TÜV SÜD | Vol.

5 March 2012

E-ssentials
PetroChem | Technical industry e-news updates essential to your operations

CONTENTS:
Detecting Corrosion Under Insulation 02
OSHA Mandates New Worker Protection 04
Requirements
2012 NDT Training Program Schedule 04
Events 06

h t t p : / / w w w. p e t r o c h e m i n t l . c o m

TÜV SÜD E-ssentials
Editorial
Welcome to the March 2012 issue of PetroChem E-ssentials,
the quarterly e-newsletter of PetroChem Inspection Services, a
subsidiary of TÜV SÜD America.
Corrosion of steel pipes and vessels that is hidden under
insulation can be a particularly difficult problem for operators
of chemical and petrochemical plants. Because of the time
and expense associated with traditional methods of inspecting
surfaces under insulation, corrosion problems can go undetected
for long periods, leading to more serious failures and even more
expensive fixes. In our lead article for this issue, “Detecting
Corrosion Under Insulation,” we review the challenge of corrosion
under insulation, and discuss how neutron backscatter technology
can save time, reduce costs, and increase operational uptime.
The U.S. Occupational Safety and Health Administration (OSHA)
has issued new regulations to further protect workers at chemical
facilities from catastrophic releases of hazardous chemicals.
OSHA’s new National Emphasis Program (NEP) establishes
policies and procedures for the inspection of facilities with highly
hazardous chemicals. Our article “OSHA Mandates New Worker
Protection Requirements” provides a brief overview of the new
requirements, and a link for additional information.
PetroChem is pleased to announce its 2012 lineup of technical
and certification courses for non-destructive testing operators.
The training courses, which will be conducted out of PetroChem’s
Houston, TX headquarters, are once again being offered
in conjunction with our partner, Lavender International, an
internationally recognized training and consulting firm to the
petrochemical industry. The article “PetroChem Announces 2012
NDT Training Program Schedule” offers a summary of each of the
planned courses and their scheduled dates.
We round out this issue of PetroChem E-ssentials with a lineup
of 2012 industry trade shows, conferences and other events that
may be of interest to our readers. If you’re planning to attend any
of these shows, please stop by our exhibition booth and say hello.
Finally, a reminder that our on-demand videos, which we released
in August 2011, provide additional details on PetroChem’s
advanced inspection services. You can view the videos at our
website at www.petrochemintl.com/videos. Be sure to check out
these excellent presentations.
Gerhard Abel
President, PetroChem Inspection Services
Detecting Corrosion Under Insulation
Corrosion of steel pipes and vessels that is
hidden under insulation can be a particularly
difficult problem for operators of chemical and
petrochemical plants. Because of the time and
expense associated with traditional methods of
inspecting surfaces under insulation, corrosion
problems can go undetected for long periods,
leading to more serious failures and even more
expensive fixes, as well as extended operation
shutdowns. What’s needed is a simple but
effective detection system that enables plant
operators to identify corrosion problems early and
at a reasonable cost.
Neutron backscatter technology is a proven and
cost-effective method for detecting water content
in the thermal insulation of pipes and vessels.
Since insulation water content is a clear indicator
of potential metal surface corrosion, neutron
backscatter detection offers an efficient and
cost-effective inspection alternative to traditional
inspection methods. This article discusses the
challenge of corrosion under insulation, and how
neutron backscatter technology can save time,
reduce costs, and increase operational uptime.
WHERE DOES CORROSION UNDER
INSULATION TYPICALLY OCCUR?
Vessels, pipes, and fittings fabricated from
carbon steel and 300-series stainless steels
are particularly susceptible to corrosion. Piping
systems that are most vulnerable to corrosion
under insulation include the following types:
• Carbon steel piping systems, including those
insulated for personnel protection, operating
between 25° F and 250° F (-4° C and 120° C).
Corrosion under insulation can be particularly
aggressive where operating temperatures cause
frequent condensation and re-evaporation of
atmospheric moisture;
•Carbon steel piping systems with in-service
operating temperatures above 250° F (120° C),
but that are used intermittently;
• Austenitic stainless steel piping systems which
operate between 150° F and 400° F (60° C and
204° C), which are susceptible to chloride stress
corrosion cracking.
Vol. 5 March 2012
Page 2
In addition to specific types of piping systems,
operating conditions and normal wear and tear
may increase the risk of corrosion under insulation.
Here are some of the scenarios in which the risk of
corrosion under insulation typically increases:
• Vibrating piping systems, which have a tendency
to inflict damage to insulation jacketing, thereby
providing a path for water ingress;
• Steam-traced piping systems that may
experience tracing leaks, especially at the tubing
fittings beneath the insulation;
• Piping systems with deteriorated coatings and/
or wrappings;
• Deadlegs and attachments that protrude
from insulated piping and that operate at a
temperature different than the active line;
• Locations where insulation plugs have been
removed to permit thickness measurements on
insulated piping.
Finally, even when none of the other previously
noted conditions exist, pipes and vessels in
particular areas of a plant are more susceptible
to corrosion under insulation than those in other
locations. Problems are typically found in the
following areas:
• Areas exposed to mist overspray from cooling
water
• Areas exposed to steam vents
• Areas exposed to deluge systems
• Areas subject to process spills, ingress of
moisture, or acid vapors.
Figure 1: Example of corrosion under insulation

