Australian Welding Q2 (June) 2019

AUSTRALIAN 1

WELDING An Industrial Evolution at

National Manufacturing Week 2019 Page 20

Welding Sparks an

International Career Page 30

A Critical Constraint:

Workforce Capability and Availability Page 34

Q2 | June 2019 Official Journal of Weld Australia www.weldaustralia.com.au

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Australian Welding: June 2019

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 2 8748 0100 E: office@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 2 8748 0100 E: g.crittenden@weldaustralia.com.au

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

Training Paul James T: +612 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.

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Contents: June 2019

Contents 20

An Industrial Evolution at NMW 2019

A Message from Weld Australia’s President

4

A Message From Weld Australia’s CEO

6

Inside the Industry Breaking News Business Essentials Australian Standards Health & Safety

8 14 16 18

Feature & Technical Articles

28

Member Profile: Master Steel

30

Welding Sparks an International Career

An Industrial Evolution at NMW 2019 Member Profile: Master Steel Welding Sparks an International Career A Critical Constraint: Workforce Capability and Availability

20 28 30 34

Inside Weld Australia

Cover image courtesy of Warner Bros.

Movie World on the Gold Coast and Village Roadshow Theme Parks.

IIW Quality Audit: WeldQ & AWCR A Giant Leap Forward IIW & IAB: Linking People, Joining Nations Advanced Welder Training Centres Hotline Update Industry Groups Update Advanced Welder Training Courses Training Calendar Member Directory Upcoming Events

36 38 40 42 44 45 46 48 51

About Weld Australia

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A Critical Constraint: Workforce Capability and Availability

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.

Visit: www.weldaustralia.com.au.

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Australian Welding: June 2019

A Message From Weld Australia’s President “

I encourage all Australian manufacturers to support the Australian Welder Certification Register (AWCR). Register your business on the AWCR, and ensure your employees and subcontractors are registered and certified via the AWCR.”

David Lake President, Weld Australia

New Weld Australia Constitution Following a review of the existing Weld Australia constitution last year, the Board decided to adopt a more modern and compliant constitution.

We used a template for not-forprofit organisations and modified it to meet the specific needs of Weld Australia. This process took several months to complete, culminating in approval by members at the Annual General Meeting (AGM) in May. We now have best practice governance procedures in place for Weld Australia and the operations of our Board.

As part of this governance review a ‘Skills Matrix’ was developed for the Weld Australia Board, which was aligned with our Strategic Plan. Our initial review indicated some areas in which we were less strong. I am pleased to report that we were able to strengthen these areas with the election of Rob Johnson to an initial three year term, commencing from his election to the Board at our AGM

in late May. Each year, a review of the ‘Skills Matrix’ will enable us to ensure that the composition of the Board delivers the skills, knowledge and experience to support our executive in achieving Weld Australia’s vision and mission.

Advanced Welder Training Centres Weld Australia is making good progress in growing our welder training initiative. The key first step of this initiative is the establishment of Advanced Welder Training Centres (AWTCs) around Australia in partnership with TAFE. The first couple of which are up and running in Victoria, South Australia, and Queensland, with more soon to come online. It is great that both the State and Federal governments have financially supported this initiative.

These centres offer a modern training path for those new to welding, enabling them to enter the trade of welding and become qualified to AS/NZS ISO 9606-1.

Those already working in the trade

can also use this path to upskill themselves, gain an AS/NZS ISO 9606-1 qualification, and be added to the Australian Welder Certification Register (AWCR).

Why AS/NZS ISO 9606-1?

I was recently asked why AS/NZS ISO 9606-1 has been used as the welder qualification standard. There are several reasons for Weld Australia’s adoption of this Standard.

ISO 9606-1 is the only Standard in the world that is accepted in both Europe and America, and is the minimum requirement for working on rolling stock, defence, infrastructure and pressure equipment projects. In fact, ISO 9606-1 is required under several international Standards, including EN 15085 Railway applications—Welding of railway vehicles and components, and DIN 2303 Welding and allied processes— Quality requirements for production and maintenance companies for military products.

A Message From Weld Australia’s President

ISO 9606-1 utilises a simple test that assesses welding competency according to a specific weld procedure, based on a practical acceptance criteria. It can be used to test the competency of a welder to complete a variety of weld procedures, from a basic butt weld up to the most complex pipe joints, utilising various positions, processes and materials.

Under ISO 9606-1, welder competency testing is focused on the three key elements required of a welder, including the ability to: 1. Set up a welding machine 2. Read a welding procedure 3. Weld a coupon in accordance with the relevant acceptance criteria Welder qualifications are valid for two or three years, and are transportable across worksites and employers, avoiding the need to requalify welders where there is evidence of maintenance of qualification. In addition, a six-monthly confirmation process is used to verify welder qualifications to ensure maintenance of welder skills, without the need for additional testing.

The confirmation process is similar

“

ISO 9606-1 is the only Standard in the world that is accepted in both Europe and America, and is the minimum requirement for working on rolling stock, defence, infrastructure and pressure equipment projects.�

to that required for welders qualified to other standards including AS/NZS 1554.1.

ISO 9606-1 does not replace either AS/NZS 1554 or AS/NZS 1796 Certification of welders and welding supervisors. Rather, ISO 9606-1 is complementary to these Standards, working well alongside both.

The Australian Welder Certification Register Having decided on this strategy, Weld Australia acquired an online system to help us manage the process of qualifying and certifying welders to ISO 9606-1: the Australian Welder Certification Register (AWCR).

Under the AWCR system, welders complete a test that qualifies them to a welding procedure as set out in ISO 9606-1. Once qualified, the welder is provided with a test certificate to that procedure, becoming a Registered Welder, and the information is recorded in the AWCR. The certificate is valid for up to three years, subject to six monthly confirmations by a responsible person (such as a supervisor or an

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approved examiner).

The AWCR system is already proving to be enormously beneficial for many organisations. It enables asset managers and owners to check the competence level of any Registered Welder against an internationally recognised Standard, minimising welder testing and reducing costs.

By qualifying welders against a recognised and certified competency level, the risk of a welder failing a weld procedure is significantly reduced. In addition, asset managers can assess welders against current, rather than past, performance, and quickly and easily identify and contact Registered Welders for employment.

I encourage all Australian manufacturers to support the AWCR. Register your business on the AWCR, and ensure your employees and subcontractors are registered and certified via the AWCR. Access to the AWCR is completely free of charge for all Weld Australia members.

For more information, visit: https://awcr.org.au

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Australian Welding: June 2019

A Message From Weld Australia’s CEO “

It is Weld Australia’s position that it does not matter where our steel infrastructure is made, as long as the fabricator is certified to AS/NZS ISO 3834, and the steel is manufactured and welded to all specified Australian or international standards.”

Geoff Crittenden Chief Executive Officer, Weld Australia

It is Weld Australia’s position that it does not matter where our steel infrastructure is made, as long as the fabricator is certified to AS/NZS ISO 3834, and the steel is manufactured and welded to all specified Australian or international standards.

Our rationale is, that given a level playing field, Australian welding is internationally price competitive and can deliver world class quality. We have developed this view after acting as advising welding engineers on many large-scale projects fabricated in Australia and overseas.

However, it appears that this is not immediately obvious to those charged with procuring multi-million dollar projects. As reported in The West Australian, in a recent speech to the West Australian Mining Club, Orica Chief Executive, Alberto Calderon, explained their billion dollar-plus Pilbara explosives plant was shut down after a “terminal cancer of leaks” caused by faulty welding done in China.

Mr Calderon said the 330,000 tonnes-a-year plant, which began

operating in 2016, made quality technical ammonium nitrate, “but after producing about 70,000 tonnes, the leaks became unsustainable”. He went on to explain that components operating at very high temperatures, including the heat exchangers, “become absolutely useless” as they “suffered this terminal cancer of leaks”. In his view, joint venture partner Yara (who was responsible for the construction and ongoing operation of the plant) did not sufficiently manage the quality of the welding completed in China.

honesty in raising the issue of weld quality. In most cases, the large multinationals and governments who suffer the same fate do everything to cover up their problems.

Orica marked down the value of its 45% share of the plant by $155 million in April 2019, indicating a total direct cost of the defective equipment of about $340 million. In 2012, the plant was expected to cost $US800 million and start production in 2015. According to Mr Calderon, the delay is “costing us millions of dollars every month”.

In line with Mr Calderon’s point on supervision, the senior engineer explained that the mining company had spent so much on production oversight and fault rectification that there was almost no cost benefit to offshoring the work. In fact, once you included the maintenance costs, it was more expensive than locally procured fabricated steel. And yet, that same mining company has just announced that 20,000 tonnes of structural steel work is to be procured from China for a new mine.

Regrettably, this is an all too common story.

Weld Australia congratulates Mr Calderon for his openness and

I recently met with a senior engineer from a large mining company who had procured substantial amounts of fabricated steel infrastructure from offshore suppliers during the mining boom. He reported that their maintenance bills were off the scale and that production was limited by the poor quality of the welding.

It would be easy to fill this entire

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A Message From Weld Australia’s CEO

publication with similar examples from mining, oil and gas, civil works, rail car and infrastructure procurement. It is certainly no secret, and to be fair, not limited to Chinese fabricators. So why is the same mistake being repeated time after time?

From an outsider’s perspective, it appears that clients are taking a very narrow view of project costs, allowing ‘cost to buy’ to dominate the procurement process rather than whole of life (cost to commission and to operate). If this is the case, then they are not demonstrating value for their shareholders or tax payers— merely concealing the true cost of the project.

There are no doubt geo-political and financial considerations to be weighed, but it is hard to see how either can offset higher overall costs.

However, if that is the case, what about local social and economic consequences of offshoring?

Since the beginning of the last mining boom, the Australian steel fabrication industry has shrunk by 30% because of exactly this type of short-sighted procurement decision.

Not surprisingly, a huge number of Australian fabrication companies have gone broke and closed their doors, resulting in thousands of welders leaving the trade.

However, in some industries there

are real signs of resurgence, mostly thanks to public money.

The $150 billion investment by the Federal Government in the defence industry has revitalised many small-to-medium enterprises within the Australian manufacturing supply chain, and brought in new investment from overseas. Despite the award of a $2.3 billion contract to South Korea from the New South Wales Government, new rail car projects in Victoria, Western Australia and Queensland are breathing life back into the rail industry.

Plus, it is estimated that Australian governments will spend upwards of $70 billion on infrastructure over the next decade. Just some of the projects announced by the Federal Government over the last few years include: the $16 billion WestConnex project in Sydney; the $12 billion Sydney Metro project; and the $11 billion Melbourne Metro Tunnel.

However, without regulations that mandate compliance to Australian Standards for the manufacture, fabrication and erection of steel, procurement decisions will continue to focus on the lowest common denominator: cost.

Apart from increasing overall costs for public and private infrastructure projects, this complete lack of regulation is putting Australian lives at risk. The problem is that, if structures and components are

“

Whether fabricated steel is manufactured in Australia or overseas, it is critical that the work is undertaken according to Australian Standards. As such, Weld Australia is currently lobbying both sides of Government to amend the necessary regulations to mandate compliance to Australian Standards, or wear the consequential loss of life.”

not fabricated in accordance to Australian Standards, there is simply no way to guarantee that they will not fail.

Whether fabricated steel is manufactured in Australia or overseas, it is critical that the work is undertaken according to Australian Standards. As such, Weld Australia is currently lobbying both sides of Government to amend the necessary regulations to mandate compliance to Australian Standards, or wear the consequential loss of life.

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Australian Welding: June 2019

Breaking News First Arafura Class Marks Ceremonial Keel-Laying The first of Australia’s Arafura Class Offshore Patrol Vessels (OPVs) recently celebrated a naval tradition— the keel-laying ceremony that brings good luck to the shipbuilders and future crew members. In the second major milestone of Australia’s newest warship construction program, the keel laying ceremony saw a commemorative coin placed under the keel of the vessel by the youngest shipbuilders in the Osborne Naval Shipyard, followed by the Chief of Navy wedging the coin under the keel.

Luerssen Australia Chairman, Tim Wagner, said the milestone marked the official start of the ship’s life, and demonstrated the significant progress made already on the Arafura Class program. “This is another reminder of the importance of the Arafura Class program towards Australia building a sovereign naval shipbuilding capability,” Wagner said. “As the prime contractor and designer for the SEA1180 program, we have been delighted with progress so far, and remain confident that we will deliver all 12 vessels on time and on budget for the Royal Australian Navy.”

ASC Chief Executive Officer, Stuart Whiley, said the Arafura Class shipbuilding program is progressing well, employing more than 150 shipbuilders. “The Arafura Class is ASC’s second shipbuilding program, commenced as we continue to successfully complete the Air Warfare Destroyer program, and we are very pleased at its progress to date,” said Mr Whiley.

Construction of the first of 12 Arafura Class OPVs commenced last November, on time, by prime contractor Luerssen Australia and shipbuilding subcontractor ASC. The first two OPVs will be constructed at the Osborne Naval Shipyard in South Australia by ASC, with the Australian steel cut in Western Australia by Civmec. The remaining ten warships will be constructed at Civmec’s facility in Henderson, Western Australia.

Navantia Australia Celebrates Hobart Class Destroyer Aviation Capability Upgrade Navantia Australia congratulates the AWD Alliance on achieving the major capability upgrade to the Hobart Class Air Warfare Destroyer (AWD), NUSHIP Sydney, one year ahead of schedule as recently announced by then Defence Minister Christopher Pyne and Defence Industry Minister Linda Reynolds.

Navantia has been providing the AWD Alliance with various consultancy services during the construction of the Hobart Class ships. These include providing design services which support the integration of MH-60R ‘Romeo’ helicopter capability aboard the AWDs.

Image: NUSHIP Sydney.

Image courtesy of Navantia Australia.

“As the designer, we are delighted to see the Hobart Class design continue to evolve,” said Navantia Australia Managing Director Alfonso Garcia-Valdes. “Our involvement in this project means continued work for our highly skilled workforce that are integrated at the Osborne Naval Shipyard. Navantia Australia is committed to ensuring the Royal Australian Navy has full capability of these magnificent ships, by providing sovereign sustainment capability wherever the Navy requires it.”

The Hobart Class Air Warfare Destroyers are based on the Navantia-designed F100 guided missile frigate and is the most lethal warship Australia has ever possessed.

It features advanced anti-submarine warfare capability, state-of-the-art radar technology and an air defence system capable of engaging enemy aircraft and missiles at an extended range.

Exclusive BOC Offer for Weld Australia Members Weld Australia is pleased to announce that all new and existing members now have access to discounted pricing on BOC equipment purchases, as well as discounts on gas and cylinder rental charges.

Image (L to R): Boilermaker Kane Ramsay, Chief of Navy Michael Noonan, and Document Editor Lauren Pitman.

Image courtesy of ASC.

Weld Australia is committed to representing the interests of its members and promoting the use of best practice technology and quality systems.

BOC is one of Australia’s leading gas and welding equipment specialists, offering gases, welders and welding supplies, PPE, workplace safety and industrial equipment. For details, visit: www.weldaustralia.com.au

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Inside the Industry: Breaking News

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Australian Welding: June 2019

Breaking News Cape Vessel Delivered to Navy Marking 73rd Patrol Boat Built by Austal Austal recently announced that the first of two CapeClass Patrol Boats for the Royal Australian Navy—the Australian Defence Vessel (ADV) Cape Fourcroy—has 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 $63 million contract to Austal in December 2015.

Austal Chief Executive Officer, David Singleton, said the delivery highlights Austal’s proven capability to design and build defence vessels, a record that has seen the company build 72 patrol boats for domestic and international markets before this delivery.

“This latest Cape Class, for the Royal Australian Navy, further strengthens Austal’s position as the only patrol boat designer and builder in Australia and a major world class exporter for this class of vessels. The delivery of the Cape Class vessel clearly shows Austal’s unrivalled ability to design and construct defence vessels on-time and on-budget.”

“Austal has been building patrol boats for over 20 years and we look forward to more work in the future. This includes the opportunity to design and build 12 new Offshore Patrol Vessels for the Australian Navy with our design partner Fassmer in a continuous shipbuilding initiative being driven by the Government,” said Singleton.

Austal currently has an order book of 20 patrol vessels to be delivered over the next four years, and has successfully competed in a number of overseas markets.

Austal is currently proposing variations of its Bay Class, Cape Class and Guardian Class Patrol Boats for customers in the Middle East and Asia, and expects this activity to bring further construction work to Australia.

