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In today’s technical job market, where retirements, automation, and emerging technology are reshaping the workforce, experience and innovation are interdependent. That balance is especially clear in nondestructive examination (NDE), where new tools enter the field every year, yet the fundamentals still rely on patience, hands-on learning, and strong mentorship. 

We sat down with Drew Harris, District Manager of our Philadelphia office at CATSI, Inc., to talk about how the skills landscape is shifting, why advanced NDE is becoming increasingly essential, and what young professionals can do to build long, successful careers in this work. 

This Q&A has been edited for clarity and organization while preserving Drew’s direct insights and perspective. 

Q&A With Drew Harris

Drew Harris
District Manager, Philadelphia Office
CATSI, Inc.
dharris@catsi.com

Q: How have technical skills changed since you started your career? 

Drew: 
“When I first got into the industry, things looked very different. People who were just starting out in this field were put with good mentors to learn from and would not dare to try and test out for a certification until they were 100% ready. This was after spending a long time in the field with an experienced inspector/technician, learning and gaining the OJT (on-the-job) training hours that are needed. 

I’m trying to bring this outlook back to CATSI when bringing on a new hire. If you can show me the work ethic and the ability to want to learn, I’d rather have them taught from the ground up by good, experienced inspectors and technicians.” 

Q: Which skills used to be essential to the job, and what’s in demand today? 

Drew: 
“The biggest things that have always mattered are work ethic, ambition, and integrity. You need the willingness to learn, especially from the person mentoring you. What’s really in demand today is advanced NDE. The East Coast is seriously lacking in people with the technical skills to do this type of work. The technology has been around for a long time, but not manypeople are willing to do it—it’s tedious and requires patience.” 

Methods like EMAT, Guided Wave, PEC, Infrared Thermography, and Phased Array Ultrasonics are becoming more central to the industry. Drew sees that shift as an opportunity. “Advanced NDE is where everything is going. It’s a skill that’s in demand and offers a lot of opportunities for growth.” 

This insight is why Drew is building a dedicated advanced NDE group at CATSI, supported by strong mentorship and the long-term development of people on his team. 

Q: You mentioned the importance of mentorship. What do you think makes a strong mentor? 

Drew: 
“I think a strong mentor is willing to invest their time and freely share their knowledge. A good mentor explains every tiny detail, like why an indication is called what it’s called, why an inspection is read to a specific code, and why you should take pride in the reporting process of the inspections being turned over to the client. The most important thing is to ask questions and encourage those questions in others.” 

Drew added that many companies fall short here. “They rush people through. They don’t ask, ‘Are you ready? Do you need more time?’ Mentorship requires patience.” 

Drew sees mentorship as central to the culture at CATSI. 

Q: What advice would you give to young professionals entering the field today? 

Drew: 
“The biggest thing is to look over the person’s shoulder every chance you get. Watch closely and ask a lot of questions. Don’t try to learn everything at once, and don’t rush to achieve every certification. Take your time and build your foundation the right way.” 

He emphasized the value of starting from the ground up—something he looks for in new hires. “Michael Barbour, a Level II Infrared Thermographer, is a great example. He came to us from the industrial cleaning side, which is incredibly labor-intensive work. But he showed work ethic and the willingness to learn, and those traits matter more than anything. Those are the people you can mold into the best professionals.” 

Q: CATSI is expanding its advanced NDE capabilities. What sparked that growth? 

Drew: 
“We use advanced NDE and inspection methods to find problems before they become costly failures. There is a gap in the market, especially here in the Northeast, of companies doing this type of work. It saves clients a lot of time and money and prevents safety hazards. So we are really focused on building our team’s skills in this area.” 

A key part of that plan was putting a team in place, led by Ed Haynicz, an Advanced NDE & Infrared Thermography Specialist. “Ed has been doing Advanced NDE for over ten years. He’s the right person to help train others. He asks the right questions, and he cares about getting things right.” 

Looking Ahead: Where Experience Meets Innovation 

Drew sees the industry continuing to evolve with advancements in technology, more automation, and a wave of retirements that will place enormous value on skilled, well-trained inspectors. 

“NDE changes constantly. There’s always something new. That’s why it’s so important for younger guys to learn from someone experienced who can show them how to use the tools the right way.” 

For Drew, the future of the field hinges on finding the right talent to be mentored and invested in. That’s how CATSI builds stronger inspectors, stronger teams, and a stronger advanced NDE program—one new professional at a time. 

Automated Ultrasonic Testing, commonly called AUT, is an advanced method of non-destructive testing that uses robotic systems to inspect materials and components. Unlike manual ultrasonic testing, AUT relies on mechanized scanners to move ultrasonic probes along a surface in a controlled and consistent manner. This approach ensures that inspections are precise, repeatable, and produce detailed digital data. 

