This presentation explores the real impact of Industry 4.0, specifically the Industrial Internet of Things (IIOT), in the context of predictive Corrosion Management, focusing on a compelling case of corrosion occurring under insulation. It discusses the implementation of digitalization tools and presents real-world examples of their application in the field. By harnessing digital data collection and predictive algorithms based on factors like moisture levels and temperature, hidden corrosion issues such as Corrosion Under Insulation (CUI) can be effectively managed.
Dr. Prafull Sharma currently serves as Chief Technology Officer of UK based CorrosionRADAR Ltd which is bringing innovative corrosion monitoring technologies using Industrial Internet of Things (IIoT). CorrosionRADAR invented a predictive CUI monitoring system which is gaining global traction addressing a big issue for the industry. Dr. Prafull Sharma brings vast industrial experience specially in digitalization of corrosion management on which there are several inventions to his credit. Dr Sharma did his PhD from Cranfield University UK. He is also credited with over fifteen international patents and innovations.
In the field of Nondestructive Testing (NDT), where human subjectivity significantly influences outcomes, a shortage of experts and the demanding nature of safety-critical component testing pose substantial challenges—AI has the potential to be a game-changer. But, how effective is AI collaboration, and what are its limitations? From a European legal perspective, the requirements for AI will be stringent. However, from a metric standpoint, our experience in NDT reliability will be beneficial. The evaluation process for AI will include simulations used for training data, serving as a foundation to assess its intrinsic capabilities. By comparing AI results with current NDT application outcomes, we will introduce a metric called the Reliability Evaluation Score based on relevant characteristic 'a' (RESa) to demonstrate the potential of the current AI applications. Furthermore, the connection to real-world applications will be highlighted. As showcased at the last NDE 4.0 conference, the real-world case involves testing railway components under the German railway system. This presentation will provide a clear view of the progress made in the AIFRI project.
Dr. Daniel Kanzler is a prominent expert in the field of reliability evaluation for non-destructive testing (NDT) systems, with over 15 years of experience in this area with significant and multifaceted contributions. Dr. Kanzler began his career at GE Sensing and Inspection Technologies, specializing in ultrasonic testing while completing his diploma and master's thesis on reliability. He later worked at the Federal Institute of Material Testing and Research in Berlin, where he completed his PhD in 2016. He is the Founder and CEO of a consulting company "Applied Validation of NDT," which supports international companies in NDT/E reliability. He is also Chairman of the International Committee for Non-Destructive Testing (ICNDT) Specialist Group on "NDT Reliability" since 2017, Leader of the standardization committee NA 068-08-28 under DIN, focusing on the "Qualification of testing methods" since September 2022.
NDE 4.0 represents several Digital Transformation aspects in the world for safety and quality assurance of high value assets. The two key words are ‘Digital’ referring to the means or enabling technologies and ‘Transformation’ referring to the result or the outcome. A very large percentage of companies fail to transform digitally, even though they have access to the same suite of digital technologies. The reason is the human mind. To overcome this, we need a shift from mindset to mindsight. A change in our thought process from what we are comfortable doing repetitively (set) to what is possible (sight) with a much higher value potential. As such, the transformation of the human mindset can be overwhelming as compared to insertion of digital technologies. And this non-technical aspect makes it critical to the success of any NDE4.0 program.
Dr. Ripi Singh is now a purposeful innovation coach with a lifetime of learning in technology, people, and process development. Starting with his PhD at IISc Bangalore followed by aging airplane program at Georgia Tech in 1992 as a post doc fellow. After decades of research work on fatigue & fracture, damage tolerance, human factors in NDE, he is now working hard to bring industry 4.0 perspective and innovation processes to the NDE community: with his virtual coaching lectures and articles. He has authored 20 books, 150+ peer-reviewed publications, and numerous invited and keynote lectures. Ripi and Johannes have produced the book – “The World of NDE 4.0” and also served as co-editors in chief for Handbook of NDE 4.0 along with Norbert Meyendorf and Nathan Ida. They shared the ASNT Robert McMaster Gold medal in 2022 and are also the motivating force behind the initiating the International NDE 4.0 conference series.
