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TÜV SÜD | Vol. 6 December 2012




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




     CONTENTS:
     API Summit Showcases PetroChem Technical Experts             02
     PetroChem Inspection Services Profile: Gerhard Abel          03
     FAQs on Mechnical Intergrity Inspection for Process Plants   05
     2013 NDT Training Program Schedule                           06
     2013 PetroChem Open House Events                             07
     2013 Trade Shows                                             08


    h t t p : / / w w w. p e t r o c h e m i n t l . c o m
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                                                    Page 2




                                                                       API Summit Showcases PetroChem Technical
Editorial                                                              Experts
Dear Reader,                                                                                                                  radiography for code quality weld inspection and
Welcome to the latest issue of PetroChem Essentials, the                                                                      acceptance. Primary consideration should be
e-newsletter from PetroChem Inspection Services, a subsidiary of                                                              given to material type, size, and thickness. Other
TÜV SÜD America.                                                                                                              considerations should be given to the type of
                                                                                                                              energy and phosphorus plate used. Protection
The publication of this issue of PetroChem Essentials coincides                                                               against backscatter is key in almost all situations.
with the 2013 American Petroleum Institute (API) Inspection            Technical experts from PetroChem Inspection
Summit and Expo, which begins on January 7th in Galveston,             Services will deliver several key presentations        This presentation will outline some methodologies
Texas. A number of PetroChem International technical experts           at the 2013 American Petroleum Institute (API)         used to help establish technique development
will be sharing their latest research in papers, presentations, and    Inspection Summit and Expo, to be held January         for code quality inspection through computerized
workshops at this year’s Summit. In this issue, we’ve provided a       7-10, 2013, at the Galveston Island Convention         radiography.
brief summary of those presentations, and hope that you’ll have        Center in Galveston, Texas.
time to attend one or more of these presentations at the Summit.                                                              “INSPECTION OF RAISED FACE HF ALKY
                                                                       The annual API Inspection Summit is the premiere        FLANGES WITH PHASED ARRAY”—
The future of energy production in the U.S. has never been brighter.   venue for petroleum industry inspection and             JOHN SELLERS, WEDNESDAY, JANUARY
But with that growth comes an increased focus on the importance        reliability professionals and examiners. The            9TH, 10:30 AM (INSPECTION/NDE – 1)
of safety. In an interview with the editors of PetroChem               2013 Summit will offer more than 100 individual        Corrosion at petrochemical and refining facilities
E-ssentials, I offer a perspective on some of the key safety issues    technical program sessions, covering topics in         will always be a major concern for piping
facing energy processors and producers in the coming years.            inspection and non-destructive testing, metallurgy     integrity. HF alkylation units face an unusual
                                                                       and corrosion, and engineering, and analysis. The      type of corrosion that attacks the raised gasket
PetroChem is a leader in the implementation of mechanical              Summit’s keynote address will be delivered by          seating surface of the flanges. Safety conditions
integrity inspection programs at processing plants around the          John Bolton, former U.S. ambassador to the United      associated with the product, as well as access to
country. In our article, “FAQs on Mechanical Integrity Inspection      Nations.                                               the area of interest affect the ability to reliably
for Process Plants,” we answer several frequently asked                                                                       inspect these areas. Identifying appropriate
questions about the mechanical integrity inspection process.           New at this year’s Summit will be an optional          inspection methods and tools is essential in
                                                                       one-day training component, scheduled for              establishing a good inspection program of these
Looking ahead, PetroChem is pleased to announce its 2013               Monday January 7th, when eight separate in-depth       flanges.
calendar of technical training courses for non-destructive testing     technical courses will be offered. The courses and
operators. Conducted in Pasadena, TX, the courses are once             workshops include a half-day workshop on Phased        Several factors must be taken into consideration
again being offered in conjunction with our partner, Lavender          Array and Time of Flight Diffraction Technique,        when implementing the inspection of the HF
International. See our article for this year’s training schedule and   led by Tim Armitt of Lavender International NDT,       alkylation units. First and foremost is safety. Others
for additional details on the program.                                 PetroChem’s training partner.                          are access, timeframe, tracking, and cost. There
                                                                                                                              are only a few ways to inspect these flanges to
We round out this issue of PetroChem Essentials with a lineup          Here is a brief summary of the four presentations      determine if they are fit for continued service. A
of 2013 industry trade shows, conferences, and other events that       being delivered by PetroChem Inspection Services       commonly used method in the industry today
may be of interest to our readers, as well as the 2013 schedule of     professionals at this year’s API Inspection Summit:    is to visually check each flange set during an
PetroChem Open Houses.                                                                                                        outage by using a straight edge on the surface
                                                                       “CODE QUALITY INSPECTION THROUGH                       and measuring the damage to see if it is in the
We hope that you enjoy this issue of PetroChem Essentials. As           COMPUTERIZED RADIOGRAPHY”—                            gasket seating area. This puts the inspector at
always, we welcome your comments or suggestions on ways to              WILLIAM BOBBITT, TUESDAY, JANUARY                     greater risk of exposure to the product and forces
improve this e-newsletter, or ideas for future topics.. Safe and        8TH, 2:15 PM (INSPECTION/NDE – 2)                     the owner of the equipment to wait until outage
Happy Holidays, and a Prosperous New Year!                             Advancements in radiography in the past decade         for cost of replacement. Phased array technology
                                                                       have been great. Computerized radiography is           can be utilized to screen many of the flanges in
Thanks!                                                                no exception, although the mainstay seems to           service, thus reducing exposure risks and providing
                                                                       be geared more toward profile and informational        estimated replacement projections in time to
                                                                       inspection. Computerized radiography is capable        budget for outages.
                                                                       of more, but in order to do so, certain steps should
Gerhard Abel                                                           be taken. Several factors must be taken into           This presentation will outline some methodologies
President, PetroChem Inspection Services                               consideration when implementing computerized           used to inspect these flanges and the benefits
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                            Page 3




for doing so. The employment of pre-assessment,       This presentation will cover actual capabilities      same assessment of the shell can be applied to
indirect/direct inspections, and post assessment      and what to expect for results on the above           the bottom allowing a thorough assessment of
can prove to be valuable instruments in obtaining     listed types of applications based on technician      tank shell and bottom settlement, allowing for the
an effective inspection.                              field experience with validated findings. False       worst area of deflection to be identified based on
                                                      expectations such as type of results to expect        the vast number of elevations collected from the
“PRACTICAL APPLICATION OF GUIDED                      and exaggerated capabilities will be addressed.       bottom. With the inspection map created of the
 WAVE INSPECTION: A TECHNICIAN’S                      Actual benefits and how to effectively utilize the    bottom, the entire affected area can be identified
 PERSPECTIVE”—MIKE SENS,                              technology will be addressed. Reported results        for the area and the profile of the bottom to allow
 WEDNESDAY, JANUARY 9TH, 10:30 AM                     and general guided wave inspection reports will       for a more accurate finite element analysis of the
 (INSPECTION/NDE – 2)                                 be analyzed. The presentation will also examine       area. Tank calibration is another area where the
Guided wave pipe testing is a specialty ultrasonic    the level and type of training, certification, and    technology can be utilized. Utilizing this technology
method that can inspect various lengths of piping     experience a technician should have, and what and     for tank calibrations can ensure that volumes
from a single location for a variety of damage        end user should look for in a quality guided wave     are derived utilizing the full surface of the tank
types or situations. Guided wave testing can be       inspector.                                            shell and bottom to include all deformations are
applied in numerous applications: piping in pipe                                                            included in the computations.
racks for CUI; piping in pipe racks for corrosion     “THREE DIMENSIONAL LASER
damage at supports; sleeved piping such as road        SCANNING OF ABOVEGROUND                              This presentation will discuss the information that
way and rail crossings; dock piping for external       STORAGE TANKS”—IDA MARIE CARDEN,                     can be obtained by deploying three dimensional
damage from environment; elevated inaccessible         THURSDAY, JANUARY 10TH, 1:30 PM                      laser technology.
piping on structures or equipment; buried piping       (INSPECTION/NDE – 2)
for general condition; piping through tank dike       The application of three dimensional laser scanning   For additional information about the 2013 API
walls; piping through concrete walls; and piping      of tanks provides owner/operators with a great of     Inspection Summit, go to http://www.api.org/
with internal erosion potential from product          information regarding their tanks. This technology    events-and-training/calendar-of-events/2013/2013-
flow. However, although guided wave testing is        can provide detailed assessment of the shell of the   inspection-summit.aspx. n
a credible inspection method, it has fallen into      tank with regard for deformations. The information
disrepute with some for inappropriate use or          collected can provide an “as is” detailed digital
impractical expectations.                             representation of any deformations present. The