Image: Cape Class Patrol Boat. Image courtesy of Austal.

Department of Defence Announces First Attack Class Submarine Subcontract The Department of Defence recently announced the signing of the first major equipment subcontract for the Future Submarine Program. Naval Group and diesel engines manufacturer MTU Friedrichshafen GmbH (MTU) have been contracted to design the Diesel Generator Rectifier (DGR) for the Attack Class submarine to turn mechanised energy into electricity.

“I am very happy to announce that after a robust procurement process, MTU has been selected as the first major equipment subcontractor for the Attack Class submarine,” the then Minister for Defence, Christopher Pyne said. “MTU has committed to establishing the necessary industrial capability in Australia, to deliver and support the DGR – a key element of achieving the sovereign build – operation and sustainment of the Attack class submarine.”

The then Minister for Defence Industry, Linda Reynolds, said while the contract is directly with MTU, the company would leverage its existing strategic partnership with Penske Power Systems Australia. “MTU will work with Penske during the design phase and will then grow Penske’s capacity in Australia. Importantly, this will transfer the technology and knowledge associated with this capability to Australia. “The DGR subcontract is part of the Government’s investment in the Attack Class submarine, part of the creation of a sovereign naval shipbuilding enterprise and the Government’s continuous naval shipbuilding capability.”

Rheinmetall Progresses Steel Qualification for Australia’s Land 400 Program Bisalloy Steels is pleased to report significant progress with the development of specialised armour steel for the Land 400 Phase 2 program, as part of the company’s partnership with Rheinmetall Defence Australia (the contracted supplier of 211 Boxer Combat Reconnaissance Vehicles (CRV) to the Australian Defence Force).

Bisalloy was selected by Rheinmetall to supply BISALLOY® Armour steel for the Land 400 Phase 2 program and the two companies are working together to achieve the required German Government qualification required to meet protection levels required on the BOXER CRV. This qualification process can take up to two years to achieve. With full qualification approaching, Bisalloy hosted members of Rheinmetall’s technical and project team at its Wollongong facility in February.

Further testing in Germany took place in April with a specific focus on blast tests.

Inside the Industry: Breaking News

Shipbuilding Infrastructure Taking Shape in SA Work is well underway at the Osborne Naval Shipyard, in South Australia, to develop the shipyard where the nine anti-submarine warfare Hunter Class frigates will be built.

The image below shows the structural steel being erected for the high Block Assembly Hall where the blocks that make up each frigate will be constructed.

This building is 28m high, 160m long and 47m wide, and will be dwarfed by the Ship Erection Hall alongside.

Approximately 89% of the 25,500 tonnes of steel required for the Osborne South Development Project has been sourced from Australian suppliers and steel fabrication and installation is being undertaken by local companies.

ASC Shipbuilding, BAE Systems Australia’s shipbuilding business, has commenced mobilisation and design work on the Hunter Class Frigate Program, with prototyping to commence in 2020 and construction of the first frigate in 2022. The program will create and sustain more than 5,000 jobs across BAE Systems and the wider Australian defence supply chain over the life of the program.

Image: Construction of Block Assembly Hall at the Osborne Naval Shipyard in South Australia.

Bombardier to Upgrade Trains for Queensland New Generation Rollingstock (NGR) Project Bombardier Transportation recently announced an order from the Queensland Government to deliver modifications to the NGR trains being introduced to the South-East Queensland rail network. With a total value of $361 million, the contract includes design, delivery, and maintenance over the remaining term of the publicprivate partnership. Bombardier is leading the Qtectic consortium, which has been contracted to deliver the NGR project, and will undertake the work to modify the trains in line with the government’s revised design specifications, with industry partner Downer EDI.

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Monadelphous Secures Second Construction Contract at BHP’s South Flank Project Engineering company Monadelphous Group recently announced it has been awarded a second construction contract, valued at $104 million, at BHP’s South Flank Project in the Pilbara region of Western Australia.

The contract includes structural, mechanical, piping and electrical and instrumentation works associated with the project’s inflow infrastructure, and brings the total value of work secured by Monadelphous on this project to $212 million. Work under the inflow infrastructure contract is expected to start immediately and be completed by March 2021.

Monadelphous Managing Director, Rob Velletri, said the award of a second contract at South Flank enables Monadelphous to realise efficiency synergies between the two packages of work, and underlined the strength of its long-term relationship with BHP. “We are pleased to secure further work on this significant project and look forward to continuing our long track record of successfully working with BHP,” Velletri said.

ANSTO Announces Space Research Collaboration ANSTO (Australia’s Nuclear Science and Technology Organisation) has an exciting new space research project on the horizon following a strategic research agreement with the National Centre for Space Studies (cnes) and the National Institute of Health and Medical Research (INSERM) in France. The research, which will utilise the expertise of both human health and radiation dosimetry scientists, as well as ANSTO’s accelerator infrastructure, will focus on characterising the impact of low energy particles on human cells in space.

“Although spacecraft have adequate shielding to protect astronauts from high energy radiation, the effect of secondary lower- energy particles is less understood,” said Professor Marie-Claude Gregoire, Leader, Human Health research at ANSTO. “When high energy particles strike the spacecraft, they can produce fragments, secondary ions that are released as energy from the collision or are ripped from the shielding materials. Theoretically the dose may not be that high, but there could be cumulative effects from heavy ions produced.”

“It is very important to understand how cells respond when exposure is chronic, as you might be living in space for up to nine months, such as in the International Space Station. Our researchers will be looking at the biological pathways in human cells that could be disturbed by exposure over time and how they respond.”

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Australian Welding: June 2019

Breaking News Joint Strike Fighter Underpins Advanced Manufacturing Growth in South Australia BAE Systems Australia has celebrated the production of the 15,000th titanium part at Edinburgh Parks in South Australia for the world’s largest defence program, the F-35 Joint Strike Fighter. These parts have delivered 500 tail sets which—together with the aft fuselage and horizontal tail sets—make up the rear section of each jet.

Production of vertical tail parts at Edinburgh Parks will continue for another two decades, possibly further, depending on global sales of the Joint Strike Fighter aircraft. Securing decades of work on the global F-35 program has underpinned the company‘s investment in bespoke titanium machining facilities at Edinburgh Parks, which was also supported by the South Australian Government.

As well as manufacturing a range of products for the F-35 Joint Strike Fighter, the company also produces bespoke components for other critically important Defence programs, including the Nulka decoy and the Evolved Sea Sparrow Missile.

Andrew Gresham (Managing Director Defence Delivery,

Naval Shipbuilding College Endorses Welding Courses Across Australia TAFE Queensland, Edith Cowan University and South Metropolitan TAFE have all recently received course endorsement from the Naval Shipbuilding College.

They will join a network of education and training providers across Australia that deliver courses aligned with the future employment needs of the naval shipbuilding industry. This includes mechanical and electrical engineering degrees at Edith Cowan University, South Metropolitan TAFE’s Certificate III in Engineering-Fabrication Trade (welding component), and TAFE Queensland’s Certificate III in Engineering – Fabrication Trade. The endorsements means

Image (L to R): Paul Whetstone from the Naval Shipbuilding College at the Cairns campus, with the TAFE Queensland (North Region) team, including Stephanie Thomas, Brad Riley, Phil Williams, and Ian Smythe.

Image: The F-35 Joint Strike Fighter. Copyright© BAE Systems.

BAE Systems Australia) said, “Australia’s strength is in the ability of manufacturers to excel in the production of highly specialised products.”

“We are undertaking very complex and advanced manufacturing in a way that is cost effective and globally competitive. Digitisation will be the next big step change to further improve our competitiveness by allowing us to collaborate seamlessly with our suppliers and partners in real time. This will mean that we can identify and resolve issues faster, improve risk management and optimise production.”

graduates of all these courses will be acknowledged by shipbuilding and supply chain industries across the country as being ‘job ready.’

Naval Shipbuilding College Training Quality and Assurance Manager, Paul Whetstone, attended TAFE Queensland’s Cairns campus for the significant milestone. “This is great news for North Queensland students who will undertake training that directly aligns with the future needs of Australia’s growing naval shipbuilding industry,’’ Whetstone said.

“A critical component of the enhanced welding course will be to skill students how to weld in a restricted position, an essential requirement for potential employers. We need skilled workers to fill the projected 15,000 jobs that will be needed to build and sustain our future fleet, including the technologically advanced Attack Class Submarines and Hunter Class Frigates.”

Duncan Powrie (Deputy Program Manager, Naval Shipbuilding College), said the College’s expansion into Western Australia continues at pace. “We are rapidly establishing endorsed courses throughout every state and territory, which means more students will graduate job-ready for naval shipbuilding. Through collaboration, we are strengthening student pathways into rewarding, long term, sustainable shipbuilding careers.”

Pipeline Repair, Hot Tapping & In-Service Welding Course Registrations Now Open 7 and 8 August | Perth, Australia Registrations are now open for the Pipeline Repair, Hot Tapping & In-Service Welding course to be held at the Novotel Perth Langley on 7 and 8 August.

Presented by international expert Bill Bruce, this course provides an in-depth overview of the various aspects of pipeline modification and repair (full encirclement sleeves, hot taps, and so on) and addresses common concerns around welding in-service pipelines.

The course is designed to help avoid pipeline shutdowns and interruptions of service, bolstering both economic and environmental benefits for operators and welders alike.

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Australian Welding: June 2019

Modern Slavery Act to Impact Supply Chains Australia has recently joined the likes of the United Kingdom, France and other nations to have specific legislation that formally brings business into efforts to address modern slavery. The Modern Slavery Act came into effect from the beginning of 2019, and is expected to see supply chains across many Australian industries evolve. While some of the largest players within Australian manufacturing, construction, infrastructure and steel supply chains, have been committed to ethical procurement practices for years, the introduction of this legislation will formalise regulatory requirements and should see more widespread adoption of sustainable, ethical procurement.

According to the 2018 Global Slavery Index, over 40 million people globally are subject to some form of modern slavery. Whilst Australia has one of the lowest rates of slavery in the world—with a prevalence of 0.6 victims for every thousand people—the realities of global trade and business make it inevitable that Australia is exposed to the risk of modern slavery through the products it imports. In fact, over US$12 billion worth of at-risk products are imported into Australia annually.

While social justice and anti-slavery groups have been quietly working towards a corporate reporting requirement on slavery behind the scenes for many years, the real push for the Act came when UK Prime Minister, Theresa May, and mining magnate and philanthropist Andrew Forrest started to directly pressure former Prime Minister

Malcolm Turnbull. Since the UK passed its law in 2015, May has been pushing other Commonwealth states to introduce legislation on modern slavery. According to May, “These crimes must be stopped and the victims of modern slavery must go free. This is the great human rights issue of our time, and as Prime Minister, I am determined that we will make it a national and international mission to rid our world of this barbaric evil.”

The issue has since been on the agenda at the 2016 Global Summit on Migration, the 2017 Commonwealth Heads of Government Meeting, and at the G20 summit in November 2018. It is also at the forefront of the Bali Process Government and Business Forum, which Australia co-chairs with Indonesia.

What is the Modern Slavery Act 2018?

The Modern Slavery Act 2018 was passed into law in November 2018, and took effect throughout Australia from 1 January 2019.

The Act defines modern slavery as any forms of exploitation in which a person cannot refuse or leave work because of violence, threats, coercion, abuse of power, or deception. In practical terms, this means that the definition of modern slavery encompasses servitude, child labour, forced labour, human trafficking, debt bondage, forced marriage and deceptive recruiting for labour.

The Act sits alongside the Commonwealth Criminal Code, where trafficking and slavery offences are defined under Divisions

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Inside the Industry: Business Essentials

“

These crimes must be stopped and the victims of modern slavery must go free. This is the great human rights issue of our time.”

270 and 271. The intention of the Act is to move from relying on reactive, criminal justice mechanisms to identify exploitation, towards encouraging Australian businesses to adopt practices that actively prevent such exploitation from occurring within their supply chains.

Under the Act, large Australian organisations, including businesses, charitable institutions and universities, with revenue of over $100 million per annum are required to report—called a Modern Slavery Statement—on the risks of modern slavery within their operations and supply chains, as well as the actions taken to assess and reduce these risks.

Under this definition, it is estimated that approximately 3,000 organisations will be required to submit a report, including the Australian Government and corporate Commonwealth entities.

The Act prescribes mandatory reporting requirements. Specifically, Modern Slavery Statements are required to include information on: • Structure, operations and supply chains • Risks of modern slavery practices in the operations and supply chains of the reporting entity, and any entities that the reporting entity owns or controls • Actions taken to assess and address those risks, including due diligence and remediation processes

•

How the reporting entity assesses the effectiveness of such actions.

Setting this minimum standard for reporting will ensure that organisations’ statements are more or less comparable; that they will provide more substance, particularly on operations and risk; and companies will have to include information on how they monitor and evaluate their efforts in order to know that what they’re doing is achieving something.

In a bid to ensure management support and buy-in, these annual reports must be approved by an organisation’s Board of Directors and signed by a company Director. The reports must then be submitted to the Minister for Home Affairs, and will be made publicly available on a central register managed by the Federal Government.

Online Modern Slavery Statements Register The Federal Government has also committed funding to provide nonbinding guidance to business and to establish an Online Modern Slavery Statements Register. This Register will be managed by the Government for free public use, to enable consumers, investors, potential employees and others to monitor performance under the Act. The first Modern Slavery Statements will not be lodged until mid-2020, and from now until then, various

companies will be working to understand the implications of the Act and how they’ll comply with these new requirements.

The Act does not include civil penalties for non-compliance, or poor compliance. However, in response to mounting pressure from the Opposition, Greens and some parts of civil society, the Federal Government made four amendments in the Senate, which add provisions that will encourage compliance.

Specifically, these amendments sought to: • Give the Minister for Home Affairs the authority to compel entities that fail to comply to provide explanations on why they failed to provide a compliant Modern Slavery Statement • Give the Minister for Home Affairs the authority to publish details of an entity that fails to comply • Require the Minister for Home Affairs to provide annual updates to the Parliament on the implementation of the Act and its effectiveness • Specifically include within the terms of the three-year review of the Act consideration of whether civil penalties are required to address non-compliance with the Act Source Moore, H. & Seagrave, M. Australia’s Modern Slavery Act: What Does it Mean (via https://lens.monash.edu)

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Australian Welding: June 2019

The Changing Face of Australian Standards Australian Standards are published documents setting out specifications and procedures designed to ensure products, services and systems are safe, reliable and consistently perform the way they are intended to. They establish a minimum set of requirements which define quality and safety criteria. To maintain their relevancy, all Standards are periodically reviewed, with amendments and revised editions published. The last few months have seen several developments, including ongoing reviews into Standards related to steel structures, and pressure equipment.

Aged Standards As indicated in the March 2019 edition of Australian Welding, following a period of public review, and committee ballot, Standards Australia has published a number of direct text adoptions of ISO Standards to replace aged Australian Standards. The Standards published include two parts of the AS/NZS ISO 3834 series (Quality requirements for fusion welding of metallic materials), specifically AS/NZS ISO 3834.5 and AS/NZS ISO 3834.6; and two parts of the AS 2205 weld test series.

The test Standards published were: AS/NZS 2205.4.1 (an adoption of ISO 9017 covering the fracture tests) to replace the aged Nick-break (AS 2205.4.1) and Fillet break (AS 2205.4.2) tests; and AS/NZS 2205.5.1 (an adoption of ISO 17639 covering macro and micro examination) to replace the aged Standard AS 2205.5.1.

Pressure Equipment As previously reported, the public review draft of the revision of AS/NZS 3992 Pressure equipment— Welding and brazing qualification is being prepared. It is expected to be released for pubic review in July.

Steel Structures The review of public comment on the revision of AS 2214 Certification of welding supervisors—Structural steel welding was completed by WD-003 in April and the document is now

being prepared for committee ballot.

The committee has also completed preparation of the draft amendment to correct an error within AS/NZS 2980 Qualification of welders for fusion welding of steels—Additional requirements for Australia and New Zealand. A public review draft will now be prepared by Standards Australia.

As previously reported, Committee BD-001 has completed the preparation of public review drafts for the revision of two of its standards, AS/NZS 5131 Structural steelwork—Fabrication and erection, and AS 4100 Steel structures.

Release of the public review drafts for comment is now expected to commence in June.

The revision of AS/NZS 1554.2 Structural steel welding—Part 2: Stud welding (steel studs to steel) has also commenced and preparation of a public review draft by the committee is well advanced. Once complete, the draft will be prepared for public comment, most likely in the latter part of 2019. As previously indicated, the draft has taken cognisance of the relevant ISO Standards and now includes provisions for the use of stainless steel studs and studs for wear applications.