AUT is particularly useful for identifying internal flaws, corrosion, and material degradation in industrial assets. By capturing high-resolution measurements of welds, pipelines, pressure vessels, and structural components, AUT provides the information needed to monitor asset health and plan maintenance effectively. 

How AUT Differs from Manual Ultrasonic Testing 

Manual ultrasonic testing requires a technician to move a probe by hand and interpret the results in real time. The quality of the inspection depends on the operator’s skill and experience. In contrast, AUT automates the scanning process, following programmed paths that cover the inspection area thoroughly. This results in consistent data quality, especially over large surfaces or repetitive inspections. 

Automation also allows for faster inspections and creates a permanent digital record of the findings. This record can be analyzed, compared with previous inspections, and used to track changes in material condition over time. 

Advantages of Automated Ultrasonic Testing 

Reliable Results: Automation reduces variation and ensures uniform inspections. 
Faster Inspections: Large areas can be scanned quickly, improving efficiency. 
Detailed Imaging: High-resolution data provides clear information about defect size and location. 
Improved Safety: Automation reduces the need for manual access to hazardous areas. 
Digital Records: Inspection results are stored digitally, allowing for long-term monitoring and analysis. 

Limitations of Automated Ultrasonic Testing 

Training Requirements: Operators must be trained to set up and interpret AUT systems. 
Equipment Cost: The initial investment for AUT technology is higher than manual methods. 
Adaptability: AUT works best for areas with regular geometry and may be less effective for irregular surfaces. 

Common Applications 

AUT is widely used in industries where asset integrity is critical. Some common applications include: 

• Oil and Gas: Inspecting pipelines, welds, and storage tanks for corrosion or cracking. 
• Power Generation: Examining turbine components, boiler tubes, and reactor vessels. 
• Chemical and Petrochemical: Inspecting pressure vessels, heat exchangers, and piping systems. 
• Infrastructure: Monitoring structural components, tanks, and large fabricated metal surfaces. 

Techniques Used in AUT 

Several ultrasonic techniques are often combined with automation to enhance inspection capabilities: 

• Phased Array Ultrasonic Testing (PAUT): Uses multiple ultrasonic elements to focus sound waves electronically for detailed imaging. 
• Time-of-Flight Diffraction (TOFD): Measures the time it takes for sound waves to reflect from defects to determine their size and location. 
• Full Matrix Capture (FMC): Records complete ultrasonic datasets for in-depth analysis and visualization of defects. 

The Importance of AUT 

Automated Ultrasonic Testing provides a precise, efficient, and reliable way to inspect critical industrial assets. By producing consistent data and creating digital records, AUT helps organizations monitor material condition, plan maintenance, and make informed decisions. As inspection technology continues to evolve, AUT is becoming an essential tool for maintaining the safety and reliability of industrial infrastructure. 

Industrial turnarounds are high-stakes periods when facilities temporarily shut down for inspection, maintenance, or upgrades. These windows are critical for maintaining operational reliability, ensuring safety, and extending asset life. When turnarounds are planned and executed effectively, facilities minimize downtime, protect personnel, and maintain asset integrity, keeping operations on track and reducing costly delays. 

Why Turnaround Readiness Matters 

Turnarounds are complex undertakings that require careful coordination of personnel, equipment, and processes. Poor preparation can result in schedule overruns, safety incidents, and unplanned equipment failures. Facilities that invest in thorough planning, advanced technologies, and proven practices gain a competitive advantage. These organizations complete maintenance cycles faster, maintain higher safety standards, and improve operational predictability, which directly impacts productivity and cost management. 

Key Practices for Effective Turnarounds 

Successful turnarounds combine technology, expertise, and safety-driven processes. Core practices include: 

• Advanced Non-Destructive Evaluation (NDE): Using cutting-edge inspection techniques to identify potential equipment or structural issues without causing damage. 
• Drone-Based Inspections: Deploying drones for high-precision assessments of tanks, piping, roofs, and other hard-to-reach areas to accelerate timelines and gather detailed data. 
• Fall Protection and Safety Services: Implementing OSHA-certified procedures and protective equipment to safeguard personnel during high-risk activities. 
• Data-Driven Planning: Leveraging inspection and operational data to prioritize maintenance tasks, optimize workflows, and reduce unnecessary downtime. 

Integrating these practices ensures that facilities complete turnarounds efficiently while minimizing operational and safety risks. 

Coordinating Turnarounds Across Complex Facilities 

Large-scale operations often involve multiple assets, interconnected systems, and overlapping maintenance requirements. Managing turnarounds across these environments requires a structured, systematic approach. Critical elements include: 

• Strategic Scheduling: Coordinating inspections and maintenance activities to maximize workflow efficiency and prevent conflicts between teams or systems. 
• Technology Integration: Using software and inspection tools to collect, analyze, and share data across sites for better decision-making. 
• Standardized Safety Protocols: Ensuring consistent adherence to safety procedures across all teams and sites, regardless of complexity. 