PetroChem Inspection Services Profile: Gerhard Abel
                               By most accounts,      distributors meet the growing demand for energy       in the U.S. and PetroChem’s important work with
                               energy production      while keeping workers safe. Gerhard Abel is the       energy processors and distributors.
                               in the U.S. is         president of PetroChem Inspection Services, and
                               entering a period of   has been involved in the safety management and        (PetroChem E-ssentials): There has been
                               significant growth,    inspection of energy assets for more than 20 years.   significant interest here in the U.S. in the past few
                               and some experts       He holds a degree in mechanical engineering           years on energy production from domestic sources,
                               are even predicting    from Technical University Wuerzburg in Germany,       and a number of government and industry reports
                               that the U.S. will     and is a certified welding engineer. From his first   are predicting a boom in domestic oil and natural
                               achieve energy         position as a certified code inspector for pressure   gas production. From your perspective, what are
                               independence in the    equipment at TÜV SÜD in Munich, Germany, to           the opportunities and challenges of the growth of
                               coming years. This     holding positions in the U.S. for the past 18 years   domestic energy?
anticipated growth is also likely to mean increased   as Regional Manager, Director Industry Service,
concerns about the safety of domestic oil and         Vice-President and now President at PetroChem         (Gerhard Abel): The boom in domestic energy
natural gas production, transportation, storage,      Inspection Services, Inc., Mr. Abel has spent         production is already happening. Through
and processing facilities, such as pipelines,         the bulk of his career involved in performing         conventional production, as well as various
storage tanks, and refining assets.                   inspections for, or managing mechanical integrity     technological advances such as horizontal drilling
                                                      programs in, the power generation, oil and gas,       and the exploration of shale energy sources
For more than 30 years, PetroChem Inspection          and chemical industries.                              and tight oil formations, the U.S. is producing
Services, a division of TÜV SÜD America, has                                                                over 6,500 million barrel of oil per day today, a
provided state-of-the-art inspection and testing      Mr. Abel recently spoke with PetroChem                production level not seen since 1998. Even more
services designed to help energy producers and        E-ssentials about the growth of the energy industry   telling is the 900-barrel-per-day increase from
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                                    Page 4




September 2011 to December 2012. That shows             operations. In addition, newly developed energy        insulation (CUI) programs have also seen increased
that the increase in production is consistently         resources such as heavy crudes pose different          use as a tool to identify suspect areas and provide
gaining steam and, by most accounts, that trend         challenges regarding corrosion of the assets           a more targeted approach in inspection programs.
will continue.                                          containing those liquids. All of these factors need    We’re also one of the first companies in the U.S.
                                                        to be accounted for when developing mechanical         to use small contained area radiography (SCAR)
This development presents tremendous                    integrity programs for these assets.                   to perform x-ray inspections. Electromagnetic
opportunities for all companies involved in the                                                                acoustic transducer, or EMAT inspections for
processing industries. These industries already         (PCE): Alternative fuels and sources of renewable      touchpoint corrosion monitoring, is also in use in
support more than 10 million jobs in the U.S., and      energy are also gaining increased attention. Do        the field, as are eddy current and IRIS technology
future job growth will help support the continued       the safety issues related to conventional energy       for the inspection of tubes in heat exchangers.
recovery of the U.S. economy. Recent research           processing and distribution apply to these newer       Alternating current field measurement (ACFM)
predicts that the U.S. will be energy independent       energy sources? If not, how do they differ?            inspections for the detection of surface cracks has
within the next 10 years or so, and eventually                                                                 been utilized by PetroChem for many years, as
become a net exporter of gas and refined products,                                                             have advanced ultrasonic inspection methods, such
a complete turnaround of what we experienced as                                                                as shear wave, phased array, and automated UT
recently as 5 to 10 years ago.                                                                                 inspections for corrosion mapping purposes.

Of course, every boom has its challenges, and the                                                              We recently acquired new equipment based on
biggest challenge in this current boom include the                                                             new technologies that use lasers for the calibration
safe transportation of gas, condensates and oil to                                                             of tanks, significantly reducing the time needed to
processing facilities, storage capacities that safely                                                          accurately calibrate the volume of a storage tank,
store the products, and assets such as pipelines                                                               and generating significantly more accurate results
and terminals that handle the safe transportation                                                              in the process.
of these products. The present infrastructure
certainly needs expanded capacity and ongoing                                                                  (PCE): What are the advantages and
maintenance, and that trend can be seen in the          (GA): There are some obvious differences in the        disadvantages (if any) of advanced non-destructive
sizeable investment being made in these areas by        safety concerns of ethanol derived from corn or        inspection and testing techniques compared with
the oil industry today.                                 sugar cane and gasoline refined from oil, such as      more traditional forms of inspection and testing?
                                                        the potential for explosions, for example. However,
(PCE): The U.S. National Transportation Safety          the protection of people and waterways, and            (GA): The key to any successful inspection is to
Board recently designated enhanced pipeline             avoiding issues such as soil contamination, apply      generate reliable results that assure continued
safety and infrastructure preservation at two of        equally to conventional fuels and alternative fuels.   safe operation of the asset inspected. Some
its priorities for industry in 2013. In your opinion,   And risks stemming from corrosion and erosion          methods are more efficient in achieving those
how safe is the domestic energy infrastructure for      in transportation and storage assets have to be        results, but there is no magic wand that replaces
workers, and what steps could energy providers          addressed in much the same way.                        an experienced, well-trained inspector, working
take to improve safety overall?                                                                                to high-quality standard procedures. Any tool is
                                                        (PCE): PetroChem Inspection Services is a leader       only as effective and as reliable as the person
(GA): It’s important to note that the safety            in the use of non-destructive inspection and           using it, which is why continued training of
performance of the 2.6 million miles of pipelines       testing techniques. Tell us about some of the more     inspection personnel is the single most important
in the U.S. has improved significantly in recent        advanced techniques that you’re presently using        aspect of any inspection program. PetroChem
years. Safety incidents are down 59% since 1999,        in the field.                                          places great emphasis on this, and maintains
a major accomplishment. In 2011, investment in                                                                 rigorous qualification standards to ensure proper
the infrastructure integrity of the industry totaled    (GA): PetroChem is driven by innovation in the         qualification of our personnel, and the highest
more than $1 billion, a huge investment in the safe     field of nondestructive inspection methodologies.      standards of inspection work we perform. I am
operation of that infrastructure.                       We understand that, if you don’t recognize and         proud of our managers and technicians in the field,
                                                        implement new inspection technologies, you are         and their commitment to quality.
However, when it comes to the safe operation of         not addressing the future of your business.
any asset involved in the transportation, storage                                                              (PCE): PetroChem Inspection Services is
or processing of oil or gas, it is never about a        PetroChem was the first inspection company in the      also a leader in providing refinery turnaround
single act. Instead, it is about developing a culture   U.S. to successfully utilize guided wave ultrasonics   management services. What are some of the key
of safety. As the infrastructure gets older, new        for the inspection of pipes in the field. Real time    selection factors for refinery operators to consider
approaches are required to assure continued safe        radiography for detection of corrosion under           when seeking turnaround management assistance?
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                              Page 5




