Australian Pressure Equipment Knowledge

 2023-06-24

1 Introduction This is an extract of a letter 16/5/2019 to David Blunt on some ideas and principles for improved AU government. All of the them were only rough but the principles, I think, are sound. The reader is in a far better position to judge.

They based on over 90 years of successful use and continual improvement in the area of industry safety and performance over 4 main periods: Catch up after WW I, World Depression, WW II, and Catch up and expansion after WW II.

They briefly describe most cases of improvements ie changes usually with problems, in 1978 to the end of 1989.

 

2 Cases. Some cases I know which helped to justify the above are:

 

A. In 1926 industry and government realized AU needed catch-up, guidance and an incentive to do better in boiler etc safety, performance and trade between states and overseas. They formed the fore-runner of the current Stds AU Committee ME-001 - the first Mech. Eng. one.

All governments and main industry interests were represented by top technologists to give a balance of all interests. It's title was. "Unification of boiler regulations". It resulted in the SAA Boiler Code CB 1 -1932 which was called up in all or most AU PE Regulations. It was over 200p and a huge advance where all States and industry gained.

Post WW II also saw a huge gap and government and industry started to fix. It was a great example of knowledgable people able to resolve many different opinions. Later I know of one case at final voting where one negative vote beat the 34 positives - based on science and truth and new information which needed understanding.

I became a member representing the Navy in 1958 and am still active to help develop and make available authoritative knowledge needed for PE safety, performance and trade in AS (and NZ).

 

B A NSW decision about 1949 was to depart from the SAA Boiler Code as it had become outdated due to WW II and advances in technology. An exemption or variation from regulations was needed to enable Caltex refinery to be built at Kurnell. This knowledge was vital to me when appointed as Chief Inspector in 1978 and then later.

 

C. In 1979 NSW started the development and issue of Regulatory Authorities Pressure Equipment Notes (PENs) to record big technical decisions made in NSW and make them available publicly - so that all AU could avoid similar problems or use advances. Many of these ended up in Standards and some led to small AU regulatory change. eg AS 4343 in WHS Regulations in most States for PE design and item registrations. Others are below.

 

D Mini-QM system introduced by NSW for AU PE manufacturers to reduce industry and regulator costs with new thinking and use of quality management systems, with no reduction in safety. It allowed transfer of material marks by manufacturers with an approved simple QM system.

 

E. First full QM in AU for PE manufacture for many reasons, including the above, at W.E.Smith, Coffs Harbour based on proven Canadian CSA 290? Terry Miller and I had worked together and great friends at AWRA and we could see the benefit to all of proper QA - especially in areas remote from big cities.

 

F First automatic acceptance and direct acceptance of PE design approvals and personnel certification (of welders, welding supervisors, boiler attendants and engine drivers) from other AU States and Territories. Reciprocal acceptance came years later.

 

G NSW Certificates of inspection (COI) a) The regulatory form was modified to also apply to 2 other NSW jurisdictions Dept. of Mines - coal and metaliferous. Saved time and $s.

b) Reduction of licensed inspector reporting, reduction of receiving and filing of these certificates from 110,000 pa to 5000 (only those reporting significant change)- it also helped two young people and satisfied the Premier's razor gang, but I was told "that's not what you do in the public service".

c) Fee for COI purchase changed from 10c to $1.0 by regulation to cover storage and handling costs and backup for industry. Income $100,000 pa.

 

H Standardised on Manufacture Data Report -a in one sheet a 4 foolscap paged government form for all AU was simplified, added to the Standards as not copyright, and eliminated the need for supply and delivery of outmoded and different government forms, and also reduced industry efforts and cost. Saved nearly $ 1 million.

 

I. NSW first to develop and adopt a system to clearly identify hazard levels to vary PE regulations, registration, and conformity assessment (various checks and inspections) so that the risks with all PE are approximately the same very low acceptable level. It via a new AS 3920.1 eliminated much confusion and many low hazard PE from unnecessary costly controls. Saved $ millions

 

J NSW regulator first to adopt and use fracture mechanics latest technology to safely relax excessively conservative regulatory requirements and practices, about 1982.