A coordinated approach not only keeps projects on schedule but also improves predictability, reduces errors, and ensures that each step of the turnaround meets regulatory and operational standards. 

Real-World Applications 

Facilities that incorporate advanced NDE methods, drone inspections, and certified fall protection experience measurable benefits. Early identification of potential issues allows teams to take targeted corrective action before problems escalate. Drone-based assessments can reduce the need for manual inspections, speeding up evaluation while maintaining precision. Safety-focused processes ensure that personnel remain protected, even in challenging environments. These methods combine to deliver turnarounds that are faster, safer, and more efficient. 

The Impact of Technology-Enabled Turnarounds 

Turnarounds that leverage advanced technology, structured planning, and safety-first execution give operators confidence that maintenance cycles will meet deadlines, maintain quality, and preserve operational continuity. By reducing downtime, minimizing risk, and improving accuracy, facilities can return to full productivity with systems that are safe, reliable, and optimized for long-term performance. 

Building data centers is fast-paced, high-pressure work. Expectations are high, timelines are tight, and budgets leave little room for error. That makes the final phase of construction — inspection — one of the most important. If your inspection team is brought in too late or lacks the right experience, it can derail everything that came before it.

Demystifying Data Center Construction

For much of their structure, data centers really are straightforward projects. Think Amazon fulfillment centers, but with more robust mechanical systems to handle cooling needs. Except for the cooling-heavy basements, these buildings are largely generic in their construction. What makes the process hard isn’t exotic techniques. It’s the scale, speed, and expectations for reliability.

The inside of a data center does demand intense coordination among trades: piping, steel, coatings. But the work itself isn’t fundamentally different from many other large-scale commercial builds. What does matter is that you’re building facilities that can’t afford to go offline. That’s why more and more contractors are pulling from best practices tried and tested across America’s long tradition of ambitious buildouts, from manufacturing plants and military-grade infrastructure to semiconductor fabrication facilities.

Why Third-Party Inspection Helps Prevent Costly Mistakes

One small oversight during construction can have major implications once a data center is operational. We’re talking about structural cracking, misaligned embeds, improperly torqued connections, surface contamination, missed coating defects, and more.

These kinds of issues may not surface right away. But when they do, the cost of rework is significant, especially after commissioning.

Bringing in an experienced third-party inspection team gives your project an extra layer of quality assurance. Not just for compliance, but for peace of mind.

What to Look for in an Inspection Team

A good inspection partner won’t just check boxes. They’ll understand what’s at stake. Look for teams who:

• Know how to navigate fast-paced project schedules
• Have experience across mechanical, structural, and civil scopes
• Work proactively with contractors and project managers to resolve issues in real time
• Can speak the same language as your field crews

Inspection isn’t just a formality. It’s a safeguard, and it needs to be treated like one.

What We’ve Learned from High-Stakes Projects

At CATSI, we’ve spent decades providing third-party inspection services on mission-critical facilities across the country. From new pipeline terminals to massive compressor stations to large-scale data centers, our team is built for high-stakes work.

We know how to operate under pressure. We know how to work with contractors, not against them. And we know how to spot the kinds of issues that cause headaches down the line.

Why Inspection Should Never Be an Afterthought

By the time inspection teams show up, your people have been in overdrive for months. It’s tempting to rush through the last few steps, but that’s exactly when things fall through the cracks.

Third-party inspection isn’t about finding flaws. It’s about making sure the work holds up, the systems are safe, and the facility is ready to perform. While the end user may be Google or Amazon, the inspection process isn’t fundamentally different from other major commercial construction projects. It’s just executed at a larger scale and on a tighter timeline. You’ve put in the work. Inspection is how you protect it.

As with so many ambitious projects throughout America’s construction history, the key to success lies not in mystique or novelty, but in steadfast process, trusted partnership, and a shared goal: get it right, safely, the first time.

Construction projects don’t succeed by accident. They succeed because every detail is verified, every standard is met, and every step is managed with precision and care. 

At CATSI, we understand that inspection is much more than a quality assurance step—it’s the backbone of effective construction management. From pre-construction planning through to final turnover, inspection ensures owners, contractors, and stakeholders remain aligned, accountable, and on track to meet project goals. 

From Planning to Close-Out: Where Inspection Adds Critical Value 

Inspection is an integral process that supports every stage of construction management: 

• Pre-Construction: Inspection validates constructability and project readiness. This includes confirming that plans, materials, and documentation are complete and comply with contract requirements before work begins. Early identification of potential issues helps avoid costly delays later. 
• Active Construction: Real-time oversight verifies that work is performed to specifications, and that safety protocols are consistently maintained. Daily inspections help detect and address nonconformities for corrective action or record keeping purposes. 
• Completion and Close-Out: Final inspections confirm system performance and compliance, prepare comprehensive documentation for project handoff, and ensure the built asset meets the expectations of all stakeholders. 