(GA): Plant shutdowns are stressful for anybody        temperatures and high pressures, the oil and           such as ultrasonic, magnetic particle, radiographic,
working in these plants. Construction activities       natural gas industry and its suppliers have a          and eddy current. As specialist in advanced
needed to repair, replace or upgrade equipment,        strong safety record. But to maintain that record,     technology, we pioneered long-range guided wave
and the associated chaos that comes with these         everyone working in the industry has to make           ultrasonics, and are an experienced provider of
activities, pose a significant safety challenge.       safety their top priority, and take advantage of the   advanced NDT services such as computerized
Facility Managers are looking for a service provider   right technologies, standards, and best practices,     radiography and ACFM.
that understands these challenges, and who             and programs. Every safety-related incident is
contributes to addressing problems rather than         important because of the danger is presents to         (PCE): Why should energy producers and
adding to them. All of our turnaround projects         people, the environment, and society in general. So    distributors choose PetroChem Inspection Services
are staffed by a senior manager with years of          safety is everyone’s job.                              as their asset integrity and compliance partner?
experience in turnaround inspection projects.
We have also significantly expanded our NDE            (PCE): How can PetroChem Inspection Services           (GA): PetroChem Inspection Services is committed
capabilities and capacities in order to provide        help petrochemical companies address these             to providing solutions. We have the experience to
the complete array of services required for any        issues?                                                implement asset integrity management systems
turnaround project, from API inspectors to the full                                                           that meet the compliance requirements of API,
gamut of NDE techniques.                               (GA): We’re a leading provider of both on-stream       OSHA, EPA, and DOT and which provide our
                                                       and turnaround visual inspection, and one of the       customers with safety, improved reliability, and
(PCE): In looking at the year ahead, what are some     largest employers of API inspectors in the U.S.        increased profits. Our mission is to consistently
of the most important asset integrity challenges for   Our mechanical integrity program is recognized         exceed our client expectations by combining
the petrochemical industry to consider? Why are        as the standard in the petrochemical industry,         traditional inspection methods with the most
they important?                                        and our ability to rapidly mobilize large groups of    advanced inspection technologies in order to
                                                       certified inspection personnel makes us a leader in    achieve superior operating safety. n
(GA): Despite a work environment that involves         turnaround services. In addition, PetroChem offers
heavy equipment, hazardous materials, high             comprehensive traditional non-destructive testing,




FAQs on Mechanical Integrity Inspection for Process Plants
                                                       and provides guidance for the future inspection        WHAT DOES A MECHANICAL INTEGRITY
                                                       of in-service piping and systems and related           INSPECTION PROGRAM INVOLVE?
                                                       documentation.                                         The program involves extensive inspection
                                                                                                              and sampling of large quantities of piping and
                                                       WHAT IS THE GOAL OF THE PROGRAM?                       equipment at random points within a system.
                                                       The goal of a mechanical integrity inspection is to    Additional inspection points are also selected
                                                       accurately assess the condition and integrity of       to accurately assess the integrity of piping and
                                                       equipment and piping systems, thereby allowing         equipment at key areas of concern.
PetroChem Inspection Services specializes in           the operator to repair or replace faulty equipment
mechanical integrity inspection programs that help     in advance of spill, explosion, or other adverse       WHAT INFORMATION IS REQUIRED TO
to ensure the integrity of piping systems, pressure    incident.                                              CONDUCT A THOROUGH AND ACCURATE
vessels, tanks, and other related equipment and                                                               INSPECTION?
components. In this brief article, we provide          WHAT TYPE OF EQUIPMENT IS                              Prior to a mechanical integrity inspection, plant
answers to some of the frequently asked questions      TYPICALLY COVERED IN A MECHANICAL                      operators should be prepared to provide extensive
regarding mechanical integrity inspection.             INTEGRITY INSPECTION?                                  documentation regarding piping and equipment to
                                                       All types of piping and equipment found in             be inspected. At a minimum, documentation should
WHAT IS A MECHANICAL INTEGRITY                         processing plants are subject to inspection            be available that addresses the following issues:
INSPECTION PROGRAM?                                    under a mechanical integrity program. These can
A mechanical integrity inspection is a method for      include pressure vessels and storage tanks, piping     •	 Materials used in the construction of the piping
identifying corrosion in pipes and other equipment,    systems and components, relief valve systems              and equipment
and for monitoring the effects of corrosion over       and devices, pumps, and alarm systems, and other       •	 Intended and actual operating pressures and
time. A mechanical integrity inspection program        instrumentation.                                          temperatures of the inspected systems
establishes minimum integrity requirements                                                                    •	 Minimum ANSI flange rating
Vol. 6 December 2012
  TÜV SÜD E-ssentials                                                                                                                                  Page 6




•	 Process fluids used in the inspected systems       •	 Prior operating history, and results from
•	 Classification information regarding the piping       previous inspections
   systems                                            •	 Findings from the current inspection
•	 Classification of the types of circuits in use     •	 Calculations of the rate of corrosion and
•	 Corrosion rate and minimum remaining life of          estimated remaining life
   circuits in use                                    •	 Maximum inspection intervals established by
•	 Actual intervals between prior external and           API 570 & 510
   internal inspections                               •	 Additional applicable requirements of any
•	 Any unusual or localized corrosion that might         authority having jurisdiction (AHJ)
   require specialized inspection techniques
                                                      Intervals should be established for various types      Of course, certifications are not a substitute for the
WHAT DOES THE INSPECTION                              of inspections, including internal inspections,        experience and judgment of qualified inspection
PRODUCE?                                              on-stream inspections, external inspections, visual    personnel.
A mechanical integrity inspection produces            inspections, and supplemental inspections.
updated documentation and drawings for all                                                                   PetroChem's approach to mechanical integrity
systems in use, as well as a description of the       WHAT KIND OF EXPERTISE IS REQUIRED                     focuses on the requirements of OSHA 1910-
inspection as performed. The final report provides    TO CONDUCT A MECHANICAL INTEGRITY                      119/API, thereby supporting efforts to conduct
written narrative descriptions of the condition of    INSPECTION?                                            cost-effective mechanical integrity inspections.
piping and equipment and any findings of corrosion.   Conducting a thorough and comprehensive                PetroChem can establish a mechanical integrity
                                                      mechanical integrity inspection requires industry      inspection program based on code compliance,
HOW FREQUENTLY SHOULD                                 professionals with extensive experience in the         as well as perform the inspection, data entry,
MECHANICAL INTEGRITY INSPECTIONS                      inspection and evaluation of piping and systems.       and data analysis needed to implement it. For
BE CONDUCTED?                                         Inspectors should be certified to the requirements     additional information about mechanical integrity
The initial mechanical integrity inspection           of API 510, 570 and 653. Technicians utilizing         inspections and PetroChem Inspection Services
will establish the maximum interval between           non-destructive testing (NDT) techniques should        mechanical integrity experience, visit our website
successive inspections, based on the following        be certified to SNT-TC-1A. Data entry personnel        at http://www.petrochemintl.com/industry/
factors:                                              should meet industry accepted practices regarding      petrochem.cfm, click here to view our product
                                                      computer-aided design and/or data management.          videos, or contact us at 800-747-4099. n