Digitalisation is beneficial! But planning & solution selection not only need an experienced decision-maker but also an architect without any commercial or personal conflict of interest. Otherwise, companies are gambling their precious funds and time. As the sole founder owner of the largest privately owned Australian TICS business, the author faced many challenges and learnt the hard way over the last decade. After learning further difficulties from other TICS Directors, the presentation includes insights, tips & traps in decision making, vulnerability & security issues, and genuine needs for the TICS industry “NDE N_Ext” that is beyond NDE 4.0 framework to adopt a factual eco-system.
Pranay Wadyalkar is a Chartered Engineer, CMatP, Metallurgist, AICIP, AINDT L3 in ET, UT, RT, MT, PT. Currently, as the MD at OMS Software, a digital automation company providing advanced LIMS & business management platform for Labs. Prior to OMS, he founded LMATS, the largest privately owned Australian business in the field of metallurgy, mechanical & chemical testing, NDT, Inspections. Pranay is appointed on the NATA’s NDT Advisory Committee, Steel Association Board, Australian delegate on the ICNDT, APFNDT & NDE4.0SIG. Pranay was the AINDT President from 2014-2016, and a director (2009-2017).
Non-Destructive Evaluation (NDE) is essential for the stable operation of important social infrastructure such as plant equipment, bridges, and building facilities. In this presentation, we report on a case where digital technology is used to not only enhance NDE performances but also to contribute to plant/asset value improvement by combining digitized inspection data with other related data.
We have extensive experiences in the engineering, manufacturing, and O&M of power plants and provide advanced NDT technologies such as phased array UT (PAUT) and laser ultrasonics. To begin with, we introduce two technologies as examples of NDT digitization. The first is an automatic probe position identification system using a SLAM technology. This technology does not require an encoder or automatic machine and can digitally record the probe position during inspection even on flexible 3D shapes. The second is a PAUT result evaluation supported by AI. This was originally developed for the core shroud of nuclear power plants and is a highly accurate AI with an error of crack depth measurement less than 1.2 mm from the manual inspection results carefully evaluated by experts.
Then, we also have the technology to analyze the progression of deterioration and predict the lifetime of structures based on their design, material, and manufacturing data. NDT data is the most important input of this process; that is, NDT data obtained in the physical domain is digitized and it is analyzed and evaluated in the cyber domain, and the analysis results achieved in the cyber domain are linked with data other than NDT and fed back to the physical domain as solutions, such as optimization of O&M, reformulating inspection/repair plans and changing operating conditions. This is expected to bring great benefits to asset owners.
In this presentation, we will discuss the inspection data and its digitization of important equipment in nuclear plants, and how it can be used for high-precision crack progression analysis that reflects residual stress and material properties to predict the actual realistic lifetime of structures.
Makoto Ochiai started his research career in 1991 at Toshiba Corporation in Yokohama, Japan. For the first 15 years, he was mainly involved in the development of advanced UT techniques such as practical laser ultrasonic testing and phased array UT. His achievements are implemented today in many turbine factories and nuclear power plants around the world. He then served as a leader engineer of the Plant O&M Technology Development, an R&D Leader for Operating Nuclear Plants, and has been the Technology Executive for Toshiba's Energy Division since 2022. Also, he is currently a member of the ICNDT SIG on NDE 4.0 and serves as a vice president of JSNDI.
NDE4.0, data collaboration, advanced UT, SLAM, AI, CPS
Non-Destructive Evaluation (NDE) plays a critical role in ensuring the integrity and safety of assets within the natural gas industry. However, many utility companies face a significant challenge: they lack qualified Non-Destructive Testing (NDT) personnel and rely on external contractors for inspection and analysis. This dependency, coupled with the increase in NDT failures reported by the Pipeline and Hazardous Materials Safety Administration (PHMSA) in recent years (DOT/PHMSA, 2023), underscores the urgent need for innovative solutions to enhance the reliability of NDT data.
