K.J. Beer Pty Ltd - Consulting Engineers

Welcome!

Our services include:

DESIGN

DESIGN VERIFICATION

INTEGRITY ASST.

INSPECTION

Pressure Vessels
Pressure Piping
Boilers

Relief Systems
Tanks
Heat Exchangers

ANALYSIS / TOOLS

Finite Element (FEA)
Stress Analysis
Fatigue

Creep Rupture
Fracture Mechanics

Please download our Capability Statement - (281k)

Recent News

11 Nov 10

Inspection and Integrity Assessment of a Dent in a Tank Combined to Recommend Continued Safe Storage of Dangerous Solvent

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KJ Beer did an inspection of a second hand storage tank used to store a dangerous industrial solvent for Profill in Wangara. The tank had incomplete design documentation which KJ Beer’s AICIP recognised inspector determined. The inspector identified a significant dent in the shell of the horizontal tank near the saddle support. The inspector measured the deformation due to the dent and found it to be greater than the allowable in API 650. The deformation due to the dent was referred to the office for a more detailed assessment in accordance with API 579 Level 2. This assessment proved that the tank was not fit for continued service. It was recommended that the tank be replaced. By combining inspection and an office based integrity assessment service KJ Beer provided Profill with a recommendation to ensure continued safe storage of a dangerous solvent in 2 working days.

9 Nov 10

Challenging Design Verification of Air Receivers with Imported 'Freefall' Amusement Ride

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		KJ Beer were requested to verify the design of two vertical air receivers which are part of the air drying equipment for the recently imported 'Freefall' amusement ride at Adventure World. The vessels had incomplete design documentation. An inspection was performed to determine the missing design information required for the design verification. It was recommended that non-destructive testing (NDT) be performed on the vessel welds to prove their soundness. Several non acceptable weld defects were discovered and a weld repair procedure was prepared. The vessels were successfully repaired, tested and registered with WorkSafe WA. There were another three air receivers located on the recently imported 'Freefall' amusement ride at Adventure World requiring design verification which also had incomplete documentation. One of the receivers was located halfway up the 'Freefall' tower making it difficult to get to, but this didn’t stop KJ Beer’s AICIP inspector getting the missing design information. The recommended NDT on the vessel welds revealed non acceptable weld defects in two vessels. Adventure World requested KJ Beer design two replacement vessels. Having engineers with AICIP competency was vital to KJ Beer finishing this challenging job.

6 Oct 10

In-situ Post-Weld Heat Treatment for BP Refinery Depropaniser

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		A 30 m tall Depropaniser pressure vessel located at BP’s Kwinana refinery was shutdown and inspection showed defects in a nozzle located approximately half way up. An in-situ repair was proposed to re-weld the nozzle followed by a post weld heat treatment (PWHT) of a full circumferential 1 metre wide band of the shell which included a manway. KJ Beer was contracted to determine whether the reduction of the yield strength in the shell at PWHT temperature (650°C) would compromise the structural integrity of the vessel during the PWHT holding time. Rigorous mathematical analysis was carried out, which involved assessment of general and localised stresses in the shell due to temperature gradient, vessel weight and wind. KJ Beer engineers worked through the weekend to meet BP’s required completion.
The results indicated that the structural integrity of the vessel was not compromised and it was safe for BP to complete the in-situ repairs and PWHT. (Click on far-left thumbnail to enlarge image)

14 Apr 10

A-Frame Gantry Crane Design

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KJ Beer was recently commisioned to assess the mechanical integrity of an A-frame gantry crane which was subjected to a 2t load, allowed to traverse the top lifting beam. The entire frame was modelled in Caear II and a total of 4 load cases were analysed, including weld and bolt stresses.
Caesar II model:

15 Feb 10

Integrity Assessment of FMC Pump Skid Base

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The team at KJ Beer has just completed an integrity assessment of an FMC pump assembly including 2 pulsation control devices, gear box and motor. The entire skid base was modelled using Caesar II's structural module, which was then analysed using 38 different load cases comprising dead weight, seismic and storm wind loads.
Caesar II model:

6 Oct 09

Australia's World Land Speed challenge

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	KJ Beer has been approached by Rosco McGlashan and his team to design the two propellant tanks that will fuel Aussie Invader 5R’s hypergolic rocket engines. We have been commissioned to design a carbon steel fuel tank capable of holding approximately 320 kg of kerosene bio-fuel and a stainless steel oxidizer tank with a capacity to contain approximately 2500 kg of High Test Peroxide (HTP). Each tank is to be rated for 500 psi of internal pressure.
We are excited to be part of this project and wishes to thank Rosco for the opportunity.