 PetroChem Inspection Services Announces 2013 NDT Training Program Schedule
                                                      ALTERNATING CURRENT FIELD                              electromagnetic yokes, permanent magnets, and
                                                      MEASUREMENT (ACFM) (5 DAYS,                            bench units. Training covers a wide range of
                                                      INCLUDING PCN EXAM, $2495)                             subjects, including testing principles for pre and in-
                                                      Alternating current field measurement (ACFM)           service inspection, types of inspection equipment,
                                                      is a computerized electromagnetic method used          technique selection, UVA inspection, product
                                                      to detect surface breaking and cracking under          technology, and codes and standards.
For the third successive year, PetroChem Inspection   material coatings. This course provides details on
Services, a division of TÜV SÜD America, is once      ACFM principles, software operation, and sizing        MANUAL UT PLATE & PIPE WELDS (10
again partnering with Lavender International Non-     methodology. It is intended for technicians and        DAYS, INCLUDING PCN EXAM; $3092)
Destructive Testing USA, to provide an extensive      supervisors starting out with ACFM testing and         This course provides the requisite training for Level
set of training and certification options for non-    evaluation. Students are expected to bring their       2 UT certification for those with a minimum of 12
destructive testing (NDT) operators in 2013.          own ACFM instruments and probes.                       months documented work experience. The course
                                                                                                             follows the PCN manual UT syllabus: covering UT
This year’s training offerings will be held in        MAGNETIC PARTICLE TESTING (5 DAYS,                     theory, calibration, sensitivity, equipment checks,
Pasadena, TX (near PetroChem Inspection’s             INCLUDING CERTIFICATION EXAM,                          plate lamination and corrosion scanning, weld
Houston headquarters), and will include the           $1420)                                                 scanning, defect detection, and characterization
following courses:                                    These magnetic particle testing courses cover          and sizing. The 80-hour course will be taught over
                                                      portable and fixed installation equipment, including   8 days, followed by two days for the PCN exam.
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                         Page 7




PHASED-ARRAY (12 DAYS, INCLUDING                      offline using the Olympus TomoView full analysis      o April 15-28
EXAM; $4175)                                          software. The course also includes information        o June 3-15
This course also meets the general requirements       on detection, characterization and sizing, which      o August 5-17
for Level 2 training and certification to the ISO     advances skills to encompass full analysis         •	 ToFD
9712, EN 473, and SNT-TC-1A certification             principles.                                           o February 4-February 15
schemes. A comprehensive course syllabus is                                                                 o March 25-April 5
available upon request. To be eligible for both the                                                         o May 20-31
course and the exam, prospective students must                                                              o July 19-August 2
hold a relevant Level 2 manual UT certification for                                                      •	 ACFM—Call for dates
weld testing using angle beam probes.                                                                    •	 TomoView Full Data Analysis—Call for dates

TOFD (10 DAYS, INCLUDING EXAM;                                                                           Tim Armitt, Technical Director of Lavender
$3655)                                                                                                   International, and a Level 3 instructor and
This course meets the general requirements for                                                           consultant, will conduct these training courses.
Level 2 training and certification to the ISO 9712,                                                      With more than 20 years of NDT experience, Tim
EN 473, and SNT-TC-1A certification schemes. A                                                           specializes in ultrasonic testing, and has developed
comprehensive course syllabus is available upon       The above courses will be conducted on the         a wide range of training programs covering NDT in
request. To be eligible for both the course and the   following dates during 2013:                       the petrochemical industry. Tim has obtained ANSI
exam, prospective students must hold a relevant       •	 Magnetic Particle Testing                       Level 3 qualifications in UT, MT, PT, ET and VT, and
Level 2 manual UT certification for weld testing          o March 4-8                                    is also a PCN Level 3 in eight separate categories.
using angle beam probes.                                  o April 29-May 3
                                                      •	 Manual UT Plate & Pipe Welds                    Additional information about the PetroChem 2013
TOMOVIEW FULL DATA ANALYSIS (4                            o January 21-February 2                        training program is available at http://lavender-ndt.
DAYS, $1545)                                              o March 11-22                                  co.uk/usa/usa.html. For questions about the program,
This course is intended for those using Omniscan          o May 6-17                                     or to register, contact Michelle Chapman, at 281-913-
instruments, and for those holding Level 3            •	 Phased-Array                                    9064 or at michelle@lavender-ndt.com. n
certification wanting to view Omniscan data               o February 18-March 2




Dates Set for 2013 PetroChem Open House Events
PetroChem Inspection Services is pleased to           •	   New Orleans, LA—April 17, 2013
announce the schedule for our Open House events       •	   Corpus Christi, TX—May 23, 2013
at selected PetroChem facilities around the country   •	   Chicago, IL—June 19, 2013
in 2013.                                              •	   Toledo, OH—July 26, 2013

Each day-long PetroChem Open House event              Our Open House events are an excellent
includes informative, “hands-on” demonstrations       opportunity to learn more about PetroChem’s
and technical presentations. Presentations and        wide range of testing and assessment services
demonstrations run from 9:00 am-12:00 pm, and         and capabilities, and to discuss your particular
from 1:00 pm-4:00 pm. A catered lunch will            challenges with our technical experts in an
also be served at each Open House event for all       informal setting.
attendees.
                                                      If you are interested in attending any of our
Open House events are currently scheduled for the     scheduled Open House events, please contact
following PetroChem facilities:                       Patty Sweeten at 281-884-5187, or at Patty_
•	 Houston, TX—February 27-28, 2013                   Sweeten@PetroChemIntl.com. Sign up for Twitter
•	 Beaumont, TX—March 20, 2013                        and follow @TUVPetroChem. n
Vol. 6 December 2012
 TÜV SÜD E-ssentials                                                                                                                                                                         Page 8




2013 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. Here’s a list of
the some of the major industry shows scheduled for 2013:

API INSPECTION SUMMIT, GALVESTON, TX, JANUARY 7-10, 2013
The annual API Inspection Summit is the premiere venue for petroleum industry inspection and reliability professionals and examiners. The 2013 Summit will
offer more than 100 individual technical program sessions, covering topics in inspection and non-destructive testing, metallurgy and corrosion, and engineering
and analysis. For more information, go to http://www.api.org/events-and-training/calendar-of-events/2013/2013-inspection-summit.aspx.

