne South area of the shipyard following a competitive tender process. Steel distribution supply was awarded to Liberty OneSteel Metalcentre Port Adelaide Liberty OneSteel Metalcentre Port Adelaide will supply approximately 2,000 tonnes of hot rolled structural product—from Liberty OneSteel’s Whyalla Steelworks— to the project, in addition to welded beams and plate.

In total, a massive 8,000 tonnes of steel product is on order for the Osborne South project. Fabrication is underway already, with full delivery of steel materials expected by the end of 2018.

Deeper collaboration between Australia and France in advanced sonar and naval robotics technology will flow from a research agreement announced in Sydney during the visit of French President Emmanuel Macron.

The Memorandum of Understanding (MoU) between Flinders University in South Australia, ENSTA Bretagne (a leading Graduate and Post-Graduate Engineering School and Research Institute in France), and Thales will deepen and extend well established research linkages between Australia and France to contribute to the Future Submarine program in Australia.

Thales Australia CEO Chris Jenkins said the President’s official visit was an opportunity to highlight the strength of the strategic relationship between Thales and France, a relationship underpinned by linkages like the research MoU announced today.

“This is all about attracting the best and brightest in both Australia and France to work on the challenges of the future submarine program, ensuring Australia gets the best capability.”

“The MoU provides a long term framework for collaboration in naval robotics applicable to both submarine and surface ship sonars, including opportunities to share testing facilities, operate exchange programs and facilitate joint research projects.

It builds on an already strong relationship between Thales and Flinders University in Australia as well as between ENSTA Bretagne and Thales in Brest, France.”

$70.9 Million Boost for NSW Road Safety Projects The most dangerous hotspots on New South Wales’ (NSW) roads will be upgraded as part of the NSW Government’s Safer Roads Program, designed to reduce deaths and serious injuries on roads.

Minister for Roads, Maritime and Freight the Hon Melinda Pavey MP announced a $70.9 million investment that will deliver over 180 vital safety upgrades this financial year. The upgrades are set to include re-engineering dangerous curves, installing rumble strips to alert tired drivers, widening shoulders and centre lines, and installing flexible wire rope barriers to help prevent run-off-road and head on crashes.

CAMS 2014 call for abstracts

The projects are estimated to save the equivalent of 425 deaths and serious injuries over the life of the program. Approximately 64% of the investment will be directed to regional NSW, delivering 125 projects.

The 3rd biennial conference of the Combined Australian Materials Societies, incorporating Materials and Austceram

T

A A A B Ce Co bu Fe Li M

Call For Abstracts Advancing Materials and Manufacturing

The 6th conference of the Combined Australian Materials Societies; incorporating Materials Australia and the Australian Ceramic Society.

Join Australia’s largest interdisciplinary technical meeting on the latest advances in materials science, engineering and technology.

Our technical program will cover a range of themes identified by researchers and industry as issues of topical interest.

Co-chairs Dr Dan Gregg ANSTO Synroc daniel.gregg@ansto.gov.au

Prof Huijun Li University of Wollongong huijun@uow.edu.au

Opportunities for sponsorships and exhibitions are available.

CAMS 2018 November 27-29 University of Wollongong NSW, AUSTRALIA www.cams2018.com.au

Conference Secretariat: Tanya Smith Advances in materials characterisation tanya@materialsaustralia.com.au Advances in steel technology T +61 3 9326 7266

Themes

Advanced manufacturing Biomaterials ements & geopolymers omposites in roadmaking & bridge uilding erroelectrics WWW.MATERIALSAUSTRALIA.COM.AU ight metals design Materials for energy generation,

Symposia Themes • Additive & advanced manufacturing (future manufacturing, processes and products) • Advances in materials characterisation • Advances in steel technology • Biomaterials & nanomaterials for medicine • Cements and geopolymers • Composite materials • Ferro electrics • Ceramics • Composites in roadmaking and bridge building • Corrosion and degradation of materials • Durable materials for demanding environments • Innovative building materials • Light metals design • Materials for energy generation, conversion and storage • Materials for extreme environments • Materials for the nuclear fuel cycle • Materials simulation and modelling • Metal casting and processing • Microstructure and properties of composites • Photonics, sensors & optoelectronics • Nanostructured materials and interfaces • Porous materials • Surfaces thin films and coatings • Use of waste materials and environmental remediation • Wear-resistant materials

www.cams2018.com.au

JUNE 2018 | 7

Photos courtesy of George Vander Voort

CAMS 2018

Closing Date: 31st July 2018

A SI 2018 CO N V ENTI O N

FUTURE STEEL 16 – 18 SEP TEM BER 2018 Park Hyatt Melbourne

Australia is experiencing a steel renaissance.

With an unprecedented pipeline of opportunity in infrastructure, defence, building and construction, investments in ‘green steel’ and renewables, increasing export capability, new product development, a dynamic geopolitical environment and developments in digitisation, robotics, automation and virtual augmented reality, the Steel Convention explores current and emerging trends in Australian industry and economy.

CONFIRMED SPEAKERS

Chris Riddell

Alan Kohler

Sanjeev Gupta

Mark Vassella

Clare Savage

Vinod Muthanna

Ross Garnaut

Des Watkins

Futurist

Executive Chairman, GFG Alliance

Deputy Chair, Energy Security Board

Economist

CEO, BlueScope

CEO, BDS VirCon

Focused on equipping Australian Steel with the tools needed to navigate a changing landscape, qualify, differentiate, compete and win business, the 2018 Steel Convention is not to be missed.

Register now at www.steelconvention.com

President, Zen Energy

Director, Watkins Steel

Inside the Industry: Breaking News

11

Breaking News Austal Opens New Shipbuilding Facility and Delivers First Two Cape-Class Patrol Boats Austal recently welcomed Australian Defence Industry Minister the Hon Christopher Pyne MP to officially open the company’s new 10,500m² Pacific Patrol Boat Replacement (PPB-R) Shipbuilding Facility in Naval Base, Western Australia and herald the commencement of Austal’s steel naval shipbuilding capability.

The PPB-R project is estimated to create up to 207 jobs across production, project management, services and support - from Perth in Western Australia to Cairns in Queensland. Austal was awarded the A$306 million PPB-R contract in May 2016 and recently completed the Detailed Design Review on schedule. The PPB-R project comprises the design, construction, delivery, training and sustainment of nineteen 39.5m Patrol Boats - to be gifted by the Commonwealth of Australia to twelve Pacific Island nations as part of Australia’s Pacific Maritime Security Program.

Construction of the Austal designed patrol boats commenced at Austal’s new PPB-R shipbuilding facility in late April 2017, with deliveries scheduled from 2018 to 2023. In addition, Austal recently advised that the first of two Cape-class Patrol Boats for the Royal Australian Navy, the Australian Defence Vessel (ADV) Cape Fourcroy, had been delivered from the company’s Henderson shipyard in Western Australia.

The two 58m patrol vessels are to be chartered by the Commonwealth of Australia on behalf of the Royal Australian Navy, which awarded the A$63 million contract to Austal in December 2015.

Image: ASC’s Portable Fire Control System.

ASC Shipbuilding-Developed Fire Safety Consoles Win International Maritime Award The Royal Institution of Naval Architects (RINA) recently awarded ASC Shipbuilding the Lloyd’s Register Maritime Safety Award 2017, recognising a significant technological contribution to improving maritime safety.

ASC Shipbuilding won the award for an in-house designed-and-built system that monitors fire risks and directs the emergency response.

ASC Shipbuilding Acting Chief Executive Officer Jim Cuthill said the award recognised the safety and learning culture of the company, which employs more than 1,000 of Australia’s leading shipbuilders.

“ASC Shipbuilding may be a young company but we are showing we have cutting edge capability and a highly productive workforce,” Cuthill said.

“This prestigious international award demonstrates our commitment to practical safety and innovation - qualities which our workforce will bring to future shipbuilding roles, starting with the Offshore Patrol Vessel program later this year.”

Image: Artists’ impression of Austal’s Pacific Patrol Boat.

Image courtesy of Austal.

The Portable Fire Control System was designed and manufactured by ASC Shipbuilding. The system comprises a network of dozens of multi-function panels, distributed throughout a major vessel under construction, that monitor and raise an alarm and also provide information on any fires or fire risks. The system is partly credited with assisting in achieving no major fire incidents, over the last eight years, at the ASC Shipbuilding facility in Osborne, South Australia.

Australian Welding: June 2018

12

Skills Show Australia & WorldSkills Championships In June, Weld Australia exhibited at Skills Show Australia; a celebration of trades, skills, vocational education and training and above all – industry excellence. The Skills Show provided visitors with an opportunity to discover future careers through interactive events, demonstrations and competitions, and played host to the WorldSkills Australia National Championships 2018.

Weld Australia had the Soldamatic augmented reality welding simulator on-site at the Skills Show Australia, giving employers, competitors and the general public a chance to try their hand at welding. The simulator allows participants to try GMAW, FCAW, MMAW and GTAW welding in a range of positions and with a number of welding procedures.

Some of Australia’s top young trades people, employers, students, parents and members of the public experienced the technology and the feedback was great. People working in the industry and trainers could really see the advantages in skills development and skills acquisition offered by the use of this technology.

WorldSkills Australia National Championships 2018 The Skills Show hosted the most prestigious skills and trade competition, the WorldSkills Australia National Championships 2018.

Australia’s most skilled young tradespeople competed in live competitions, battling for their place to represent Australia at the 45th WorldSkills International Competition in Kazan, Russia.

Over the course of 18 hours across three days, WorldSkills welding competitors were required to: • Weld MMAW and GMAW butt and fillet welds in various positions, which were assessed to AS 1796-2001 • Using MMAW, GMAW, FCAW and GTAW, weld a pressure vessel • Using GTAW, weld aluminium

• • •

and stainless steel Assemble modules to drawings: print reading and interpretation Work in a safe manner Produce all types of weld joints, fillets, butts and corners, in all positions with full penetration and no internal defects

Weld Australia would like to congratulate all the welding competitors, particularly Gold Medallist Jacob Offner from Macquarie in New South Wales, Silver Medallist Adam Dixon from the Central Coast in New South Wales, and Bronze Medallist Kayden Stafford from Tasmania.

About WorldSkills WorldSkills Australia is one of over 60 WorldSkills International member countries. Every two years, participating members converge at the world’s largest skills competition – the WorldSkills International Competition.

Competitors must advance from the regional to the national level to prove their commitment and skills in their chosen field and to secure a place in the Skillaroos team; the International Competition is the ultimate test.

Members of the Skillaroos team become ambassadors not only for their skill, but also their local region, state and country.

The work of WorldSkills Australia is essential in ensuring that young Australians are given the opportunity to develop and improve their skills in their chosen vocation.

“Choosing a vocational education

and training path can open up some incredible and varied career opportunities,” WorldSkills Australia CEO Brett Judd said. “Many of the occupations predicted to have the strongest jobs growth in the next five years are offered by our vocational education and training sector.”

Judd also pointed out the competition’s importance in demonstrating VET or vocational forms of education as a viable alternative to a university education.

“By and large, parents want three things for their children: they want them to be happy and healthy, want them to have a better lifestyle than what they hand, and want them to have a better income than they have.”

“A lot of people see university as the pathway to those three things. I think that’s an ill-informed decision. VET pathways are terrific. They are also shorter and sharper. In VET you can get a lot of experience in six months then join the workforce as you continue to learn so you are valuable to an employer and you are at the coalface,” said Judd.

WorldSkills Australia is a social enterprise that passionately believes skills drive a young person’s future and Australia’s prosperity. Since 1981 WorldSkills has been one of the leading voices for skills excellence in vocational, technological and service careers. For more information, visit www.worldskills.org.au

Inside the Industry: Skills Show Australia & WorldSkills Competition

Top (L to R): Welding Gold Medallist Jacob Offner from New South Wales; Welding Silver Medallist Adam Dixon from New South Wales; and Welding Bronze Medallist Kayden Stafford from Tasmania.

Middle Left: A competitor completes one of the welding assessments at the WorldSkills National Competition 2018.

Middle Right: People lined up, ready to try their hand at the Soldamatic augmented reality welding simulator at the Weld Australia exhibition stand.

Bottom: A competitor completes one of the welding assessments at the WorldSkills National Competition 2018.

13

14

Australian Welding: June 2018

2018 National Manufacturing Week Held in Sydney in May, National Manufacturing Week (NMW) 2018 showcased the transformation of the manufacturing industry into a thriving ecosystem heavily focused on collaborative and integrated technologies.

With the nation’s manufacturing industry experiencing continuous growth for 19 consecutive months, NMW reflected the newfound optimism within the industry—over 4,500 visitors attended the event.

This year’s event attracted more than 200 leading companies showcasing the latest technology advancements.

NMW 2018 also presented an engaging conference program, officially opened by Senator the Hon Michaelia Cash MP. In her opening speech, Cash detailed why the Australian manufacturing sector is so strong. “Australian manufacturing remains competitive.

Why? Because we have embraced competition. Australia has achieved a world record 26 consecutive years of economic growth and 17 consecutive months of jobs growth - the longest run ever recorded in Australia’s history,” said Cash.

“This strong performance also extends to manufacturing. According to the AI Group’s performance of manufacturing index, Australian manufacturing has expanded for 19 consecutive months; the longest run of continuous expansion since 2005.

The result indicates that not only are Australian manufacturing firms taking advantage of market conditions in key sectors, they are also being more innovative and deploying new technologies in their operations, as well as seeking out and targeting new domestic and international customers,” said Cash.

“The Australian economy is undergoing a structural transition from goods producing industries to more high value knowledge intensive industries. Manufacturing is supporting over 300,000 businesses, investing $4 billion in research and contributing $100 billion to the economy in value add through exports annually.”

Claims over work-related injuries, diseases and fatalities also cost the compensation system $558 million over the same period.

“Australia’s access to global international markets will be fundamental to the continued success of our local manufacturing industry. The Government is working hard to secure open economic settings, attract investment and implement free trade agreements that will create opportunities for our manufacturers. Not only will these policies open additional markets for Australian businesses, they will also further integrate our domestic manufacturers into lucrative global supply chains,” said Cash.

Kean said SafeWork NSW would kick start the plan alongside manufacturing businesses, employers, workers, industry associations, and worker representatives. “Together they will explore ideas and opportunities for simple and practical safety solutions that reduce or eliminate the most common types of injuries.”