International Standards As mentioned in previous articles, ISO 14731 Welding coordination— Tasks and responsibilities has been under revision by ISO. This standard is a core standard referenced by the AS/NZS ISO 3834 Standard series, and is now being referenced in some other Australian standards. The 2019 edition of ISO 14731 was published in February and consideration is likely to be given to its adoption in Australia in due course.

With the successful adoption of ISO 9606‑1 Qualification testing of welders—Fusion welding—Part 1: Steels in Australia and New Zealand as AS/NZS ISO 9606‑1, Committee WD-003 has moved to facilitate its use by adopting key referenced ISO Standards as AS ISO or AS/NZS ISO Standards. Accordingly, AS/NZS ISO 5817 Welding— Fusion‑welded joints in steel, nickel, titanium and their alloys (beam welding excluded)—Quality levels for imperfections was published in March following a period of public review and ballot.

Committee Vacancy Weld Australia is seeking expressions of interest from members with expertise in the welding of copper and its alloys, to represent the interest of members on a Standards committee. For further information, please contact Bruce Cannon (Technical Publications Manager, Weld Australia) via b.cannon@weldaustralia.com.au.

Further Information For further information, or questions related to Australian Standards, contact the Weld Australia Hotline: www.weldaustralia.com.au/hotline.

Inside the Industry: Australian Standards INCLUDES 15 INTERNATIONAL AND AUSTRALIAN SPEAKERS PROUDLY PRESENTED BY:

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SPONSORED BY:

International Symposium

Advances Corrosion Science Corrosion Engineering 24 - 25 July 2019 | Melbourne Marriott Hotel, Cnr Lonsdale & Exhibition Streets, Melbourne

The Australasian Corrosion Association (ACA) is holding an International Symposium to celebrate the significant contributions of the following ACA legends:

Day Registration Includes: attendance at all sessions, morning/ afternoon tea, lunch and a hard copy book of proceedings. Day registrants are welcome to participate at the social functions on their day of registration, included in ticket price.

• Les Boulton • Bruce Hinton • Brian Kinsella • Brian Martin • Greg Moore • David Nicholas

Registration Fees (inclusive of GST)

Overview of Event

Fifteen high calibre International and Australian speakers will each present a keynote of 45 minutes duration

Full Registration (includes book, social functions)

$1200

Day Registration (includes book, relevant social function)

$800

Guest Dinner Ticket

$180

A panel discussion and open forum will be held at the end of each day. Technical papers of high quality and substantive length will be available to delegates.

(Dinner & Networking Drinks included in Full and Day Registrations)

REGISTRATION – ONLINE

Sponsorship IS STILL AVAILABLE

Full Registration Includes: attendance at all sessions, morning/ afternoon tea, lunch and attendance at the social functions (including dinner on Wednesday evening) at the symposium. A hard copy book of the proceedings is included.

DAY ONE Session

ACA Technical Events may be eligible for CPD Points.

To register visit the events tab at corrosion.com.AU DAY TWO

Speaker

Topic 1 – Engineering Alloys | Chair: Bruce Hinton Alloy design for corrosion resistance

John Scully, University of Virginia (USA)

Corrosion of light metals: Status and in-situ analysis

Nick Birbilis, Australian National University (Canberra)

Topic 2 – Corrosion Resistant Alloys | Chair: Les Boulton Duplex Stainless Steels – The versatile alloys

Roger Francis, RF Materials (UK)

Facades to structures: Corrosion resistance and mechanical property developments in stainless steels

Graham Sussex, Nickel Institute/ASSDA (Aust)

Topic 3 – Corrosion Modelling & Prediction | Chair: Thunyaluk (Kod) Pojtanabuntoeng Modelling of localised corrosion under atmospheric conditions in the presence of galvanic coupling

Rob Kelly, University of Virginia (USA)

Analysing the past to predict the future: Corrosion modelling and prediction

Aaron Sudholz, BAE Systems (Aust)

Topic 4 – Cathodic Protection | Chair: Brian Martin On the mechanism of cathodic protection Markus Buchler, Swiss and its implications on criteria including Society for Corrosion AC and DC interference conditions Protection (Switzerland) Networking Cocktail Function & Exhibition Dinner | Awards Presentation to Boulton, Hinton, Kinsella, Martin, Moore & Nicholas

Session

Speaker

Topic 4 – Cathodic Protection (continued) | Chair: Brian Martin The true meaning of cathodic protection measurements

Bruce Ackland, Bruce Ackland & Associates (Aust)

Topic 5 – Oil & Gas | Chair: Brian Kinsella Corrosion modelling for Oil & Gas applications

Srdjan Nesic, Ohio University (USA)

Topic 5 – Oil & Gas (continued) The Battle against Microbiologically Influenced Corrosion: Lessons learned and challenges for the Future

Laura Machuca, Curtin University (Aust)

Recent advances in investigating chemical inhibition of mild steel corrosion

Katerina Lepkova, Curtin University (Aust)

Topic 6 – Water & Wastewater | Chair: Greg Moore Corrosion can be where you least expect it: Degradation of plastic pipes in the water industry

Graeme George, Queensland University of Technology (Aust)

Corrosion of cast iron water mains – Developing models for long-term prediction

Rob Melchers, University of Newcastle (Aust)

Topic 6 – Water & Wastewater (continued) | Chair: David Nicholas Advances in condition assessment of Water Industry Assets Networking Farewell Cocktail Function

Paul Vince, WSP (Aust)

Australian Welding: June 2019

18

Electrical Safety Hazards in Welding Electricity is one of the most important power sources used every day. But, if it is not properly managed, electricity can cause serious injuries and even death. According to Safe Work Australia, between 2003–2015: 142 workers died as a result of contact with electricity (an average of 11 workers each year); 87% of these deaths happened during the installation of electrical infrastructure; and almost half of worker deaths occurred in the construction industry. The risks associated with using electricity must be controlled and the control measures clearly communicated, particularly in welding.

Safety is a critical consideration for any welding project. Arc welding is a safe occupation when proper precautions are taken. But, if safety measures are ignored, welders face an array of hazards which can be potentially dangerous, including electric shock and electrocution.

Exposure to electromagnetic fields can also be a potential hazard for workers with some medical conditions. Exposure can lead to severe injury or death, either from the shock itself or from a fall caused by the reaction to a shock.

Electric Shock According to Safe Work Australia’s Welding Processes Code of Practice, electric shock or electrocution can occur through direct contact with an electrode, live parts, a work piece, or through contact with a device such as an unearthed cable or tool. The risk of electric shock can be exacerbated by moisture and high humidity.

Control Measures The following measures should be employed when welding: • Use fully insulated electrode holders. The holder should never be dipped into water to cool, or be placed on conductive surfaces • Prevent the contact of electrodes

• • • •

or welding wire with bare hands when in the holder or welding gun (wear dry welding gloves), and make sure that holders or welding guns are never held under the armpits Prevent holders or electrodes from coming into contact with any other person Check working areas do not have any potentially live structures, components or wet areas Install an RCD Inspect all equipment to check that it is in good condition prior to use, including power switches, terminals, connections, cables and insulation

The working environment should be designed to minimise the risk of electric shock. For example, areas where welding is undertaken should be insulated and air-ventilated to prevent workers from perspiring, as perspiration is a conductor of electricity. Table 1 (opposite) lists several ways to minimise the risk of electric shock when welding.

Electromagnetic Fields Electric arc welding produces strong electric and magnetic fields close to the power source and around the current-carrying cables.

Electromagnetic fields can disrupt the operation of pacemakers,

permanent defibrillators or other medical devices which could cause the heart to stop or slow down. A worker will not be aware of a magnetic field hazard unless a heart pacemaker or other device is behaving irregularly.

Electromagnetic fields can also occur wherever power is being generated and near transmission lines. Before working in these types of areas, check with the electricity supply company to make sure work will not affect the supply of power, or if there are any special precautions welders need to take.

Control Measures The following measures should be employed when welding: • Use barriers to isolate people who are not directly involved in the welding process • Use signs to indicate that there are strong electromagnetic fields to alert people to risks • Ensure workers do not stand close to the power source or drape the welding cable around their body • Workers with pacemakers or other susceptible devices should substitute work that involves exposure to electromagnetic fields for another type of welding

Inside the Industry: Health & Safety

1919

Further Information Further guidance about electrical safety is available via: • Safe Work Australia’s Code of Practice: Managing Electrical Risks at the Workplace • Weld Australia’s Technical Note 22: Welding Electrical Safety • AS 1674.2: Safety in welding and allied processes – Electrical • AS 60974.1: Arc welding equipment – Welding power sources (Sections 11 and 13)

•

process, such as performing oxy-fuel welding instead of electric arc welding Seek medical advice before exposing a worker wearing such a device to welding related electromagnetic fields

Inspect, Test and Tag Inspection helps identify damage, wear and electrical faults. Regular inspection and testing ensures that electrical faults and deterioration are detected at an early stage, thus allowing rectification before an injury occurs. Inspection and testing must

be undertaken by a competent person, which, depending on the jurisdiction, may be a licensed or registered electrician or a licensed electrical inspector. Inspection and testing assists business owners and employers to meet their workplace health and safety requirements.

Table 1: Procedures to minimise the risk of electric shock Work Phase

Procedure •

Before Welding

• • •

During Welding

After Welding

• • • • • •

Become familiar with the procedures and emergency plans for your workplace and make sure you understand how to perform welding activities safely and what you need to do if a person suffers an electric shock Do not work in an environment that is damp, humid or wet, or where a you may be exposed to rain Check that all equipment is well maintained. For example, conductors should be well insulated to prevent contact with live conductors Install shut down mechanisms such as fuses, low voltage safety switches or residual current devices on equipment

• • •

In hazardous working environments, avoid working alone Use an appropriate hazard reducing device Avoid leaning against the material or structure during welding Wear personal protective equipment including welding gloves and rubber insulated shoes Where practicable, stand, lay or sit on non-conducting material while carrying out welding Always keep the welding machine terminals and cable connections clean and tight and only use welding cables that are fully insulated for their entire length Minimise perspiration by allowing time to dry equipment during breaks, changing clothing, gloves, using ventilators and using an air fed welding mask Do not change electrodes by hand whilst simultaneously touching the bench or the work piece Do not connect or change welding cables before switching off the power at the mains Where devices have an earth (ground) connection, it is essential it is connected at all times

• •

Check the condition of all equipment after use Report any defects

•

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Australian Welding: June 2019

An Industrial Evolution at NMW 2019 Held at the Melbourne Convention & Exhibition Centre, National Manufacturing Week 2019 cemented its status as one of the focal points of Australia’s manufacturing industry. The 20th edition of the event showcased manufacturing’s industrial evolution—being spurred on by Industry 4.0 and advanced manufacturing processes—throughout the conference sessions and the exhibition floor.

This year’s event focused on supporting manufacturing’s continuing evolution to a high-tech, highly integrated and innovative industry, while providing the latest expert insights, industry research and technology to generate even greater momentum.

The recent growth and momentum of Australia’s $383.2 billion manufacturing industry—which is projected to achieve a growth rate of 1.2% over the next five years to $405.8 billion in 2023-2024— was reflected in the strong visitor attendance and atmosphere of this year’s event. Over 11,000 visitors attended NMW 2019.

Robby Clark, Exhibition Director of National Manufacturing Week, said the strong industry response from manufacturers, especially those looking to continue or kick-start their evolution to advanced manufacturing processes and integration of Industry 4.0, created a platform for future manufacturing events in 2020 and beyond. “National Manufacturing Week in 2019 focused on supporting

“

The recent growth and momentum of Australia’s $383.2 billion manufacturing industry was reflected in the strong visitor attendance and atmosphere of this year’s event.

Over 11,000 visitors attended NMW 2019.”

manufacturers in their adoption of high-tech solutions, advanced manufacturing processes and integration of Industry 4.0 into their operations. With visitors, exhibitors and conference speakers’ eagerness to celebrate recent successes and generate further momentum characterising this year’s event.”

“We’d like to thank all of our sponsors, partners, conference speakers, exhibitors – both local and international – for their incredible and long-standing support of NMW. We’re proud to be able to support the manufacturing industry in Australia, a key sector of our nation’s economy, and look forward to continuing this support in 2020 with the inaugural Advanced Manufacturing Expo in Sydney,” said Clark.

The Welding Technology Zone The Welding Technology Zone at NMW offered manufacturers the latest new technology, advanced manufacturing products and welding solutions, as part of an exhibition featuring over 200 leading industrial suppliers. Welding technology exhibitors at NMW 2019 included Austedan Fabrications, BOC, Ensitech, Gullco, Kemppi Australia, Leussink Engineering, Lincoln Electric, Supagas and Tesuco.

The other zones at NMW this year included: Automation and Robotics, Engineering, Industrial Internet of Things, Safety, and Manufacturing Solutions.

Weld Australia’s Advanced Welder Training Hub was a key feature of this year’s exhibition,

Inside the Industry: National Manufacturing Week

showcasing the innovative new ways of training tradespeople in today’s digital world. The Advanced Welder Training Hub highlighted how augmented and virtual reality training systems offer an effective training method that allows students to learn at their own pace, while becoming faster, better and safer. This new interactive technology training method provides welding novices, and those up-skilling their knowledge and techniques, to benefit from gaining hands-on experience in a safe and controlled environment. As a more advanced training system, it also changes the learning experience for future welders looking to acquire the skills and self-confidence they need before moving into real world workshops and operations.

WorldSkills Australia National Manufacturing Week also played host to two WorldSkills Australia competitions, in Mechatronics and Welding, with the aim of discovering the nation’s next generation of skilled champions.

Both the WorldSkills Mechatronics and Welding competition ran simultaneously across the three days of NMW, with each area facilitating three one day competitions. The Welding competition was assessed on strict industry standard codes to ensure a high level of quality was obtained and covered a range of welding processes and materials.

WorldSkills Australia’s regular competitions celebrate excellence while creating opportunities for young people, who are passionate about their skills and training, to test themselves against their peers.

Conference Sessions The NMW 2019 conference sessions, spread across the Industry 4.0 Theatre and Connected Manufacturing Theatre, were developed in partnership with Austech and the Advanced Manufacturing Growth Centre (AMGC). Featuring over 90 industry leading expert speakers and panellists, the conference was opened by Dr Jens Goennemann, Managing Director of AMGC, followed by a welcome from the Hon Martin Pakula MP, Minister for Jobs, Innovation and Trade.

Images clockwise from right Michael Pitt (National Business Development Manager, Weld Australia) demonstrates a welding simulator.

Kemppi Australia demonstrate their technology to NMW attendees.

One of Robot Technologies-Systems Australia (RTA) Kawasaki robots delights NMW 2019 attendees.

A BOC demonstration at NMW 2019.

NMW attendees inspect one of Lincoln Electric’s welding robots at NMW 2019.

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22

Chief Scientist, Dr Alan Finkel The keynote speech delivered by Australia’s Chief Scientist, Dr Alan Finkel AO was entitled Reversing the Flow: What Manufacturing Can Teach AI. The concept of Artificial Intelligence (AI) is not new.

It has been promised since the early 1950s. What is new in 2019 is the challenge of responsible deployment, and manufacturing is a focal point in the global debate.

Dr Finkel made the case for AI developers to learn from industrial revolutions past and prioritise quality assurance – with close regard to the systems manufacturers have evolved. Dr Finkel focused on the challenge of responsibly deploying AI in manufacturing, and how to integrate with manufacturers evolving systems.

According to Dr Finkel, “Industry 4.0 is the era where Artificial Intelligence has ascended. This is coupled with the rapidly accelerating progress of the Internet of Things, additive manufacturing, nanotechnology, biotechnology, materials science, energy storage, digitalisation, and embedded computing. We’re entering an era with AI at its core.”

The Industry 4.0 Theatre The Industry 4.0 Theatre program offered attendees the latest research and expert opinion on the future impact of Industry 4.0 on their businesses. Expert speakers discussed advanced processes, designs and technologies designed to help local manufacturers stay ahead of the game.

Dr Mark Goodsell (Director NSW, AiGroup) spoke about Australian manufacturing in 2019 and beyond.

According to Dr Goodsell, the manufacturing industry has been one of the quiet achievers of the Australian economy in the last few years in terms of output, employment, exports and even profits. It has a bright future given the right policy settings and a sound grasp of its prospects by the nation’s leaders and the community. It will also need a continued evolution in the mindset of those who invest, manage and work in it.