NISTM 15TH ANNUAL INTERNATIONAL ABOVEGROUND STORAGE TANK CONFERENCE AND TRADE SHOW, ORLANDO, FL
MARCH 13-15, 2013
Sponsored by the National Institute for Storage Tank Management (NISTM), the 15th Annual Conference and Trade Show will feature more than 50 technical
sessions on aboveground storage tank (AST) operations, AST integrity management, and AST environmental issues, and will also cover a number of specialty
topics such as aviation fuel storage. For additional details, go to http://www.nistm.org.

ASTN 22ND ANNUAL RESEARCH SYMPOSIUM & SPRING CONFERENCE, MEMPHIS, TN, MARCH 18-21, 2013
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/sc13/sc13.htm.

ASME PLANT ENGINEERING, INSPECTION AND MAINTENANCE TRADE SHOW, PASADENA, TX, APRIL 19, 2013
The American Society for Mechanical Engineers (ASME) Technical Chapter will host its ninth 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.

 ILTA, HOUSTON, TX, JUNE 3-5, 2013
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/2013/2013info.htm.

 INTERNATIONAL FUEL ETHANOL WORKSHOP & EXPO, ST. LOUIS, MO, JUNE 10-13, 2013
Since 1985, the International Fuel Ethanol Workshop & Expo has delivered essential and timely presentations on every aspect of commercial-scale ethanol
production, including production yield management, quality control, and regulatory compliance. For more details, go to http://www.fuelethanolworkshop.com.

PetroChem Inspection Services, a division of TÜV SÜD America, will be exhibiting and/or presenting at many of the above events. Stop by our exhibit booth,
meet our petrochemical industry experts, and learn more about how PetroChem can help you address your specific challenges, or sign up for Twitter and follow @
TUVPetroChem for the latest updates.

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 ||

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PetroChem Essentials december 2012