Manufacturing Work Health and Safety Sector Plan 2018-2022 The Manufacturing Work Health and Safety (WHS) Sector Plan 2018-2022 was officially launched at NMW by the Hon Matthew Kean MP (Minister for Innovation and Better Regulation) and Elizabeth Tosti (Director Metropolitan Operations and Sector Initiatives, SafeWork NSW).

Kean said manufacturing is one of New South Wales’ highest risk industries. “The manufacturing sector is one of the state’s most significant industries, producing a wide range of goods and injecting thousands of vital jobs into the economy. However, from July 2013 to July 2016 there were almost 41,000 workers compensation claims, and tragically there were 24 fatalities,” said Kean.

“The rate of injury remains far too high, and that’s exactly why we’re launching a new safety plan to help protect every worker across this important sector,” Kean said.

This will include workgroups to guide industry in managing key risks, developing tools like manuals and fact sheets to make compliance simpler, as well as forklift and machine safety blitz’s to ensure workplaces have proper safeguards in place.

Panel Discussions This year’s panel discussions were also a highlight of NMW 2018, with industry leaders offering thoughtprovoking opinions on opportunities and challenges in the manufacturing industry. Panel discussions centered around innovation and collaboration, Industry 4.0 and new technologies, automation and robotics, powering up the manufacturing process, advanced materials, industry opportunities, and optimisation and process improvement.

Most notably, the Weld Australia panel highlighted new welding technologies that are expanding opportunities in the healthcare,

Inside the Industry: National Manufacturing Week

Left: Geoff Crittenden, Chief Executive Officer of the WTIA.

defence and aerospace sectors, while the Australian Manufacturing Forum’s panel brought together experts from Innovative Manufacturing CRC, Retriever Communications, ANCA, Transition Group and REDARC to discuss digital transformation.

Weld Australia Soldamatic Demonstrations Weld Australia had a Soldamatic augmented reality welding simulator in operation at its stand throughout NMW. It proved to be extremely popular with the crowds; there were people literally lining up to try their hand at this innovative advanced welding training technology that offers myriad benefits.

Top: The NMW 2018 exhibition floor.

Middle: Mehdi Tajfar (Welding Consultant, Weld Australia) teaches an attendee how to use the Soldamatic augmented reality training technology.

Right (Top): Geoff Crittenden (CEO, Weld Australia) and Chris Brugeaud (CEO, SSS Manufacturing) speaking at NMW 2018.

Right (Bottom): Crowds lining up to try the Soldamatic augmented reality system at the Weld Australia stand.

15

16

Australian Australian Welding: Welding: June June 2018 2018

Pipeline Repair & In-Service Welding The process of in-service welding is frequently used in the repair, modification and extension of high-pressure pipelines. A common technique used in this application is ‘hot tapping’, which facilitates the creation of connections within existing pressurised vessels, pipelines and networks without the need to empty any of these pressurised systems. Inservice welding is also commonly used during pipe maintenance procedures, including the installation of sleeves to repair damaged sections within pipelines.

A thorough understanding of the factors that affect welding on inservice pipelines helps avoid pipeline shutdowns and interruptions of service, thereby bolstering both economic and environmental benefits for operators and welders alike. Plus, repairs can be undertaken efficiently, effectively and with full confidence.

According to Alistair Forbes, Weld Australia Technology Operations Manager, “The advantages of inservice welding are significant and wide-reaching, particularly in the gas and oil industries, where the process can be used to avoid costly shutdowns and service interruptions and maintain continuity of supply to customers.”

“In comparison, in situations where in-service welding is impossible, sections of the pipeline undergoing repair or replacement must be sealed and degassed before welding can commence, and must then be repurged once welding is complete.

This complicated process is costly, time-consuming, and damaging to the environment, with considerable greenhouse gas emissions a frequent result,” said Forbes.

In-Service Welding Considerations There are several factors that can make in-service pipeline welding difficult. The first factor is that the gas or liquid flowing through the

pipeline can cause a considerable loss of heat through the wall of the pipe. This, in turn, causes the weld to cool at an accelerated rate.

Depending on the type of steel used to construct the pipeline, rapidly cooled welds can increase weld hardness, as well as the likelihood of cracking in the heat affected zone.

The second factor that can cause issues during in-service welding occurs when the strength of the pipe wall is reduced during the welding process. If the wall of the pipe becomes too weak, the structural integrity of the pipe can be compromised, causing the wall of the pipe to burst under the greatly increased internal pressure. This is also referred to as ‘burn-through’.

Both of these problems can be exacerbated by the steels most commonly used to construct pipelines in Australia. Australian pipeline fabricators often use high yield strength steels. X70 and X80 steels often have walls as thin as 5mm, which makes in-service welding difficult due to the increased risk of both accelerated weld pool cool down and burn-through during welding. These high strength steels are also especially susceptible to increased hardness at accelerated cooling rates.

Pipeline Repair Seminar Facilitated by Weld Australia, the upcoming Pipeline Repair, Hot

The Pipeline Repair, Hot Tapping and In-Service Welding Seminar will be held in Sydney from 23 to 24 October 2018.

For information and to register, visit: weldaustralia.com.au/ pipelinerepair Tapping and In-Service Welding Course will include a review and critical analysis of available thermal analysis models, including the original Battelle model, the heat sink capacity method and the PRCI thermal model for hot tap welding.

Course attendees will learn why these models, while useful as planning tools, should not be regarded as ‘magic bullets’ against hydrogen cracking in hot tap welding. This course will give an unbiased analysis of the best strategies for avoiding burn through and the development of crack susceptible weld microstructures.

The two day course will also cover the latest defect assessment methods for pipeline engineers and managers, from simple, quick assessments through to more detailed ‘fit for purpose’ analysis.

Pipeline Repair, Hot Tapping & In-Service Welding Course 17

Avoid Shutdowns & Service Interruptions. Realise Economic & Environmental Benefits.

Facilitated by Weld Australia, this course will provide an in-depth overview of the various aspects of pipeline modification and repair, and address common concerns associated with welding onto in-service pipelines.

A thorough understanding of the factors that affect welding onto in-service pipelines helps avoid pipeline shutdowns and interruptions of service, thereby bolstering both economic and environmental benefits for operators and welders alike. Plus, repairs can be undertaken efficiently, effectively and with full confidence.

Who Should Attend?

Pipeline engineers, designers, operators and service professionals who are involved with the maintenance, design, inspection and repair of oil and gas pipelines.

“

A must attend course for pipeline repair personnel.

Excellent course material.”

Course Overview

The course includes a review and critical analysis of available thermal analysis models, including the original Battelle model, the heat sink capacity method and the PRCI thermal model for Hot Tap Welding.

Course attendees will learn why these models, while useful as planning tools, should not be regarded as ‘magic bullets’ against hydrogen cracking in hot tap welding by utilising comparative examples.

This course will give an unbiased analysis of the best strategies for avoiding burn through and the development of crack susceptible weld microstructures.

It will also cover the latest defect assessment methods for pipeline engineers and managers, from simple, quick assessments through to more detailed ‘fitness for purpose’ analysis.

Course Details • • • •

Date: 23 to 24 October Location: Sydney Register Now: weldaustralia.com.au/pipelinerepair Further Details: • events@weldaustralia.com.au • 02 8748 0130

Register Today Weld Australia Member: $3,100 + GST Non Weld Australia Member: $3,380 + GST weldaustralia.com.au/pipelinerepair

www.weldaustralia.com.au | events@weldaustralia.com.au | +61 (0)2 8748 0100 | Building 3, Level 3, 20 Bridge Street, Pymble NSW 2073

18

Australian Welding: June 2018

Welding Gas Safety & Storage Considerations The most commonly used welding gases are argon, oxygen and argon based shielding gases, each of which requires different precautions when it comes to safety and proper handling. Each of these gases has a different risk profile and characteristics that must be respected. Some of the most important safety considerations and precautions for each of these gases are outlined below.

Argon Argon is heavier than air and will readily displace oxygen. Therefore, in low lying areas or rooms, it can cause asphyxiation. The symptoms of oxygen deficiency include dizziness, headaches, nausea and in extreme conditions, death. During general handling, if used in well ventilated areas, argon is safe to use.

For specific information in relation to argon, a Safety Data Sheet should be consulted. Employee training and induction processes should also outline the systems detailed above.

Shielding Gases Shielding gases have similar properties to pure argon; risks associated with these gases also include asphyxiation. However, the density of these gases varies. Safety Data Sheets should be referred to for all gases for both technical and safety details.

Pure Oxygen Pure oxygen, which is often used for steel cutting, carries a different gas risk profile. Oxygen is a reactive gas that readily supports combustion and is used to increase combustion temperatures. It is important to remember that pure oxygen will violently react with oils, greases and some metals.

Handling and equipment used for oxygen must be kept oil free and clean from any presence of hydrocarbons. They are often sold and labeled as ‘oxygen safe’ or ‘oil free’ for this specific gas.

Gas Cylinder Safety Australian Welding spoke to Andrew Barnes (Retail Manager, Supagas) about some of the most important safety considerations when it comes to gas cylinders.

Personal Protective Equipment General Personal Protective Equipment (PPE) should be worn when using and handling welding gases. PPE should include gloves, safety glasses and hearing protection in some applications.

Direct contact with high pressure gas can cause injury and must be respected. As such, never aim or direct a gas jet towards yourself or another person. This also includes any compressed gas such as air.

Identification and Labelling of Gas Cylinders Gas cylinders are required to be labelled with the following: • Class label and any subsidiary risk labels • The proper shipping name • A four-digit United Nations number • Manufacturer or importer’s name

The valve basically contains the contents of the cylinder that is under pressure. Cylinder valves are fitted with pressure relief valves of different types (depending on the cylinder) to protect against catastrophic failure of the cylinder valve,” said Barnes.

“It is particularly important to note that cylinder valves on flammable gases have a left-hand thread to attach the regulator. This is to distinguish them from non-flammable gases. Also, valves should never be opened without a regulator attached, and should always be opened slowly,” said Barnes.

The regulator is the next most important safety device to be fitted to a gas cylinder before it is used.

The regulator allows the highpressure contents of the cylinder to be brought down to a usable, working pressure. Regulators come as both single stage for short term applications and two stage for long term applications.

Cylinder sizes are denoted by a letter code. The gas content of cylinders is measured in cubic metres, litres or kilograms. If volume unit is given, it refers to standard temperature and pressure of 15°C (101.3 kPa).

Regulators are also constructed from different materials, mainly brass or stainless steel. The type of gas being used will determine what sort of regulator you need. If you’re unsure which type of regulator to use, it is always best to consult your gas supplier. See AS 4267: 1995 Pressure Regulators for use with industrial compressed gas cylinders for more information and details.

Valves and Regulators “The valve is the primary safety mechanism on a gas cylinder and should never be tampered with.

Flow Meters When setting up your welding equipment, it is also important to calibrate the flow of gas to ensure

19

Inside the Industry: Health & Safety

“

If you suspect a leak, turn off all appliances and sources of ignition.

Companies regularly using and storing gas cylinders must have adequate emergency responses procedures in place.

For more information, visit: www.supagas.com.au

weld quality and enough gas is available at the torch end. Without enough gas weld quality, porosity and embrittlement can occur. Too much gas will result in waste and additional cost to the employer. This can be measured simply via the use of the gas flow meter readily available at your gas supplier.

Consult Supagas for technical advice in regards to gas flow rates.

Storing Gas Cylinders All high-pressure containers need to be stored below 45°C, in a secure space that is not in a high traffic area. Gas cylinders need to remain upright and be secured against a wall; a chain with hooks is the best and safest method.

The storage area should be well ventilated, dry and constructed from a non-combustible material.

The floor should be firm (preferably concrete) and level. The storage area should be located away from emergency exits and heavily trafficked areas. The storage area should be well ventilated in order to prevent gas cloud formation.

According to Barnes, “Gas stores

should be located outdoors, preferably in a secure, cage protected from sunlight. Storage indoors is not recommended unless the building has been designed for that purpose, with appropriate fire rated walls and ventilation.”

“Where gases are stored indoors, additional safety considerations and control measures need to be given consideration. Supagas recommends that if you store significant quantities of gas in cylinders that you consult AS 4332 The Storage and Handling of Gases in Cylinders for guidance, or consider the services of a dangerous goods consultant,” said Barnes.

There are a few things that need to be kept away from cylinders, including power points, hot water heater (gas and electric), air conditioning units, lights, light switches, any potential sources of ignition, and drains.

Transporting Gas Cylinders Transporting gas cylinders in enclosed vehicles is not recommended. If you do decide

to transport gas cylinders in your private vehicle, the regulations in the Australian Dangerous Goods Code and NTC Load Restraint Guide must be followed. Just some of these safety regulations include: • Keep windows open to promote ventilation • Do not leave cylinders in car for long periods at a time • Restrain cylinders upright securely in place to avoid cylinders moving around • LPG, Acetylene and CO2 cylinders must be stored in an upright position (limited quantities) • Flammable gas (acetylene) must be stored in an approved gas tight cabinet What To Do In The Event of A Gas Leak If you suspect a leak, turn off all appliances and sources of ignition.

Consult the Safety Data Sheet of the leaking gas for safety advice.

In addition, companies that regularly use and store gas cylinders must have adequate emergency response procedures in place.

Australian Welding: June 2018

20

The Changing Face of Australian Standards Australian Standards are living documents. They reflect progresses in science, technology and systems. To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen several developments, including an urgent review into standards related to rubber hoses for welding, cutting and allied processes, and ongoing reviews into standards related to pressure equipment and steel structures.

Safety Alert Recently, it was brought to Weld Australia’s attention that hose supplied to a fabricator for flame cutting and associated processes was non‑compliant with AS 1335 Hose and hose assemblies for welding, cutting and allied processes.

Further investigation has indicated that the standard (which was originally published in 1995 and then amended in 1998) was declared “Aged” by Standards Australia in 2016. Following a period of public review in the absence of an active drafting committee, the standard was withdrawn.

On querying the supplier, the fabricator was advised that as the relevant standard AS 1335 had been withdrawn, the supplier was under no obligation to sell compliant hose.

Given the serious safety implications of using non‑compliant hose, Weld Australia (with the active support of Standards Australia), has

“

Hose destined for use in welding, cutting and allied processes that is noncompliant with AS 1335 or ISO 3825 should not be purchased or used.

commenced an urgent review of the situation, including a review of the equivalent ISO standard, which is ISO 3825 Gas welding equipment - Rubber hoses for welding, cutting and allied processes.