TÜV SÜD E-ssentials
HOW DOES NEUTRON BACKSCATTER
MOISTURE DETECTION WORK?
The use of neutron backscatter technology for
detecting moisture in insulation is based on the
principles of how neutrons interact with matter. A
radioactive source emits fast neutrons with high
energies that are difficult to detect. However,
when these fast neutron interact with matter, they
become slow or thermal neutrons. Neutrons are
most likely to interact with atoms that are similar
in size to the neutron itself. Hydrogen is the atom
closest in size and mass to these thermal neutrons,
so the majority of fast neutron interaction occurs
with hydrogen atoms.
When a fast neutron collides with a hydrogen atom,
it releases energy and becomes a slow or thermal
neutron. These thermal neutrons are scattered
in all directions but travel only short distances.
Some of these thermal neutrons are scattered
back towards the scanning head of a detection
device, and are then counted by the detector. The
more hydrogen atoms present in a given material
means that more thermal neutrons are created that
can also be detected. The measurement of these
thermal neutrons is calculated as the hydrogen
bulk density (HBD) of the material being tested.
Vapors typically have a low HBD, and will have
few thermal neutrons reflected back to the detector
head. Hydrocarbons and water have a greater HBD,
reflecting more neutrons back to the detector, and
resulting in higher count rates. Any hydrogenous
material can be measured in this manner, including
water, hydrocarbons, acids, bases, organic liquids,
concrete, and earth. When used in conjunction
with corrosion detection equipment, a neutron
backscatter detection device is an effective
screening tool that can be used to quickly locate
areas of trapped moisture and to detect areas
where corrosion under insulation is likely.
WHAT ARE THE ADVANTAGES OF
NEUTRON BACKSCATTER DETECTION?
Neutron backscatter detection is a non-invasive,
non-contacting method that remains external
to vessel under inspection. The technique is
independent of vessel geometry, since it requires
access to only one side of vessel being inspected.
Level measurements can be taken on both vertical
and horizontal storage tanks and vessels, and
testing can calculate accurate volumes for either
type of vessel when the vessel geometry is known.
Figure 2: Neutron backscatter detection device in use
Neutron backscatter detection devices incorporate
a number of features that offer significant
advantages in the detection of moisture and
possible corrosion under insulation. An integrated
moisture measurement gauge allows the test
engineer to quickly determine the amount of
water content in the thermal insulation of pipes
and vessels. Often, a “quick test” mode is
available that allows for automatic readings and
comparisons with dry standards. The detector
design provides for maximum accessibility in hard-
to-reach places, and a telescopic pole allows the
detector head to be positioned at distances of up
to 10 feet or more. These capabilities and features
allow for the inspection of thousands of feet of
insulated pipe in a single day.
Neutron backscatter devices also usually include
a built-in data logger that allows for the entry
of numerical identifiers and time/date stamping
for each test. And, because neutron backscatter
detection devices are microprocessor-based, tests
can be identified by location, and test data can be
stored for future use or uploaded to a computer for
further analysis.
Figure 3: Neutron backscatter device accessing hard-to-
reach areas
Vol. 5 March 2012
Page 3
CAN NEUTRON BACKSCATTER
DETECTION BE USED VIA ROPE ACCESS?
In many inspection and testing situations,
accessing equipment located at extreme heights is
a challenging proposition. Temporary scaffolding
has been the standard approach for accessing
such locations, but fixed scaffolding is expensive
and time-consuming to install, and often doesn’t
provide the flexibility necessary to ensure
uncompromised access and worker safety.
Rope access technology involves the application
of specialized techniques to safely place workers
in hard-to-reach job locations. Technicians use
ropes and descend, ascend, and traverse open
spaces to access equipment. As such, rope access
technology represents a proactive approach
to hazard identification and risk management,
producing a safe and compliant system for work at
any height.
Rope access technology is currently used for a
wide range of inspection tasks involving hard-
to-reach locations. Almost all nondestructive
inspection and testing services, including neutron
backscatter detection, can be conducted using rope
access technology.
ARE THERE OTHER APPLICATIONS FOR
NEUTRON BACKSCATTER DETECTION?
In addition to moisture detection, neutron
backscatter technology can be used in a number of
other applications in evaluating pipes and vessels
at chemical and petrochemical plants and facilities.
Here is just a brief list of possible alternative uses
for neutron backscatter detection:
• Determination of fluid levels inside vessels
• Calibration or verification of existing level
gauges
• Determination of contact interfaces (i.e., vapor,
hydrocarbon, water, solids, etc.)
• Investigation of foaming, frothing, and emulsion
layers
• Determination of catalyst levels in reactors
• Determination of liquid height in “down-comers”
• Determination of liquid height in distributors and
draw trays
• Location of hydrate, polymer or solids build-up in
process lines
• Quantification of sludge build-up in tanks and
flare headers
 Vol. 5 March 2012
TÜV SÜD E-ssentials Page 4