Australian Welding: June 2019

Dr Nico Adams (Director, Factory of the Future, Swinburne University) discussed Operationalising Industry 4.0 in Manufacturing. According to Dr Adams, this requires a three-step process: articulate the business outcomes; define the value drivers; and define the technology required to deliver the value drivers.

Dr Adams encouraged Australian manufacturers to ‘be a scientist’ (use rapid ideation, prototyping and testing to experiment) and to ‘de-risk’ by tapping into low cost resources such as university collaborations and leveraging innovation support.

Anna Reid (General Manager for Manufacturing, Asahi Beverages) and Dr Lucy Liu (Head of Supply Chain Academy Manager, Asahi Beverages) spoke about strategically integrating people capability with emerging technologies to build a smarter value chain.

Des Watkins (Managing Director, Watkins Steel) discussed the transformative power of digital technology, showcasing the journey of Watkins Steel. Traditionally, Watkins Steel’s services included steel detailing, fabrication and installation. However, over the years they have implemented changes that have seen a significant shift from labour-based to technologybased processes. Since developing a digital work flow, Watkins Steel has significantly increased the efficiency and accuracy of the steel fabrication and installation process and has received international recognition for their innovative practices.

Images from the top Dr Jens Goennemann (Managing Director, AMGC) opens NMW 2019.

Dr Alan Finkel (Chief Scientist) gives the keynote presentation at NMW 2019.

The Hon Martin Pakula MP, Minister for Jobs, Innovation and Trade welcomes NMW 2019 attendees.

The Working Together: Collaboration in the Age of Industry 4.0 panel.

Des Watkins (Managing Director, Watkins Steel) gives a presentation.

Inside the Industry: National Manufacturing Week

23

AMGC Launches Manufacturing Academy at NMW The Advanced Manufacturing Growth Centre (AMGC) launched its new Manufacturing Academy at NMW 2019.

Designed to deliver free and exclusive industry insights on how to increase commercialisation and capitalise on innovation, the Manufacturing Academy offers industry over 500 pages of in-depth research, interviews with more than 20 Australian manufacturers, and over 50 hours of video content, distilled into eight inspirational, informative modules.

According to Jens Goennemann (Managing Director, AMGC), “AMGC has produced pages and pages of respected research.

However, in practical terms, it is

difficult for Australian manufacturers to find the time to read, and then apply, these rich research outcomes to their daily business operations. We needed to find a way in which to make these insights more accessible—Manufacturing Academy has been created to achieve exactly that.”

“The entire AMGC team—including all State Directors—was involved in the design and delivery of the Academy, ensuring superior quality, depth and breadth of information is included in its eight modules.

A turnkey learning management system, the Academy is flexible, agile and infinitely scalable, allowing for seamless incorporation into the operations of Australian manufacturing businesses.”

“We have distilled our research insights, supported by tangible evidence of project examples, into a concise, easily digestible format. Australian manufacturers can delve into real-world examples and discover— from their peers— what has delivered successful commercialisation and innovation outcomes.”

“Australian manufacturers will learn how others have found success, why their process works, and how to begin incorporating similar processes within their own business,” said Goennemann.

For further information or to access the Manufacturing Academy, visit: https://www. manufacturingacademy.org.au

Right: The launch of the Manufacturing Academy at NMW 2019.

Panellists (L to R): Ty Hermans (Managing Director, Evolve Group), Ross George (Director, Austeng), Lyn George (Director, Austeng), Chris Bridges-Taylor (B&R Enclosures), and Sean Hyde (Sales Development Manager, iOrthotics).

Sharon Robertson (CEO, IBSA Manufacturing) emphasised how a skilled workforce is a priority for governments and businesses alike, as economies and organisations continue to respond to industry changes. Robertson’s presentation examined what industry is saying about the changing nature of the workforce; how vocational training can prepare employees and future generations to thrive in shifting manufacturing landscapes; and the environment needed to enable future skills development.

The program also featured several informative and engaging panels, including the AMGC’s Innovation Stories Series. Attendees had the opportunity to hear from Australian manufacturers as they shared their innovation success stories in research and development,

international engagement, collaboration, commercialisation, product diversification and more.

Panellists included Monique Filer (CEO, b.box), Dr Matt Dingle (Managing Director, FormFlow), Professor Michelle Gee (RMIT), and Dr Roger Lumley (Senior Technical Specialist, AW Bell).

The Trials and triumphs of Australian machinery manufacturers panel was well received by delegates. Hosted

by Peter Roberts (Editor, @AuManufacturing news), Grant Anderson (Director, Sutton Tools), Alf Taylor (CEO, TNA Solutions), Byron Kennedy (CEO, SPEE3D) and Barry Hendy (Managing Director, ADDE) discussed how to succeed as an Australian producer of manufacturing equipment. The panel covered a range of topics including access to finance, remoteness form markets,

and management skills.

The Working Together: Collaboration in the Age of Industry 4.0 panel also proved popular. This Victorian Government-led panel discussed opportunities and challenges for collaborative innovation within the Australian manufacturing industry.

It delved into initiatives underway in Victoria to strengthen links between industry and universities, and to support collaborative research and development. Panel members included Tim Piper (Head of Victoria, AiGroup), Anna Reid (General Manager for Manufacturing, Asahi Beverages), Professor Bronwyn Fox (Director, Manufacturing Futures Research Institute), and David Latina (Deputy Secretary – Jobs, Innovation & Business Engagement, Department of Jobs, Precincts and Regions).

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Australian Welding: June 2019

New Technology Revolutionising Welder Training Geoff Crittenden (CEO, Weld Australia) spoke on the topic of New Technology Revolutionising Welder Training. According to Crittenden, the annual growth rate of the welding industry in 2016-2017 was 0.2%.

While not a strong growth rate, at least the industry was profitable.

In 2018-2019, industry growth has dropped, but profits have increased.

“So, welding is not exactly a massively successful industry at the moment. Four years ago, when I took over the role as CEO of Weld Australia, I was convinced that there would soon be no welding industry in Australia because of the amounts of imports that we were facing. But, you can see that we have just about pulled ahead of the game,” said Crittenden.

“In 2005-2015, Australia went from having 5% imported steel to 30%. A lot of this imported fabricated steel was coming into the mining industry in Western Australia. That’s why, when I joined Weld Australia four years ago, I was concerned about our future.”

“Since 2015, imported fabricated steel has reduced to 17% of the market share. But, honestly, the trend is back up again. With the three mines currently being built in Western Australia, I wouldn’t be surprised if these numbers head back up, closer to 30%,” said Crittenden.

“One of the biggest challenges the Australian fabrication industry is facing is the welding skills base. In a recent survey, 75,000 tradesmen identified as being welders. Of these, just 10% actually hold a welding qualification.”

“One of the biggest challenges the Australian fabrication industry is facing is the welding skills base. In a recent survey, 75,000 tradesmen identified as being welders. Of these, just 10% actually hold a welding qualification. Not surprisingly, when it comes to completing a welding coupon—an AS/NZS 1554 full penetration fillet weld—the failure rate is 80%. For a weld that complies with ISO 9606, the failure rate is nearly 90%.”

“Welder training in Australia is outdated and underfunded. The TAFE welding course and curriculum was last amended in 1995 and bears no relation to what is actually required by industry. In fact, in terms of welder training, nothing much has change in over 130 years. Until now.”

Crittenden explained that old-school welder training techniques are being replaced with innovative methods that rely on augmented and virtual reality systems. “Augmented reality and virtual reality welding simulators are fantastic technology. But, the technology is not the final solution.

It does not replace getting into a welding booth and striking an arc.

But it takes a lot of cost and time out of the training process.”

Augmented and virtual reality training systems are student-focused, allowing individuals to progress at their own pace. Students can learn welding procedures and techniques through a more interactive training method, gaining hands-on experience in a controlled, safe environment.

Above: Geoff Crittenden (CEO, Weld Australia) presents at NMW 2019 on the New Technology Revolutionising Welder Training.

Augmented reality transforms training from boring theory and text books into high-quality interactive experiences that capture the imagination.

With zero risks involved, apprentices can respond to realistic scenarios without pressure or fear of injury.

Augmented and virtual reality training is enabling future welders to acquire the skills and the self-confidence they need before moving into real-world workshops.

Adopting Technology: The Pain and the Gain Weld Australia hosted a panel that explored the technologies revolutionising Australia’s manufacturing industry, the challenges that the sector faces, and the role that digitalisation can play in addressing them. Panelists included Chris Brugeaud (CEO, SSS Manufacturing), and Des Watkins (Managing Director, Watkins Steel).

According to Watkins, when it came to digitising Watkins Steel, “We didn’t have a choice. We were one of 400 steel fabricators—all competing on manhours per tonne and price.

So, we had to be different. Everyone says they’re different—but we had to dramatically and drastically change the traditional way we did things, to make sure we were different. What

Inside the Industry: National Manufacturing Week

Above: The Weld Australia Panel at NMW (L to R): Geoff Crittenden (CEO, Weld Australia), Chris Brugeaud (CEO, SSS Manufacturing), and Des Watkins (Managing Director, Watkins Steel).

I found was, the staff that were with me were hungry for change as well.

We’ve embraced a culture of change and momentum.”

“The first catalyst was that we had our senior management team do a design innovation workshop.

We talked to a heap of different customers to work out what their pain points were. Whilst they all wanted their steel suppliers to be on time and on budget, everyone had a different approach. What we found was, by visiting companies overseas and doing workshops, we discovered we could really change things up.”

“We’re now more of a design consultant and can add value to builders in areas that we weren’t previously able to.”

“What we’ve found is that for every line of robotics we put on, we increase our staff by 10. For the robotic welders we’re currently looking at for in-line beam welding, our modelling shows we’ll be looking at an increase of 25 staff. We’ve doubled in size in the last three years,” said Watkins.

For Brugeaud, finding that point of difference within a crowded market was equally as important, “We have the capacity to automate the whole chain. For instance, we’re assisting our clients to automate the drawing process. Previously, in medium-rise construction, it was an 8 to 10 week design effort. We’ve cut that back to about two weeks.”

“One of the dangers with a greenfield opportunity is that we sought to control everything.

We went in wanting all the IP to be ours, we wanted to own all the technology. We even started designing and building our own robotics. Fundamentally, that is not the way to go. You can spend your R&D effort in much better areas. It’s about collaborating with partners that have the capability—we have Bosch and Farrow as collaborative parters. We lean on the capabilities of our partners so that we can focus on our core capabilities and what we can commericalise,” said Brugeaud.

Collaborating with other companies has also been essential to both Watkins Steel and SSS Manufacturing. “Up until a few years ago, everyone was a competitor.

Everyone was very secretive with what they were doing. But then I realised, the size of the market—just in our local region of south-east Queensland—is $2 billion per year.

25

We have around 1% of the market.

So, by working with other steel fabricators, some of them actually became our biggest customers.

They also have capacity in skills that we don’t have. By leveraging off someone else, it gives you greater value,” said Watkins.

According to Brugeaud, “Some of our core customers are fabricators as well. The fabricators initially responded with: ‘No, you’re our competitor, we don’t want to deal with you.’ Until they realised that as a combined, collaborative offer, there was much more strength. There was more capability together in the joint organisations, than going it alone.

There is no doubt that the ability to collaborate is key to success.”

“What we’ve found is that for every line of robotics we put on, we increase our staff by 10.

For the robotic welders we’re currently looking at for in-line beam welding, our modelling shows we’ll be looking at an increase of 25 staff.

We’ve doubled in size in the last three years.”

NATIONAL 26

Australian Welding: June 2019

MANUFACTURING

SUMMIT 2019

SKILLS FOR THE FUTURE REGISTER NOW 22 AUGUST 2019 THE AUSTRALIAN SYNCHROTRON MELBOURNE Australia is facing a significant shortage of skilled, qualified trades workers. Without action, the nation will be unable to meet future demand on major projects in industries as diverse as defence, shipbuilding, aerospace, infrastructure, rolling stock, and resources.

Despite the manufacturing sector experiencing a period of growth, industry participants continue to cite workforce capability and availability as a critical constraint. This constraint is the basis of the 2019 National Manufacturing Summit’s theme: Skills for the Future.

Register now: https://manufacturingsummit.com.au

NATIONAL MANUFACTURING SUMMIT 2019 CO-SPONSORS

https://manufacturingsummit.com.au | 02 8748 0130 | events@weldaustralia.com.au

Inside the Industry: National Manufacturing Week

27

2019 Endeavour Award Winners Announced The 16th annual Endeavour Awards saw leaders from the Australian manufacturing industry celebrate their success at the Arts Centre Melbourne in May. Sponsored this year

by Weld Australia, the Endeavour Awards are presented annually by Manufacturers’ Monthly, supported

by National Manufacturing Week.

Recognised as the premier Awards program within the manufacturing industry, the evening is a chance to celebrate the many successes within Australian manufacturing.

Manufacturer of the Year: Australian Munitions (Thales Australia) Australian Munitions is one of the largest suppliers of explosive ordnance to the Australian Defence Force, delivering ammunition, propellants, and explosives.

Technology Application Award: RMIT University, Advanced Manufacturing Precinct – Additive Manufacturing of Cutting Tools The Advanced Manufacturing Precinct is a $35 million technology and research facility at RMIT University. The project is delivering new tooling solutions through the use of additive manufacturing technology.

Environmental Solution of the Year: Australian Munitions – Recycling of Energetic Waste Australian Munitions treated 170 tonnes of nitrocellulose waste,

Far Right: Geoff Crittenden (CEO, Weld Australia) speaks at the Endeavour Awards ceremony.

Right: Geoff Crittenden (CEO, Weld Australia) presents the Outstanding Start-up Award to Prime Creative’s Syed Shah on behalf of Persistent Aerospace at the Endeavour Awards.

stockpiled at its Mulwala site, in an environmentally compliant manner using a safe, cost-effective process.

Outstanding Start-up Award: Persistent Aerospace Persistent Aerospace is a Western Australian manufacturer of militaryspecification drones. Their tethered unmanned aerial vehicle is able to remain airborne carrying up to 45kg almost indefinitely. Weld Australia was proud to sponsor this award category.

Global Supply Chain Integration of the Year: iOrthotics iOrthotics is one of the first orthotic manufacturers in the world to implement 3D printing technology at large-scale, supplying products throughout Australia and exporting to the US, the UK, New Zealand, Canada, and China.

Best Industrial IoT Application: Vivid Technology – MATRIXX Intelligent IoT Lighting Platform Vivid Technology’s 4.0 MATRIXX system delivers up to 90% energy efficiency savings and carbon reductions. It captures and converts smart data to drive efficiencies and provide intelligence.

Safety Solution of the Year: HMS2000 Mini Loader The HMS2000 Mini Loader was designed for low‐access, confined spaces and hazardous areas.

Remote controlled, the HMS Mini Loader can be operated without the need for expensive shutdowns. This ensures productivity is maintained, without compromising safety.

Excellence in Manufacturing Skills Development: Ai Group and Swinburne University – Industry 4.0 Higher Apprentice Program In collaboration with Siemens, the AiGroup and Swinburne University established the first Industry 4.0 Higher Apprentice Program. The Program helps prepare students for emerging jobs, and combines elements of an apprenticeship with a higher education degree.

Australia Industrial Product of the Year: REDARC Electronics – RedVision RedVision by REDARC is a Total Vehicle Management System which allows the control and monitoring of multiple on-board devices in a 4WD, caravan, camper trailer, or motorhome in one place.

Most Innovative Manufacturing Company Award: Andrew Donald Design Engineering Andrew Donald Design Engineering (ADDE) is a specialist in industrial automation solutions. ADDE integrates a combination of robotics, custom machinery, tooling, sensors, and control systems to deliver unique manufacturing solutions.

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Australian Welding: June 2019

Master Steel Awarded ISO 3834 Certification Master Steel was founded in 1993 in the Gold Coast by an engineer-tradesman duo. The workshop was initially built for large fabrication, with 2,400m2 of usable space and the ability to accommodate 25m transport vehicles. In recent years, Master Steel acquired the help of Gabriel Dio – a mechanical engineer by background – in the role of managing director. The company has since moved towards niche technical fabrication, recruiting a certified welding supervisor to control quality and recently attaining certification to IIW MCS ISO 3834:3 Quality requirements for fusion welding of metallic materials.

Quality, Capability and Expertise According to Gabriel Dio (Managing Director, Master Steel), “Our mission as a company really is to restore quality, capability and expertise to the Australian manufacturing sector.