Although AS 1335 and ISO 3825 are not identical, AS 1335 contains similar technical requirements to those of ISO 3825, including the colour coding of hoses. Whilst hoses compliant with AS 1335 remain readily available from major suppliers, Weld Australia recommends that only hose compliant with AS 1335 be specified and purchased. If this is not available, then hose compliant with ISO 3825 should be specified and purchased. Hose destined for use in welding, cutting and allied processes that is non-compliant with either AS 1335 or ISO 3825 should not be purchased or used.

Aged Standards Committee WD‑003 recently undertook action to update or reconfirm a number of aged standard in its portfolio. The ISO standard ISO 13916 was adopted as AS ISO 13916 Welding - Guide on the measurement of preheating temperature, interpass temperature and preheat maintenance temperature in 2003 but it has since been revised by ISO in 2017.

A project is now underway to implement a direct text adoption of the revised ISO standard.

The AS/NZS ISO 3834 Quality requirements for fusion welding of

21

Inside the Industry: Australian Standards

metallic materials series of standards have also been declared “Aged”.

In its recent meeting, Committee WD‑003 resolved to reconfirm parts 1 to 4 inclusive. In 2015, ISO released a revised edition of part 5 of the series and a project has been initiated to implement a direct text adoption of this part of the series.

Given the increasing importance of the AS/NZS ISO 3834 series in Australia, the Committee also resolved to commence a direct text adoption of the guide to the series ISO/TR 3834-6.

Pressure Equipment As previously reported in Australian Welding, a project to correct and clarify requirements within AS/NZS 3992 Pressure equipment - Welding and brazing qualification has been initiated within Committee ME‑001. At its recent scoping meeting on this project, subcommittee ME-001-15 expanded the scope of the project and has commenced a revision of the standard. Work will be ongoing over

the coming months to prepare a public review draft.

Steel Structures Committee WD-003 has completed its preparation of the draft revision of AS 2214 Certification of welding supervisors - Structural steel welding.

A public review draft is now being prepared by Standards Australia for release in the coming months.

Committee BD-001 has also recently completed the preparation of public review drafts to two of its standards.

With the publication of AS/NZS 5131 Structural steelwork - Fabrication and erection, the Committee has revised its AS 4100 Steel structures to remove the overlapping requirements.

The opportunity is also being taken to further revise AS/NZS 5131 to align with the Australian Building Codes Board requirements for secondary reference documents. Public review drafts are now being prepared by Standards Australia for release in the coming months.

Committee BD-082 has completed its work on AS/NZS 4600 Coldformed steel structures and published the document on 15 May 2018.

International Standards In 2015, ISO released its technical report ISO/TR 18491 Welding and allied processes - Guidelines for measurements of welding energies.

This technical report specifies requirements to measure the heat input parameters associated with waveform control technologies in particular. ISO has now commenced implementing the recommendations of this technical report in a number of its welding procedure qualification standards.

As it is known that errors of up to 50% can readily occur with the incorrect measurement of electrical parameters in waveform control technologies, it is likely that as Australian welding standards are revised, cognisance will be taken of this report commencing with the revision of AS/NZS 3992.

HOW TO REGISTER 1.

2.

3.

4.

5.

6.

Go to www.awcr.org.au Click on ‘Click Here to Register’.

Click on ‘Create An Account’.

Enter your contact details.

Verify your email address.

Login and complete your profile.

REGISTER NOW: AUSTRALIAN WELDER CERTIFICATION REGISTER

CR

Australian Welder Certification Register

02 8748 0100

|

info@weldaustralia.com.au

|

www.weldaustralia.com.au

|

www.awcr.org.au

22

Australian Welding: June 2018

Facility For Intelligent Fabrication Launched The Facility for Intelligent Fabrication (FIF) combines the knowledge and resources of the University of Wollongong (UOW), TAFE NSW and Weld Australia. FIF was formed in recognition of the changing business climate, as the Illawarra transitions from large-scale heavy manufacturing, and the need for local manufacturers to innovate and adapt to remain competitive.

The facility draws on decades of research-based welding and automation expertise and welding training at both UOW and TAFE NSW, enabling local firms with their own history of fabrication expertise to access specialised knowledge and skills in automation.

FIF will develop and implement solutions to industry challenges and provide demonstrations of technology and proof-of-concept, including prototype development. It will also support the adoption of new technology with technical education, training and certification support.

Deputy Premier, Minister for

Right: (L to R): Geoff Crittenden (CEO, Weld Australia), Professor Judy Raper (Deputy Vice-Chancellor Research and Innovation, University of Wollongong), Kerry Penton (Regional General Manager of South, TAFE NSW), Gareth Ward (Local Member for Kiama and Parliamentary Secretary for the Illawarra and South Coast) at the launch of the Facility for Intelligent Fabrication.

Regional New South Wales, Minister for Skills, and Minister for Small Business the Hon John Barilaro MP said the facility would be a valuable resource to ensure that manufacturing firms in the Illawarra and across NSW had access to the latest technology, training and certification.

“There are current and emerging opportunities for local fabrication companies to participate in steel intensive defence and infrastructure projects that will be a source of longterm skilled jobs,” Barilaro said.

“Connecting industry with training and accreditation partners and research will put local businesses at a competitive advantage and will be a game-changer for the region.”

Parliamentary Secretary for Education and the Illawarra and South Coast the Hon Gareth Ward MP said the FIF was an example of how governments, businesses, industry and training organisations can work together to promote innovation.

“This type of business transformation program will help industry transition to a new future and attract additional investment to the region. A strong economy will mean more jobs and go a long way to ensuring that Australia’s manufacturing industry is competitive on the global stage.”

The facility is an extension of existing UOW research, consulting and education expertise, combined with TAFE’s complementary training and facilities, and Weld Australia’s network of companies in the welding and fabrication space and internationally accredited certification.

Services the FIF partners offer include: expert, research-backed advice on automation technology adoption and implementation; robotics and automation fabrication solutions; augmented reality welding training for apprentices and trainees and ongoing welding training certification; and industry linkages and partnerships that offer opportunities for collaboration and sharing of knowledge.

Facility for Intelligent Fabrication

23

A one-stop-shop that provides expertise, technology, equipment and training in automating steel fabrication to help manufacturing businesses adapt and compete was recently launched at the University of Wollongong (UOW) by the Hon Gareth Ward MP (Parliamentary Secretary for Education and the Illawarra and South Coast), on behalf of the Hon John Barilaro MP (Deputy Premier, Minister for Regional New South Wales, Minister for Skills, and Minister for Small Business).

UOW Faculty of Engineering and Information Sciences Executive Dean Professor Valerie Linton said welding technology remained an integral part of the manufacturing industry, but firms needed to evolve rapidly.

“Solving challenges in adopting automation, accessing apprentice training and gaining welding certification would typically require multiple touchpoints with more than one agency or organisation,” Professor Linton said.

“Here we are creating a onestop-shop where they can access impartial expert advice to improve their business.”

Head of the TAFE NSW SkillsPoint for Innovative Manufacturing, Robotics and Science Karen Humphreys said TAFE NSW worked collaboratively with UOW and Weld Australia to establish a facility with capabilities across planning, research, vocational training and development as well as access to the latest technology.

“TAFE NSW works in close partnership with industry, business and employers to design training that looks to the future and supports local economies,” Humphreys said.

“TAFE NSW students are equipped with the skills and training that they need to respond to the opportunities provided by high-growth and emerging industry sectors as well as existing employer needs.”

Weld Australia CEO Geoff Crittenden said, “The launch of the Facility for Intelligent Fabrication offers innumerable benefits to Australian welders, as well as manufacturing firms in Illawarra and across New South Wales.”

“Together, the University of Wollongong, TAFE NSW and Weld Australia will strive to secure the future of the Australian welding industry by producing highly skilled, qualified welding professionals, and delivering solutions that promote the adoption of advanced welding technology such as robotics and automation,” said Crittenden.

Top: A demonstration of the Soldamatic augmented reality welding training system.

Bottom (L to R): Kerry Penton (Regional General Manager of South, TAFE NSW), Gareth Ward (Local Member for Kiama and Parliamentary Secretary for the Illawarra and South Coast), Professor Paul Wellings (Vice-Chancellor of University of Wollongong), and Professor Valerie Linton (Faculty of Engineering and Information Sciences Executive Dean) at the launch of the Facility for Intelligent Fabrication.

24

Australian Welding: June 2018

2018 National Manufacturing Summit The 2018 National Manufacturing Summit saw a diverse group of industry stakeholders assemble at Parliament House in Canberra on Tuesday 26 June. Hosted by Weld Australia, with the theme ‘Solutions to Critical Issues: Energy and Technical Training’, the Summit sought solutions to the two crucial constraints faced by the manufacturing sector in Australia: energy insecurity and Australia’s fragmented skills and training.

Welcome Dinner A Welcome Dinner was held on the evening of Monday 25 June at Australian Parliament House, to welcome delegates and encourage early networking opportunities.

Delegates enjoyed a highly engaging keynote address by Michael McLeod (Chairman and Director, Indigenous Defence and Infrastructure Consortium). Michael’s inspirational journey to his role in corporate Australia is not the typical route of Australia’s senior businesspeople.

Michael is a member of Australia’s stolen generation and a Ngarrindjeri Monaro man from Southern New South Wales. By his mid-twenties, he was a chronic alcoholic and heroin addict. By his early thirties, Michael was homeless and living on the streets of Sydney. A successful rehabilitation program has seen Michael clean and sober for over fifteen years.

Key Themes Australia’s manufacturing industry has survived a difficult period, in the face of both domestic and global challenges. However, several indicators now suggest that the opportunities in manufacturing have improved significantly. Employment has increased over the last few years, exports and profits have expanded, and business confidence is positive. Yet, there are two major constraints holding back Australia’s manufacturing industry: energy insecurity and fragmented skills and training.

of innovative, sustainable and environmentally ethical solutions to return much needed certainty and security to Australian businesses, making a significant contribution to the renewal of manufacturing.

Energy Insecurity Australia’s energy supply is among the world’s costliest and dirtiest.

It has also become increasing unreliable, with regulators recently warning a gas shortfall on the east coast is highly likely this year.

“Ten years ago Australia had the developed world’s cheapest natural gas – about a third of prices in the US. Today, our prices are about three times higher than in the US,” said Garnaut.

Michael’s future is aimed at advocating the need for Australian society (particularly the private sector and our Governments) to embrace, and support, the challenge Indigenous people face when his people begin the journey towards economic independence.

Many of the industry’s leading figures have called upon Australian governments to take a stand. Paul O’Malley (then the Chief Executive of BlueScope Steel), said energy costs in the US were up to 10 times lower than what his company paid in Australia. O’Malley warned of an ‘energy catastrophe’ in Australia unless baseload energy supplies can be guaranteed.

Delegates also heard from Craig Robertson (Chief Executive Officer, TAFE Directors Australia), who spoke in detail about the importance of the TAFE system to the future of technical training in Australia.

Many of the keynote speakers, including Professor Ross Garnaut (President, SIMEC Zen Energy) and the Hon Mark Butler (Shadow Minister for Climate Change and Energy) highlighted the importance

Professor Ross Garnaut (President, SIMEC ZEN Energy) The opening keynote speaker, President of SIMEC ZEN Energy, Professor Ross Garnaut, spoke about the missed opportunities for manufacturing and exports in the past, citing several causes for lack of competitiveness in energy prices.

“Why? Because the development of a liquid natural gas export industry in Queensland has raised the gas prices paid in eastern Australia to ‘export parity’ level – the much higher price producers could get by selling their gas to Japan or China (less the cost of liquefaction and freight).”

“It’s worse than that. Because foreign investors were allowed to install far too much capacity for LNG exports – meaning none of them is likely to recover their cost of capital – they’ve been so desperate for throughput they’ve sometimes bid gas prices well above export parity.”

But, he saw promise in the fact that the likes of Sanjeev Gupta, Chairman

25

2018 National Manufacturing Summit

Left: Professor Ross Garnaut (President, SIMEC ZEN Energy).

Below Left: Geoff Crittenden (Chief Executive Officer, Weld Australia) opens the Summit.

Below Middle: Delegates at the 2018 National Manufacturing Summit.

Below Right: The Hon Mark Butler (Shadow Minister for Climate Change and Energy).

Bottom: Michael McLeod (Chairman and Director, Indigenous Defence and Infrastructure Consortium) speaks at the Welcome Dinner.

of GFG Alliance, are investing in the domestic market, noting that it showed a growing confidence in the sector and that the stars are aligning for the sector to grow.

According to Garnaut, this growth will be possible through renewable energy sources, balancing the intermittence of these sources with battery technologies, and investing in training skills for the manufacturing sector. In fact, Garnaut says Australia also has a comparative advantage in the new world of renewables.

“Nowhere in the developed world are solar and wind resources together so abundant as in the west-facing coasts and peninsulas of southern Australia. South Australian resources are particularly rich…”

“Play our cards right, and Australia’s exceptionally rich endowment per person in renewable energy resources makes us a low-cost location for energy supply in a low-carbon world economy,” said Garnaut. “That would make us the economically rational location within the developed world of a high proportion of energyintensive processing and manufacturing activity.”

“

Play our cards right, and Australia is a superpower of the low-carbon world economy.”

The Hon Mark Butler (Shadow Minister for Climate Change and Energy) Butler highlighted the issues with the Australian energy sector. “The National Energy Guarantee, and its inadequate emissions reduction target of 26% is unsustainable into the future. It will shift a whole range of responsibilities for emissions reduction to other sectors of the economy like manufacturing, that simply don’t have the ability — the low-cost technology — to engage in emissions reduction in the way that electricity sector could do if it were allowed to by Malcolm Turnbull. Labor is committed to not only real emissions reductions, but a transition to a competitive, low pollution and growing manufacturing industry,” said Butler.

26

Technical Training With increasing employment opportunities in manufacturing (particularly in light of the Australian Government’s $90 billion Naval Shipbuilding Plan), highly skilled workers are required now more than ever, by defence prime contractors, a range of subcontractors and numerous manufacturing companies.

If projects are to be delivered efficiently and Australian companies are to take full advantage of the opportunities available, technical training needs an overhaul.