Whether the project is a gas transmission facility, a utility pipeline, or an industrial manufacturing site, construction management succeeds only when inspection is woven through every phase. 

What Inspection Actually Looks Like On-Site 

Inspection translates expectations into outcomes. At CATSI, our on-site inspection processes include: 

• Verification that installed work matches project specifications, engineering design, and regulatory standards. 
• Safety Monitoring through daily toolbox talks, pre-job briefings, and hazard assessments that protect personnel and maintain compliance. 
• Oversight of Critical Activities such as welds, tie-ins, electrical and mechanical installations, ensuring technical integrity and durability. 
• Daily Documentation capturing progress updates, nonconformities, corrective actions, and communication with all involved parties. 
• Coordination with contractors, trades, subcontractors, and third-party inspectors to maintain clarity and consistency throughout the project. 
• Permit and Procedure Compliance checks to confirm all required permits, environmental protections, and owner standards are consistently met. 

Inspection is highly visible on the job site—it’s what empowers construction teams to move forward confidently with minimal disruption. 

Tailoring Inspection to Each Project’s Needs 

No two projects are alike, so inspection strategies must be customized to fit the scope, phase, and complexity of each job. CATSI provides specialized inspection services that include: 

• Certified Discipline-Specific Visual Inspectors with expertise across mechanical, electrical, civil, and structural disciplines. 
• Construction Coordinators and Facilitators who bridge the gap between detailed plans and actual field execution. 
• Shop and Material Inspectors who proactively identify material or fabrication issues before components arrive on-site. 
• OQ- and DOT-Specific Inspection Services designed for regulated assets subject to operational qualification and transportation safety standards. 
• Safety Inspectors and QA Vendor Surveillance Teams to reinforce compliance and hazard mitigation. 
• Third-Party Oversight to ensure contractors and owners meet contractual and regulatory obligations. 

By aligning technical requirements with on-site realities, CATSI helps reduce delays, prevent rework, and ensure quality throughout the project lifecycle. 

Documentation: The Foundation of Accountability and Quality 

Inspection involves creating a clear, traceable record that supports accountability and continuous improvement. 

CATSI ensures every project maintains robust documentation including: 

• Detailed inspection results and site observations logged daily. 
• Records of contractor activities and performance metrics. 
• Material delivery logs and installation verifications. 
• Documentation of safety meetings, incident reports, and corrective actions. 
• Tracking of change orders, deviations, and final punch lists. 

This thorough documentation streamlines project close-out, strengthens trust between owners and contractors, and provides defensible evidence of quality and compliance. 

Beyond Compliance: Building Confidence Into Every Project 

Inspection protects regulatory compliance by safeguarding: 

1. People: Reinforcing safe work practices and raising hazard awareness reduces risk and injury. 
2. Budgets: Catching defects and deviations early reduces costly rework and prevents budget overruns. 
3. Schedules: Identifying potential issues ahead of time helps avoid delays and keeps projects on track. 
4. Facilities: Confirming system integrity ensures long-term operational performance and asset reliability. 
5. Stakeholders: Providing transparent and verifiable quality control builds confidence in the project’s success. 

Doing things right means doing the right things, and inspection is a proactive strategy that protects the long-term value of every construction effort. 

Inspection Is Integral to Construction Success 

Inspection isn’t a final checklist item. It’s a core strategy for managing risk, ensuring quality, and driving successful construction outcomes. 

At CATSI, inspection is not an afterthought—it’s a foundational element of construction management. With discipline, thorough documentation, and deep field expertise, we help build projects that stand the test of time.

If your aboveground storage tanks are more than 20 years old—and many are—you may not have a clear picture of what’s going on beneath the surface. 

That’s not just an oversight. It’s a risk. One that can compromise safety, environmental compliance, and the long-term reliability of your operations. 

At this year’s NISTM Conference, leaders across tank storage, energy, and inspection services came together to discuss the industry’s biggest vulnerabilities. And one issue kept coming up: we don’t know what we don’t know about our tanks.

“We’re seeing tanks that are 30, 40 years old. The problem isn’t that they’re old. The problem is nobody knows what’s been done to them—or when.” 
— Josh Appel, Business Development Manager, CATSI

The Aging Tank Dilemma 

Storage tanks—especially in petrochemical, power generation, and manufacturing sectors—are built to last. But “lasting” and “maintained” are two very different things. 

Here’s the typical scenario we see: 

• The tank is still operating. 
• No obvious leaks or signs of failure. 
• Inspection history is patchy—or nonexistent. 
• Turnarounds are tight. Budgets are tighter. 

