Dr Russell Coade

Principal Materials Engineer

Professional Background

Over 37 years' experience in the development of inspection and NDT programs for major plant and equipment, development of inspection procedures and assessment criteria. Plant inspections and risk assessments for compliance with the Plant Regulations. Development of risk-based inspection programs. Pressure vessel inspection and data management systems. Development and auditing of pressure equipment management systems (AS 3873).

Areas of Expertise

  • Investigation and application of methods to assess the remaining life of high temperature plant.
  • Development of a high temperature creep-rupture test facility.
  • Failure investigations for conventional and advanced power plant, and the petroleum and petrochemical industries.
  • Risk assessment and the development of risk-based inspection programs for power plants and refineries resulting in increased reliability and safety.
  • Assessment of the structural integrity of large engineering plant.
  • Microstructural assessment to determine degree of structural degradation, including creep degradation.
  • Participation in the US Electric Power Research Institute (EPRI) 'Corrosion. Fatigue' project and management of the 'Header Stress Monitoring' program while seconded to Ontario Hydro.  
  • Written and presented courses on:
    "Failure Analysis" for the Materials Australia, and "Creep In Engineering Materials" for the Central Queensland University Masters course titled ENPG22003 Plant Materials.

Relevant Project Experience

  • PROJECT: Failure of a steam turbine nozzle block vane, West Papua
    Client: PT Freeport
    Role: Investigation and determination of root cause of failure.
    Key achievements:
    Site inspection and identification of key factors relevant to failure.  Laboratory metallurgical investigation and determination of failure mechanism. Collection of skills including vibration analysis, finite element analysis and computational fluid dynamics to determine the root cause of failure.
    Preparation of experts report for PT Freeport's lawyers to contest liability of manufacturer.  Successful outcome with manufacture paying for redesign and repair.
  • PROJECT: Investigation in extensive cracking found in a condensate tank
    Client: Alcoa Australia Limited
    Role: Visual inspection of a large condensate tank and subsequent non-destructive examination and failure investigation of cracks found in the welds.
    Key achievements:
    Site inspection identified multiple cracks in the welds of the tank wall. NDT used to define extend of cracking and determine the depth of larger cracks. Metallurgical analysis identified the failure mechanism as stress corrosion cracking but determined the cracks were now dormant.  Critical crack size was calculated confirming these cracks were presently innocuous.Tank was able to be returned to service as cracks were stable, driving force for cracking was no longer present and extremely unlikely to be present in the future. Crack monitoring implemented.
  • PROJECT: Risk assessment and risk-based inspection (RBI)
    Client: Clients in Victoria, Queensland and Western Australia
    Role: Review plant history, determine areas known to be deteriorating. Based on history, operating conditions and industry experience, determine probably failure mechanisms, consequence and likelihood of failure, to determine risk. Provide plan to mitigate risks and build and inspection program to ensure plant can be operated reliably and safely.
    Key achievements: Risk mitigation achieved through application of the appropriate inspection technique in a timely manner. Maintenance budget focused on areas of highest risk resulting in increased reliability without every increasing inspection costs.


  • B. Eng (hons)
  • PhD (Monash University)

Professional Associations and Memberships

  • NATA Signatory for pressure vessel inspection
  • Graduate member of the Australian Institute of Company Directors
  • Senior AICIP inspector
  • Senior Weld Australia Replica Assessor
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