To achieve the necessary degree of skill and competence, a significant amount of both individual and company up-skilling and technical training is required to meet global standards. Many of the Summit’s keynote speakers—including Dr Jim Stanford (Economist and Director, Centre for Future Work), Neil Coulson (Victorian Skills Commissioner, and the Hon Dough Cameron (Shadow Minister for Skills, TAFE and Apprenticeships)—focused on the importance of technical training to the future of Australian manufacturing, and what action needs to be taken now to ensure Australia has the workforce capability to deliver major projects.

Dr Jim Stanford (Economist and Director, Centre for Future Work) Dr Jim Stanford launched a brand new report at the Summit, Advanced Skills for Advanced Manufacturing: Rebuilding Vocational Training in a Transforming Industry.

“Manufacturing is again making a positive contribution to Australia’s economic progress after over a decade of decline. We don’t want

Australian Welding: June 2018

to squander this potential,” said Stanford. “If Australia doesn’t get its act together on vocational training, this will be a wasted opportunity for manufacturing.”

•

on their skills to new apprentices Inclusion of provisions guaranteeing access to further training in industry awards and enterprise agreements.

“Recent experiments with marketbased vocational training have been a waste, they have damaged confidence in the skills system among both potential students and employers. Stable, well-funded, high-quality public institutions must be the anchors of any successful VET system. Public institutions are the only ones with the resources, the connections, and the stability to provide manufacturers with a steady supply of world-class skilled workers.”

Neil Coulson (Victoria Skills Commissioner) Australia’s manufacturing sector remains a strong employer, despite the loss of the automotive sector, said Victorian Skills Commissioner, Neil Coulson.

“No sector feels the pain of the failure of vocational training more than manufacturing, precisely because advanced skills are so essential for the success of advanced manufacturing techniques.”

In the Commissioner’s keynote address at the Summit, he cited several examples of how the Victorian Government is working to encourage school-leavers to transition into careers within the manufacturing sector. The Commissioner explained that the Victorian Government’s priority is to establish and grow skills pathways, particularly in priority sectors where there is industry demand for skilled jobs, such as manufacturing.

“

Manufacturing stakeholders need to work together to strengthen vocational education and training.”

Key principles for rebuilding vocational education in manufacturing, discussed in the report, include: • A greater reliance on courses and apprenticeships through public-sector TAFE (rather than private providers) • Phased-in retirement programs to allow senior workers to pass

Indeed, the Australian Industry Group’s Performance of Manufacturing Index Activity levels has held steady or improved for 16 consecutive months, the longest stretch of improvement since 2005.

“Delivering the right training and education and ensuring that the right pathways are available for people to transition from training into work are vital,” said Coulson.

“Industry input can lead to more strategic and targeted interventions to align the training system with industry needs. As such, the manufacturing industry can help

Left: Dr Jim Stanford (Economist and Director, Centre for Future Work) speaking at the 2018 National Manufacturing Summit.

Right: Neil Coulson (Victoria Skills Commissioner) speaks at the 2018 National Manufacturing Summit.

27

2018 National Manufacturing Summit

The Hon Doug Cameron (Shadow Minister for Skills, TAFE and Apprenticeships).

Penny Prasad (Director, The Eco Efficiency Group).

facilitate information sharing and collaboration between government, employers, trade unions and training providers,” he said.

to Cameron, finding the best way forward will be complex. “It will be both intellectually and practically challenging - but it needs to be done.”

The Hon Doug Cameron (Shadow Minister for Skills, TAFE and Apprenticeships) Shadow Minister for Skills, TAFE and Apprenticeships, Doug Cameron, addressed the increasing demand for technical skills throughout Australia’s manufacturing sector—an area where is Australia is falling short, according to Cameron.

“We need a system built on quality, collaboration, depth, reliability and transferability that: equips people with knowledge and education for good working lives; skills the workforce for existing and emerging jobs; produces skills that power innovation and good jobs; provides greater social engagement and inclusion by guaranteeing access to quality lifelong learning and further education; in apprenticeships, provides a contract for employment and a contract for training with nationally recognised portable skills; and recognises the importance of highly skilled TAFE teaching professionals.”

“Demand for deeper technical skills for the workforce, particularly in advanced manufacturing, is growing. This is taking place in the context of accelerating technological change such as automation, artificial intelligence, machine learning, and the internet of things, additive manufacturing and synthetic biology,” said Cameron.

“The change is rapid and requires the generation and acquisition of complex, high order technical knowledge and skills. This suggests a need for robust, deep and transferrable qualifications to provide a strong base for life-long learning and skill development. Equally we need a strong culture of training and development in our workplaces.”

“Instead we face a series of inter-dependent factors that are constraining and undermining our skill formation system. The system is characterised by low investment and fragmentation – and a growing propensity for short and partial qualifications increasingly directed at training to the enterprise.” According

The Hon Karen Andrews (Assistant Minister for Vocational Education and Skills) The Summit was closed with a speech by Assistant Minister for Vocational Education and Skills, Karen Andrews, who spoke about rebuilding confidence in the manufacturing industry.

“Australia’s manufacturing industry has come through a difficult period, in the face of both domestic and global challenges,” said Andrews.

“The Turnbull Government is committed to seeing an extra 300,000 apprenticeships over the coming four years through the Skilling Australians Fund and I expect that many of them will find on-going employment with Australia’s various manufacturers.”

David Lake (President, Weld Australia) asks a question.

“

Rebuilding confidence in the industry will grow the demand for skilled workers as well, presenting an opportunity to thousands of Australian apprentices and trainees.”

Andrews said five states and territories have already signed on to the Skilling Australians Fund, which commenced on 1 July 2018, injecting an estimated $3 billion into the VET sector in state and federal funding.

“The Skilling Australians Fund will kick-start Australia’s skilled labour sector, sparking what is possibly one of the largest recruitment drives we’ve seen for apprentices.

I expect the influx of new skilled workers will boost industries like the manufacturing sector.”

“I am confident the apprentices in the coming years and the qualified workers they will become will have the exact skill sets needed by the manufacturing sector to deliver major projects to world standard and beyond,” said Andrews.

Other keynote speakers included Michael Sharpe (Director – East, Advanced Manufacturing Growth Centre), Penny Prasad (Director, The Eco Efficiency Group), Gordon Wymer (Chief Commercial Officer, Snowy Hydro), and Geoff Crittenden (Chief Executive Officer, Weld Australia).

28

Panel Sessions: Energy The increasing cost and unreliability of Australia’s energy supply is putting Australian manufacturing under considerable pressure, undermining the sector’s competitiveness in today’s global market.

The Summit program featured two Energy themed panel sessions.

These sessions highlighted the importance of innovative, sustainable and environmentally ethical solutions to return much needed certainty and security to Australian businesses, making a significant contribution to the renewal of manufacturing.

Paul Hodgson (General Manager Innovation and Stakeholder Engagement - East Coast, NERA) believes that competitiveness and collaboration could be one way to improve Australia’s energy market.

“As the Industry Growth Centre for the energy resources sector, NERA (National Energy Resources Australia) welcomes increased productivity and competitiveness from industry while working with

Australian Welding: June 2018

established operators and the supply chain to encourage manufacturers adopt energy efficiency technologies, negotiate competitive deals with suppliers and retailers and help the sector transition towards a sustainable and low carbon energy future,” said Hodgson.

Hodgson encouraged Australian manufacturers to take control of energy by looking at: • The role and use of energy in your operations and how you could transform processes to significantly reduce energy usage, as well as generate or store your own electricity from waste or renewable sources • The role and use of energy by your customers when using your end product, as well as innovative ideas to reduce energy usage for your customers • The retail and wholesale deals, community energy partnership opportunities, different energy sources, storage, technologies, suppliers, and business models Other Energy panel members

Left: Pat Forward (on the right) speaks to a Summit delegate.

Middle: Energy Panel One (L to R): Daniel Walton, Chris Lamont, Paul Hodgson, Milo Foster and Ben Oquist.

Bottom: Energy Panel Two (L to R): Tanya Barden, John Pierce AO, Tony Wood AM, Tony Dixon and Stephen Fallet.

included Ben Oquist (Executive Director, The Australia Institute), Daniel Walton (National & NSW Secretary, Australian Workers Union), Milo Foster (General Manager - Albury Mill, Norske Skog), Chris Lamont (Director of Policy and Advocacy, NSW Business Chamber), Tony Wood AM (Energy Program Director, The Grattan Institute), Tanya Barden (Chief Executive Officer, Australian Food and Grocery Council), Tony Dixon (Chief Executive, Australian Steel Institute) and John Pierce AO (Chairman, Australian Energy Market Commission).

Panel Sessions: Technical Training The Summit program featured two Technical Training themed panel sessions. These sessions focused on the importance of technical training to the future of Australian manufacturing, including exploring and identifying the actions that need to be taken now to ensure Australia has the workforce capability to deliver major projects to an international standard.

According to Panel Chair, Dr Jens Goennemann (Managing Director, Advanced Manufacturing Growth Centre), “We are witnessing a remarkable transformation in global manufacturing in terms of innovation, digital integration and mass customisation. Therefore, Australia’s industry must increase its technical leadership, servitisation offerings and overall skillset to remain competitive and relevant. This Summit is part of an important momentum to address concerns and discuss opportunities.”

Panelist Pat Forward (Deputy Federal Secretary and Federal TAFE Secretary, Australian Education Union) emphasized the important role that TAFE has to play in the future of the Australian manufacturing industry.

“Vocational education is critical to the future of the manufacturing sector in Australia. As the sector addresses the challenges of the last few decades, building the capability of its workforce is essential, and

29

2018 National Manufacturing Summit

Australia’s trusted, high quality network of TAFE colleges is best placed to support the manufacturing industry into the future,” said Forward.

“Governments must work with the manufacturing industry, and with its own TAFE system to re-invest in vocational education, and allow TAFEs to play a key role in the reinvigoration of the industry. This can and must be done collaboratively, and key features of that collaboration include investing the TAFE teaching workforce to ensure they maintain the high level educational and technical skills to support employers.

“TAFE colleges are the trusted anchor institutions in the vocational education system. They are the ‘local actor’ which can link social partners (particularly those that support the most disadvantaged communities) and develop locally responsive approaches that meet the needs of key industries like manufacturing, as well as students and communities,” said Forward.

Similarly, panelist Jon Black (Managing Director, TAFE NSW) expressed just how important the role of TAFE will be in overcoming Australia’s crippling skills shortage.

According to Black, “TAFE is the answer here. We need to squash the stigma around TAFE and the preconceived idea that university is more prestigious.”

“While almost 80% of parents want their kids to get a university education, TAFE is the option of greatest return. We offer on-the-job training and a structured program, which allows you to earn while you learn, and gain a nationally recognised qualification,” said Black.

“This year, we’ll continue to leverage our existing industry connections and forge new ones through our ground-breaking SkillsPoints initiative which we launched last year. SkillsPoints serve as an intersection ‘point’ where TAFE NSW and business and industry come together to design training to provide students with the skills they need for

Top: Technical Training Panel One (L to R): Jon Black, Pat Forward, Michael Wright, Carl de Koning and Geoff Crittenden.

Middle: Technical Training Panel Two (L to R): Dr Jens Goennemann, Craig Robertson, Lauren Tiltman, Jack Cullen and Alisha Fisher.

Right: Lauren Tiltman answers questions.

Bottom Right: Neil Coulson (left) speaks to a Summit delegate.

the jobs of today and the careers of the future.”

“SkillsPoints are a complete overhaul of the way we develop, teach, and maintain course curriculum, and will ensure our students finish their studies with precisely the skills they need to be job ready.”

“In response to the changing nature of work and rise of new technologies, we’ve also introduced cutting edge courses including anti-money laundering and counter terrorism, workplace innovation and drone technology. More than ever, we are investing in state-of-the-art facilities, systems, technology and teachers to power the workforce we need today and tomorrow,” said Black.

Other Technical Training panel members included Geoff Crittenden (Chief Executive Officer, Weld Australia), Carl de Koning (Executive General Manager, Business Development and External Relations, Quickstep), Michael Wright (Australian Steel Liaison, Naval Group), Alisha Fisher (Managing Director, Asia Pacific Simulation

Alliance), Craig Robertson (Chief Executive Officer, TAFE Directors Australia), Jack Cullen (Chief Executive Officer and Founder, JAR Aerospace) and Lauren Tiltman (National Executive Director, National Apprentice Employment Network).

Sources https://www.zenenergy.com.au http://www.manmonthly.com

2019 Manufacturing Summit Planning for next year’s Summit has already begun. If you would like to register your interest to attend, sponsor or participate in 2019, visit: manufacturingsummit.com.au

30

Australian Welding: June 2018

Moving the Manufacturing Paradigm

Determining what the future of manufacturing looks like—and requires—is a work in progress.

Family-owned manufacturing company, L&A Pressure Welding is looking near and far for ideas.

Past models won’t serve the future, according to L&A Pressure Welding’s General Manager David Fox. ‘Get out of the building’ was an indispensable piece of advice given to Fox during L&A’s transformation.

This transformation began with raising management capability.

“I embraced that and went and met hundreds of people, and it just opened up my world. Then, of course, I brought that back and got Norman Chouaifaity (L&A’s Innovation Director and son of founders Louis and Anne) engaged in this same process; and so he is now also out of the building most of the time,” said Fox. Based in Revesby in Western Sydney, L&A began to see signs it needed to change tack in 2012.

Revenues from oil and gas—its major customer base—were slowing, and a significant chunk of its workforce was edging toward retirement age.

It looked like the operation might run out of puff. According to Weld Australia there is a major shortage of qualified welders in Australia. Not surprisingly then, attracting the next generation of welders emerged as a major issue for L&A.

“Then we started to think about how could we make our business more sexy for the younger generation,” said Fox. “How could we make it the new Google or that sort of thing? Is that even possible? So how do we do that?”

A quest to find out if fabricating heavy industrial assets could be made appealing has attracted an expanding network of collaborative partners, from schools, TAFEs and universities, to enterprise software company PTC, and the Advanced Manufacturing Growth Centre.

Inspiration has come from some unexpected corners across industry and research institutions.

Fox says the ongoing journey has involved several “connecting dots” moments over the years, beginning with a speech by industry thinker Goran Roos in 2014. This was followed by conversations with design led innovation expert Sam Bucolo, what became a “pretty instrumental” relationship with STEAMpop, and an open night for Science, Technology, Engineering and Maths (STEM) educational company Cuberider.