The entire reason we established the business is because we believe Australian manufacturing is definitely capable of providing a level of quality that complies with the strictest global standards. Australia was a leader within the global manufacturing industry in the 1990s—when manufacturing was the primary industry in Australia—there is no reason that we cannot be again.”

“On a more local scale, our mission is to enhance the already solid reputation that the Gold Coast has for quality fabrication. In our experience and understanding of the local market, quality fabrication is

more synonymous with Brisbane— fabrication work for local projects is often shipped up to Queensland’s capital. I believe we can help raise the level of competency within the local region, and therefore keep fabrication work for local projects, local,” said Dio. A Range of Services Master Steel provides fabrication and manufacturing services, and assembly of complex steel components for the construction, commercial, heavy and public sectors. From structural steel to test bed machinery – no project is too complex. Their services include: weld traceability and compliance; manufacturer’s data reports; conformance and nondestructive testing; post-weld heat treatment and other post-processing requirements; and documentation

Images courtesy of Warner Bros. Movie World on the Gold Coast and Village Roadshow Theme Parks.

control including ITP sign-off.

“Our primary trade is steel manufacturing and fabrication to a high quality. We also engineer, design and manufacture our own products, primarily lifting and inspection equipment. We also perform steel erection and installation services for the construction industry,” said Dio. “Primarily, we serve the commercial and industrial markets. And, with the help of Weld Australia and our recent certification to ISO 3834, we are looking to move into the public and government sectors as well.”

Complex Steel Projects Master Steel’s focus on quality allows the company to cater to exacting requirements on complex steel projects for meticulous clients.

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Member Profile: Master Steel

Having specialised in structural steel for over 20 years, Master Steel has worked on everything from theme park rides, public signs, and beach front villas, through to residential mansions, and childcare centres.

Master Steel has worked on several of the Gold Coast theme parks.

The company was commissioned for the new thrill ride at Village Roadshow Theme Parks’ Movie World: Doomsday Destroyer. With a height of 21m, the ride features a ‘Suspended Twin Hammer’.

Master Steel supplied and installed the circular component to which the hammer is attached. They also provided the structural steel components for the Wet’n’Wild Kamikaze water slide. The ride has a vertical drop of 11m at a steep 70 degree angle, and reaches speeds of up to 50km per hour.

“One project that I am particularly proud of is the Joker sign on the DC Rivals HyperCoaster at Warner Bros.

Movie World on the Gold Coast. The sign is 13m tall and sits over 70m high, making it visible along the Gold Coast’s major highways,” said Dio. “We also recently completed a logistics warehouse in Eagleby, Brisbane, a Sikh Temple in Helensvale, and seven wastewater processing tanks that will process contaminated water from derelict mines in regional Queensland. Our experience is quite diverse.”

ISO 3834 Certification In April 2019, Master Steel was awarded certification to IIW MCS ISO 3834:3 Quality requirements for fusion welding of metallic materials.

According to Dio, the decision to embark upon the certification process was an easy one. “A lot of Australia’s manufacturing is no longer completed locally. This is simply not acceptable. Australia has qualified people—experienced people—and the technology and capabilities to be a global hub for quality steel fabrication. This was evident in World War Two when the American and Allied Forces relied on BHP in Newcastle to push the allied war

machine forward, right through to the booming manufacturing industry of the 1980s and 1990s. Since then, a lot of this experience and capability has been lost, with increasing importation of overseas fabrication.”

“We wanted Master Steel to become ISO qualified to help ensure that Australia can deliver fabricated products and services at a global quality Standard.”

Above (Left): Master Steel provided structural steel for a Sikh Temple in Helensvale, Queensland.

Above (Right): Master Steel is presented with ISO 3834 certification.

L to R: David Walsh (Welding Coordinator, Master Steel), Gabriel Dio (Managing Director, Master Steel), Bianca Dio (Secretary, Master Steel) and Paolo Corronca (Qualification and Certification Manager, Weld Australia).

Far Left: Master Steel fabricated the 13m high Joker sign on the DC Rivals HyperCoaster at Warner Bros. Movie World on the Gold Coast.

“Personally, I want Australia to be known as a country where you purchase quality products from – one way to provide clients with peace of mind is through ISO certification,” said Dio.

“We achieved certification through the help of Weld Australia—they explained what the requirements were and had confidence in us as a company that we would succeed. It was not simply a tick-box exercise.

It was a really beneficial process that has improved our operations in so many ways.”

“The actual certification process itself was extremely positive. Before we started, we weren’t aware of what the process involved, and we still went from zero to being certified in a relatively short amount of time. This was testament to Weld Australia’s staff, particularly Paolo Corronca (Senior Welding Engineer - Qualification and Certification Manager) and Abhishek Trivedi (Senior Welding Engineer).”

“If you are considering certification for your business, my first tip is not to be daunted by the technical requirements. Instead, pick up the phone and talk to Weld Australia.

The Weld Australia team is extremely helpful, and will help you understand the requirements. Weld Australia will help you protect your business and build the right assurances into your processes,” said Dio.

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Australian Welding: June 2019

Welding Sparks An International Career Myles Considine started his welding apprenticeship in 1981 in Melbourne. Since then, his welding career has seen him travel throughout Australia, Asia, the United States and Europe. He toured with Cirque Du Soleil during their Alegria and Saltimbanco world tours, tasked with redesigning their mobile welding fabrication workshop. Myles has worked with some of the world’s largest organisations from Monadelphous and Worley-Parsons through to AECOM and John Holland. Today, he is a Senior Field Welding Engineer, employed by Bechtel to assist in the construction of a Vitrification Plant in the United States. According to Myles, with the right experience and certifications, a career in welding really can take you anywhere in the world. Myles provides some insights into his career below.

Describe your current job.

I am currently employed by Bechtel as a Senior Field Welding Engineer at the Vitrification Plant in Washington State, USA. The ‘Vit Plant’ is being constructed to stabilise the radioactive waste left over from the production of plutonium during World War II and beyond.

My duties include weld inspections, welding advice and troubleshooting of welding issues in conjunction with the relevant engineering departments that reside on site. From both a welding and weld inspection perspective, this project includes pipework (ASME B31.3 and B31.1), tanks and vessels, (ASME VIII and API 650), structural steelwork (AWS D1.1 and AWS D1.6), and rebar welding (AWS D1.4). The concrete walls at the Vitrification Plant can be as thick as 1.8m, filled with rebar that is up to 4cm in diameter, fullpenetration joints are mostly used when welding the rebar joints. Some of the vessels we are currently installing weigh as much as 160 tons, so detailed lifting plans are required before any heavy lifts.

We have engineering and construction teams comprised of personnel from both the USA and several other countries. So there are some very experienced people here. It is advantageous that some of the team members have worked on past nuclear projects as the Vit

Plant is also being constructed to Nuclear quality and safety standards.

Welders travel from all over the USA to complete ‘Gate’ weld tests.

These tests ensure they have the extremely high level of skills required to work as welders here. For pipe welders, their first five piping groove welds (three 6G tests then their first two production welds) are 100% volumetrically tested by either Radiographic Testing or Automated Ultrasonic Testing before they are cleared to work full time.

These multiple checks at every stage of construction ensure total confidence that nothing is missed.

As safety is a huge focus on this project, we have to ensure that any new personnel—who may not have previously worked with the stringent and detailed safety requirements that these large projects demand—have full awareness of the safety rules from day one. I spend most of my work day at the Vit Plant in the field, wearing a radio and conducting inspections.

On this project we use most welding processes, including SMAW, GTAW, Orbital GTAW, FCAW, GMAW, brazing, and thermite welding for our overhead crane rails. The piping that transfers the radioactive waste from the underground storage tanks to the processing facilities is of a double wall construction—basically a pipe within a pipe. This helps alleviate the risk of leakage into the environment. The outer pipe is also coated and wrapped, and both visual and volumetric Non-Destructive Examination (NDE) is applied to the inner and outer pipe via set hold points on the welding documents.

Where else have you worked?

I have worked for a number of companies, including Transfield, Monadelphous, Worley-Parsons, UGL, Fluor, Clough, AECOM, and John Holland. I’ve also had a variety of roles within the refinery world (both greenfield and shutdowns) including gas plants, power stations, offshore fabrication projects, military, petrochemical, fabrication shops, pipelines, mining, and the commercial HVAC industry.

There are many inspection hold points on our welded components, not only for our own in-house Bechtel inspectors, but also for the Washington State third party inspectors and the Federal Department of Energy inspectors.

To be honest, once you have been in this game for a while, a lot of the opportunities, from welding and quality assurance through to inspection, are word of mouth. I have always been lucky to be in the right place at the right time.

What has your career progression looked like?

After starting my apprenticeship

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Welding Sparks an International Career

at 16 years of age in 1981, I was a coded pressure pipe welder and pipefitter for approximately 25 years.

In 2005, I was offered a position by Transfield as a welding inspector on a refinery shutdown.

While working on a long hot camp job during the construction of a power station in the Northern Territory outback in the 1990s, I met a welding inspector who advised me that I should get into welding inspection as it had allowed him to travel the world and get paid good money to do it.

So, I enrolled at a college in Melbourne and began several years of night school—in addition to my full time welding day job—to gain my WTIA (now Weld Australia) Welder Certification to AS 1796 Certification of welders and welding supervisors Certificate 10, and Welding Supervisor to AS 2214 Certification of welding supervisors - Structural steel welding, as well as Certified Welding Inspector (CWI), and (SCWI) certifications. I also hold the American Welding Society (AWS) Certified Welding Inspector (CWI), IIW Welding Inspector certification, ASNT-SNT-TC-1a Personnel Qualification and Certification in Nondestructive Testing Level II VT (Bechtel certified), and AS 1796 welding Certificates 1 to 9.

I used to travel a lot for work, both within Australia and sometimes internationally, but not as much since I met my beautiful wife Lori and then we were very lucky to have our daughter Haylee. I was just away from home too much.

What inspired you to choose a career in welding?

When I was in high school I wanted a trade where I could be mobile and get a job anywhere. Welders, especially pipe welders and pipe fitters, always seemed to be in great demand. During my apprenticeship, (and on many jobs since then), I have worked with some extremely talented welders, boilermakers, pipefitters and fabricators, who have worked on landmark projects both in Australia and around the globe. I already had the travel bug but after

Image: Myles Considine in front of two 160 ton stainless steel vessels waiting to be lifted into position at the Vitrification Plant.

Image: Double wall transfer lines to carry radioactive waste material are to be encased in concrete and backfilled after welding and pressure testing is complete.

Image: Vessel skirts being welded in by boilermakers before 160 ton vessels are placed on top and welded down to skirt top plate at the Vitrification Plant

listening to their great travel stories, I realised the common denominator with all of them was not only did they have the welding and trade skills, but they also had the relevant certifications to match. So, if I wanted to be able to travel and get paid to do it, I decided that I had to try to better myself as a welder, and get some further education.

Who has inspired you professionally?

I would answer this by giving a lot of credit to the apprenticeship system itself and to all the instructors at the trade colleges worldwide. I was a 16

“

I realised the common denominator with all of them was not only did they have the welding and trade skills, but they also had the relevant certifications to match. So, if I wanted to be able to travel and get paid to do it, I decided that I had to try to better myself as a welder, and get some further education.”

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year old with a bad attitude when I began my apprenticeship and I know that I was provided with a lot of good direction from both the college trade instructors and the tradesmen I worked with when I was young.

I definitely recognise the same excellent value of the apprenticeship system here in the USA as in Australia; the younger tradespeople have some great guidance and direction for the four or five years of their apprenticeship and, like me, they will be shaped by this for the rest of their lives both on the job and in their personal lives.

What is the best project you’ve worked on to date? Why? I would say my current project; the Vitrification Plant would be one of the largest, and the most important as far as what is being completed

Australian Welding: June 2019

here for the future. This project has the most varied scope I have ever experienced in relation to the range of materials welded (carbon, stainless,AL6XN, hastelloy, and inconel) and equipment installed, as well the range of piping, vessel and structural codes involved.

There are so many components that make up this project, I never get stuck doing the same thing or inspecting the same equipment every day. I enjoy working here in the field, helping to solve both welding and quality assurance and control issues when they arise.

This project definitely puts inspectors and quality assurance and control types under the microscope every day. There is no going back to fix or rework components later on this project due to the high radioactivity

and other associated dangers to both workers and the public when this project becomes operational.

You’ve worked with Cirque Du Soleil in the past. Can you tell us a bit about this experience?

Initially, I was employed by Cirque Du Soleil to travel to New Zealand before the start of the Alegria world tour. I was tasked with helping to redesign their mobile fabrication workshop so that welding and fabrication could be completed inhouse. Previously, their welding and fabrication work was outsourced and was very expensive. Plus, due to the constant travel to different countries, the weld quality could not be guaranteed.

Not only was there lot of structure transported during a tour that required repairs or replacement,

Left: Myles Considine undertakes inspections at the Vitrification Plant. The inner pipe is AL6XN, while the outer pipe is 316L material.

Middle (Top): GTAW welding of the outer Clamshell pipe fitting.

Middle (Bottom): Local 598 union pipefitter welding a 3-way valve into a process line using manual GTAW. Right: Completed inner pipe using orbital GTAW; outer pipe being bevelled before installing and welding the twopiece outer Clamshell pipe fitting.

Welding Sparks an International Career

repairs were also required on pressure equipment such as mobile, self-contained HVAC and boiler plant—sometimes, more than 80 semi-trailers were used for transport.

I was given a budget to procure some new welding machines and associated equipment to allow for high quality GTAW/SMAW capability, so we then had GTAW, SMAW, FCAW and GMAW processes. I then travelled with the tours for a while throughout Australia, Asia, the USA, then Europe and basically repeated the introduction of the welding equipment to the mobile workshops on each tour to allow for immediate in-house welding repairs and fabrication while at the tour site.

The job was always interesting, sometimes crazy, but there was always a daily requirement for welding inspection of equipment, and the decision whether to repair or replace. The Cirque Du Soleil crew were great and I met some wild circus people from all around the world. We usually stayed at the best hotels and visited cities such as Sydney, Singapore, Madrid, Bilbao, Brussels, and more; sometimes staying in these cities for months.

One of the strangest project requests I had was during the Saltimbanco tour: to fabricate and weld a rigging space frame for the ceiling of the Royal Albert Hall in London to rig some heavy equipment for the Cirque Du Soleil London show. The rigging frame was tubular steel with Y and K type connections added for strength, and the fabrication tolerances were extremely tight as it had to fit into a very restricted space in the ceiling of the theatre.

At the time, I was busy in the mobile fabrication workshop in Madrid, during the tour of Spain, and I could not travel to London to get any site measurements. So I was sent some original blueprints from London of the construction of the Royal Albert Hall, which were created in around the 1800s.

I converted the measurements from the ceiling blueprints into metric, built a jig and applied strong backs.

I welded the frame using GTAW

and, with a bit of luck thrown in, the frame was then shipped to London and fit into position correctly. While on the European tour, due to the constant fatigue of the structures and equipment, we also introduced more in-service inspections of the infrastructure. This way, the welding repairs could be completed before the shows started, resulting in less down time and interruptions. This was crucial to both public and performer safety due to the sheer volume of people seeing the shows, and the number of shows completed per city.

How did you come across and secure the Cirque Du Soleil role?

I had just returned from a long term pipe welding job building a new refinery in northern Queensland, to work on a project in Melbourne. The traffic driving to the job was driving me nuts as I had been living outside of main cities for a few years. As a bit of a joke, due to my frustration with being back in the big smoke, I showed my flat mate in Melbourne a job advertisement for a trade certified welder and fabricator to set up in a mobile fabrication shop and tour the world with Cirque Du Soleil.

I remarked to my flat mate, “This is my ticket out of here”. My flat mate offered to fax my resume to Cirque Du Soleil. I agreed and forgot all about it. The job was advertised both in Australia and internationally—so I thought there was no way I’d be successful.

I was shocked when I received a phone call about six weeks later and Cirque Du Soleil flew me to Sydney for an interview and I was offered the job. So, while a lot of people think about running away with the circus, I actually did it. The moral of the story is, you don’t realise how broad and varied the demand for welders is around the world until you actually get out there and experience it…you never know where you might end up.

What do you believe is the biggest challenge for the welding industry?

I see a need for an increase in budgets for on-the-job and weld college training for apprentices

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“

The moral of the story is, you don’t realise how broad and varied the demand for welders is around the world until you actually get out there and experience it…you never know where you might end up. and experienced welders who want to keep ahead of the game.