The assumption is: if it isn’t broken, don’t fix it. 

But the truth is, by the time something breaks, it’s too late. A tank bottom with undetected corrosion or a shell weld that hasn’t been inspected since install isn’t a time bomb—but it’s close. 

And regulators like the EPA and state DEPs are paying closer attention. So are insurers. 

The Hidden Costs of Neglecting Inspection 

Neglecting regular inspections may seem like a way to save time or money, but it usually ends up costing far more in the long run. 

Let’s break it down: 

• Unplanned downtime 
  Emergency repairs often mean a full shutdown, not just of the tank, but of upstream and downstream processes. 
• Environmental risk 
  Undetected corrosion or roof damage can lead to leaks, contamination, and regulatory violations. 
• Inaccurate service life projections 
  If you don’t know the current condition, how can you forecast longevity? 
• Limited insurance coverage 
  Some policies may not cover failure if maintenance records are missing or outdated. 

The real problem? Most of these failures were preventable. But only if you had the right data at the right time. 

What a Modern Inspection Strategy Looks Like 

At CATSI, we believe inspections shouldn’t be about ticking boxes. They should be about building confidence—confidence in your assets, your safety, and your ability to plan ahead. 

Here’s what we see working in the field: 

1. Risk-Based Inspection Schedules (RBI) 

The days of “inspect every 10 years” are long gone. API 653 allows for flexible scheduling based on: 

• Tank age 
• Contents 
• Environmental conditions 
• Previous findings 

We help our clients build RBI programs that actually reflect real-world risk—not just code minimums. 

2. Non-Destructive Examination (NDE) That Goes Deeper 

From ultrasonic thickness (UT) readings to magnetic particle testing, CATSI uses proven NDE methods to assess: 

• Corrosion rates 
• Weld integrity 
• Settlement and foundation shifts 
• Coating and lining performance 

These tools give you a clearer picture of what’s happening inside your tank—without taking it offline longer than needed. 

3. Digital Documentation and Traceability 

Most facilities struggle with documentation. We make it easy. Our inspection reports are: 

• Delivered digitally 
• QR-coded for instant access 
• Easily shareable with regulators, engineers, and internal teams 

It’s not just more efficient—it’s how you maintain continuity when teams change or facilities expand. 

What Clients Gain by Getting Ahead 

We’ve worked with clients across power, chemical, and refining sectors who initially came to us “just to get compliant.” 

But what they gained was far more: 

• Clarity about what’s really going on with their assets 
• Credibility with regulators and stakeholders 
• Control over maintenance planning and budgeting 
• Confidence in extending the useful life of their infrastructure 

Some even identified issues that could’ve led to catastrophic failure—and fixed them months or years in advance. 

Why Thought Leadership Matters in Inspection 

This year’s NISTM reinforced something we’ve believed for decades: Inspection should be proactive, not reactive. 

The industry doesn’t need more vendors. It needs partners—teams that understand the real-world challenges of running critical infrastructure, and who can apply expertise without disrupting operations. 

With 40+ years in the field, CATSI has earned that trust. 

But more importantly, we want to share that knowledge, not just sell services. That’s why we’re committed to putting out educational content like this—to raise the standard across the board. 

Final Thought: Don’t Let “Nothing’s Wrong” Be Your Risk Strategy 

If you haven’t reviewed your tank inspection program recently—or you don’t know when the last full internal was conducted—it’s time to start asking questions. 

Not because it’s required. Because it’s smart. 

Let’s take a look together. 
Contact CATSI to schedule a conversation or site visit. We’ll help you understand where you stand—and how to move forward with confidence.

In the industrial and energy sectors, knowing the true condition of critical assets isn’t just helpful—it’s essential. Advanced Non-Destructive Examination (NDE) provides the detailed insight operators need to detect flaws early, prevent failures, and make smarter maintenance decisions. But what exactly is Advanced NDE, how does it work, and why should it matter to your operations? 

What Is Advanced NDE and Why Does It Matter? 

Non-Destructive Examination refers to methods of testing materials and components without causing damage. Advanced NDE takes this a step further by using state-of-the-art technology to reveal internal defects and subtle anomalies that conventional inspections might miss. 

Why is this important? Because unseen flaws—such as cracks, corrosion, or weld defects—can silently worsen over time, risking equipment failure, costly downtime, and safety hazards. Advanced NDE catches these issues early, allowing maintenance to be proactive rather than reactive. 

How Advanced NDE Works: Key Technologies 

Several cutting-edge techniques make advanced NDE so effective: 

Phased Array Ultrasonic Testing (PAUT)

PAUT uses multiple ultrasonic elements that send sound waves into materials at various angles and depths. This creates detailed, high-resolution images of welds, corrosion, and internal cracks—even in complex or hard-to-reach areas. The result? Reliable detection of flaws long before they become critical. 