  • 1. TÜV SÜD | Vol. 6 December 2012 E-ssentials PetroChem | Technical industry e-news updates essential to your operations CONTENTS: API Summit Showcases PetroChem Technical Experts 02 PetroChem Inspection Services Profile: Gerhard Abel 03 FAQs on Mechnical Intergrity Inspection for Process Plants 05 2013 NDT Training Program Schedule 06 2013 PetroChem Open House Events 07 2013 Trade Shows 08 h t t p : / / w w w. p e t r o c h e m i n t l . c o m
  • 2. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 2 API Summit Showcases PetroChem Technical Editorial Experts Dear Reader, radiography for code quality weld inspection and Welcome to the latest issue of PetroChem Essentials, the acceptance. Primary consideration should be e-newsletter from PetroChem Inspection Services, a subsidiary of given to material type, size, and thickness. Other TÜV SÜD America. considerations should be given to the type of energy and phosphorus plate used. Protection The publication of this issue of PetroChem Essentials coincides against backscatter is key in almost all situations. with the 2013 American Petroleum Institute (API) Inspection Technical experts from PetroChem Inspection Summit and Expo, which begins on January 7th in Galveston, Services will deliver several key presentations This presentation will outline some methodologies Texas. A number of PetroChem International technical experts at the 2013 American Petroleum Institute (API) used to help establish technique development will be sharing their latest research in papers, presentations, and Inspection Summit and Expo, to be held January for code quality inspection through computerized workshops at this year’s Summit. In this issue, we’ve provided a 7-10, 2013, at the Galveston Island Convention radiography. brief summary of those presentations, and hope that you’ll have Center in Galveston, Texas. time to attend one or more of these presentations at the Summit. “INSPECTION OF RAISED FACE HF ALKY The annual API Inspection Summit is the premiere FLANGES WITH PHASED ARRAY”— The future of energy production in the U.S. has never been brighter. venue for petroleum industry inspection and JOHN SELLERS, WEDNESDAY, JANUARY But with that growth comes an increased focus on the importance reliability professionals and examiners. The 9TH, 10:30 AM (INSPECTION/NDE – 1) of safety. In an interview with the editors of PetroChem 2013 Summit will offer more than 100 individual Corrosion at petrochemical and refining facilities E-ssentials, I offer a perspective on some of the key safety issues technical program sessions, covering topics in will always be a major concern for piping facing energy processors and producers in the coming years. inspection and non-destructive testing, metallurgy integrity. HF alkylation units face an unusual and corrosion, and engineering, and analysis. The type of corrosion that attacks the raised gasket PetroChem is a leader in the implementation of mechanical Summit’s keynote address will be delivered by seating surface of the flanges. Safety conditions integrity inspection programs at processing plants around the John Bolton, former U.S. ambassador to the United associated with the product, as well as access to country. In our article, “FAQs on Mechanical Integrity Inspection Nations. the area of interest affect the ability to reliably for Process Plants,” we answer several frequently asked inspect these areas. Identifying appropriate questions about the mechanical integrity inspection process. New at this year’s Summit will be an optional inspection methods and tools is essential in one-day training component, scheduled for establishing a good inspection program of these Looking ahead, PetroChem is pleased to announce its 2013 Monday January 7th, when eight separate in-depth flanges. calendar of technical training courses for non-destructive testing technical courses will be offered. The courses and operators. Conducted in Pasadena, TX, the courses are once workshops include a half-day workshop on Phased Several factors must be taken into consideration again being offered in conjunction with our partner, Lavender Array and Time of Flight Diffraction Technique, when implementing the inspection of the HF International. See our article for this year’s training schedule and led by Tim Armitt of Lavender International NDT, alkylation units. First and foremost is safety. Others for additional details on the program. PetroChem’s training partner. are access, timeframe, tracking, and cost. There are only a few ways to inspect these flanges to We round out this issue of PetroChem Essentials with a lineup Here is a brief summary of the four presentations determine if they are fit for continued service. A of 2013 industry trade shows, conferences, and other events that being delivered by PetroChem Inspection Services commonly used method in the industry today may be of interest to our readers, as well as the 2013 schedule of professionals at this year’s API Inspection Summit: is to visually check each flange set during an PetroChem Open Houses. outage by using a straight edge on the surface “CODE QUALITY INSPECTION THROUGH and measuring the damage to see if it is in the We hope that you enjoy this issue of PetroChem Essentials. As COMPUTERIZED RADIOGRAPHY”— gasket seating area. This puts the inspector at always, we welcome your comments or suggestions on ways to WILLIAM BOBBITT, TUESDAY, JANUARY greater risk of exposure to the product and forces improve this e-newsletter, or ideas for future topics.. Safe and 8TH, 2:15 PM (INSPECTION/NDE – 2) the owner of the equipment to wait until outage Happy Holidays, and a Prosperous New Year! Advancements in radiography in the past decade for cost of replacement. Phased array technology have been great. Computerized radiography is can be utilized to screen many of the flanges in Thanks! no exception, although the mainstay seems to service, thus reducing exposure risks and providing be geared more toward profile and informational estimated replacement projections in time to inspection. Computerized radiography is capable budget for outages. of more, but in order to do so, certain steps should Gerhard Abel be taken. Several factors must be taken into This presentation will outline some methodologies President, PetroChem Inspection Services consideration when implementing computerized used to inspect these flanges and the benefits
  • 3. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 3 for doing so. The employment of pre-assessment, This presentation will cover actual capabilities same assessment of the shell can be applied to indirect/direct inspections, and post assessment and what to expect for results on the above the bottom allowing a thorough assessment of can prove to be valuable instruments in obtaining listed types of applications based on technician tank shell and bottom settlement, allowing for the an effective inspection. field experience with validated findings. False worst area of deflection to be identified based on expectations such as type of results to expect the vast number of elevations collected from the “PRACTICAL APPLICATION OF GUIDED and exaggerated capabilities will be addressed. bottom. With the inspection map created of the WAVE INSPECTION: A TECHNICIAN’S Actual benefits and how to effectively utilize the bottom, the entire affected area can be identified PERSPECTIVE”—MIKE SENS, technology will be addressed. Reported results for the area and the profile of the bottom to allow WEDNESDAY, JANUARY 9TH, 10:30 AM and general guided wave inspection reports will for a more accurate finite element analysis of the (INSPECTION/NDE – 2) be analyzed. The presentation will also examine area. Tank calibration is another area where the Guided wave pipe testing is a specialty ultrasonic the level and type of training, certification, and technology can be utilized. Utilizing this technology method that can inspect various lengths of piping experience a technician should have, and what and for tank calibrations can ensure that volumes from a single location for a variety of damage end user should look for in a quality guided wave are derived utilizing the full surface of the tank types or situations. Guided wave testing can be inspector. shell and bottom to include all deformations are applied in numerous applications: piping in pipe included in the computations. racks for CUI; piping in pipe racks for corrosion “THREE DIMENSIONAL LASER damage at supports; sleeved piping such as road SCANNING OF ABOVEGROUND This presentation will discuss the information that way and rail crossings; dock piping for external STORAGE TANKS”—IDA MARIE CARDEN, can be obtained by deploying three dimensional damage from environment; elevated inaccessible THURSDAY, JANUARY 10TH, 1:30 PM laser technology. piping on structures or equipment; buried piping (INSPECTION/NDE – 2) for general condition; piping through tank dike The application of three dimensional laser scanning For additional information about the 2013 API walls; piping through concrete walls; and piping of tanks provides owner/operators with a great of Inspection Summit, go to http://www.api.org/ with internal erosion potential from product information regarding their tanks. This technology events-and-training/calendar-of-events/2013/2013- flow. However, although guided wave testing is can provide detailed assessment of the shell of the inspection-summit.aspx. n a credible inspection method, it has fallen into tank with regard for deformations. The information disrepute with some for inappropriate use or collected can provide an “as is” detailed digital impractical expectations. representation of any deformations present. The PetroChem Inspection Services Profile: Gerhard Abel By most accounts, distributors meet the growing demand for energy in the U.S. and PetroChem’s important work with energy production while keeping workers safe. Gerhard Abel is the energy processors and distributors. in the U.S. is president of PetroChem Inspection Services, and entering a period of has been involved in the safety management and (PetroChem E-ssentials): There has been significant growth, inspection of energy assets for more than 20 years. significant interest here in the U.S. in the past few and some experts He holds a degree in mechanical engineering years on energy production from domestic sources, are even predicting from Technical University Wuerzburg in Germany, and a number of government and industry reports that the U.S. will and is a certified welding engineer. From his first are predicting a boom in domestic oil and natural achieve energy position as a certified code inspector for pressure gas production. From your perspective, what are independence in the equipment at TÜV SÜD in Munich, Germany, to the opportunities and challenges of the growth of coming years. This holding positions in the U.S. for the past 18 years domestic energy? anticipated growth is also likely to mean increased as Regional Manager, Director Industry Service, concerns about the safety of domestic oil and Vice-President and now President at PetroChem (Gerhard Abel): The boom in domestic energy natural gas production, transportation, storage, Inspection Services, Inc., Mr. Abel has spent production is already happening. Through and processing facilities, such as pipelines, the bulk of his career involved in performing conventional production, as well as various storage tanks, and refining assets. inspections for, or managing mechanical integrity technological advances such as horizontal drilling programs in, the power generation, oil and gas, and the exploration of shale energy sources For more than 30 years, PetroChem Inspection and chemical industries. and tight oil formations, the U.S. is producing Services, a division of TÜV SÜD America, has over 6,500 million barrel of oil per day today, a provided state-of-the-art inspection and testing Mr. Abel recently spoke with PetroChem production level not seen since 1998. Even more services designed to help energy producers and E-ssentials about the growth of the energy industry telling is the 900-barrel-per-day increase from