I would push for more specialised training, such as welding exotic materials, and advanced pipe welding techniques. In my current role, where I am on the ground with tradespeople all day, I can really see that the money and time spent on welder training is repaid many times over. Rework is minimised or eliminated because the welders have the best up-to-date training, coupled with experience. This gives them increased confidence, which is a key factor on any welding project.

What do you believe is the biggest opportunity for the welding industry?

There are some great projects on the horizon in Australia. I have been reading about the Naval shipbuilding project building submarines in South Australia. I imagine this will be a fantastic opportunity for experienced inspection and quality assurance and control professionals, as well as for anyone thinking of getting into the welding industry and progressing to a high level. Automation of welding has gained a foothold in some industries but even on my current project, we still hand weld pipe a lot due to the restricted spaces and the types of pipe fitting connections, so the need for good manual welders world-wide is always going to be there.

Any advice for people considering a welding career?

My advice is to complete your apprenticeship or your engineering degree and don’t stop there. Continue your education and keep up with the latest developments. Having extra certifications makes a big difference both now and into the future.

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Australian Welding: June 2019

A Critical Constraint: Workforce Capability and Availability There is widespread evidence that Australia’s manufacturing sector is growing. According to the Australian Industry Group Australian Performance of Manufacturing Index (Australian PMI®), the sector experienced a 26-month long run of uninterrupted expansion from 2016 to 2018. More recently, the Australian PMI® rose by 3.8 points to 54.8 in April, indicating even faster growth across the manufacturing sector, with production, sales, exports and new orders all gaining ground.

However, industry participants continue to cite a critical constraint: workforce capability and availability.

Finding and retaining skilled workers is front of mind for manufacturing industry business owners and operators, as is maintaining currency of skills and knowledge.

86,000 over the past 12 months—the highest growth rate of any Australian industry—closely followed by both the mining and construction industries. There is also further projected employment growth over the next five years for structural steel and welding trade workers.

This employment growth rate is not surprising given some of the major projects on the horizon, from the Federal Government’s $90 billion Naval Shipbuilding Program, through to major infrastructure projects such as the $12 billion Sydney Metro project, and the $5 billion Melbourne Airport Rail Link.

The skills shortage is clearly reaching breaking point in Australia.

Australia requires a significant increase in skilled, qualified trades workers to meet future demand on major projects in industries as diverse as defence, shipbuilding, aerospace, infrastructure, rolling stock, and resources.

Having an appropriately sized, skilled, readily-available workforce at the right time is key to delivering these major projects. Developing this workforce presents a complex and long term challenge—it requires a significant amount of individual training and company up-skilling to meet global standards.

According to a recent employment outlook survey in Australia, skilled trades workers (such as electricians and welders), engineers (electrical, civil and mechanical) and technicians are scarce. In fact, 34% of Australian employers admit that filling job vacancies is increasingly difficult, mainly due to lack of applicants (25%), lack of skills (21%), and lack of experience (19%).

Perhaps more importantly, it requires a shift in thinking and a focus on the skills that will be essential to the manufacturing industry of the future, such as automation, robotics, advanced manufacturing processes. Government, industry and education all play a role in solving this complex, long-term challenge, and in attracting, skilling and retaining workers.

This is compounded by the fact that approximately 30% of Australia’s existing welding workforce is aged over 45 years. This heavy proportion of older skilled trade workers, particularly welders, puts into focus the looming issues that industrial sectors are likely to face when baby boomers finally reach retirement age— welding positions will simply become impossible to fill, particularly given the projected increased demand.

2019 National Manufacturing Summit This critical constraint of workforce capability and availability is the basis of the 2019 National Manufacturing Summit’s theme: Skills for the Future.

Hosted by Weld Australia, the Summit will be held at The Australian Synchrotron in Melbourne on 21 and 22 August 2019.

Our lack of skilled workers combined with an aging workforce demographic is exacerbated by strong employment growth. Recent labour force data from the Australian Bureau of Statistics indicates that employment growth among manufacturers surged by

The Summit gathers leading representatives from all major Australian manufacturing stakeholders— business, unions, universities, finance, suppliers, and government—to discuss the sector’s prospects, and identify promising, pragmatic policy measures designed to support an industrial turnaround. The

Inside the Industry: National Manufacturing Summit

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Do you struggle to fill vacant positions?

Concerned about the future of Australian manufacturing? Want to upskill your workforce with global-standard training? With the theme of Skills for the Future, the National Manufacturing Summit is a must-attend event for anyone with a vested interest in manufacturing, skills, training and apprenticeships.

2019 Summit program will focus on how business, governments, industry bodies and the education system can work together to deliver actionable, practical solutions. The National Summit is a mustattend event for anyone with a vested interest in manufacturing, skills, training and apprenticeships.

Program Highlights The 2019 Summit speaker program is being developed with the intent of facilitating a progressive, constructive, and forward-looking discussion on key issues relating to skills and training that are affecting the manufacturing industry in Australia right now.

The focus will be on how industry can work with governments, industry bodies and the education system to deliver actionable, practical solutions. Just some of the speakers already confirmed include: • The Hon. Gayle Tierney (Minister for Training and Skills, Minister for Higher Education) • Chris Brugeaud (CEO, SSS Manufacturing) • Geoff Crittenden (CEO, Weld Australia) • Dr Jens Goennemann (Managing Director, Advanced Manufacturing Growth Centre) • Jim Stanford (Director, Centre for Future Work) • Craig Robertson (CEO, TAFE Directors Australia) • Adrian Boden (Executive Director, SEMMA) • Professor Michelle Gee (Director, Sir Lawrence Wackett Centre)

Register now: https://manufacturingsummit.com.au References http://downloads.manpowergroup.com.au/talent-shortage-2018 https://www.businessinsider.com.au/australia-unemploymentmanufacturing-jobs-growth-2018-9 https://nationalindustryinsights.aisc.net.au/industries/manufacturingand-related-services/metal-engineering-and-boating-industries

Venue: The Australian Synchrotron

The Australian Synchrotron is a major research facility located in Clayton—a technology and innovation hub of southeast Melbourne. It is one of Australia’s most significant pieces of scientific infrastructure.

The Australian Synchrotron produces powerful beams of light that are used at individual experimental facilities to examine the molecular and atomic details of a wide range of materials. The advanced techniques are applied to research in many important areas including health and medical, food, environment, biotechnology, nanotechnology, energy, mining, agriculture, advanced materials and cultural heritage.

More than 5,000 researchers a year use synchrotron instruments. The facility has been directly involved in the generation of more than 3,000 publications in refereed journals.

Delegates will have the opportunity to tour the facilities at The Australian Synchrotron as part of the Summit program of events.

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Australian Welding: June 2019

IIW Quality Audit: WeldQ & AWCR A Giant Leap Forward Weld Australia is the Australian representative member of the IIW, and manages the IIW IAB system for training qualification and certification of joining personnel throughout Australia. As such, Weld Australia is the Authorised Nominated Bodies (ANBs) and the Authorised Nominated Bodies for Company Certification (ABCCs) for Australia.

Weld Australia is also regionally responsible for the certification of companies according to ISO 3834.

ANBs are responsible at the national level for: • Assessment and monitoring of Approved Training Bodies (ATBs) • The conduct of examinations • Assessment of applicants for certification • The issue of Diplomas and Certificates IIW Quality Audit In December 2018, a regular quality audit was performed on the Australian ANB and ANBCC by both a Lead Assessor and a Peer

Assessor, as assigned by the IIW IAB. This is a periodical event that occurs approximately every two and a half years.

According to Ing. Henk J. M. Bodt IWE (IIW IAB Lead Assessor for Australia), “During these audits, it was noted that the new administrative system—WeldQ and the Australian Welder Certification Register (AWCR)—that has been introduced by Weld Australia over the last couple of years brought the ANB a giant leap forward compared with the last audit in 2015.”

“The new system makes the operation transparent and easy to understand and use. A similar system is under construction for the ANBCC. We also noted the great enthusiasm and knowledge of the Weld Australia employees who work with the system. They understand the underlying principles of the system and the way to operate it very well.”

“The audit witnessed was in conformance with the requirements and the recommendation was: full authorisation for the ANB to continue IWE, IWT, IWS, IWP, IWIP, DL-IWE, DL-IWS, DL-IWT, IWSD, PCS (IIW); full authorisation for the ANBCC to continue: IIW MCS ISO 3834. This recommendation was confirmed by the IIW IAB Group B meeting in January 2019,” said Bodt.

What is WeldQ and the AWCR? Developed and managed by Weld Australia, the AWCR provides a national framework for qualifying and testing welders to International Standard ISO 9606-1 Qualification testing of welders - fusion welding.

It allows qualified and certified Registered Welders (RW) to be able to work on any site without further testing resulting in a significant cost saving to industry; provides industry with access to a database of welders with up to date certification and details of their career history; and generates data for a skills gap analysis which will allow the development of a detailed suite of training initiatives to upskill the workforce.

Run on the WeldQ platform (a fully cloud-based system with a supporting mobile application), the welder qualification functionality of the AWCR has been operational since March 2017. Since then, more than 1,100 Australian welding related personnel have registered on the AWCR. This has allowed welders for example, to qualify via the AWCR to for welding within the tunnel boring, transport, pressure equipment, and general welding industry.

While some early teething problems were encountered, these were

Inside Weld Australia: IIW Quality Audit

quickly resolved. In fact, according to feedback received to date, by affording independently verified welder qualifications, the AWCR is able to reduce both costs and risks for employers in Australian industry.

Employers are able to confirm the competence level of any RW against an internationally recognised standard, minimising the need for welder testing. This is particularly beneficial for employees who are required to move from site-to-site; they do not need to be re-qualified, resulting in a huge cost savings for employers.

In addition, Weld Australia has given several presentations to industry groups on the operation of both WeldQ and the AWCR, with very positive feedback received in relation to cost savings, improved record keeping and access to an unparalleled skills database, all without comprising weld quality or welder capability.

Qualification A number of qualification programs have been developed and are undergoing testing within WeldQ to suit specific industries, as well as specific roles. One such program is that for the certification of welders and welding supervisors to AS 1796. Weld Australia will develop

Premier Welding Training Weld Australia delivers a comprehensive range of training and certification services, designed to help Australian welders and fabrication companies achieve and maintain a competitive advantage. As the premier welding certification body in Australia, an IIW Authorised Nominated Body (ANB) and an Authorised Training Body (ATB), Weld Australia offers training in: • Welding Inspector • Welding Specialist • Welding Technologist • Welding Engineer • AS1796 Welding Supervisor Certificate 10 • AS2214 Welding Supervisor

additional, tailored programs as the need arises.

Weld Australia is currently to transiting all qualifications and training courses to WeldQ. For personnel who hold existing qualifications, discussions are underway to import these records directly into WeldQ in the most efficient and timely manner possible.

This will allow existing qualifications to be verified by employers looking for evidence of qualifications held by prospective and existing employees.

Certification There are numerous certification programs available now within WeldQ, including those for welding inspectors, supervisors, technologists, engineers and welding practitioners. The key benefit offered by WeldQ is the ‘Work Diary’ functionality of the Professional experience tab. This allows users to log their work history. This greatly simplifies both certification application and assessment processes.

Reporting and Privacy Weld Australia is currently developing a range of reports within WeldQ that will enable companies to search for qualifications and certifications held by employees and any other person linked to their company.

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“

The new administrative system—WeldQ and the Australian Welder Certification Register (AWCR)—that has been introduced by Weld Australia over the last couple of years brought the ANB a giant leap forward compared with the last audit in 2015. The new system makes the operation transparent and easy to understand and use.”

These independent records will simplify record keeping for quality management, particularly as auditors will be able to search and view evidence in real-time online.

It should be noted that privacy issues were considered during the development of WeldQ and its search functionality. The private details of welders do not automatically appear in a search.

If a company wishes to contact a registered user, they must first seek the user’s permission through Weld Australia.

Australian Welding: June 2019

38

IIW & IAB: Linking People, Joining Nations

By Ing. Henk J. M. Bodt IWE (IIW IAB Lead Assessor for Australia) The increasing demands and developments of technology in industrial manufacturing affects the need for international cooperation in the field of materials joining. This not only applies to research and development, but also to training, qualification and certification of personnel. The International Institute of Welding (IIW) plays an essential role in helping the welding and joining industry contribute to the world’s industrial growth.

On 5 June 1947, during a symposium in the Netherlands, a world-wide collaboration in welding was established. Later that year, during a conference in London, the basis for an international welding organisation was established by representatives from 13 countries, with the following objectives: • To promote and encourage the development of welding and provide for the exchange of scientific and technical information relating to welding research and education • To assist in the formulation of international standards for welding in collaboration with ISO • To organise periodical congresses

Finally, on 9 June 1948, the International Institute of Welding (IIW) was formally founded. The first meeting of the Governing Council took place a few days later to confirm rules on membership, finances, management, officers and the structure of commissions were established.

Europe In 1961, an important development occurred in Europe. The European Commission introduced harmonised Standards that were mandatory throughout the entire European Union. This led to the creation of Standards such as EN 287 (qualification testing of welders), EN 288 (welding procedures), EN 719 (welding coordination)

and EN 729 (weld quality). The introduction of harmonised Standards across Europe, gave rise to harmonised training and education.

Following the European Council for Cooperation in Welding (ECCW) in 1992, the European Welding Federation (EWF) was founded, which became known as the European Federation for Welding Joining and Cutting. In the same year, the first Guidelines for European Welding Engineer (EWE), European Welding Technologist (EWT) and European Welding Specialist (EWS) were created.

Several other Guidelines (European Welding Practitioner and Inspector, European Welder, Thermal Sprayer,

Figure 1: The EWF / IIW IAB Qualification System Professional Qualification Combined System EWF & IIW IAB

Rules for the Approval of

ANBs & ATBs; EWF & IIW IAB

EWF System

Qualification Levels / Guidelines Qualification Levels / Guidelines

IWE/EWE: Engineer IWT/EWT: Technologist IWS/EWS: Specialist IWP/EWP: Practitioner IWIP/EWIP: Inspection Personnel (3 levels) IW/EW: Welder (3 levels, 4 processes) IWSD: Structures Designer (2 levels) Distance Learning European/International Mechanised, Orbital and Robot Welding (2 levels)

EAE/EAS/EAB: Adhesive Bonding EWS-RW/EWP-RW: Resistance Welding ETSS/ETSP/ETS: Thermal Spraying MMA EW: Diver Laser Processing EN 1090: Dedicated Knowledge for (R)WC-S/B Railsafe: Aluminothermic; Arc Welder

Special Courses at ‘Specialist Level’ Reinforcing Bars Weld Imperfection for NDT Personnel Macro and Micro Examination Heat Treatment Risk Management in Welding Fabrication

39

Inside the Industry: IIW & IAB and so on) and a system for company certification to EN ISO 3834 were also developed.

Global Application The most important European Guidelines were licensed to the International Institute of Welding (IIW) in 2000, resulting in the qualifications we know today, such as International Welding Engineer, International Welding Technologist, and so on. The IIW quickly established its own body to oversee qualification, certification and authorisation systems: the International Authorisation Board (IAB). The IAB offers internationally recognised qualifications for personnel in the field of welding and allied technologies worldwide.

The complete structure for professional qualification under the EWF and the IIW IAB is demonstrated in Figure 1. Some of the Guidelines are still limited to European use (right side of the figure), as they apply to subjects that are of less global interest.

The IIW IAB’s education, training, qualification and certification system is now used in more than 45 countries, and is continuing to grow rapidly worldwide. It is an open system that ensures that every person, anywhere in the world, has unrestricted access to education, training, qualification and certification in welding and related technologies, in accordance with international Standards.

Quality Assurance The IIW IAB system is underpinned

by a rigorous quality assurance regime which ensures the required Standards are met uniformly throughout the world in an impartial and non-discriminatory way, complying with international trade legislation. In order to comply with these requirements, the IIW IAB system is based on a network of Authorised Nominated Bodies (ANBs) and Authorised Nominated Bodies for Company Certification (ABCCs), each of which specialises in a specific scope and must comply with the IIW IAB quality assurance system.