Automated Ultrasonic Testing (AUT)

AUT relies on mechanized scanners to carry out fast and consistent inspections. It’s especially useful in high-volume applications, like pipeline welds or long seam welds on storage tanks, where manual inspection would be slow and prone to variability. Automation ensures precision, reduces human error, and speeds up data collection. 

Infrared Thermography

This technique uses thermal imaging cameras to detect heat patterns and anomalies without touching equipment. It’s ideal for spotting electrical faults, mechanical inefficiencies, and insulation problems in real time. Because it’s non-contact and non-invasive, it’s perfect for predictive maintenance without disrupting operations. 

Real-World Use Cases: Why Advanced NDE Works 

Advanced NDE isn’t just theory—it delivers real value on the ground. For example, in one recent project, CATSI’s team used PAUT to identify critical weld defects missed by traditional methods. Detecting these defects early prevented an unexpected shutdown, saving time and millions in potential losses. 

Across industries, advanced NDE supports: 

• Pipeline integrity by mapping corrosion and detecting cracks before leaks occur 
• Weld quality assurance ensuring joints meet safety standards 
• Electrical system health checks preventing faults before they cause failures 
• Mechanical inspections to identify wear and prevent breakdowns 

Each use case demonstrates the power of early detection and precise measurement—two key advantages that help operators maintain safe, reliable systems. 

Why CATSI Uses Advanced NDE 

At CATSI, we combine advanced NDE technologies with skilled technicians who understand the nuances of complex industrial environments. Our goal is to provide accurate, actionable data that helps clients optimize maintenance, improve safety, and avoid costly surprises. 

We don’t just inspect—we provide insight. By delivering clear, reliable results tailored to each facility’s needs, we empower operators to make informed decisions that extend asset life and reduce risk. 

Conclusion 

Advanced Non-Destructive Examination is more than just a testing method—it’s a strategic approach to asset management. By going beyond surface-level inspections, it uncovers hidden issues early, helping operators prevent failures, reduce downtime, and save costs. With the right technology and expertise, advanced NDE transforms data into decisions that keep critical infrastructure safe and efficient.

By November 18, 2036, every fixed ladder in your facility—regardless of its installation date—must comply with OSHA’s updated safety standards. This means relying solely on cages or wells for fall protection will no longer be sufficient. Instead, each ladder must be equipped with either a personal fall arrest system (PFAS) or a ladder safety system that meets the latest OSHA requirements. 

At CATSI, we’re helping industrial facilities stay ahead of this deadline with turnkey solutions to bring your ladders into full compliance—efficiently, safely, and cost-effectively. 

What OSHA Requires—and Why It Matters 

Under OSHA 1910.28(b)(9)(i)(B), ladders over 24 feet require either a PFAS or a ladder safety system if: 

• The ladder was installed on or after November 19, 2018, or 
• A worker could fall more than 24 feet (even if a single section of the ladder is less than 24 feet). 

Cages alone will no longer be acceptable, and by 2036, all existing ladders must comply with this rule. 

Learn more on OSHA's site 

CATSI’s Solution: From Inspection to Installation 

CATSI has been trusted by numerous facilities to assist with compliance, offering turnkey solutions or addressing specific gaps in your existing systems. Our range of services includes: 

• Fall Protection Surveys 
• Existing Fall Protection Inspections and Evaluations 
• Fall Protection Master Planning 
• Fall Protection System Design and Specification 
• Fall Protection System Installation 

Case Study 

We recently partnered with a major industrial plant to install 3M SmartLoc retractable lanyard systems at 10 ladder locations. Our work included: 

Design & Planning 

• Evaluating site conditions and ladder structure 
• Providing and installing fall arrest systems, including dual systems for dual ladders 
• Creating a master structure list with part and serial numbers for future compliance tracking 
• Creating record drawings of systems 

Field Installation 

• Inspecting each ladder for structural integrity 
• Installing PFAS equipment and ladder anchors 
• Certifying the ladder and safety system upon completion 
• Ensuring the site is left clean and debris-free 

Project Closeout 

• Delivering as-built CAD drawings and digital documentation 
• Providing certification that the system meets all OSHA and manufacturer standards 

Our experienced team is skilled at bringing outdated ladders and elevated structures up to code, using in-house personnel and strictly adhering to all safety protocols. 

Don’t Wait—Start Now 

With over a decade left until the 2036 deadline, it might be tempting to delay fall protection upgrades. However, acting now means: 

• Safer workplaces today 
• Easier scheduling (before demand surges in 2035-2036) 
• Avoiding costly last-minute retrofits 

CATSI is ready to help you get started. Whether you’re planning phased upgrades or a site-wide installation, we offer the expertise and execution to ensure your ladders meet OSHA’s evolving safety standards. 