• Examination of levels or deposits on the shell

side of exchangers OSHA Mandates New Worker Protection
• Conduct of separator studies Requirements
• Location of water ingress under insulation
• Location of voids in the earthen support under The U.S. Occupational Safety and Health catastrophic releases, as well as unprogrammed
storage tank floors Administration (OSHA) has issued new regulations inspections at PSM-covered facilities. OSHA
to further protect workers at chemical facilities says that the intent of the new NEP is to conduct
ARE THERE LIMITATIONS TO THE USE OF from catastrophic releases of hazardous chemicals. focused inspections at facilities randomly selected
NEUTRON BACKSCATTER DETECTION? from a list of workplaces likely to have highly
The effective limits of neutron backscatter OSHA’s new National Emphasis Program (NEP) hazardous chemicals in large quantities.
detection are those imposed by the short distances was implemented in late 2011, following a
travelled by thermal neutrons. Accurate readings two-year pilot program focused on chemical According to OSHA, the new NEP does not apply
can only be obtained within 4 to 5 inches of facilities that are covered by the agency’s process to petroleum refineries. However, OSHA personnel
the detection head of the scanning device. This safety management (PSM) standard. The new have begun conducting inspections of facilities
limitation means that the thickness of cladding, NEP establishes policies and procedures for the with highly hazardous chemicals according to the
insulation and the shell thickness combined should inspection of facilities with highly hazardous NEP provisions.
not exceed three inches. In most cases, adhering chemicals. The NEP’s inspection process includes
to this thickness limit is sufficient to obtain good detailed questions designed to gather facts OSHA has published detailed instructions for
measurements without additional intervention. In related to PSM requirements, and verification carrying out inspections related to the new NEP
some situations, the inspecting technician may be that employers’ written and implemented PSM for chemical facilities. A copy of the instructions
required to remove a small strip of insulation to programs are consistent. is available at http://www.osha.gov/OshDoc/
better position the detection head and obtain the Directive_pdf/CPL_03-00-014.pdf. n
desired results. The NEP covers programmed inspections, that is,
inspections at facilities that have a known risk of
CONCLUSION
When a company suspects that corrosion
under insulation has occurred, it often spends
considerable time and money to confirm its
suspicions. Scaffolding must be erected, insulation
must to be removed, and resources and personnel
must be diverted from other tasks to conduct the
necessary inspection. Moisture detection with
neutron backscatter technology is a more cost-
effective and efficient alternative to traditional
inspection processes. It can dramatically reduce
the need for scaffolding and insulation removal,
resulting in saving of as much as 40% compared
with other inspection methods. And neutron
backscatter detection saves time, with less effort
devoted to inspection and minimal impact on
continued plant operations.