Weld Australia is the Australian representative member of the IIW, and manages the IIW IAB system for training qualification and certification of joining personnel throughout Australia. As such, Weld Australia is the ANB and the ANBCC for Australia. Weld Australia is also regionally responsible for the certification of companies according to ISO 3834. ANBs are responsible at the national level for: • Assessment and monitoring of Approved Training Bodies (ATBs) • The conduct of examinations • Assessment of applicants for certification • The issue of Diplomas and Certificates The practical delivery of the courses, leading to the international qualifications, is performed by Authorised Training Bodies (ATBs), which are authorised by the ANBs. Once authorised to deliver the international courses, the ATBs can operate wherever they want worldwide, within their authorised

scope of operation. Each ANB and ANBCC must have its scope established to describe its present level of authorisation to deliver IIW products. This scope of authorisation includes the minimum technical requirements necessary to support their product range and delivery system.

IIW Activities Today The IIW now has 56 member countries, all of which are focused on helping the industries that utilise welding as an enabling technology. IIW members also assist organisations, governments and universities to improve weld quality, and the design and performance of welded structures while reducing the cost of the fabrication, improving safety, and ensuring environmental sustainability. Guiding principles for IIW members include: the sharing of knowledge and networking to enable technology diffusion; and the promotion of welding education, training, qualification and certification.

IIW member societies appoint individuals to represent their country in the IIW Working Units, including 16 Commissions, 5 Select Committees and 2 Study Groups.

The areas of interest covered by these Working Groups are outlined in Figure 2 (below). The Working Units are collaborative forums which utilise and foster the expertise of practitioners, scientists, engineers and other specialist personnel from around the world. Their input and consensus leads to the generation of many types of technical output.

Figure 2: The Areas of Interest Covered by IIW Working Groups Human Factors • • • • •

Terminology Health, Safety and Environment Education and Training Research, Strategy & Collaboration Quality Management

Joining Processes •

• • • • • • • • •

Thermal Cutting & Surfacing Filler Materials Resistance and Solid State Welding Power Beam Process Arc Welding Process Polymer Joining and Adhesives Brazing, Soldering and Diffusion Bonding Physics of Welding Micro and Nano Joining

Industrial Applications

Structural Integrity

•

•

•

• • • • •

Pressure Vessels, Boilers and Pipelines Automotive and Road Transport Shipbuilding Aircraft Engineering Micro Joining Civil Engineering Oil & Gas andPetrochemicals

•

• • •

Quality Control and Quality Assurance Behaviour of Materials Subjected to Welding Fracture Avoidance Fatigue of Components and Structures Design, Analysis and Fabrication

40

Australian Welding: June 2019

Key Developments Continue at the AWTCs The last quarter has seen key developments at several of the Advanced Welder Training Centres (AWTCs) across the nation. The AWTC at TAFE SA’s Regency campus was officially opened, and funding for a new AWTC at Federation University was announced. In addition, ‘Train the Trainer’ courses have been delivered at a number of the AWTCs, and pilot programs have been launched with students undertaking training using the cutting edge augmented reality welding simulators.

South Australia’s First AWTC Now Open South Australia’s first AWTC is now open for business at TAFE SA’s Regency Campus. Equipped with a state-of-the-art augmented reality lab featuring the most advanced welding simulators available anywhere in the world, the AWTC will help ensure local welders are ready to meet the huge demand that will be created by the naval shipbuilding program.

It is anticipated that the continuous naval shipbuilding program in South Australia will require around 2,600 tradespeople from 2020 to 2027.

Almost half of this demand will be for welders.

Minister for Education, the Hon John Gardner MP and Minister for Industry and Skills, the Hon David Pisoni MP were both on-hand at the official

opening ceremony. Minister for Industry and Skills, David Pisoni said the state-of-the-art equipment will provide a valuable training platform to supply skilled workers to the Osborne naval shipyard when the program commences next year.

“There are enormous naval shipbuilding opportunities on the horizon that are heading to South Australia and the Marshall Liberal Government is ensuring that we provide the right resources to fill these jobs through appropriate skills and training. Welding techniques required for shipbuilding are of a higher quality standard than regular welding techniques and these simulators will allow students to practice their technique until they consistently meet the quality standard,” said Pisoni.

Education Minister John Gardner was excited to see TAFE SA students being skilled in areas that lead to jobs. “This new Advanced Welder Training Centre offers an incredible training opportunity for TAFE SA students to learn using the most advanced welding simulators currently available. These simulators are another example of TAFE SA utilising the latest technology in an educational environment to prepare students with the skills and knowledge for long and successful careers,” said Gardner.

According to Geoff Crittenden (Chief Executive Officer, Weld Australia), “This technology is three times cheaper, faster and more effective when compared to traditional training methods. By using this technology, TAFE SA will not only be able to

Far Left: A student at TAFE SA’s Regency Campus AWTC. Top Left: Augmented reality training lab at TAFE Queensland SkillsTech.

Bottom Left: ‘Train the Trainer’ at Illawarra TAFE in Wollongong.

Right: Minister for Industry and Skills, David Pisoni and a student at the launch of South Australia’s first AWTC at TAFE SA’s Regency Campus.

Far Right: Geoff Crittenden (CEO, Weld Australia) addresses the media at the launch of South Australia’s first AWTC.

Inside Weld Australia: Advanced Welder Training Centres

upskill existing welders, but also train transitional workers and apprentices to be part of the defence program.

Without a doubt, the successful implementation of this innovative training initiative will revolutionise welder training in Australia. It will raise the standard of welder education in Australia exponentially, putting our welder training on par with the best in Europe and America,” said Crittenden.

The training delivered at the AWTC will quickly qualify welders to the only industry Standard in the world that is accepted in both Europe and America: ISO 9606-1 Qualification testing of welders - Fusion welding.

ISO 9606-1 is the minimum requirement for working on rolling stock, defence and infrastructure projects.

“The combination of a curriculum based on global best practice delivered via advanced training technology will help ensure a strong supply of capable welders, both now and well into the future,” said Crittenden.

The virtual and augmented reality welding technology increases the rate of engagement in learning and allows students and lecturers to analyse and review welding techniques and performance in a digital environment. The result is that students then perform more effectively in the live workshop environment, where it counts.

TAFE SA Director Defence Industries, Penny Johnston, said that there were many advantages for students to use the cutting-edge technology as part of their training. “This new Advanced Welder Training Centre offers an incredible training opportunity for students to learn using the most advanced welding simulators currently available.”

“The detailed feedback a student receives on their performance on the simulator is instantaneous and increases the rate at which they acquire an understanding of how they can improve. Students analyse the data fed back on their angles, travel speeds and arc lengths to adjust their welding performance and increase improvement. Students are able to build muscle memory with welding techniques much more quickly and the techniques learned can then be taken to the workshop to be performed in a live environment,” said Johnston.

Federation University Secures Funding for AWTC Federation University in Ballarat (north-west of Melbourne) will become home to the newest AWTC. Weld Australia has secured $650,000 worth of State Government funding to help establish the AWTC. This funding will be used to establish a stateof- the-art augmented reality welder training lab, featuring six Soldamtic simulators.

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A skills shortage in welding across the western Victorian region prompted FedUni TAFE to instigate the new project to attract more welding students and improve the skills of existing welders.

“These augmented reality welders are like a standard welder but instead of touching the stick to metal, you touch it to plastic which contains a sensor. As a student you get feedback through the handpiece whether you are close enough or travelling at the right speed,” said FedUni TAFE spokesman Bill Mundy (Workforce and Business Development Manager).

“It allows them to practice, repeatedly, in a very safe environment and build muscle memory before they actually go in to a real welding environment.”

‘Train the Trainer’ Courses Weld Australia continued with the roll-out of its in-depth ‘Train the Trainer’ courses this quarter. Weld Australia delivered a ‘Train the Trainer’ course at Illawarra TAFE in Wollongong, covering AS/NZS ISO 9606-1, the Australian Welder Certification Register (AWCR) and the Soldamatic and augmented reality welding simulators.

Initial training on the simulators was also provided at both TAFE Queensland SkillsTech in Brisbane, and Bendigo TAFE in Victoria. Weld Australia’s experts also facilitated ‘Train the Trainer’ at the Tasmanian Minerals and Energy Council (TMEC) Centre of Excellence in Burnie, Tasmania, as well as at SkillsTech in Brisbane.

Pilot Programs SkillsTech TAFE in Brisbane held its first pilot program, training five welders according to AS/NZS ISO 9606-1. Box Hill TAFE in Melbourne also completed its first pilot training program utilising the new simulators and the brand new curriculum, training and testing five welders according to AS/NZS ISO 9606-1.

Both pilot programs were very well received by all in attendance.

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Australian Welding: June 2019

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.

The Weld Australia Hotline was recently contacted by several member organisations seeking information on the question: How do I demonstrate welder compliance?

There are two key components to demonstrating welder compliance: • A welder must be able to complete a sound, safe, highquality weld that meets the design standards specified by the relevant International or Australian Standards.

• A welder must be able to weld in accordance with all relevant Workplace Health and Safety legislation and regulations.

International or Australian Standards AS/NZS 1554.1 Structural steel

welding - Welding of steel structures offers two methods to qualify welders, thereby demonstrating welder compliance: • Qualification via a weld procedure test and macro for each welding procedure in use on a specific job; OR • Qualification to a specific welder qualification Standard, including: • AS/NZS 2980 Qualification of welders for fusion welding of steels - Additional requirements for Australia and New Zealand • AS 3992 Pressure equipment - Welding and brazing qualification • AS/NZS ISO 9606.1 Qualification test of welders—Fusion welding— Steels

“

Unless otherwise specified, it is the fabricator’s choice as to whether welders are qualified via a weld test and macro for each welding procedure, or according to a qualification Standard.

For general structural fabrication including work defined as Construction Category One (CC1) or Construction Category Two (CC2) by AS/NZS 5131 Structural steelwork - Fabrication and erection, qualification via a procedure test and macro is more than adequate to demonstrate a welder’s compliance.

For higher risk work such as public infrastructure—typically defined as Construction Category Three (CC3) under AS/NZS 5131—welders must be qualified via AS/NZS 2980 or AS/NZS ISO 9606.1.

There are two key components to demonstrating welder compliance: a welder must be able to complete a sound, safe, high-quality weld that meets the design standards specified by the relevant International and Australian Standard; and a welder must be able to weld in accordance with all relevant Workplace Health and Safety legislation and regulations.”

Inside Weld Australia: Hotline Update

Given its broad range of applications and benefits, Weld Australia has based its WeldQ system and the Australian Welder Certification Register on AS/NZS ISO 9606.1.

Originating from European practices, AS/NZS ISO 9606.1 provides for a standardised method of testing a welder’s skill utilising welding processes, materials, consumables and procedures likely to be encountered during the fabrication of steelwork.

Consistent with most welder qualification Standards, it not only qualifies the welder for the conditions of test but also for all other conditions considered easier to weld in accordance with the standard. Whilst the Standard provides a method of testing consistent with many other national application Standards, it likewise also assumes that the welder has suitable industrial experience or training with the relevant welding process.

Unlike other welder qualification Standards used in Australia, AS/NZS ISO 9606-1 is not specifically limited or linked to any specific industry sector. As such, it provides for a broad range of application without complexity or compromising quality. This affords fabricators and welders alike the opportunity to work across industry sectors without the costs associated with requalifying welders welding on similar joints and materials.

Valid for up to three years, the welder qualifications are transportable across worksites and employers, avoiding the need to requalify welders where there is evidence of maintenance of qualification. Welder qualifications utilises a six monthly confirmation process to ensure maintenance of welder skills without the need for additional testing. In addition, the test system is based on welding to qualified weld procedures.

If you wish to have your company’s welders qualified and certified according to your Welding Procedures—so that you can demonstrate welder compliance— Weld Australia is more than happy to assist via the WeldQ system: https://wtia.weldq.com.

Workplace Health and Safety Legislation and Regulations Welding without the proper precautions can be a dangerous and unhealthy practice. For instance, many common welding procedures involve an open electric arc or flame, increasing the risk of burns.

Welders are also often exposed to dangerous gases and fumes, such as carbon dioxide and ozone, which can prove dangerous if ventilation is inadequate.

As such, irrespective of the method of qualification, it is important that a welder has sound knowledge of the Workplace Health and Safety legislation and regulations.

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There are several resources available to welders that explain Workplace Health and Safety issues: • Safe Work Australia’s Welding Processes Code of Practice, which is available via: https:// www.safeworkaustralia.gov.au • Weld Australia’s Technical Note 7: Health and Safety in Welding, which is available via: http://weldaustralia.com.au Weld Australia also offers a comprehensive Weld Safety online course, available via: http:// weldaustralia.com.au. Developed by leading industry experts, this course is divided into 11 easily manageable modules, which welders can access 24/7 from any computer with an internet connection. Course modules cover everything from preventing hazards such as radiation, electric shock, fires, burns, fumes and gases, through to PPE and process specific welding safety.

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.

44

Australian Welding: June 2019

Weld Australia Industry Groups Update Weld Australia’s Industry Groups provide a forum for technology transfer and research and development, linking members with industry and research organisations. Weld Australia works with Industry Group members to ensure they remain diverse and resilient in the ever-changing and increasingly challenging global markets. Industry Group members engineer innovative solutions that enhance safety, manage risk, reduce cost, and optimise operating efficiency by: sharing the cost of implementing new technologies; developing best practices; and providing a forum to brainstorm common needs and effective solutions.

Infrastructure Industry Group The Infrastructure Industry Group completed and delivered the Austroads Steel Fabrication Specification to Austroads in 2018.

It is still under review by Austroads, and yet to be published.

The Group is now working on the development of the Austroads Stainless Steel Fabrication Specification (ASSFS). This specification will set out the minimum requirements for the preparation, welding, inspection, testing, and final acceptance of stainless steel structures and components. It will provide rules for the welding of a wide range of stainless steel fabrications, applicable to both statically and dynamically loaded welds. It will emphasise that weld preparations, consumables and procedures should be qualified welding commences.

The next Infrastructure Industry Group meeting will be held in July 2019 in Melbourne at VicRoads.

Power Generation Industry Group The Power Generation Industry Group met in Melbourne in early April. The meeting was attended by representatives from AGL, ALS, Delta Electricity, CS Energy, Energy Australia, HRL Technology, Quest Integrity, Nuffield Group, Stanwell, Synergy, and Weld Australia.

A major focus of the meeting

was Maintenance and Outages: Managing Welding Quality. Several presentations were provided, including: Maintenance and Outages: Managing Welding Quality by Melissa Odendaal (Welding Engineer, Weld Australia); Quality Assurance: Failures and Success by Wayne Hill, Plant Capability Lead (Operations Support, Energy Australia NSW); Management of Welding and Quality

by Doug Harman (Quality Assurance Controller and Responsible Welding Coordinator, Synergy); Welding and Quality Coordination by Mehdi Tajfar (Welding Engineer, Weld Australia); and Third Party Inspection for Overseas Procurement by Helena Zhu (Inspection Engineer, HRL).

Following the presentations, a discussion around strategies to improve industry-wide welding quality issues ensued. As a result, Weld Australia has requested feedback from all attendees on what should be specified for welder products, especially for safety critical plant such as HEP, turbines and generators. Based on this feedback, Weld Australia will be in a position to generate a Technical Guidance Note which can then be used by plant engineers, personnel and procurement staff.

Weld Australia will also conduct gap analysis at the Yallourn and Stanwell Power Stations, and provide commentary on both provide commentary on welder qualifications, as well as ISO 14731 Welding coordination - Tasks

and responsibilities roles and responsibilities of a Responsible Welding Coordinator.

The second focus of the meeting was The Importance of Process Safety. Several members provided an overview of process safety at their organisation, including Bob Hazard (Asset Engineering Specialist Integrity, CS Energy), and Dr Stuart Mann (Principal Engineer, AGL Energy). Barbara Lucas (Principal Consultant, Nuffield Group) presented on the topic Process Safety Lessons Learned from Major Hazard Industries, while Dr Nan Xu (Senior Metallurgist, ALS Global) provided a case study on quality assurance and documentation of weld repairs.

During the meeting, Weld Australia provided updates on the progress of several important projects, including the Australian Welder Certification Register, the Advanced Welder Training Centres, and certification of companies to AS/NZS ISO 3834.

The next Power Generation Industry Group is scheduled to be held in Brisbane in November.

To become a Weld Australia Industry Group member contact us via membership@ weldaustralia.com.au or +61 2 8748 0100.

Inside Weld Australia: Industry Group Update

Advanced Welder Training Courses Fusion Welding Courses There are two ISO 9606 Qualification test of welders — Fusion welding —Part 1: Steels courses listed on Training.gov.au, the National Register of Vocational Education and Training (VET) in Australia. This is the authoritative source of Nationally Recognised Training and Registered Training Organisations (RTOs). These courses were developed in Victoria in 2018. One is intended for inexperienced welders, the other for experienced welders. Both use augmented reality welding simulators as a key component of the training.