As CATSI celebrates its first anniversary in Philadelphia, the company reflects on a year of growth, strategic expansion, and solidifying its presence in the region’s thriving oil, gas, and chemical sectors. The opening of the Philadelphia office was a key move aimed at tapping into the local talent pool, expanding capabilities, and fostering strong client relationships in industries critical to the area’s economic growth.

Drew Harris, District Manager of the Philadelphia office, shared his thoughts on the significance of this expansion. "Opening our Philadelphia office was a strategic decision to better serve the growing demand in the region’s oil, gas, and chemical sectors," said Harris. "This expansion allows us to build deeper local partnerships, tap into Philadelphia’s skilled talent pool, and provide direct support for our projects. At CATSI, we’re committed to safety, innovation, and delivering advanced solutions that help our clients succeed in these critical industries."

Over the past year, CATSI has made significant strides in establishing its footprint. The company successfully launched operations in Philadelphia and began offering an expanded range of services, particularly focusing on oil, gas, and chemical sectors. CATSI has also been committed to maintaining the highest safety standards, with the Philadelphia office celebrating one full year without any safety incidents—a testament to the company’s emphasis on ensuring safe and successful project completion.

Central to the success of CATSI’s Philadelphia operations has been its strategic approach to talent acquisition and development. Drew Harris, with his experience on the end-user side, brought invaluable insight into the needs of the local market. His leadership has been pivotal in building a skilled team that specializes in advanced non-destructive testing (NDE) services, risk-based inspections (RBI), and asset integrity solutions. With this focus, CATSI has been able to meet the specific needs of Philadelphia’s industrial landscape.

The company’s first year also saw an expansion of its services, including a strong emphasis on advanced NDE services and the implementation of risk-based inspections. These innovative services are vital for ensuring the reliability, safety, and efficiency of assets within the region’s core industries.

Looking ahead to the next year and beyond, CATSI is committed to further growth and innovation. The company plans to continue expanding its team, further developing local talent, and strengthening partnerships within the oil, gas, and chemical industries. CATSI’s focus on embracing new technologies and expanding its service offerings will ensure that it remains a leader in providing cutting-edge solutions to its clients.

As CATSI looks to the future, the company remains dedicated to supporting the growth of Philadelphia’s key industries, contributing to the region’s success, and continuing to deliver safe, reliable, and innovative solutions. The first year in Philadelphia has laid a strong foundation, and the company is excited for the continued opportunities and challenges that lie ahead.

In industries where safety, reliability, and operational efficiency are paramount, Non-Destructive Testing (NDT) plays a critical role in ensuring asset integrity. Among the most advanced and effective NDT methods available today is Phased Array Ultrasonic Testing (PAUT)—a superior alternative to conventional ultrasonic and radiographic testing. 

At CATSI, we integrate PAUT into our advanced NDE solutions, delivering real-time, high-resolution imaging, enhanced flaw detection, and improved inspection efficiency. Our recent success in identifying critical defects—missed by traditional inspection methods—demonstrates the power of PAUT in preventing costly failures and ensuring structural integrity across multiple industries. 

What is Phased Array Ultrasonic Testing (PAUT)? 

PAUT is an advanced ultrasonic examination technique that utilizes multiple elements in a single probe to steer and focus ultrasonic beams dynamically. Unlike conventional ultrasonic testing (UT), which relies on a fixed-angle beam, PAUT electronically sweeps the inspection area, providing a comprehensive and detailed view of internal structures. 

This capability allows for multi-angle scanning, real-time imaging, and greater accuracy in detecting and characterizing flaws, including: 

• Cracks 
• Lack of fusion or penetration 
• Porosity and inclusions 
• Wall thinning and corrosion 

By eliminating gaps in coverage, PAUT significantly improves defect identification while reducing the need for multiple test setups, making it ideal for critical weld inspections, corrosion mapping, and structural integrity assessments. 

Key Advantages of PAUT Over Conventional Methods 

1. Superior Flaw Detection & High-Resolution Imaging 

PAUT provides real-time, high-resolution images of internal structures, enabling precise defect characterization. Unlike manual UT, which relies on single-angle amplitude signals, PAUT generates cross-sectional and 3D views, making it easier to interpret results and identify hidden defects. 

2. Faster Inspection, Reduced Downtime 

Industries relying on continuous operations cannot afford extensive downtime for inspections. Compared to radiographic testing (x-ray), which requires film processing and radiation safety protocols, PAUT delivers: 

• Instant results with on-site evaluation 
• Minimal operational disruption—inspections can be performed without system shutdown 
• Rapid data collection with multi-element transducers 

3. Cost & Efficiency Benefits 

PAUT improves efficiency by:

• Minimizing setup time 
• Reducing probe changes 
• Lowering overall inspection costs by shortening time spent on in-field inspections 

For industries such as oil & gas, power generation, and manufacturing, PAUT provides a cost-effective alternative while maintaining compliance with stringent industry standards. 