“One of the things that saw the

penny drop for us was when I met with a few students who’d taken Cuberider’s technical data on roll, yaw, and pitch from the international space station. The students converted the absolute values of this technical data to the notes of a piano, so it created music,” said Fox. “I thought that was really interesting, that was taking just a spreadsheet with numbers on it and doing something really creative. I thought ‘wow.’”

Starting the Conversation L&A has invested in digitising its welding supply chain and processes, experimented with virtual and augmented reality technology, and engaged the University of Technology Sydney and Western Sydney University Launchpad on projects related to the Industrial Internet of Things.

The foray into Industry 4.0 technologies has pointed to the need for a host of new skills way beyond welding. Just some of these skills include cybersecurity, sensor applications, user experience and narrowband wireless communications.

The company’s first school engagement was a STEM expo at Knox Grammar with Lincoln Electric. At the expo, L&A saw that technology might also be the missing ingredient in reaching the next

Moving the Manufacturing Paradigm

generation of welders. A VR welder was “an easy in”, according to Fox. “We realised digital was a vehicle to at least get the conversation started.”

In late 2016, a period of soul searching saw L&A distill its purpose into one sentence: Inspiring jobs for future generations. Reaching the next generation has required a re-evaluation of how L&A puts itself forward. The importance of marketing—not a major concern in the past—became clear.

“We need marketing, so we can have a brand, to engage with young people and be something,” said Fox. Being able to articulate their business in tangible terms became necessary. L&A Welding makes infrastructure that is everywhere but not obvious.

“We were at Knox Grammar and I was telling the kids we make pressure vessels. They all responded with, ‘What’s that?’ So I immediately explained that a pressure vessel is like a BBQ gas bottle, but 4m diameter and 30m long,” said Fox. “The students still didn’t understand.

So I tried explaining the concept using the example of gas cooking, because most people can relate to the fact that there is gas in the house. We asked the kids, well how do you get gas? We started to engage the kids by talking about the concept in a more relatable way.

Then we had these little charts we made up to show how gas goes

31

into our houses, back into the underground, into the main pipes, back down to where it comes out under the ground,” said Fox.

“Melissa Silk, Founder & Director of STEAMpop said to me STEAM education it is about the experience,” recalls Fox.

The Art of STEAM With the goal of establishing a local educational hub, L&A is implementing engagement programs with students, sharing what a manufacturing career might look like, and providing lessons through practical Science, Technology, Engineering, Art and Maths (STEAM) projects, based on real-world problems.

The format this and other engagement programs will take is a work in progress. As is figuring out exactly what skills L&A’s workforce of tomorrow will need. However, the list is bound to include skills and knowledge such as metallurgy, project management, ICT and software engineering. The application of data harvested from the company’s increasingly connected products is also a work in progress.

Stefan, a Liverpool Boys High School student, participated in a ten week ‘What Is Engineering?’ internship, through the school’s Big Picture Program, between October last year and February 2018 at L&A. Over the course of Stefan’s internship, the roles of different engineering disciplines were explained and made more accessible. Stefan gained first-hand experience in applied chemical, electrical, mechanical and thermal engineering design. This experience was made possible through regular workshop tours and detailed inspections of two giant air coolers under construction by L&A for Caltex’s Queensland refinery.

The overall focus of Stefan’s internship was aerospace engineering, particularly fluid dynamics, theory of flight, digital engineering tools, and physics equations. Stefan put all his newfound experience to work, building a paper plane launcher.

“But we do not forget about the kids who like traditional trades. A key point to remember in the Internet of Things is that you still need the traditional trades,” said Fox. Whatever the future looks like, L&A’s leadership will spend many hours out of the office trying to determine the trajectory of a fast-changing industrial world. According to Fox, learning how and when to break with traditions that started back in 1981 (when L&A was established), is essential to long-term survival and success.

“We used to just work really hard.

We delivered good products but did not really succeed. We are only just starting to know what we did not know. All these years in business, and we did not know half the stuff we should to make the L&A business successful,” said Fox. “Networking has become really important. And looking at the fringe of what we do has been very important for us.”

For more information about L&A Pressure Welding, visit: www.lapressure.com.au

Top Left: L&A Pressure Welding’s General Manager, David Fox. Left: L&A Pressure Welding’s facilities in Revesby in Western Sydney

32

Australian Welding: June 2018

Bombardier Australia Certified to EN 15085 Bombardier Transportation Australia has become the first Australian company to be internationally recognised with certification to EN 15085 Railway applications – Welding of railway vehicles and components. In partnership with IIS CERT (the certification arm of the Italian Institute of Welding Group of Companies), Weld Australia recently performed the certification audit at Bombardier’s facility in Dandenong, Victoria. Originally developed for the European market, EN 15085 has quickly become the internationally expected Standard for railway manufacture and repair.

The benefits of EN 15085 certification for Australian fabricators are myriad, particularly given the opportunities for local fabricators to participate in international supply chains and ongoing maintenance and repair activities. All rail industry designers specify compliance to EN 15085, regardless of the country of origin or destination.

According to Paolo Corronca (Qualification and Certification Manager, Weld Australia), “Weld Australia is delighted to support IIS CERT in offering EN 15085 certification services to the Australian welding industry at an affordable cost.”

“EN 15085 certification will enable Australian fabricators to participate in large, profitable international supply chains. With most railway vehicles currently in service in Australia being designed and manufactured internationally according to EN 15085, this certification will ensure that Australian fabricators’ capabilities to maintain our fleet of trains are recognised and acknowledged. Workshops that have the capability to weld new projects and perform maintenance in compliance with EN 15085 will be in high demand.”

Not surprisingly, Bombardier recognises the importance of this scheme to the Australian fabrication industry. Australian asset managers and government transport

departments are increasingly opening their tenders to international suppliers to ensure adherence to the correct level of quality. More and more, EN 15085 certification is gaining interest and attention from Australian government departments and railway industry manufacturers as part of the tender assessment process.

According to Bombardier, the level of competitiveness that the EN 15085 certification brings to manufacturers is very high. Bombardier believes that—more and more—such standards will become a prerequisite to competitive market tenders.

Bombardier Transportation’s Head of Operations Australia, David Collomb said, “As a local manufacturer, Bombardier is proud to have achieved this next level of recognition of our local industrial capabilities.

In a very dynamic and competitive environment, it is key for Bombardier Transportation Australia to lead the way in terms of quality and applicable standards. Investing in skills and capabilities is the best way for us to support and grow a sustainable rail industry in Australia.”

“We are proud to be the first in Australia to achieve this on behalf of our industry. This welding standard is key to quality rollingstock manufacturing, and maintaining the sustainable value of public transport.”

IIS CERT is accredited to ISO 17065 for company certification

to EN 15085. It is also one of the founding committee members of the European Committee for Welding of Railway Vehicles (ECWRV) and is an accredited Manufacturer Certification Body (MCB) for the same register.

Thanks to the strong partnership with Weld Australia, over the next few months IIS CERT will be able to provide certification to EN 15085 in Australia using Australia-based qualified auditors. Certified Australian companies will be included on the online register: www.en15085.net.

The IIS CERT Technical Manager, Stefano Morra said, “IIS and IIS CERT have always supported the industry, both locally and internationally, promoting and encouraging in every field the development of welding and allied technologies, contributing to its knowledge and diffusion. Over the years, we have developed a strong friendship and we are glad to support Weld Australia in its local activities.”

“Plus, with the IIS CERT-Weld Australia partnership offering EN 15085 certification services locally, Australian fabricators will not need to cover the cost of international travel expenses for an auditor to perform the certification and surveillance audit.”

A Brief History of EN 15085 Before the introduction of EN15085, the requirements for the manufacture and maintenance of railway vehicles were imposed by individual countries.

Bombardier Australia Certified to EN 15085

As such, the import and export of railway goods between countries was severely hampered. Often, common technical requirements were omitted or incompatible, making it almost impossible for contractors to source sub-components from international suppliers. This situation seriously limited supply chains; prices increased dramatically and potentially excellent small-to-medium suppliers were essentially excluded from the international market.

In 1996, the CEN (European Committee for Standardisation) commenced work on a draft Standard: Welding of Railway Vehicles and Components.

The work undertaken by the CEN resulted in the publication of the final draft of prEN 15085 in 2001.

Composed of five sections, the prEN

15085 set of Standards introduced a series of technical requirements, as well as the concept of ‘third party certification’. In October 2007, prEN 15085 was published and its enforcement began.

EN 15085 helped overcome the inconsistencies in quality and technical requirements that were hampering international supply chains. The series of Standards requires that sub-contractors are certified to an appropriate, specific and consistent certification level.

In addition, under EN 15085 manufacturers must verify their certification via completion of periodic audits. During these audits, manufacturers must demonstrate their ability to deliver on the requisite product quality standards and other contractual obligations.

Images: Welding operations at Bombardier’s facilities in Dandenong, Victoria.

“

33

While international uptake of the certification has grown in recent years, in Australia there are still very few EN 15085 certified manufacturers.

Clearly, the potential market share that newly EN 15085 certified Australian manufacturers could capture is huge.”

For more information, contact Paolo Corronca (Qualification and Certification Manager, Weld Australia) on p.corronca@ weldaustralia.com.au or +61 438 012 099.

34

Australian Welding: June 2018

Wynyard Station Welcomes Interloop A grand sculpture installed at Wynyard Railway Station in Sydney’s Central Business District has attracted widespread public praise for its unique design and preservation of an important part of Sydney’s urban transport heritage.

Australian contemporary artist and sculptor Chris Fox unveiled the installation, which is suspended from the ceiling above a bank of escalators linking York Street to the main concourse level of Wynyard Station, in December 2017.

The installation, titled Interloop, is a vast twisting accordion-shaped sculpture that loops together two pairs of reconfigured heritage escalators into a stitched form.

Suspended between two ends of the building, Interloop measures more than 50m in length and incorporates 244 wooden escalator treads and four escalator combs from the historic Wynyard escalators.

Part of a $100 million renewal and redevelopment program, Interloop is a major landmark for Sydney

and for Transport for NSW, who commissioned the installation.

The five tonne sculpture took six months to design and engineer.

Leading Queensland fabrication company, Lumark then fabricated the sculpture over 12 weeks, with over a kilometre of welding required.

According to Paul Sloper (General Manager, Lumark), “We had three fabricators, three trades assistants and two welders working full time on the Interloop project, with additional

Wynyard Station

35

help provided as and when required to meet the project’s tight deadline.”

Interloop was built from high strength marine grade aluminium and suspended via new steel beams installed into Wynyard Station. The wooden treads from the original escalators have been refastened to the accordion like aluminium surface.

“All materials used in the Interloop project were 5083 aluminium.

Approximately 90% of the welding was MIG welding. In some places that were not reachable via MIG welding, we used TIG welding.

All welding was undertaken in accordance with Lloyd’s welding standard, in which Lumark is certified,” said Sloper.

Once the fabrication was complete, the main structure was then transported to the site in 16 separate sections, before an intensive 48-hour installation period.

“The installation process firstly required fitting the end section by bolting seven parts together on the ground, and then chain blocking this into its location with around 10 chain blocks. Then we fitted the comb and first sections into place. The joining sections were then lifted in to join all the section’s together. No welding was used in the installation as all parts were powder coated in Brisbane before transporting to Sydney. All parts were bolted together on-site,” said Sloper.

Lumark did face some challenges along the way, but was able to overcome these. “The biggest challenge was that each section was fully welded. We had to weld these by spreading the heat evenly to prevent distortion and warping of the aluminium. The sections were powder coated, which meant that distortion would show up easily.

If even one mounting plate on a section was out then it would have affected the layout of the artwork,” said Sloper.

Design Inspiration Artist Chris Fox said, “Connecting yesterday and tomorrow, Interloop interrogates the conceptual and

All photography by Josh Raymond.

material boundaries between art and architecture. Made of the old, heritage escalator treads, this sculpture stitches two looping stairways, evoking past histories and future journeys.”

“Wynyard escalators were installed in 1931 and have been operating for more than 80 years and have only recently been removed. The heritage escalators were really exciting because they were an important part of urban planning and urban design for Sydney. Interloop really talks

“

Interloop floats above the heads of commuters as they travel on the escalators linking York Street to the main concourse level of Wynyard Station in Sydney’s Central Business District.

36

about that in terms of the history of the material of those escalators and their amazing journey,” said Fox. “The inspiration for this project is really about the pause that people have in their journey on the escalators. Over 80 years these escalators have been in use, and throughout people’s day, they’d pause, moving up in space and time.

This project talks about those past and future journeys.”

“The process required about six months of design and iterations to come up with a project that was exciting for the space and able to work with all the different constraints present in the public realm.”

“One of the most challenging parts of the project was to rethink the whole structural design only three months out before we were scheduled to install the work. The project then had to facilitate a weekend install.”

“Previously, we’d allowed about two weeks for the installation. This meant we had to rethink the whole design that was initially made up of different components with a steel section inside it as the structure. The whole thing had to be made up of 16 pieces that were complete and then bolted together on-site,” said Fox. With the re-purposing of the wooden

Image: Recreated car, the Ti22 MkII, manufactured by Bob Lee. Image courtesy of Melinda Stewart.

Australian Welding: June 2018

treads, the sculpture aims to evoke memories of passengers and modes of travel from the past while conjuring complimentary ideas of journey and travel, start and finish, here and there, as well as past and future.

The History of Wynyard Station Approximately 100,000 people pass through Wynyard Station each day, making it Sydney’s third busiest train station. And Transport for New South Wales expects the daily average to rise to 150,000 within the next decade.

Until their removal, the station’s wooden escalators were among just a handful still in operation around the world. The first three were installed in 1931 – the same year the Sydney Harbour Bridge was opened – and the fourth added in 1952.

But their wide wooden treads could be a trap, especially for high heels.

Guide dogs were also injured after getting their claws stuck in the combs of the escalators.

According to reports by the Sydney Morning Herald, Coordinator General of Transport for New South Wales, Marg Prendergast said many people had emotional attachments to the wooden escalators, making it important to honour the station’s heritage.

“Everyone has a memory about Wynyard Station and we really wanted to recreate something that was pretty funky – that people could look at,” said Prendergast. “We really wanted to give a nod to the history of the station and to the impressive wooden escalators.”