  • 4. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 4 September 2011 to December 2012. That shows operations. In addition, newly developed energy insulation (CUI) programs have also seen increased that the increase in production is consistently resources such as heavy crudes pose different use as a tool to identify suspect areas and provide gaining steam and, by most accounts, that trend challenges regarding corrosion of the assets a more targeted approach in inspection programs. will continue. containing those liquids. All of these factors need We’re also one of the first companies in the U.S. to be accounted for when developing mechanical to use small contained area radiography (SCAR) This development presents tremendous integrity programs for these assets. to perform x-ray inspections. Electromagnetic opportunities for all companies involved in the acoustic transducer, or EMAT inspections for processing industries. These industries already (PCE): Alternative fuels and sources of renewable touchpoint corrosion monitoring, is also in use in support more than 10 million jobs in the U.S., and energy are also gaining increased attention. Do the field, as are eddy current and IRIS technology future job growth will help support the continued the safety issues related to conventional energy for the inspection of tubes in heat exchangers. recovery of the U.S. economy. Recent research processing and distribution apply to these newer Alternating current field measurement (ACFM) predicts that the U.S. will be energy independent energy sources? If not, how do they differ? inspections for the detection of surface cracks has within the next 10 years or so, and eventually been utilized by PetroChem for many years, as become a net exporter of gas and refined products, have advanced ultrasonic inspection methods, such a complete turnaround of what we experienced as as shear wave, phased array, and automated UT recently as 5 to 10 years ago. inspections for corrosion mapping purposes. Of course, every boom has its challenges, and the We recently acquired new equipment based on biggest challenge in this current boom include the new technologies that use lasers for the calibration safe transportation of gas, condensates and oil to of tanks, significantly reducing the time needed to processing facilities, storage capacities that safely accurately calibrate the volume of a storage tank, store the products, and assets such as pipelines and generating significantly more accurate results and terminals that handle the safe transportation in the process. of these products. The present infrastructure certainly needs expanded capacity and ongoing (PCE): What are the advantages and maintenance, and that trend can be seen in the (GA): There are some obvious differences in the disadvantages (if any) of advanced non-destructive sizeable investment being made in these areas by safety concerns of ethanol derived from corn or inspection and testing techniques compared with the oil industry today. sugar cane and gasoline refined from oil, such as more traditional forms of inspection and testing? the potential for explosions, for example. However, (PCE): The U.S. National Transportation Safety the protection of people and waterways, and (GA): The key to any successful inspection is to Board recently designated enhanced pipeline avoiding issues such as soil contamination, apply generate reliable results that assure continued safety and infrastructure preservation at two of equally to conventional fuels and alternative fuels. safe operation of the asset inspected. Some its priorities for industry in 2013. In your opinion, And risks stemming from corrosion and erosion methods are more efficient in achieving those how safe is the domestic energy infrastructure for in transportation and storage assets have to be results, but there is no magic wand that replaces workers, and what steps could energy providers addressed in much the same way. an experienced, well-trained inspector, working take to improve safety overall? to high-quality standard procedures. Any tool is (PCE): PetroChem Inspection Services is a leader only as effective and as reliable as the person (GA): It’s important to note that the safety in the use of non-destructive inspection and using it, which is why continued training of performance of the 2.6 million miles of pipelines testing techniques. Tell us about some of the more inspection personnel is the single most important in the U.S. has improved significantly in recent advanced techniques that you’re presently using aspect of any inspection program. PetroChem years. Safety incidents are down 59% since 1999, in the field. places great emphasis on this, and maintains a major accomplishment. In 2011, investment in rigorous qualification standards to ensure proper the infrastructure integrity of the industry totaled (GA): PetroChem is driven by innovation in the qualification of our personnel, and the highest more than $1 billion, a huge investment in the safe field of nondestructive inspection methodologies. standards of inspection work we perform. I am operation of that infrastructure. We understand that, if you don’t recognize and proud of our managers and technicians in the field, implement new inspection technologies, you are and their commitment to quality. However, when it comes to the safe operation of not addressing the future of your business. any asset involved in the transportation, storage (PCE): PetroChem Inspection Services is or processing of oil or gas, it is never about a PetroChem was the first inspection company in the also a leader in providing refinery turnaround single act. Instead, it is about developing a culture U.S. to successfully utilize guided wave ultrasonics management services. What are some of the key of safety. As the infrastructure gets older, new for the inspection of pipes in the field. Real time selection factors for refinery operators to consider approaches are required to assure continued safe radiography for detection of corrosion under when seeking turnaround management assistance?
  • 5. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 5 (GA): Plant shutdowns are stressful for anybody temperatures and high pressures, the oil and such as ultrasonic, magnetic particle, radiographic, working in these plants. Construction activities natural gas industry and its suppliers have a and eddy current. As specialist in advanced needed to repair, replace or upgrade equipment, strong safety record. But to maintain that record, technology, we pioneered long-range guided wave and the associated chaos that comes with these everyone working in the industry has to make ultrasonics, and are an experienced provider of activities, pose a significant safety challenge. safety their top priority, and take advantage of the advanced NDT services such as computerized Facility Managers are looking for a service provider right technologies, standards, and best practices, radiography and ACFM. that understands these challenges, and who and programs. Every safety-related incident is contributes to addressing problems rather than important because of the danger is presents to (PCE): Why should energy producers and adding to them. All of our turnaround projects people, the environment, and society in general. So distributors choose PetroChem Inspection Services are staffed by a senior manager with years of safety is everyone’s job. as their asset integrity and compliance partner? experience in turnaround inspection projects. We have also significantly expanded our NDE (PCE): How can PetroChem Inspection Services (GA): PetroChem Inspection Services is committed capabilities and capacities in order to provide help petrochemical companies address these to providing solutions. We have the experience to the complete array of services required for any issues? implement asset integrity management systems turnaround project, from API inspectors to the full that meet the compliance requirements of API, gamut of NDE techniques. (GA): We’re a leading provider of both on-stream OSHA, EPA, and DOT and which provide our and turnaround visual inspection, and one of the customers with safety, improved reliability, and (PCE): In looking at the year ahead, what are some largest employers of API inspectors in the U.S. increased profits. Our mission is to consistently of the most important asset integrity challenges for Our mechanical integrity program is recognized exceed our client expectations by combining the petrochemical industry to consider? Why are as the standard in the petrochemical industry, traditional inspection methods with the most they important? and our ability to rapidly mobilize large groups of advanced inspection technologies in order to certified inspection personnel makes us a leader in achieve superior operating safety. n (GA): Despite a work environment that involves turnaround services. In addition, PetroChem offers heavy equipment, hazardous materials, high comprehensive traditional non-destructive testing, FAQs on Mechanical Integrity Inspection for Process Plants and provides guidance for the future inspection WHAT DOES A MECHANICAL INTEGRITY of in-service piping and systems and related INSPECTION PROGRAM INVOLVE? documentation. The program involves extensive inspection and sampling of large quantities of piping and WHAT IS THE GOAL OF THE PROGRAM? equipment at random points within a system. The goal of a mechanical integrity inspection is to Additional inspection points are also selected accurately assess the condition and integrity of to accurately assess the integrity of piping and equipment and piping systems, thereby allowing equipment at key areas of concern. PetroChem Inspection Services specializes in the operator to repair or replace faulty equipment mechanical integrity inspection programs that help in advance of spill, explosion, or other adverse WHAT INFORMATION IS REQUIRED TO to ensure the integrity of piping systems, pressure incident. CONDUCT A THOROUGH AND ACCURATE vessels, tanks, and other related equipment and INSPECTION? components. In this brief article, we provide WHAT TYPE OF EQUIPMENT IS Prior to a mechanical integrity inspection, plant answers to some of the frequently asked questions TYPICALLY COVERED IN A MECHANICAL operators should be prepared to provide extensive regarding mechanical integrity inspection. INTEGRITY INSPECTION? documentation regarding piping and equipment to All types of piping and equipment found in be inspected. At a minimum, documentation should WHAT IS A MECHANICAL INTEGRITY processing plants are subject to inspection be available that addresses the following issues: INSPECTION PROGRAM? under a mechanical integrity program. These can A mechanical integrity inspection is a method for include pressure vessels and storage tanks, piping • Materials used in the construction of the piping identifying corrosion in pipes and other equipment, systems and components, relief valve systems and equipment and for monitoring the effects of corrosion over and devices, pumps, and alarm systems, and other • Intended and actual operating pressures and time. A mechanical integrity inspection program instrumentation. temperatures of the inspected systems establishes minimum integrity requirements • Minimum ANSI flange rating