4. Complex Geometry Inspection 

Unlike traditional UT methods that struggle with irregular or difficult-to-reach areas, PAUT excels in inspecting complex geometries, including: 

• Curved surfaces (pipes, pressure vessels, turbine blades) 
• Thick or multi-layered welds 
• Intricate castings and forgings 

This makes PAUT particularly beneficial for pipeline inspections, aerospace components, and power generation structures. 

5. Safety Advantages: A Non-Radiation Alternative to X-Ray 

Unlike radiographic testing (RT), which uses ionizing radiation, PAUT is completely safe for both inspectors and surrounding personnel. This allows inspections to be conducted without restricted access zones, special safety procedures, or environmental hazards, making it the preferred method in confined spaces and densely populated facilities. 

6. Compliance with Industry Standards 

PAUT is a code-approved and widely accepted method for weld and pipeline inspections, adhering to: 

• ASME Section V (Boiler & Pressure Vessel Code) 
• API 1104 (Pipeline Welding Code) 
• AWS D1.1 (Structural Welding Code) 

Many industries are now prioritizing PAUT over x-ray inspections, ensuring compliance while benefiting from faster and safer evaluations. 

How CATSI Uses PAUT to Deliver Reliable Results 

At CATSI, we incorporate PAUT into our advanced NDE services to ensure our clients receive precise, data-driven assessments for their most critical infrastructure. 

In a recent inspection project, CATSI was brought in to examine welds that had previously been tested using traditional NDE methods. Despite the initial clearance from conventional testing, our PAUT scan revealed multiple defects, including a through-wall crack, that had been missed. Had these defects gone undetected, they could have led to: 

• Major structural failures 
• Unplanned shutdowns 
• Significant safety risks 

This case highlights why PAUT is superior to older NDE methods and how CATSI’s expertise in phased array ultrasonic technology helps clients mitigate risks, reduce maintenance costs, and prevent costly downtime.

Industries Benefiting from PAUT 

The versatility of PAUT makes it an essential tool across multiple industries: 

• Oil & Gas – Ensuring pipeline integrity, detecting weld flaws, and assessing corrosion risks 
• Power Generation – Inspecting boilers, turbines, and pressure vessels for defects and material fatigue 
• Aerospace – Verifying aircraft component integrity to prevent fatigue failures 
• Manufacturing & Construction – Conducting structural weld inspections to meet compliance standards 

By implementing cutting-edge PAUT technology, industries can: 

• Improve safety 
• Maintain compliance 
• Reduce maintenance costs 
• Extend the lifespan of critical infrastructure 

CATSI: Leading the Way in Advanced Inspection Solutions Tailored to Our Clients’ Needs 

With decades of NDT experience, we deliver inspections grounded in safety, quality, and precision—using the latest technology and adhering to the highest industry standards. 

Through the application of Phased Array Ultrasonic Testing (PAUT), CATSI continues to push the boundaries of what is possible in non-destructive testing, identifying flaws that traditional methods might miss. Our approach ensures that industries—from oil and gas to aerospace—are equipped with the insights they need to make informed decisions and enhance the longevity of their assets. 

By embracing the most advanced testing techniques available, CATSI provides clients with not just results, but peace of mind in knowing their assets are safe, reliable, and built to last. 

Citations & References 

1. American Society of Mechanical Engineers (ASME). (2024). ASME Boiler and Pressure Vessel Code, Section V: Nondestructive Examination. Retrieved from https://www.asme.org 
2. American Petroleum Institute (API). (2023). API 1104: Welding of Pipelines and Related Facilities. Retrieved from https://www.api.org 
3. American Welding Society (AWS). (2024). AWS D1.1: Structural Welding Code – Steel. Retrieved from https://www.aws.org 
4. International Society of Automation (ISA). (2023). Introduction to Phased Array Ultrasonic Testing. Retrieved from https://www.isa.org 
5. U.S. Department of Energy (DOE). (2024). Ultrasonic Testing and Phased Array Technology in the Energy Sector. Retrieved from https://www.energy.gov 
6. NDT Resource Center. (2023). Phased Array Ultrasonic Testing: Principles and Applications. Retrieved from https://www.ndt-ed.org 
7. The Welding Institute (TWI). (2023). The Benefits and Applications of Phased Array Ultrasonic Testing (PAUT). Retrieved from https://www.twi-global.com 
8. Non-Destructive Testing (NDT) of Materials. (2022). A Comprehensive Guide to Phased Array Ultrasonic Testing. Retrieved from https://www.ndt.net