“Whilst the station itself is far improved, it’s really good to honour what used to be. [The wooden escalators] evoke memories, and so part of the heritage plan was to make it a living part of the station.”

According to the ABC, Prendergast said she wanted to allay any concerns brought up by the public regarding the structure’s safety.

“We made sure that all of the safety in terms of attachment [and] fire retardant measures are undertaken,” she said. “They are perfectly safe and people can come, look at them and enjoy them.”

Interloop is already winning awards, recently taking out two categories in the National Trust’s 2018 Heritage Awards, including the Judge’s Choice category, and the Education and Interpretation category.

Sources: www.smh.com.au www.abc.net.au

Wynyard Station

About Chris Fox Fox has exhibited in numerous solo, group and collaborative exhibitions in Australia, the USA and Europe, with an established sculptural practice of large scale public and private commissioned artworks. Fox holds a Bachelor of Visual Arts and a Bachelor of Architecture both with Honours, and recently completed a Master of Fine Arts. He is a senior lecturer at the University of Sydney in Art Processes and Architecture. For more information, visit: www.chrisfox.com.au About Mark Webb and Lumark Mark Webb began his career with Lloyds Ships in 1984. With a passion for the industry, he went on to hone his skills in metal fabrication and head the division of a large boat building company in Queensland.

Mark founded Lumark in 2007 and has since become one of the leading marine fabricators in Australia.

Mark has built a talented team that upholds his commitment to providing clients with an exceptional finish.

With many and varied capabilities, Lumark not only supplies the marine industry but applies their quality workmanship to architectural applications within the building industry. For more information, visit: www.lumark.com.au.

Left: The five tonne Interloop sculpture took Lumark 12 weeks to fabricate, requiring over a kilometre of welding.

Right: The main Interloop structure was transported to the Wynyard Station site in 16 separate sections, so that Lumark could install the sculpture over an intensive 48 hour period.

All photos on pages 36 and 37 by Chris Fox.

37

38

Australian Welding: June 2018

Case Study: AGL Loy Yang Shut Down Prior to and during the Unit 1 Major Outage at AGL Loy Yang in 2017, Weld Australia provided welding and quality assurance related support, ensuring that welding and quality related activities were compliant with workscope and standard acceptance criteria. Melissa Odendaal (Welding Consultant, Weld Australia) worked extensively on the project.

Work started on Loy Yang A Unit 1 in the week of 18 October 2017, with the outage scheduled for completion by 10 December 2017. Loy Yang A has four generating units with a combined capacity of 2,200MW. Each unit runs autonomously so they can be taken offline individually for maintenance without any impact on the operation or output of the remainder of the power station. To ensure that the station operates efficiently and to prevent unexpected breakdowns, each unit requires scheduled routine maintenance.

Approximately 500 to 600 people worked on-site to meet the tight and challenging schedule. It was a busy time, and AGL employees and contractors worked hard to ensure continuous and reliable energy for the coming years. With most contractors staying in the region, the outage was also a significant economic boost for the Latrobe Valley.

The scope of work planned for the outage included extensive inspection surveys and repairs, HP turbine exchange, IP turbine exchange, two main steam strainer replacements and turbine valve remnant life checks, During the Outage, over 150,000 resource hours of work was completed.

According to Andrew Speairs (U1 Major Outage Manager),

“Melissa has been a wonderful addition to the Unit 1 Major Outage at AGL Loy Yang. Her pre-outage work with several contractors helped them to better understand the criticality of AS/NZS ISO 3834, particularly in critical Boiler and Turbine installations.”

Loy Yang uses brown coal, supplied exclusively by the adjacent open cut mine, as the fuel source to generate electricity. The mine has an annual output of approximately 30 million tonnes of coal. The power station and mine operate 24 hours a day, seven days a week.

“She has an excellent understanding of her area of expertise and has a very personable manner which enables her to communicate her experience and knowledge easily.”

The power station includes four 500+MW turbo generators which were brought into service between 1984 and 1988. Until the year 2000, Loy Yang had a base generating nameplate capacity of 2,000MW. Upgrades through major maintenance programs and plant enhancements have taken generation capability to over 2,200MW.

“

AGL has had an excellent working relationship with Weld Australia in the past and have continued to build on this during this Major Outage. They look forward to working with Weld Australia again in the future.”

The AGL Loy Yang Power Station The AGL Loy Yang site is located in the Latrobe Valley, 165km south east of Melbourne. It covers an area of approximately 6,000 hectares.

Each year, AGL Loy Yang produces approximately 15 TWh of electricity, enough to power over 2 million Australian homes. It is an integral part of Australia’s national electricity market. AGL Loy Yang supplies approximately 30% of Victoria’s power requirements.

Acquired in June 2012, AGL Loy Yang comprises the 2,200 megawatt Loy Yang A power station and adjacent Loy Yang coal mine. AGL

A seven year, $60 million ICMS (Integrated Control and Monitoring System) conversion project completed in October 2014, converted all AGL Loy Yang operating units from an ageing analogue system to a state of the art digital control system. The project has been vital in ensuring energy security and reliability of supply to Victoria.

About AGL AGL is one of Australia’s leading integrated energy companies. It is taking action to responsibly reduce its greenhouse gas emissions while providing secure and affordable energy to its customers. Drawing on 180 years of experience, AGL serves its customers throughout eastern Australia, providing gas, electricity, solar PV and related products.

AGL has a diverse power generation portfolio including base, peaking and intermediate generation plants, spread across traditional thermal generation and renewable sources including hydro, wind, solar, landfill gas and biomass.

Case Study: AGL Loy Yang Shut Down

Top Left: The AGL Loy Yang Power Station with some of the local native wildlife.

Top Right: Melissa Odendaal (Welding Consultant, Weld Australia) with the Latrobe Valley in the background.

Middle Left: (L to R): Melissa Odendaal (Welding Consultant, Weld Australia) and Ben Knight (Welder).

Middle Right: The AGL Loy Yang Power Station. Image courtesy of AGL. Bottom: The AGL Loy Yang Power Station. Image courtesy of AGL.

39

40

Australian Welding: June 2018

Case Study: Pipeline Joint Couplings’ Failure At the request of the Client, Weld Australia was invited to provide an expert opinion in relation to a series of joint couplings welded into a pipeline for slurry media transport. The Client reported that the welding between the rings and the pipe failed during the execution of the hydrostatic test, showing leakage. The job was originally completed by an overseas fabricator.

A Local Contractor with ISO 3834 accreditation (not awarded by Weld Australia) had been engaged to rectify the defect in the pipeline.

However, the repair had not been executed successfully.

As such, the Client sought an expert opinion from Weld Australia, particularly focused on: • Validation of the existing weld size as per the drawing and working conditions provided • Review of the technical queries exchange between the Client and the Couplings’ Provider • Whether the Local Contractor had discharged its contractual obligation

Summary of Findings Weld Design (Minimum Design Throat Thickness) Following a thorough review by Weld Australia, it was determined that the couplings provided had been specified with two welds on each ring. These welds included a fillet weld with a minimum size of 3/8”, plus a partial penetration weld. In terms of the partial penetration weld, no size had been specified.

Weld Australia determined that the specified minimum size of the fillet weld satisfied the requirement of a sleeve joint as per AS 4041 Pressure piping.

Welding Code to Be Adopted There was no evidence in the drawings of the requirement for a full penetration weld. In addition, the only welding Standard referenced in the drawings was an Overseas Structural Code; there were no restrictions imposed regarding the adoption of any other international or Australian Standards.

Weld Australia concluded that the recommended welding code was not a sound choice for joint couplings welded into a slurry pipeline. In addition, the choice of a welding code or Standard should have been clarified between the parties before the fabrication of the spool pipes, and should have involved the Client.

Clearly, the technical and quality requirements for the joints were not communicated clearly by all parties involved in the project.

This type of issue is usually symptomatic of a weak contract review process, as well as a poor understanding of the necessary welding quality requirements. This issue is covered in detail (and can be avoided by implementing) IIW MCS ISO 3834 - Quality requirements for fusion welding.

Weld Australia concluded that a properly executed weld joint, which followed a correct joint preparation and weld sequence, performed according to qualified welding procedures and by qualified

Case Study: Pipeline Joint Couplings’ Failure

41

“

Weld Australia concluded that a properly executed weld joint, which followed a correct joint preparation and weld sequence, performed according to qualified welding procedures and by qualified welding personnel with appropriate acceptance criteria would have not failed during the hydrostatic test.

welding personnel with appropriate acceptance criteria would have not failed during the hydrostatic test.

clarification of the contract requirements would have been undertaken.

All these issues (such as weld sequence, qualified welding procedures and qualified welding personnel) are also covered by IIW MCS ISO 3834, and could have been eradicated had this Standard been followed. AS/NZS ISO 3834 specifies the production control requirements expected for fusion welded products globally, whether fabricated on-site or in a workshop.

It is the internationally recognised benchmark for welding quality.

The Local Contractor proposed a weld size of 2mm x 5mm to rectify the defect in the pipeline. The proposed 2mm x 5mm size was actually smaller than the required minimum size indicated in the drawings of the Couplings’ Provider.

Rectification Performed by Local Contractor It was not clear to Weld Australia whether the correct scope of work was clarified with the Local Contractor. In addition, it remains unclear what the Local Contractor was planning to achieve with its scope of work, including supporting technical documentation, failure analysis and findings, and expected deliverables.

It is the opinion of Weld Australia that the acceptance criteria, final inspection and test should have been negotiated with the Client, including the remediation policy in case of failure. Unfortunately, none of these factors were included in the scope of work. Again, had IIW MCS ISO 3834 been implemented,

The defect repair procedure (leakage during hydrostatic test) would have required full excavation of the weld metal in the fail area, and its restoration would likely have required weld runs larger than 2mm x 5mm. As such, the repair procedure proposed by the Local Contractor was not sufficient.

Welding Procedure Specification Provided by Local Contractor One Welding Procedure Specification (WPS) developed by the Local Contractor was provided to Weld Australia for review. The WPS was developed by the Local Contractor in accordance with AS/NZS 1554.1 – Structural steel welding - Welding of steel structures.

There was no evidence that the proposed welding Standard had been accepted by either the Couplings’ Provider or the Client. In addition, Weld Australia found that the WPS was not qualified for the actual joint, and was therefore

deemed inapplicable for the repair of the defect in the pipeline.

Conclusion Had the project specified IIW MCS ISO 3834 as the required welding Standard, many of the issues would have been eradicated.

ISO 3834 is a factory production control system, drafted to complement—rather than replace— quality management systems such as ISO 9001. Many companies across the world are certified to ISO 9001 for their quality management systems. However, where a special process such as fusion welding is used, ISO 9001 fails to demonstrate the specialist capability required by a company to manufacture products according to the necessary quality standard. ISO 3834 certification overcomes this shortfall by controlling the entire lifecycle of the welding process, from design right through to inspection. It considers all aspects that could affect weld quality.

This type of approach is essential because it is impossible to undertake complete verification of a welded joint without destroying it. Unfortunately, inspection after completion does not guarantee weld serviceability. As such, quality must be built into the welding process, right from the very beginning.

42

Australian Welding: June 2018

The Secret to Precision Metal Group’s Growth & Success Precision Metal Group (PMG) offers a broad range of services from mechanical engineering and machinery maintenance, through to onsite machining and welding. Company founder and Managing Director, Jason Elias, is the driving force behind the innovative company.

Elias established PMG in 2000 in Yennora western Sydney after his highly successful boilermaker apprenticeship—he was named Apprentice of the Year three years in a row.

After eight successful years as a sole trader, Elias formed a company and moved into bigger premises at Wetherill Park. Ten years on, PMG boasts up to 45 employees and is involved with some of Australia’s biggest companies and projects.

Precision Metal Group now occupies some 2,000m2 within the Wetherill Park industrial complex that they call home – and the company is already looking at further expansion, with major clients including some of Australia’s biggest companies, such as BlueScope, Liberty OneSteel, Arrium, CSR, James Hardie, BOC and the Australian Defence Force.

The main reasons for the company’s rapid growth over the last ten years are seemingly simple: state-of-theart equipment, specialisation and— of course—certification.

State-of-the-Art Equipment Just some of Precision Metal Group’s equipment includes: a CNC plasma cutter with a 3,000mm x 1,500mm table; a guillotine with a capacity of 3,200mm x 12mm; a pressbrake with a 4,000mm and 220 tons capacity; and a Doosan CNC lathe with Y-axis milling, Hartford vertical machining centre, and pressure vessel manufacturing equipment up to 40 tonnes. Precision Metal Group also offers a range of cranes, trucks and Elevated Work Platforms (EWPs) for on-site installation.

Specialisation Precision Metal Group has cornered the market in niche areas, specialising in the supply and repair of cryogenic vessels, which are sold to major gas suppliers including BOC and Coregas. According to Elias, “As far as I am aware we are the only certified facility left in Australia manufacturing, refurbishing and certifying sub-temperature cryogenic equipment,” says Elias.

“This is a highly specialised job and previously nearly all of these vessels were imported.”

43

Precision Metal Group

Certification Precision Metal Group was awarded certification to AS/NZS ISO 3834 - Quality requirements for fusion welding of metallic materials in late 2017. According to Elias, “Precision Metal Group decided to push forward with AS/NZS ISO 3834 certification to ensure that our business was up-to-date with all relevant standards, processes and procedures. We also wanted to reward the efforts of all our employees, and ensure that their high-quality workmanship was officially recognised throughout the entire industry.”

AS/NZS ISO 3834 helped bolster Precision Metal Group’s successful bid on the LAND 400 Phase 2 project; they were recently announced as one of the Australian companies confirmed to contribute to the project.

“The certification process was extremely educating and rewarding.

Given that ISO 3834 certification controls the entire lifecycle of the welding process, from design right through to inspection, we had the opportunity to review and improve all of our internal processes,” said Elias.

The project is tipped to create 1,450 jobs across the country, with 330 to be created in Queensland, 170 in Victoria and 140 in New South Wales during the project’s acquisition phase. Of the $5.2 billion contract, $2.8 billion will be spent during the acquisition phase.

“One of the major benefits of becoming certified to ISO 3834 is that the certification has opened many doors for us in terms of new work, particularly projects commissioned by the Australian Defence Force.”

“To any other companies considering ISO 3834 certification, I would encourage them to go for it.

