Radiation Protection Challenges and Practices in the Metallurgy and Oil & Gas Sectors – Global Industrial Cases

Introduction

The use of ionizing radiation in the metallurgy and oil & gas industries represents a widespread, yet often underappreciated, occupational and environmental risk. Radiation sources—particularly sealed radioactive sources—are extensively employed for non-destructive testing (NDT), process control, level gauging, and density measurements. While these applications are indispensable for quality control and operational safety, they pose distinct challenges for radiation protection that differ markedly from those in the medical or nuclear power sectors.

This presentation aims to explore the specific radioprotection issues encountered in these industries, with reference to real-world practices from major international operators such as TotalEnergies (France), Tata Steel (India), Qatar Steel, and others. Emphasis will be placed on radiation risk exposure scenarios, operational constraints, source management, and regulatory frameworks.

1. Industrial Use of Radioactive Sources: Applications and Risks

In both the petroleum and metallurgical sectors, the most commonly used radionuclides are:

• Iridium-192 and Cobalt-60 for industrial radiography (e.g., weld inspection)

• Cesium-137 for level measurement in storage tanks and silos

• Am-241/Be neutron sources for moisture and density gauging

These sources are deployed in sealed form, often within portable or fixed devices. However, their operational environments—ranging from offshore platforms to steel foundries—are frequently hot, confined, remote, or high-risk.

Key Radiation Risks Include:

• External exposure to operators during source manipulation, maintenance, or equipment failure

• Loss of shielding integrity due to corrosion, impact, or poor maintenance

• Exposure of untrained personnel in shared workspaces (e.g., scaffolding crews, electricians)

• Potential for orphan sources in sites with poor inventory tracking or improper disposal

2. Case Study: TotalEnergies – Offshore NDT Radiography

TotalEnergies, a major global energy company, operates numerous offshore platforms requiring regular radiographic inspections of pipelines and pressure vessels.

Challenges Identified:

• Confined environments (e.g., FPSO hulls) limit operator distancing

• Equipment often needs to be airlifted, increasing the risk of mishandling

• Concurrent operations (SIMOPS) raise the probability of unintended exposure to third parties

Mitigation Strategies:

• Implementation of remote-controlled exposure systems

• Zoning with real-time radiation monitors and interlocked barriers

• Rigorous dose tracking using both passive and active dosimetry

• Multi-disciplinary coordination during planning (radiographers, production, HSE teams)

These measures comply with EURATOM directive 2013/59, integrated into the company’s HSE-MS (Health, Safety, Environment Management System).

3. Case Study: Tata Steel – Process Control and Legacy Source Issues

Tata Steel, operating large steel plants in Jamshedpur and Europe, utilizes numerous fixed radiation gauges across production lines (e.g., thickness gauges, slag monitors).

Radiation Protection Concerns:

• High-activity Cs-137 and Co-60 sources embedded in aging equipment

• Mechanical vibrations and heat compromising shielding over time

• Risk of orphaned sources during plant retrofitting or decommissioning

• Mixed skill levels among maintenance staff increases exposure potential

Countermeasures:

• Centralized sealed source registry and maintenance scheduling

• Decommissioning of obsolete devices in collaboration with Atomic Energy Regulatory Board (AERB)

• Upgrading to X-ray based non-radioactive systems where feasible

• Routine training and in-field radiation awareness audits

Tata Steel’s approach demonstrates alignment with IAEA safety standards (GSR Part 3) and AERB guidance.

4. Case Study: Qatar Steel – Radioprotection in Extreme Environments

Qatar Steel, based in Mesaieed Industrial City, routinely uses Cesium-137-based level and thickness gauges in its melt shops and casting areas.

Site-Specific Risks:

• Extreme ambient temperatures affect electronic monitoring systems

• High humidity and corrosive atmospheres degrade containment enclosures

• Inspections during shutdowns often involve simultaneous tasks, increasing radiation risk to non-radiographers

Protective Measures:

• Redundant shielding and condition-based maintenance protocols

• Use of environmentally hardened detectors and enclosures

• Temporary exclusion zones enforced by safety marshals during radiographic work

• Integration of radioprotection protocols into ISO 45001-certified safety management system

Qatar Steel’s radioprotection regime reflects compliance with Qatari Ministry of Environment & Climate Change and IAEA safeguards.

5. Regulatory and Global Frameworks

Radiation protection practices in industrial settings are governed by a combination of national regulations and international standards, including:

• IAEA Basic Safety Standards (GSR Part 3)

• EURATOM Directive 2013/59

• ICRP Publication 103 (principles of justification, optimization, and dose limitation)

• Local licensing authorities (e.g., ASN – France, AERB – India, MECC – Qatar)

Common regulatory requirements include:

• Source registration and tracking

• Controlled and supervised area designation

• Periodic leak testing and safety assessments

• Qualification and certification of radiation workers

• Emergency preparedness plans for radiological incidents

Conclusion

The integration of radiation protection into operational planning in metallurgy and oil & gas industries is both a regulatory obligation and a critical safety necessity. While the risk profiles vary depending on application and geography, commonalities include the need for:

• Engineering controls (shielding, interlocks)

• Administrative controls (training, zoning, permits)

• Continuous monitoring and audits

• Strong safety culture across all levels

Through detailed case analysis of TotalEnergies, Tata Steel, Qatar Steel, and others, it is clear that radiation safety is achievable even in the most complex industrial environments—provided that it is proactively managed, consistently enforced, and regularly reviewed.

References

1. IAEA Safety Standards Series GSR Part 3 – Radiation Protection and Safety of Radiation Sources

2. EURATOM Directive 2013/59

3. ICRP Publication 103 (2007) – The 2007 Recommendations of the International Commission on Radiological Protection

4. TotalEnergies HSE Management System – Internal Radiological Risk Assessment Documents

5. AERB Guidelines for Industrial Radiography and Sealed Source Handling

6. Qatar Ministry of Environment – Industrial Radiological Safety Requirements

7. Tata Steel Annual Sustainability Reports and Safety Audits