PetroChem Inspection Services personnel have

extensive experience in the use of neutron
backscatter technology for moisture detection
and possible corrosion, as well as in a wide range
of other applications. For additional information
about PetroChem’s neutron backscatter inspection
services, visit www.petrochemintl.com, or contact
Justin Lecourias at JLecourias@petrochemintl.com. n

TÜV SÜD E-ssentials
PetroChem Inspection Services Announces 2012 NDT Training Program Schedule
PetroChem Inspection Services has once again
partnered with Lavender International Non-
Destructive Testing USA, to provide an extensive
list of training and certification options for non-
destructive testing (NDT) operators in 2012.
This year’s training offerings will be held at
PetroChem Inspection’s Pasadena, TX headquarters,
and will include the following courses:
TOFD (10 DAYS, INCLUDING EXAM:
$3,450)
This course meets the general requirements for
Level 2 training and certification to the ISO 9712,
EN 473, and SNT-TC-1A certification schemes. A
comprehensive course syllabus is available upon
request. To be eligible for both the course and the
exam, prospective students must hold a relevant
Level 2 manual UT certification for weld testing
using angle beam probes.
PHASED ARRAY (12 DAYS, INCLUDING
EXAM: $3,950)
This course also meets the general requirements
for Level 2 training and certification to the ISO
9712, EN 473, and SNT-TC-1A certification
schemes. A comprehensive course syllabus is
available upon request. To be eligible for both the
course and the exam, prospective students must
hold a relevant Level 2 manual UT certification for
weld testing using angle beam probes.
TOMOVIEW FULL OFFLINE DATA
ANALYSIS (4 DAYS, $1,500)
This course is intended for those using Omniscan
instruments, and for those holding Level 3
certification wanting to view Omniscan data
offline using the Olympus TomoView full analysis
software. The course also includes information
on detection, characterization, and sizing, which
advances skills to encompass full analysis
principles.
MANUAL UT COURSE: BUTT WELDS IN
PLATE PCN CATEGORY 3.1 (FOR THOSE
WITH AT LEAST 5 YEARS EXPERIENCE, 5
DAYS, INCLUDING PCN EXAM: $1,595)
This course will refresh operators on applicable
general and specific theory, and also brush up
manual UT skills including sensitivity calibration,
scanning, detection, flaw characterisation and
sizing technique. PCN Manual UT Category 3.1
Butt Welds in Plate exam follows directly after
the training. Prospective students must hold
a minimum of manual UT Butt Welds In Plate
category 3.1, and have at least five or more years
of experience to attend this course.
MANUAL UT COURSE: BUTT WELDS IN
PLATE PCN CATEGORY 3.1 (FOR THOSE
WITH LESS THAN 5 YEARS EXPERIENCE,
10 DAYS, INCLUDING PCN EXAM: $2,895)
This course provides the requisite training for Level
2 UT certification for those with a minimum of 12
months documented work experience. The course
follows the PCN manual UT syllabus, covering UT
theory, calibration, sensitivity, equipment checks,
plate lamination and corrosion scanning, weld
scanning, defect detection, and characterization
and sizing. The 80 hour course will be taught over
8 days, followed by two days for the PCN exam.
ALTERNATING CURRENT FIELD
MEASUREMENT (ACFM), LEVEL 1 (5
DAYS, INCLUDING PCN EXAM: $3,350)
Alternating current field measurement (ACFM)
is a computerized electromagnetic method used
to detect surface breaking and cracking under
material coatings. This course provides details on
ACFM principles, software operation, and sizing
methodology. It is intended for technicians and
supervisors starting out with ACFM testing and
evaluation. Students are expected to bring their
own ACFM instruments and probes.
MAGNETIC PARTICLE TESTING
COURSES, LEVEL 1 AND LEVEL 2 (5 DAYS,
INCLUDING CERTIFICATION EXAM:
$1,275)
These magnetic particle testing courses cover
portable and fixed installation equipment, including
electromagnetic yokes, permanent magnets
and bench units. Training covers a wide range
of subjects, including testing principles for pre-
and in-service inspection, types of inspection
equipment, technique selection, UVA inspection,
Vol. 5 March 2012
Page 5
product technology, and codes and standards.
The courses below will be conducted on the
following dates during the first half of 2012:
• TomoView Full Offline Data Analysis—April 2-5
• Manual UT Course (for those with 5 or more
years experience)—April 16-20
• Manual UL Course (for those with less than 5
years experience)—April 16-27
• ACFM, Level 1—May 14-18
• Phased-Array—June 4-June 16
• Magnetic Particle Testing Course, Level 1 and
Additional course dates for the second half of 2012
will be announced shortly.
Tim Armitt, Technical Director of Lavender
International, and a Level 3 instructor and
consultant, will conduct these training courses.
With more than 20 years of NDT experience, Tim
specializes in ultrasonic testing, and has developed
a wide range of training programs covering NDT in
the petrochemical industry. Tim has obtained ANSI
Level 3 qualifications in UT, MT, PT, ET, and VT, and
is also a PCN Level 3 in eight separate categories.
Additional information about the PetroChem 2012
training program is available at http://lavender-
ndt.co.uk/usa/usa.html. For questions about the
program, or to register, contact Michelle Chapman,
at 281-913-9064 or at michelle@lavender-ndt.com.
n
 Vol. 5 March 2012
TÜV SÜD E-ssentials Page 6