1 Aug 09

Proof Engineering Study - Pluto Supply Base Fuels Project

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20 Jul 09

Post Weld Heat Treatment Error Saved by Fracture Mechanics Assessment

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1 Jul 09

Heat Exchanger and Pressure Vessel Design for Worsley Alumina Expansion Project

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12 Mar 09

Tank Mechanical Integrity and Design Modifications in Accordance with API 650-2007

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22 Dec 08

Power Piping Integrity Assessment

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21 Jul 08

WA Pressure Vessel Expertise Reaches Record Heights

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KJ Beer was recently approached to assess the structural integrity of four existing flocculant and carbon-in-leach residue storage tanks and to perform the design of proposed modifications to the tanks in accordance with API 650-2007. The tanks range in capacity from 60 m³ to 1200 m³ and the calculations included designs for shell and nozzles, flanges, floor plate, roof, wind and earthquake loads, platform loads, baffle loads, nozzle loads and anchorage requirements. The tanks also have several complex geometries requiring Finite Element Analysis such as internally fitted containment floors, complex floor drain nozzles and cyclically loaded internal baffle supports.
Example FEA plots:


1. Containment floor deformed FEA plot	2. Floor drain nozzle deformed FEA plot


The KJ Beer team was contracted by Fuel Tank & Pipe and their customer, The Shell Company of Australia, to carry out a proof engineering study on a new diesel bunkering pipeline at the King Bay Supply Base in Western Australia. Caesar II piping software was used to analyse static and dynamic (surge) loads for the above-ground and underground pipelines. Load cases including sudden valve closure and pump trip were analysed to ensure a safe pipeline design. Buried pipe conditions were incorporated into the model.
Example Caesar II plot:


A box header of an Air Cooled Heat Exchanger (ACHE) for Apache Energy spent insufficient time at the post-weld heat treatment (PWHT temperature specified in the PWHT procedure). This manufacturing error was discovered after the ACHE was installed at Varanus Island off the coast of Western Australia. KJ Beer was asked to determine if the ACHE was safe to be put into service without removing the ACHE from the gas processing plant to repeat the PWHT. The team at KJ Beer were able to conservatively determine the residual stresses in the box header and used these results in a fracture mechanics assessment. The results of the analysis showed that the ACHE could be commissioned and put into service. In addition, remaining life calculations provided the customer with an appropriate inspection strategy for the box header during its service life.


KJ Beer was engaged by GEA Process Engineering France (Division KESTNER) to design all of the pressure equipment for an evaporation plant expansion project at the Worsley Alumina refinery in Collie, WA. The scope of work included the design of 26 shell and tube heat exchangers and 18 pressure vessels. The 44 items of pressure equipment required approximately 500 tonnes of pressure vessel steel plate and efficient design, in accordance with AS 1210 and owner specifications, was required to keep manufacturing costs to a minimum. Design was performed using sophisticated 'in-house' VESSEL software and specialised FEA Software. The design engineers achieved high levels of efficiency and productivity throughout the project which was completed to a tight budget 4 weeks ahead of schedule.


A naphtha splitter column was recently delivered to the BP Refinery in Kwinana. This massive pressure vessel was designed by KJ Beer under contract to the manufacturer, United Group Resources. The vessel weighs 348 tonnes empty, is 4.572 metres in diameter and 61.675 metres high. The team at KJ Beer thanks our client, United Group Resources for the opportunity to be part of the project and we are proud to have designed a vessel that was fabricated in Western Australia. For the full article, please click here.