  • 6. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 6 • Process fluids used in the inspected systems • Prior operating history, and results from • Classification information regarding the piping previous inspections systems • Findings from the current inspection • Classification of the types of circuits in use • Calculations of the rate of corrosion and • Corrosion rate and minimum remaining life of estimated remaining life circuits in use • Maximum inspection intervals established by • Actual intervals between prior external and API 570 & 510 internal inspections • Additional applicable requirements of any • Any unusual or localized corrosion that might authority having jurisdiction (AHJ) require specialized inspection techniques Intervals should be established for various types Of course, certifications are not a substitute for the WHAT DOES THE INSPECTION of inspections, including internal inspections, experience and judgment of qualified inspection PRODUCE? on-stream inspections, external inspections, visual personnel. A mechanical integrity inspection produces inspections, and supplemental inspections. updated documentation and drawings for all PetroChem's approach to mechanical integrity systems in use, as well as a description of the WHAT KIND OF EXPERTISE IS REQUIRED focuses on the requirements of OSHA 1910- inspection as performed. The final report provides TO CONDUCT A MECHANICAL INTEGRITY 119/API, thereby supporting efforts to conduct written narrative descriptions of the condition of INSPECTION? cost-effective mechanical integrity inspections. piping and equipment and any findings of corrosion. Conducting a thorough and comprehensive PetroChem can establish a mechanical integrity mechanical integrity inspection requires industry inspection program based on code compliance, HOW FREQUENTLY SHOULD professionals with extensive experience in the as well as perform the inspection, data entry, MECHANICAL INTEGRITY INSPECTIONS inspection and evaluation of piping and systems. and data analysis needed to implement it. For BE CONDUCTED? Inspectors should be certified to the requirements additional information about mechanical integrity The initial mechanical integrity inspection of API 510, 570 and 653. Technicians utilizing inspections and PetroChem Inspection Services will establish the maximum interval between non-destructive testing (NDT) techniques should mechanical integrity experience, visit our website successive inspections, based on the following be certified to SNT-TC-1A. Data entry personnel at http://www.petrochemintl.com/industry/ factors: should meet industry accepted practices regarding petrochem.cfm, click here to view our product computer-aided design and/or data management. videos, or contact us at 800-747-4099. n PetroChem Inspection Services Announces 2013 NDT Training Program Schedule ALTERNATING CURRENT FIELD electromagnetic yokes, permanent magnets, and MEASUREMENT (ACFM) (5 DAYS, bench units. Training covers a wide range of INCLUDING PCN EXAM, $2495) subjects, including testing principles for pre and in- Alternating current field measurement (ACFM) service inspection, types of inspection equipment, is a computerized electromagnetic method used technique selection, UVA inspection, product to detect surface breaking and cracking under technology, and codes and standards. For the third successive year, PetroChem Inspection material coatings. This course provides details on Services, a division of TÜV SÜD America, is once ACFM principles, software operation, and sizing MANUAL UT PLATE & PIPE WELDS (10 again partnering with Lavender International Non- methodology. It is intended for technicians and DAYS, INCLUDING PCN EXAM; $3092) Destructive Testing USA, to provide an extensive supervisors starting out with ACFM testing and This course provides the requisite training for Level set of training and certification options for non- evaluation. Students are expected to bring their 2 UT certification for those with a minimum of 12 destructive testing (NDT) operators in 2013. own ACFM instruments and probes. months documented work experience. The course follows the PCN manual UT syllabus: covering UT This year’s training offerings will be held in MAGNETIC PARTICLE TESTING (5 DAYS, theory, calibration, sensitivity, equipment checks, Pasadena, TX (near PetroChem Inspection’s INCLUDING CERTIFICATION EXAM, plate lamination and corrosion scanning, weld Houston headquarters), and will include the $1420) scanning, defect detection, and characterization following courses: These magnetic particle testing courses cover and sizing. The 80-hour course will be taught over portable and fixed installation equipment, including 8 days, followed by two days for the PCN exam.
  • 7. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 7 PHASED-ARRAY (12 DAYS, INCLUDING offline using the Olympus TomoView full analysis o April 15-28 EXAM; $4175) software. The course also includes information o June 3-15 This course also meets the general requirements on detection, characterization and sizing, which o August 5-17 for Level 2 training and certification to the ISO advances skills to encompass full analysis • ToFD 9712, EN 473, and SNT-TC-1A certification principles. o February 4-February 15 schemes. A comprehensive course syllabus is o March 25-April 5 available upon request. To be eligible for both the o May 20-31 course and the exam, prospective students must o July 19-August 2 hold a relevant Level 2 manual UT certification for • ACFM—Call for dates weld testing using angle beam probes. • TomoView Full Data Analysis—Call for dates TOFD (10 DAYS, INCLUDING EXAM; Tim Armitt, Technical Director of Lavender $3655) International, and a Level 3 instructor and This course meets the general requirements for consultant, will conduct these training courses. Level 2 training and certification to the ISO 9712, With more than 20 years of NDT experience, Tim EN 473, and SNT-TC-1A certification schemes. A specializes in ultrasonic testing, and has developed comprehensive course syllabus is available upon The above courses will be conducted on the a wide range of training programs covering NDT in request. To be eligible for both the course and the following dates during 2013: the petrochemical industry. Tim has obtained ANSI exam, prospective students must hold a relevant • Magnetic Particle Testing Level 3 qualifications in UT, MT, PT, ET and VT, and Level 2 manual UT certification for weld testing o March 4-8 is also a PCN Level 3 in eight separate categories. using angle beam probes. o April 29-May 3 • Manual UT Plate & Pipe Welds Additional information about the PetroChem 2013 TOMOVIEW FULL DATA ANALYSIS (4 o January 21-February 2 training program is available at http://lavender-ndt. DAYS, $1545) o March 11-22 co.uk/usa/usa.html. For questions about the program, This course is intended for those using Omniscan o May 6-17 or to register, contact Michelle Chapman, at 281-913- instruments, and for those holding Level 3 • Phased-Array 9064 or at michelle@lavender-ndt.com. n certification wanting to view Omniscan data o February 18-March 2 Dates Set for 2013 PetroChem Open House Events PetroChem Inspection Services is pleased to • New Orleans, LA—April 17, 2013 announce the schedule for our Open House events • Corpus Christi, TX—May 23, 2013 at selected PetroChem facilities around the country • Chicago, IL—June 19, 2013 in 2013. • Toledo, OH—July 26, 2013 Each day-long PetroChem Open House event Our Open House events are an excellent includes informative, “hands-on” demonstrations opportunity to learn more about PetroChem’s and technical presentations. Presentations and wide range of testing and assessment services demonstrations run from 9:00 am-12:00 pm, and and capabilities, and to discuss your particular from 1:00 pm-4:00 pm. A catered lunch will challenges with our technical experts in an also be served at each Open House event for all informal setting. attendees. If you are interested in attending any of our Open House events are currently scheduled for the scheduled Open House events, please contact following PetroChem facilities: Patty Sweeten at 281-884-5187, or at Patty_ • Houston, TX—February 27-28, 2013 Sweeten@PetroChemIntl.com. Sign up for Twitter • Beaumont, TX—March 20, 2013 and follow @TUVPetroChem. n
  • 8. Vol. 6 December 2012 TÜV SÜD E-ssentials Page 8 2013 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. Here’s a list of the some of the major industry shows scheduled for 2013: API INSPECTION SUMMIT, GALVESTON, TX, JANUARY 7-10, 2013 The annual API Inspection Summit is the premiere venue for petroleum industry inspection and reliability professionals and examiners. The 2013 Summit will offer more than 100 individual technical program sessions, covering topics in inspection and non-destructive testing, metallurgy and corrosion, and engineering and analysis. For more information, go to http://www.api.org/events-and-training/calendar-of-events/2013/2013-inspection-summit.aspx. NISTM 15TH ANNUAL INTERNATIONAL ABOVEGROUND STORAGE TANK CONFERENCE AND TRADE SHOW, ORLANDO, FL MARCH 13-15, 2013 Sponsored by the National Institute for Storage Tank Management (NISTM), the 15th Annual Conference and Trade Show will feature more than 50 technical sessions on aboveground storage tank (AST) operations, AST integrity management, and AST environmental issues, and will also cover a number of specialty topics such as aviation fuel storage. For additional details, go to http://www.nistm.org. ASTN 22ND ANNUAL RESEARCH SYMPOSIUM & SPRING CONFERENCE, MEMPHIS, TN, MARCH 18-21, 2013 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/sc13/sc13.htm. ASME PLANT ENGINEERING, INSPECTION AND MAINTENANCE TRADE SHOW, PASADENA, TX, APRIL 19, 2013 The American Society for Mechanical Engineers (ASME) Technical Chapter will host its ninth 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. ILTA, HOUSTON, TX, JUNE 3-5, 2013 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/2013/2013info.htm. INTERNATIONAL FUEL ETHANOL WORKSHOP & EXPO, ST. LOUIS, MO, JUNE 10-13, 2013 Since 1985, the International Fuel Ethanol Workshop & Expo has delivered essential and timely presentations on every aspect of commercial-scale ethanol production, including production yield management, quality control, and regulatory compliance. For more details, go to http://www.fuelethanolworkshop.com. PetroChem Inspection Services, a division of TÜV SÜD America, will be exhibiting and/or presenting at many of the above events. Stop by our exhibit booth, meet our petrochemical industry experts, and learn more about how PetroChem can help you address your specific challenges, or sign up for Twitter and follow @ TUVPetroChem for the latest updates. 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 ||