2012 Industry Trade Shows and Events

For professionals in the petrochemical, refining, and power generation industries, keeping up with changes in technologies and regulations is a continuous effort.
Attendance at industry conventions, conferences, and trade shows is an effective and efficient way to stay current with the latest industry trends. PetroChem
Inspection Services will be exhibiting and/or presenting at many of the events below. Stop by our exhibit booth, meet our petrochemical industry experts, and
learn more about how PetroChem can help you address your specific challenges. We encourage you to visit http://tuvamerica.com/tuvnews/shows.cfm and pre-
register for a meeting with one of our experts attending the shows and receive a complementary PetroChem baseball cap! Here’s a list of the some of the major
industry shows scheduled for 2012:

ASTN 21ST ANNUAL RESEARCH SYMPOSIUM & SPRING CONFERENCE, DALLAS, TX, MARCH 19-23, 2012
Sponsored by the American Society for Non-Destructive Testing (ASNT), this annual symposium provides a forum for the exchange of theoretical and scientific
information on non-destructive testing between researchers, engineers, inspectors, and equipment manufacturers in the chemical and petrochemical industries.
For more information, go to http://www.asnt.org/events/conferences/sc12/sc12.htm.

ASME PLANT ENGINEERING, INSPECTION AND MAINTENANCE TRADE SHOW, PASADENA, TX, APRIL 19, 2012
The American Society for Mechanical Engineers (ASME) Technical Chapter will host its tenth annual trade show, dealing with all aspects of engineering,
inspection, and maintenance of refinery and petrochemical fixed and rotating equipment. Proceeds from the show will help fund ASME’s South Texas Section
university scholarship program. For more information, go to http://asmepem.org.

API/AFPM SPRING 2012 OPERATING PRACTICES SYMPOSIUM, DALLAS, TX, APRIL 24, 2012
Jointly sponsored this year by the American Petroleum Institute (API) and the American Fuel & Petrochemical Manufacturers (AFPM), this semi-annual gathering
provides a forum for the exchange of information and ideas on safe operating procedures and sharing of “best practices” within refineries and petrochemical
plants. For additional details, or to register, go to http://www.api.org/en/events-and-training/calendar-of-events/2012-events/spring-ops.aspx.

ITLA 32ND ANNUAL INTERNATIONAL OPERATING CONFERENCE AND TRADE SHOW, HOUSTON, TX, MAY 21-23, 2012
The annual conference and trade show of the International Liquid Terminals Association (ILTA) is for professionals in the petroleum and chemical industries,
including environmental and safety managers and engineers. For further information, go to http://www.ilta.org/CalendarofEvents/AOCTS/2012/2012info.htm.

ASNT FALL CONFERENCE AND QUALITY TESTING SHOW, ORLANDO, FL, OCTOBER 29-NOVEMBER 1, 2012
The American Society for Non-Destructive Testing (ASNT) Fall Conference and Quality Testing Show showcases the latest advances in the area of non-
destructive testing. For additional information, go to http://www.asnt.org/events/conferences/fc12/fc12.htm.

Your PetroChem contacts worldwide:

Americas Europe
PetroChem Inspection Services, Inc. TÜV SÜD Chemie Service GmbH
Toll-free: 1-800-747-4099 Phone: +49 214 30-62653
Fax: 281-884-5199 Email: beate.seiss@tuev-sued.de
Email: info@tuvam.com Web: www.tuev-sued.de/technical_installations/chemical_service
Web: www.petrochemintl.com

DISCLAIMER
All reasonable measures have been taken to ensure the quality, reliability, and accuracy of the information in this newsletter. However, TÜV SÜD is not responsible for the third-party content
contained in this newsletter. TÜV SÜD makes no warranties or representations, expressed or implied, as to the accuracy or completeness of information contained in this newsletter. This newsletter
is intended to provide general information on a particular subject or subjects and is not an exhaustive treatment of such subject (s). Accordingly, the information in this newsletter is not intended
to constitute consulting or professional advice or services. If you are seeking advice on any matters relating to information in this newsletter, you should – where appropriate – contact us directly
with your specific query or seek advice from qualified professional people. The information contained in this newsletter may not be copied, quoted or referred to in any other publication or materials
without the prior written consent of TÜV SÜD. All rights reserved © 2012 TÜV SÜD America Inc.
|| PetroChem | Technical industry e-news updates essential to your operations ||