NDE 4.0 brings significant advancements to the industry through digital twins, artificial intelligence, and automated defect recognition systems. By automating large portions of the inspection process, these technologies allow for faster data collection, increased accuracy in defect detection, and comprehensive asset monitoring. This capability helps companies to preemptively identify risks and manage potential failure points before they become critical, fundamentally enhancing both safety and cost-efficiency. Additionally, NDE 4.0 facilitates more efficient data integration and visualization, enabling stakeholders to make informed decisions with real-time insights.
The benefits extend to predictive maintenance and lifecycle management. With enhanced data reliability and advanced analytics, utility companies can transition from a reactive “repair after failure” model to a proactive maintenance approach. This shift results in fewer disruptions, reduced maintenance costs, and extended asset lifespan, which is especially crucial in an industry where asset integrity directly impacts public and environmental safety.
Con Edison (Con Ed) and other utility companies are exploring ways to use the Ooga platform and NDE 4.0 tools to support this shift, leveraging automation to increase quality and establishing a robust framework for continuous, predictive monitoring. By converting data lakes into actionable insights, these innovations pave the way for safer, more efficient operations and strengthen the resilience of gas infrastructure across the industry.
Ajay Pasupuleti is an entrepreneur with over 18 years’ experience in image processing, data management and archival technologies. As founder and CEO of Ooga Technologies he strives to bring the worldwide NDT community closer through the Ooga Platform by improving efficiencies, and ensuring knowledge is not lost through attrition and/or retirements. Under Ajay’s leadership, Ooga Technologies was awarded the 2024 Grepbeat startups to watch honoree. Ajay received his Ph.D., in Electrical and Microsystems Engineering from Rochester Institute of Technology, Rochester NY in 2006.
Non-Destructive Evaluation (NDE) plays a critical role in ensuring the integrity and safety of assets within the natural gas industry. However, many utility companies face a significant challenge: they lack qualified Non-Destructive Testing (NDT) personnel and rely on external contractors for inspection and analysis. This dependency, coupled with the increase in NDT failures reported by the Pipeline and Hazardous Materials Safety Administration (PHMSA) in recent years (DOT/PHMSA, 2023), underscores the urgent need for innovative solutions to enhance the reliability of NDT data.
NDE 4.0 brings significant advancements to the industry through digital twins, artificial intelligence, and automated defect recognition systems. By automating large portions of the inspection process, these technologies allow for faster data collection, increased accuracy in defect detection, and comprehensive asset monitoring. This capability helps companies to preemptively identify risks and manage potential failure points before they become critical, fundamentally enhancing both safety and cost-efficiency. Additionally, NDE 4.0 facilitates more efficient data integration and visualization, enabling stakeholders to make informed decisions with real-time insights.
The benefits extend to predictive maintenance and lifecycle management. With enhanced data reliability and advanced analytics, utility companies can transition from a reactive “repair after failure” model to a proactive maintenance approach. This shift results in fewer disruptions, reduced maintenance costs, and extended asset lifespan, which is especially crucial in an industry where asset integrity directly impacts public and environmental safety.
Con Edison (Con Ed) and other utility companies are exploring ways to use the Ooga platform and NDE 4.0 tools to support this shift, leveraging automation to increase quality and establishing a robust framework for continuous, predictive monitoring. By converting data lakes into actionable insights, these innovations pave the way for safer, more efficient operations and strengthen the resilience of gas infrastructure across the industry.
Prashanth Kadaba is a seasoned professional with extensive experience in the natural gas sector. Currently serving as the Department Manager for Gas Engineering Welding Center of Excellence at Con Edison in New York. Con Edison operates one of the world’s largest energy delivery systems providing energy for 10 million people who live in New York City and Westchester County. In his current role, Prashanth leads a team of welding engineers, Nondestructive Testing (NDT) professionals, and data analysts, focusing on establishing a centralized group for welding and NDT related guidance and support. Prashanth is also actively involved in the industry committees such as the ANSI Z380 (Gas Piping Technology Committee), AGA/API Joint Committee for welding of pipelines (API 1104 Committee), and ASTM E.07 (Nondestructive Testing) Committee. He is a currently a participant in the ASNT’s prestigious RISE Leadership Program and actively involved in their Industry Energy Council to streamline the industry gaps related to NDT. He is a native of Bengaluru but lives with his wife and two children in New York.