 

K NSW regulator with great leadership by Pat Hills and John Fahey successfully:

a) resolved 4 big appeals which could have restricted AU, i.e. new beer barrel (saved about 20 lives in 30 years);

b) extended inspection intervals (from yearly to world best practice- saved $millions);

c) at public rally resolved a LPG vessel NIMBY. (Not in my back yard); and

d) introduced simple controls to resolve big public and medical pleas to ban fire-works.

b) played a leading role in:

* development of LPG auto fuel vessels and use in cars (organised fire tests at DIR Londonderry test facility on 6 used taxis supplied free by NRMA, with ALPGA support, different fuel vessels free by makers, installed free by vessel installers, with safety aided by free Fire brigade. A great industry-government cooperation for national good where valuable new knowledge resolved safety and performance concerns for AU. Standards were adjusted and all gained:

* new fire etc test on innovative FRP reinforced LPG auto fuel vessels.

* CNG in cars - HP aluminium alloy with fibre glass reinforced plastic hoop wrapping.

* first rules for Cryogenic pressure vessels, including LNG fuel vessels for trucks, with great

help from Mal de Silva.

* first to ok use of UT (ultrasonics) for PE in place of RT (radiography). Recognised in AU Std about

10 years before US PE standard.

* first to ok and use AET(acoustic emission) for PE - on new 9000 tonne refrigerated LPG vessel

pressure test at Botany to give extra on old

12000 tonne refrigerated ammonia vessel. Recognised in pressure vessel AU Standards

after top testing by Metasonics, BOC and SA Gas Cylinder Committee who accepted it for very

large hydrogen gas cylinders ("tubes") and changed the Standard.

* LPG road and rail tanker safety largely based on critical investigation on 2 very serious

accidents on main roads - one a BLEVE, another head-on collision; and also a LPG rail tanker

that BLEVED.

* resolving many PE consumer complaints via Consumer Affairs - a great simple cheap safe

means of solving technical problems, helping CA, consumers and broadening knowledge. (

Led to AU playing big role in the science and engineering of a new mode of failure “Sustained

load cracking” in pressure equipment. First experienced in NY Fire Dept breathing cylinder and 3

months later with a gas cylinder valve in Sydney CBD bank. Mainly done by Dr Hugh Stark at

UNSW, Dr Ralph Forester at BOC and DIR. This led to 2 PhDs and improved safety)

* helped Police detectives investigate 2 separate attempts to blow up buildings and people

using LPG in PE -we all learnt. Also testing of paint ball rifle.

* All of many serious incidents involving PE (boilers, pressure vessels, pressure piping and gas cylinders) were investigated with the prime aim of determining all causal factors, failure modes, means of preventing again on same or similar cases, advising corrective action, prosecution where necessary, and feedback to advise others in AU and NZ.

Feedback was to help prevent further incidents by improved Standards, upgrade AU PE personnel and practice, and suggest desirable national research. It was done by direct contact, PENs, an annual PE Branch report (which included our target KPI of less than 2 deaths/a in NSW due to PE (numbering over 10 million); an annual one day meeting for exchange of ideas and new information with Licensed Boiler Inspectors (NSW was the only State which used these for routine inspection of installed PE), and by feedback at conferences and Standards AU meetings.

 

3 Acknowledgment None of the above would have happened except for the :

a) fantastic very early advice and information in 1978 given over a simple lunch from the deputy Secretary of the Dept of Industrial Relations (JackFitzgerald);

b) foresight of legislators to provide flexibility in regulations without seeking ministerial technical exemptions;

c) cooperation of industry, and a terrific team of men and women with great skill, input and kindness, who made it happen in addition to normal day to day duties, and

d) Barb and my boys.

This note has given me the opportunity to record and to long-overdue thank all those who helped make some big changes and improvements for NSW and AU. SAA 26/8/2022

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