The certification process itself will help to streamline your processes, improving your productivity and efficiency and therefore bottom line. Plus, it will help your entire workforce to better understand it’s

Undoubtedly, certification to

Right: (L to R): Jason Elias (Managing Director, Precision Metal Group) is presented with AS/NZS ISO 3834 certification by Paolo Corronca (Training & Certification Manager, Weld Australia).

Left: Precision Metal Group is a specialist in mechanical engineering services, onsite machining, machinery maintenance, machinery relocation and welding. The company prides itself on its ability to be a one-stop shop, offering support to its clients 24 hours a day, seven days a week.

For more information on how to gain AS/NZS ISO 3834 certification, visit: www.weldaustralia.com.au

The LAND 400 Phase 2 project will see the Australian Army acquire up to 225 Rheinmetall Boxer CRVs, which will replace the ageing Australian Light Armoured Vehicle fleet. The vehicles will be built in Brisbane, with 69% of the total project cost slated to go towards Australian industry content.

“

The certification process was extremely educating and rewarding. Given that ISO 3834 certification controls the entire lifecycle of the welding process, from design right through to inspection, we had the opportunity to review and improve all of our internal processes.” role within the broader industrial sector,” said Elias.

AS/NZS ISO 3834 certification increases the likelihood of global supply chain opportunities and repeat business, bolstering profitability. Certification helps Australian businesses demonstrate their ability to deliver a compliant, quality fusion welded product on time and to budget. AS/NZS ISO 3834 is the minimum benchmark for welding quality globally. As more companies become certified to the standard, those without it will find it harder to win work from local and international suppliers alike.

44

Australian Welding: June 2018

Austedan Fabrication: The Extraction Experts Newcastle-based Austedan Fabrication has specialised in dust, fume and vacuum systems for over 25 years. The fact that they design, fabricate and install their own systems, enables them to create purpose built solutions for customers. In addition to extensive experience in ductwork, fans, high pressure vacuum systems and reverse pulse dust collection systems, they also offer re-bagging, re-valving, retrofitting and other maintenance services to existing dust collectors for most brands.

According to Steve Upton (Director, Austedan Fabrication), “Here at Austedan, we really take the time to work with our customers. We understand that they require reliable and affordable solutions for welding fume and dust extraction. We help our clients minimise the amount of air borne pollutants in the worksite and fumes omitted to atmosphere through tailor made, specially designed dust, fume and vacuum systems.”

“Not only do we supply these systems, but we also design, fabricate and install them. We offer everything from discharge options, ducting and extraction arms, right through to purpose built extraction systems that can be added to Demmeler jigging and welding tables supplied by Leussink,” said Upton.

Austedan’s Capabilities Austedan’s fume extraction and dust collecting systems have become a popular option for fabricators, particularly given the almost infinite customisation possibilities.

According to Upton, “Austedan Fabrication virtually covers every aspect of weld fume and dust extraction and filtration. Our ability to customise extraction systems has been central to Austedan Fabrication’s success.”

Austedan’s systems can be fitted with silencers and lagging for additional fan noise reduction if required, while filter bags and cages can be manufactured to suit the scope of individual dust and fume filtration systems.

Austedan can fit options to ventilation dust collection systems such as Differential Pressure (DP) demand clean systems from Pentair.

Plus, all their dust collectors are fitted with a galvanised access platform that allows for easy valve and header maintenance. Austedan is also equipped to provide services and advice on other items like coal float sinks, downdraft tables, fume cupboards, vacuum lifting devices, portable and fixed fume extraction arms, underground mining access doors and conveyor structures.

Wall Mounted Extraction Arms & Reverse Pulse Dust Collectors One of Austedan’s most popular systems is a wall mounted extraction arm—in either single or a multiple

Left: Austedan has designed and installed rear backdraft hoods throughout Australia, particularly in TAFEs, colleges and training schools.

Top Right: A central welding fume dust collection system for ten welding stations performing welds of heavy duty mills and rollers with flux core wires (reclamation work).

Bottom Right: A welder using flux cored hard facing wire for repair work. Austedan fabricated a special 250mm diameter arm to allow for a higher than normal extraction rate of approximately 4,000m3 per hour, providing a clean, fume-free working area for the welder.

For more information, visit: www.austedan.com.au

Austedan Fabrication: The Extraction Experts

arm system configuration—ducted to a common fan and exhausted to atmosphere or filtered by one of their reverse pulse dust collectors.

According to Upton, their reverse pulse dust collectors are not only efficient, but effective. “Some of our specialised welding fume central systems are pulling out approximately 750 litres of welding fume waste dust per week. Best of all, even with this amount of waste fume dust, some of our reverse pulse dust collectors still have their original bags installed— even after six years in operation.

We’ve learnt over the years that by lowering the air to cloth ratio slightly, better results are achieved. Reverse pulse systems clean better, so you get a lower rate of emissions and your bags last longer.”

Rear Backdraft Hoods “Austedan has been a key player in the move towards rear backdraft hoods, set up behind small fixed benches. We have supplied these systems throughout Australia, particularly to TAFEs, colleges and schools,” said Upton.

“Austedan’s back draft hood extraction system performs better than traditional styles, which feature a rectangular hood that sits above the bench and pulls the fumes through the welders breathing zone. Our rear backdraft hoods can be banked together and run off one central fan.

They ensure that fumes are extracted back away from the breathing zone, before being filtered by self-cleaning reverse pulse dust collectors or exhausted to atmosphere.”

Downdraft Tables Austedan’s purpose built downdraft tables pull the welding fume down, away from the welders’ breathing zone. Recently, Austedan adapted their downdraft table concept, fitting it to fitted to a Demmeler jigging and welding table supplied by Leussink Industries.

On-Torch Fume Extraction Guns “We also supply design and install Binzel on-torch MIG fume extraction gun systems that have the capacity to cope with anywhere from one

45

Austedan recently supplied a purpose built weld fume extraction system fitted to a Demmeler jigging and welding table supplied by Leussink Industries. The table was designed to work like a downdraft weld extraction table through the 28ø Jigging holes in the table, with the fumes pulled into one of Austedan’s purpose built reverse pulse dust collectors.

Top Right: Weld fume enters the welder’s breathing zone. Austedan’s fume extraction system is not in use.

Bottom Right: Weld fumes are efficiently and effectively drawn down into Austedan’s custom designed and built extraction system.

MIG welder to over ten welders, all welding at the same time. These systems require high vacuum and extremely strong reverse pulse dust collectors to combat the high pressure requirements,” said Upton.

“In one large factory near the New South Wales and Victoria boarder, we designed and installed a five gun high vacuum weld fume system around nine years ago. As this was so successful, we then installed another five gun system, plus an eight gun system around four years ago. Other sites include up to ten gun systems. However, more guns can also be accommodated.”

Air Fed Helmets “Austedan is currently in negotiations with a leading European company to bring in a state-of-the-art air fed helmet, complete with spark arrestor, Hepa filtration and activated carbon filters,” said Upton. “By offering air fed helmets, Austedan will be able to offer every weld and dust filtration and extraction option available.”

Other Extraction Systems Austedan also offers on-tool central vacuum and dust extraction systems for grinding, linishing and metal sanding operations. Plus, large wall and roof mounted extraction fans (to atmosphere only general workshop ventilation) are one of their specialties.

The Results The team at Austedan Fabrication was asked to create an extraction system for flux cored hard facing

wire welding, which creates particularly high fume levels. To accommodate for the extra fumes, the team fabricated special 250mm diameter arms, which are capable of extraction rates of 4,000m3 per hour, covering a weld fume area of approximately 1m cube.

Another of Austedan’s customers is still using their original filter bags— nine years after they were installed.

These filter bags are part of a central welding fume dust collection system that is used to provide extraction and filtration for ten welding stations. These stations are used in reclamation work to weld heavy duty mills and rollers with flux core wires. As such, the stations create enormous amounts of fume and dust. Austedan designed a system to suit a 1.5m3 bin. This system works so well that even after one and half to two weeks, the bin doesn’t need emptying, even with over 1,200 litres of hazardous dusts collected during this period.

46

Australian Welding: June 2018

An Update from Weld Australia’s Hotline Weld Australia offers a ‘Hotline’ service to all Corporate Members. The purpose of the Hotline is not to provide a solution, but to advise the enquirer on practical next steps. For further advice, Weld Australia’s highly experienced welding consultants can speak to you over the phone or visit your site in person. If you have a Hotline query complete our online contact form and we will respond as soon as possible: www.weldaustralia.com.au/hotline.

Weld Australia was recently contacted by a member organisation seeking information about working with offshore fabricators based in China and South-East Asia, particularly the most common pitfalls and quality issues that should be monitored. Weld Australia’s Technology Manager Louise Petrick tailored an in-house workshop for the member organisation, focused specifically on their needs.

An overview of this workshop is provided below.

Setting the Scene China and many other South-East Asian countries have not yet fully embraced the risk-management practices that are commonplace in Western countries. As such, common concerns for every importer start with finding a qualified SouthEast Asian offshore factory. Once a qualified factory is selected, a

reliable factory verification must be undertaken, and the Chinese company must be willing to adhere to accepted and expected codes of conduct and production standards.

The initial production sample may be fine; but with each successive production run, Weld Australia’s inspectors find more and more poor workmanship instances.

Quality Challenges South-East Asian manufactures often make promises to secure a contract. However, once the contract is won, the business relationship often goes downhill­, albeit in small steps. Generally speaking, this is due to two main product quality challenges: quality fade and quality concealment. Quality fade is the quiet and incremental degradation of a product’s quality over time; it is one of the more common issues experienced with product sourced from Asia.

When manufacturing complex products, the issue of quality fade adds an ever increasing amount of risk. This is especially so with products such as electric machines, hydraulic systems, tyres, electrical cables, pressure vessels, vehicles, and hoist cylinders.

Importers usually never notice what’s happening because downward changes are subtle but progressive.

Quality concealment has been consistently observed by Weld Australia across several projects.

It supports the conclusion that suppliers are reticent to report non-conformance and deviations from process. This is particularly obvious in activities such as product testing, schedule status, resource management, “buy-outs”

This Hotline update covers a specific query encountered during the last few months. Whilst accuracy in welding is critical, it is impossible to report in detail the full circumstances of the query. As such, Weld Australia recommends that further technical advice is sought in relation to specific, individual circumstances.

Inside Weld Australia: Hotline Report

(out-sourced components or raw materials), material certification, and general workmanship failures.

This failure of offshore suppliers is often attributed to cultural reasons, as well as the idea that ‘what the buyer can’t see, won’t hurt them’.

Where Western consumers are used to receiving exactly what they ordered, low-cost country manufactures have a slightly different philosophy when it comes to customer relationships; they often believe that the buyer’s exact wishes mattered only as far as they were necessary to capture the initial order.

This is exacerbated by a lack of quality management in the factories and too little corrective oversight from the business. Implementing quality management processes is often seen as a barrier to increased profitability.

As a result, negative outcomes are often hidden from the client.

The issue is that where product failures occur they can be catastrophic. Rework, fines, lost production, significant injuries and even fatalities are all possible depending on the nature of the failure and the type of the product being manufactured.

How Guanxi Affects Quality The concept of Guanxi is best described as the relationships that individuals cultivate with other individuals—it is a central idea in Chinese society. It is based on the idea of associating oneself with others in a hierarchical manner, in order to maintain social and economic order. Implicit mutual obligations, reciprocity and trust, are the foundations of Guanxi and Guanxi networks. As such, in China, it is necessary to spend time getting to know your Chinese counterparts outside the boardroom during tea sessions and dinner banquets.

The problem is that Guanxi creates considerable difficulties in both the gathering of information, particularly for ‘outsiders’, and the enforcement of contract exchange terms.

Quality assurance can be widely variable and hard to assess due to

protected ‘Guanxi relations’. This challenge is particularly prevalent at the sub-supplier level. Suppliers are often reluctant to share information about raw material providers because they have special deals that set them apart from other suppliers, which is part of their quest to keep their own costs down. Anonymity of supply in these cases is a highly guarded secret and seen not to be the concern of the buyer.

The problem with this system is in maintaining the consistency of product to meet the buyer’s specification over the medium to long-term. Quality transparency in terms of reporting is thwarted under this arrangement.

Recommendations For Working With Offshore Suppliers When embarking on a relationship with an offshore supplier, it is essential to develop a culturally realistic, operationally feasible, viable and effective risk mitigation strategy.

It is absolutely crucial to carefully investigate vendors and undertake rigorous supply chain verification before engaging in any kind of trade. Primary emphasis should be given to finding vendors that have ISO certification and a strong positive market reputation. It is also advisable to carry out factory audits in order to have clear vision about the shortlisted options. It is also recommended that buyers communicate early-on that even the slightest compromise on quality could result in them being replaced.

When entering into purchase agreements from China as an example, ensure that a well-drafted contract (in English and Chinese) is created and that it is enforceable in China. It is essential that quality level expectations are clearly specified in all contracts. For welding, Weld Australia recommends ISO 38342:2005. This contract should also provide for a mechanism whereby the foreign buyer can exercise constant control over the quality of the product.

The standard procedure in many low cost offshore countries for dealing

47

with defects is through a discount on future purchases. This option must not be used. Wherever possible, defective products should never be permitted to leave the factory.

Once a reputable vendor is contracted, it is essential that suitable quality control systems are established and maintained.

Wherever possible, suitable quality control systems should be initiated via the buyer company’s representatives or through professional, reputed third party quality assurance and control experts.

The foreign buyer must also follow through and constantly monitor the quality of the product delivered. This may be sporadic inspections, or 100% supervision, depending on the product and application. While this can be an expensive and tiresome process, buyers who do not monitor the quality of products are almost guaranteed to experience problems.

In addition, buyers should ensure that all relevant occupational health and safety standards are met, particularly sub-standard working conditions, excessive working hours and the personal safety of workers.

Offshore standards for corporate social responsibility should also be followed, as well as social and environmental compliance with Chinese production standards and auditing processes are implemented.

References • http://www.fmglobal.com/assets/pdf/ SupplyChain_RiskStudy.pdf • https://www.chinalawblog.com/ • https://www.chinalawblog.com/2012/08/ china-product-quality-only-you-canprevent-quality-fade.html • https://www.chinalawblog.com/2011/07/ china_oem_agreements_because_the_ foreign_version_wont_cut_it.html • https://www.chinalawblog.com/2012/03/ china-oem-manufacturing-agreementsthe-term-sheet.html

If your company needs detailed information about any welding related topic, contact Weld Australia.