Transition Workers To complete the Course in Fusion Welding to AS/NZS ISO 9606 for Transition Workers, you must successfully complete seven units of competency (four core and three elective). Core units: • Simulate fusion welding processes using augmented reality equipment • Identify welding processes, safe welding practices and use of hand and power tools • Interpret and apply AS/NZS ISO 9606 for fusion welding processes • Perform fusion welding procedures to meet the procedures of ISO 9606-1 (Steels – carbon steels) Experienced Welders To complete the Course in Fusion Welding to AS/ NZS ISO 9606 for Experienced Welders, you must successfully complete three units of competency (one core and two elective). The core unit is: Interpret and apply AS/NZS ISO 9606 for fusion welding processes.

Elective Units Other elective units available include: • Perform fusion welding procedures to meet AS/NZS ISO 9606-1 (Steels – stainless steel) • Perform fusion welding procedures to meet AS/NZS ISO 9606-2 (Aluminium and aluminium alloys) • Perform fusion welding procedures to meet the requirements of AS/NZS ISO 9606-3, 4 or 5 (Exotic metals) • Perform routine manual metal arc welding • Perform routine gas metal arc welding • Perform manual heating and thermal cutting • Read and interpret technical drawings and make measurements for a welding procedure Further Information For further information, please contact: training@weldaustralia.com.au or +61 2 8748 0100, or visit www.weldaustralia.com.au.

Enrol in a Fusion Welding Course Today

You can enrol in a Fusion Welding course through any of the Advanced Welder Training Centres across Australia. These are all listed below.

Queensland TAFE Queensland Caboolture Campus https://tafeqld.edu.au Tallon Street, Caboolture, Queensland TAFE Queensland SkillsTech https://tafeqld.edu.au 247 Bradman Street, Acacia Ridge, Queensland South Australia TAFE SA Regency Campus https://www.tafesa.edu.au 137 Days Road, Regency Park, South Australia Tasmania Tasmanian Minerals and Energy Council https://tasminerals.com.au 13 Wellington Street, Burnie, Tasmania Victoria Box Hill Institute https://www.boxhill.edu.au 465 Elgar Road, Box Hill, Melbourne, Victoria Bendigo TAFE http://www.bendigotafe.edu.au 23 Mundy Street, Bendigo, Victoria Federation University https://federation.edu.au Lydiard Street South, Ballarat, Victoria

Image: The Advanced Welder Training Centre at TAFE SA’s Regency Campus.

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Australian Welding: June 2019

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2019 Training Calendar Weld Australia delivers a comprehensive range of training and certification services, all of which are designed to help Australian welders and fabricators achieve and maintain a competitive advantage.

As the premier welding certification body in Australia, an International Institute of Welding (IIW) Authorised Nominated Body (ANB) and an Authorised Training Body (ATB), Weld Australia offers individual certifications, including: Welding Inspector, Welding Specialist, Welding Technologist, Welding Engineer, AS 1796 Welding Supervisor Certificate 10, and AS 2214 Welding Supervisor.

International Welding Inspector - Basic Location

Dates

Adelaide

11 - 15 Nov 2019

Brisbane

10 - 14 Jun 2019 2 - 6 Sep 2019

Mackay

15 - 19 July 2019

Melbourne

16 - 20 Sep 2019

Perth

10 - 14 Jun 2019

Sydney

17 - 21 Jun 2019 9 - 13 Sep 2019

International Welding Specialist Location

Dates

Brisbane

Week 1: 24 - 28 Jun 2019 Week 2: 22 - 26 Jul 2019 Week 3: 19 - 23 Aug 2019 Week 4: 23 - 27 Sep 2019 Week 5: 21 Sep - 25 Oct 2019

Mackay

Week 1: 5 - 9 Aug 2019 Week 2: 2 - 6 Sep 2019 Week 3: 30 Sep - 4 Oct 2019 Week 4: 4 - 8 Nov 2019 Week 5: 2 - 6 Dec 2019

Perth

Week 1: 26 - 30 Aug 2019 Week 2: 23 - 27 Sep 2019 Week 3: 21 - 25 Oct 2019 Week 4: 18 - 22 Nov 2019 Week 5: 16 - 20 Dec 2019

Sydney

Week 1: 5 - 9 Aug 2019 Week 2: 16 - 20 Sep 2019 Week 3: 14 - 18 Oct 2019 Week 4: 18 - 22 Nov 2019 Week 5: 9 - 13 Dec 2019

International Welding Inspector - Standard Location

Dates

Adelaide

IWI-S Part 1: 17 - 21 Jun 2019 IWI-S Part 2: 1 - 3 Jul 2019

Brisbane

IWI-S Part 1: 5 - 9 Aug 2019 IWI-S Part 2: 26 - 28 Aug 2019

Mackay

IWI-S Part 1: 24 - 28 Jun 2019 IWI-S Part 2: 1 - 3 Jul 2019

Melbourne

IWI-S Part 1: 15 - 19 Jul 2019 IWI-S Part 2: 29 - 31 Jul 2019

Sydney

IWI-S Part 1: 23 - 27 Sep 2019 IWI-S Part 2: 19 - 11 Oct 2019

Welding Workshop Supervisor (Blended Learning Program) Location

Dates

Australia-wide 7 Jan 2019 - 20 Dec 2019 Quality Control Welding Coordinator (QCWC) Location

Dates

Sydney

19 - 23 Aug 2019

“

The practical and theoretical knowledge of the trainers was excellent, the opportunity to draw on their knowledge was fantastic.�

Inside Weld Australia: 2019 Training Calendar

47

“

This is the second IWI course I have taken and on both accounts I have been very impressed with the presenters. The level of knowledge from all the teachers is impressive.”

International Welding Engineer Location

Dates

Wollongong

Module 1: 23 - 27 Sep 2019 Practical Phase: 25 - 29 Nov 2019 Module 2: 2 - 6 Dec 2019 Module 3: 10 - 14 Feb 2020 Module 4: 4 - 8 May 2020

International Welding Technologist Location

Dates

Wollongong

Module 1: 23 - 27 Sep 2019 Practical Phase: 25 - 29 Nov 2019 Module 2: 2 - 6 Dec 2019 Module 3: 10 - 14 Feb 2020 Module 4: 4 - 8 May 2020

Welding Technology Appreciation for Engineers (3DE) Location

Dates

Adelaide

26 - 28 Aug 2019

Brisbane

29 - 31 July 2019

Sydney

1 - 3 July 2019

Perth

9 - 11 Jul 2019

Melbourne

23 - 25 Jul 2019

Weld Australia reserves the right to cancel or change dates of any training course due to insufficient registrations or other reasons beyond its control, and reserves the right to refuse enrolments.

The Benefits of Training & Qualification Weld Australia training and certification is a strong addition to your career portfolio. It demonstrates to employers that you possess advanced welding knowledge, essential to ensuring the highest levels of workmanship. Qualification demonstrates to employers that you are dedicated to continually learning and growing in your field. These are qualities that are essential for success in team leadership roles or for more complex projects.

Online & Blended Learning In conjunction with the American Welding Society (AWS), Weld Australia offers online courses to help develop your welding knowledge and to better inform you for your professional development.

The content has been developed by senior people within the profession and is regularly updated. These courses are available any time, day and night, and are designed as self-paced modules which will allow the student to complete them in their own time.

Courses include: • Economics of Welding • Fabrication Maths (Basic and Advanced) • Metallurgy (Basic and Advanced) • Non-Destructive Testing • Welding Fundamentals (Basic and Advanced) • Welding Safety • Welding Sales Representative • Welding Symbols In-House Training Weld Australia can present any of its courses to your employees in-house at the location of your choosing.

We can also tailor training courses specifically for your company and employees.

Further Information For further information, or to enrol in a Weld Australia training course today, please contact: training@weldaustralia.com.au or +61 2 8748 0150, or visit www.weldaustralia.com.au.

48

Australian Welding: June 2019

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 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

Navantia Australia www.navantia.com.au (02) 6269 5900 navantia.australia@navantia.es

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

LYB Operation & Maintenance Loy Yang B Power Station www.loyyangb.com.au +61 3 77 2000 contactus@loyyangb.com

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 AWS Centre of Excellence https://australianweldingsolutions. com.au +61 8 8374 3415 admin@awsglobal.com.au Baker & Provan www.bakerprovan.com.au +61 2 8801 9000 info@bakerprovan.com.au 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 Coregas http://coregas.com.au +61 2 9794 2222 info@coregas.com

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

Santos www.santos.com +61 8 8116 5000 reception.ade@santos.com

Liberty www.libertygfg.com 1800 178 335 capital@libertygfg.com

Scaffstand https://www.scaffstand.com.au +61 405 981 070 Tronox Management www.tronox.com +61 8 9411 1444 info@tronox.com

Lincoln Electric www.lincolnelectric.com +61 2 9772 7222 sales@lincolnelectric.com.au

UGL Pty Limited www.ugllimited.com +61 2 8925 8925 uglinfo@ugllimited.com

LMATS http://lmats.com.au +61 8 9200 2231 admin@lmats.com.au

Welding Industries of Australia (WIA) www.welding.com.au 1300 300 884 info@welding.com.au

Main Roads Western Australia www.mainroads.wa.gov.au 138 138 enquiries@mainroads.wa.gov.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

Join Weld Australia Today.

Help Secure the Future of

Australian Welding +61 2 8748 0100

|

membership@weldaustralia.com.au

|

www.weldaustralia.com.au

50

Corporate Members 3M Australia: 3m.com.au A & B Welding: abwelding.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 AF Gason: gason.com.au Aitken Welding: aitkenwelding.com Alltek Welding: alltek.net.au Ancon Building Products: ancon.com.au Antec Group: antec.com.au ARL Laboratory Services: arllabservices.com.au ATTAR: attar.com.au Austal: austal.com Austedan Fabrications: austedan.com.au Austin Engineering: austineng.com Austral: australtechnologies.com.au Australian Rail Track Corporation: artc.com.au Australian Welding Supplies: awsi.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 BlueScope Steel: bluescopesteel.com.au BMC Welding: bmcgroup.com.au Bombardier Transportation: bombardier.com/en/transportation.html 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 Caltex Refineries (QLD): caltex.com.au CCR Group: ccrgroup.com.au Central Engineering: centralengineering.com.au Chess Engineering: chessindustries.com.au

Australian Welding: June 2019

CPT Engineering: cptengineering.com.au CQ Field Mining Services: cqfma.com.au CQ Steel Industries: cqsteel.com.au Crisp Bros Haywards: haywards-steel.com Cruisemaster Australia: cruisemaster.com.au Cullen Steel: cullensteel.com.au D&L Engineering Services: fabinox.com.au DGH Engineering: dghengineering.com.au Diverse Welding: diversewelding.com.au DJM Fabrications: djmfab.com 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 Frontline Manufacturing: frontlinemanufacturing.com.au Furphy Engineering: furphys.com.au G & G Mining Fabrication: ggminingfab.com Global Manufacturing Group: gmqld.com.au Hamilton Maintenance Group Hilton Manufacturing: hiltonmanufacturing.com.au HVAC Queensland: hvac.com.au Industrial Installation & Maintenance: iimaust.com.au Ingal EPS: ingaleps.com.au Jacmor Engineering: jacmor.com.au JB Specialised Engineering: jordbellows.com.au JR’s Marine Engineering: jrsgroup.com.au JVA Engineering: jvaengineering.com.au Kangaroo Training Institute: kangarootraininginstitute.com.au Kenro Products: kenrometal.com.au Keppel Prince Engineering: keppelprince.com Knox Engineering: knoxeng.com LaserBond: laserbond.com.au Lendlease: lendlease.com/au Loclur Engineering: loclur.com.au LSW Group: lswgroup.com.au Mainetec: mainetec.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 Group Aust: precisionmetalgroup.com QSM Fabrication: qsmfabrication.com.au Quality Process Services: qpspl.com.au Queensland Nitrates Plant: N/A Radio Frequency Systems: rfsworld.com 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 South32 Temco: south32.net 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 The Bloomfield Group: bloomcoll.com.au Topline Steel Fabrications: N/A Trade and Investment NSW: industry.nsw.gov.au Uneek Bending: uneek.com.au Victorian Testing & Inspection Services: victesting.com.au Walz Construction: walzgroup.biz Welding Guns of Australia: unimig.com.au WGASA: wga.com.au

51

Inside Weld Australia: Upcoming Events

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 2 8748 0100.

July 2019 72nd IIW Annual Assembly and International Conference 7 to 12 July, Bratislava, Slovakia http://iiwelding.org

2019 APGA Convention and Exhibition 12 to 15 October, Adelaide http://www.apga.org.au November 2019

13th International Conference on Bulk Materials Storage, Handling and Transportation 9 to 11 July, Gold Coast https://www.newcastle.edu.au

5th SIA Submarine Science, Technology and Engineering Conference 2019 (SubSTEC5) 18 to 21 November, Fremantle https://www.submarineinstitute.com

August 2019

World Engineers Convention 20 to 22 November, Melbourne https://www.wec2019.org.au

Pipeline Repair, Hot Tapping and In-Service Welding Course 7 to 8 August, Perth https://weldaustralia.com.au 22nd International Conference on Composites Materials 11 to 16 August, Melbourne https://iccm22.com

Corrosion and Prevention Conference 24 to 27 November, Melbourne https://conference.corrosion.com.au Weld Australia & IIW Exam Dates 2019

National Manufacturing Summit 21 to 22 August, Melbourne https://manufacturingsummit.com.au

IWE and IWT • 22 July: IWE EA3 exam and IWT TA3 exam in Wollongong

(AIMEX) Asia-Pacific’s International Mining Expo 27 to 29 August, Sydney https://www.aimex.com.au

National Examinations All exams are to be held in state capital cities where sufficient registrations are received: • 12 June: IWS and National Welding Supervisor Paper A • 13 June: • Welding Supervisor B1: AS 1796 Certificate 10 • Welding Supervisor B2: AS 2214 Welding Supervisor • 6 November: IWS and National Welding Supervisor Paper A • 7 November: Welding Supervisor B1 and B2 Code exams

September 2019 Coasts and Ports 2019 10 to 13 September, Hobart www.coastsandports2019.com.au Australian Steel Convention 15 to 17 September www.steel.org.au October 2019 Pacific Rim Stainless 9 to 10 October, Gold Coast https://www.assda.asn.au

Exam applications must be made online via WeldQ, six weeks prior to the exam date. For enquiries, contact qnc@weldaustralia.com.au.

NATIONAL MANUFACTURING

SUMMIT 2019 Event Spotlight: National Manufacturing Summit Weld Australia will again host the National Manufacturing Summit in 2019. Attended each year by over 100 delegates, the Summit program is designed to open new ground in the policy dialogue over how to sustain and nurture manufacturing: a vital segment of Australia’s economy.

With the theme, Skills for the Future, the Summit will see a diverse group of industry stakeholders assemble at The Australian Synchrotron in Melbourne on 22 August.

For further information, visit: manufacturingsummit.com.au

Australian Welding: June 2019 52 Weld Australia’s Innovative, Expert

Engineering and Advisory Services By taking advantage of Weld Australia’s engineering and advisory services, you have access to the peak industry body in Australia’s welding industry. Your commercial enterprise can access expert advice services, delivered by highly qualified welding engineers and materials specialists. Each member of the Weld Australia advisory team is an International Welding Engineer (IWE). This qualification, issued by the International Institute of Welding, is the highest postgraduate professional welding qualification available. Our consulting services can help you substantially increase the operational life of your plant and equipment, and reduce your maintenance and repair overheads.

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

Design and qualification of welded connections Review of structural and pressure vessel designs Drafting and review of design specifications Evaluation of materials and facilities Analysis and resolution of complex welding problems Design, development and project management of fabrication solutions Optimisation of maintenance for risk mitigation Comprehensive failure investigations and engineering critical assessments

Resources

• • • • • • • •

Advising of safety practices as they pertain to welding, cutting and joining Expert evidence and witnessing services Comprehensive failure investigations Inspection and testing services Welding quality management to ISO 3834 Pipeline in-service welding, repairs and hot tapping Specialised welding and associated technologies (laser, ultrasonic peening and underwater welding) R&D and application of technology

Infrastructure

Power Generation

Securing the future of Australia’s welding industry Manufacturing

Defence

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