We can tailor in-house workshops and training courses specifically for your company and employees.

48

Australian Welding: June 2018

Member Directory Weld Australia is dedicated to providing members with a competitive advantage through access to industry, research, education, government, and the wider welding community.

When you join Weld Australia you become part of a network of engaged companies and individuals, with which you can share technology transfer, best practices, and professional opportunities. For further information, please contact membership@weldaustralia.com.au or +61 (0)2 8748 0100.

Weld Australia Industry Group Members Weld Australia hosts and administers several Industry Groups, providing a forum for technology transfer and R&D, linking members with industry and research organisations. The Weld Australia Industry Groups: represent a source of vital technical welding information; optimise welding practices through standard development and tools; and assist members to prepare specifications.

AGL Energy www.agl.com.au 131 245 customer.solutions@agl.com.au

Transport and Main Roads (Queensland) www.tmr.qld.gov.au +61 7 3066 6358 TMRStructuralMaterials@tmr.qld.gov.au

ANSTO www.ansto.gov.au +61 2 9717 3111 enquiries@ansto.gov.au

Newcrest Mining www.newcrest.com.au +61 3 9522 5333 corporateaffairs@newcrest.com.au

ASC www.asc.com.au +61 8 8348 7000 David.Price@asc.com.au

NRG Gladstone Operating Service www.nrggos.com.au +61 7 4976 5211 cmcguinn@nrggos.com.au

Ausgrid www.ausgrid.com.au +61 2 4951 9555 cchiodi@ausgrid.com.au

Stanwell Corporation www.stanwell.com 1800 300 351 www.stanwell.com/contact-us

Austal www.austal.com +61 8 9410 1111 info@austal.com

Synergy www.synergy.net.au +61 8 9781 6720 Doug.Harman@synergy.net.au

CB&I www.cbi.com +61 8 93245555 www.cbi.com/contact

Thales Australia www.thalesgroup.com +61 2 8037 6000 MaritimeBusinessSupport@thalesgroup.com.au

CS Energy www.csenergy.com.au +61 7 3854 7777 energyinfo@csenergy.com.au

Transport for NSW www.transport.nsw.gov.au +62 2 8202 2200 stakeholder.relations@transport.nsw.gov.au

Energy Australia www.energyaustralia.com.au 133 466 Wayne.Hill@energyaustraliansw.com.au

Vales Point Power Station (Delta) www.de.com.au +61 2 4352 6111 info@de.com.au

IPM Operation & Maintenance Loy Yang www.gdfsuezau.com +61 3 5177 2000 www.gdfsuezau.com/contact-us/Contacts

VicRoads www.vicroads.vic.gov.au +61 3 8391 3216 vicroadstechnicalservices@roads.vic.gov.au

49

Inside Weld Australia: Member Directory

Premium Corporate Members ALS Industrial www.alsglobal.com/au +61 2 4922 2400 powerservices@alsglobal.com Applied Ultrasonics Australia www.appliedultrasonics.com.au +61 2 9986 2133 info@appliedultrasonics.com.au

Hardchrome Engineering www.hardchrome.com.au +61 3 9561 9555 office@hardchrome.com.au

QENOS www.qenos.com +61 3 9258 7333 enquiry@qenos.com

Howden Australia www.howden.com +61 2 8844 9100 sales@howden.com.au

Quest Integrity Group www.questintegrity.com +61 7 5507 7900 Info-APAC@questintegrity.com

HRL Technology Group www.hrlt.com.au 1800 475 832 info@hrl.com.au

Arrium (One Steel) www.onesteel.com 1800 178 335 capital@onesteel.com

Kemppi Australia www.kemppi.com +61 2 87852000 sales.au@kemppi.com

Austal Ships www.austal.com +61 8 9410 1111 info@austal.com BlueScope Steel www.bluescopesteel.com.au 1800 800 789 steeldirect@bluescopesteel.com BOC www.boc-limited.com.au +61 2 8874 4400 contact@boc.com Callidus Welding Solutions http://callidusgroup.com.au +61 8 6241 0799 info@callidusgroup.com.au CIGWELD www.cigweld.com.au 1300 654 674 enquiries@cigweld.com.au

Lincoln Electric www.lincolnelectric.com +61 2 9772 7222 sales@lincolnelectric.com.au LMATS http://lmats.com.au +61 8 9200 2231 admin@lmats.com.au Main Roads Western Australia www.mainroads.wa.gov.au 138 138 enquiries@mainroads.wa.gov.au Mitsubishi Hitachi Power Systems www.anz.mhps.com +61 7 3878 0888 general@anz.mhps.com

Santos www.santos.com +61 8 8116 5000 reception.ade@santos.com Tronox Management www.tronox.com +61 8 9411 1444 info@tronox.com UGL Pty Limited www.ugllimited.com +61 2 8925 8925 uglinfo@ugllimited.com Water Corporation of WA www.watercorporation.com.au + 61 8 9423 7777 darren.vile@watercorporation.com.au Welding Industries of Australia (WIA) www.welding.com.au 1300 300 884 info@welding.com.au Wilmar Sugar www.wilmarsugarmills.com.au +61 7 4722 1972 info@wilmar.com.au

MMG www.mmg.com +61 3 9288 0888 info@mmg.com

Coregas http://coregas.com.au +61 2 9794 2222 info@coregas.com

Join Weld Australia Today.

Help Secure the Future of

Australian Welding +61 (0)2 8748 0100

|

membership@weldaustralia.com.au

|

www.weldaustralia.com.au

50

Corporate Members 3M Australia: 3m.com.au A&G Engineering: agengineering.com.au Abrasion Resistant Materials: arm.com.au Able Industries Engineering: ableind.com.au Adept Inspections & Training: adeptengineering.com.au Aerison: aerison.com Aitken Welding: aitkenwelding.com Allthread Industries: allthread.com.au Ancon Building Products: ancon.com.au Antec Group: antec.com.au ARL Laboratory Services: arllabservices.com.au Arup: arup.com ASME Projects: asmeprojects.com.au ATTAR: attar.com.au Austal: austal.com Austedan Fabrications: austedan.com.au Austral: australtechnologies.com.au Australian Infrastructure Manufacturing: ausim.com.au Australian Rail Track Corporation: artc.com.au Australian Welding Academy: australianweldingacademy.com.au Australian Welding Supplies: awsi.com.au Aztec Analysis: wga.com.au BAE Systems: baesystems.com Barker Hume Homes: N/A Baxter Institute: baxter.vic.edu.au Beenleigh Steel Fabrications: beenleighsteel.com.au Ben Baden Services: craneconnection.com.au Berg Engineering: bergengineering.com.au Bisalloy Steels: bisalloy.com.au BMC Welding: bmcgroup.com.au Bombardier Transportation: bombardier.com Bradken: bradken.com Brezac Constructions: brezac.com.au Broadspectrum: broadspectrum.com Brosco Enterprises: brosco.com.au Browns Precision Welding: brownswelding.com.au Brunton Engineering & Construction: brunteng.com CCR Group: ccrgroup.com.au Central Engineering: centralengineering.com.au

Australian Welding: June 2018

Chess Engineering: chessindustries.com.au CQ Industries: cqind.com CQ Steel Industries: cqsteel.com.au Crisp Bros Haywards: haywards-steel.com Cullen Steel: cullensteel.com.au D&L Engineering Services: fabinox.com.au DGH Engineering: dghengineering.com.au Diverse Welding: diversewelding.com.au DT Hiload Australia: dthiload.com E&A Contractors: ottowayfabrication.com.au Excel Marine: excelmarine.net.au Extrin: extrin.com.au FIELD Engineers: fieldengineers.com.au Flexco: flexco.com.au Fortress Systems: fortressresistors.com Foxheat: foxheat.com G & G Mining Fabrication: ggminingfab.com Global Engineering & Construction: globalec.com.au Hilton Manufacturing: hiltonmanufacturing.com.au HVAC Queensland: hvac.com.au Industrial Installation & Maintenance: iimaust.com.au Ingal EPS: ingaleps.com.au J Furphy & Sons: furphys.com.au Jacmor Engineering: jacmor.com.au JB Specialised Engineering: jordbellows.com.au JR’s Marine Engineering: jrsgroup.com.au Kangaroo Training Institute: kangarootraininginstitute.com.au Kenro Products: kenrometal.com.au Keppel Prince Engineering: keppelprince.com Knox Engineering: knoxeng.com K-TIG: k-tig.com LaserBond: laserbond.com.au LD Engineering Services: ldo.com.au Lendlease: lendlease.com/au/ Loclur Engineering: loclur.com.au LSW Group: lswgroup.com.au Mechanical Maintenance Solutions: mms.auz.net Mechanical Testing Services: N/A Melco Engineering: melcoeng.com.au Midway Metals: midwaymetals.com.au Millmerran: intergen.com

Monadelphous Group: monadelphous.com.au Monash University: monash.edu Newmont Asia Pacific: newmont.com Nix Engineering Group: nixengineering.com.au Obadare: obadare.com.au Orrcon Manufacturing: orrconsteel.com.au OSD Pipelines: osdlimited.com Precision Metal: precisionmetalgroup.com QSM Fabrication: qsmfabrication.com.au Quality Process Services: qpspl.com.au Radio Frequency Systems: rfsworld.com RCR Energy: rcrtom.com.au RJB Industries: rjb-industries.com Robert Vernon: N/A Robot Technologies-Systems Australia: robottechnologies.com.au Rockpress: rockpress.com.au Russell Mineral Equipment: rmeglobal.com S&L Steel: slsteel.com.au Samaras Group: samarasgroup.com Saunders International: saundersint.com Schenck Process Australia: schenckprocess.com SMW Group: smwgroup.com.au Smenco: smenco.com.au Snowy Hydro: snowyhydro.com.au Southern Cross Industrial Supplies: scis.com.au SSS Manufacturing: sssmanufacturing.com Steel Mains: www.steelmains.com Structural Integrity Engineering: siepl.com.au Supagas: supagas.com.au SWA Water Australia: swawater.com.au Taurus Mining Solutions: taurusminingsolutions.com Testing, Inspection & Calibration Services: ticsndt.com The Bloomfield Group: bloomcoll.com.au Topline Steel Fabrications: N/A Trade and Investment NSW: industry.nsw.gov.au Uneek Bending: uneek.com.au Vehicle Components: vehiclecomponents.com.au Victorian Testing & Inspection Services: victesting.com.au Walz Construction: walzgroup.biz Welding Guns of Australia: unimig.com.au

Inside Weld Australia: Upcoming Events

51

Upcoming Events Whether you need to brush up on skills learnt years ago, want to try your hand at something new, or crave some networking opportunities, there is an industry event for you.

For further information on the events listed below, or any Weld Australia events, please email events@weldaustralia.com.au or phone +61 (0)2 8748 0100.

July 2018

November 2018

The 71st IIW Annual Assembly and International Conference 15 to 20 July, Bali www.iiw2018.com

2018 AWS Professional Program 5 to 8 November, Atlanta, USA www.aws.org

September 2018 9th International Symposium on Steel Bridges 2018 10 to 11 September, Prague, Czech Republic www.steelbridges2018.com Australian Engineering Conference 17 to 19 September, Sydney www.ausengcon.com.au Australasian Structural Engineering Conference 25 to 28 September, Adelaide www.aseconference.org.au October 2018 PacRim Stainless 2018 3 to 4 October, Surfers Paradise www.assda.asn.au 2018 Welding Summit 16 to 17 October, Texas, USA www.aws.org

FABTECH 6 to 8 November, Atlanta, USA www.aws.org The World Engineers Convention 18 to 24 November, Melbourne www.wec2019.org.au CAMS 2018 27 to 29 November, Wollongong www.materialsaustralia.com.au December 2018 9th International Conference on Advances in Steel Structures 5 to 7 December, Hong Kong www.icass2018.com Weld Australia & IIW Exam Dates 2018 IWI B and IWI S 27 and 28 September Welding Supervisor (AS 1796 Cert 10 and AS 2214) 7 and 8 November

Event Spotlight: Weld Australia Pipeline Repair Seminar Facilitated by Weld Australia, the upcoming Pipeline Repair, Hot Tapping and In-Service Welding Course will include a review and critical analysis of available thermal analysis models, including the original Battelle model, the heat sink capacity method and the PRCI thermal model for hot tap welding.

Course attendees will learn why these models, while useful as planning tools, should not be regarded as ‘magic bullets’ against hydrogen cracking in hot tap welding. This course will give an unbiased analysis of the best strategies for avoiding burn through and the development of crack susceptible weld microstructures.

The Pipeline Repair, Hot Tapping and In-Service Welding Course will be held in Sydney from 23 to 24 October 2018. For further information, please visit: www.weldaustralia.com.au/ pipelinerepair

Australian Welding: June 2018 52 Weld Australia’s Expert Advisory

Services And Technical Support: Independent Advice You Can Trust Weld Australia has a team of highly qualified welding engineers and materials specialists available to provide expert advisory services on all welding and materials related matters. With expertise in a wide range of industries, from manufacturing to composites, we have a unique capability to solve your joining problems. Our advice can help you substantially increase the operational life of your plant and equipment, thereby reducing your maintenance and repair overheads.

Our Areas of Expertise • • • • • • • • • • • •

Welding procedure development Welding coordination and management systems Material performance and weldability Welding processes and related equipment Welding health and safety Failure investigation Expert witness in welding and related matters On-site welding technology assistance On-site auditing of welding quality systems Welding codes and standards Inspection and testing Non-destructive testing

Resources

Manufacturing

• • • • • • • • • • • •

Mechanical testing Heat treatment in welding Welding quality management to ISO 3834 Welding specialists (IWE, IWT, IWS) for site work Pipelines-in-service welding, repairs and hot tapping Specialised welding and associated technologies (laser, ultrasonic peening and underwater welding) R&D and application of technology Engineering critical assessment fracture mechanics Structural and pressure equipment design Finite element analysis Weld cost estimating Life estimation

Infrastructure

Defence

Power Generation

Helping secure the future of Australia’s welding industry.

+61 (0)2 8748 0100 | info@weldaustralia.com.au | www.welaustralia.com.au | Building 3, Level 3, 20 Bridge Street, Pymble, NSW 2073