By Marlo Brooke, Scott Toppel & Joe Pikas
This paper presents best practices for implementing Augmented Reality in Ultrasonic and Non-Destructive Testing Area for Oil and Gas Industry. These best practices support the oil and gas pipeline industry to set up AR and a Digital Transformation roadmap.
There are many ways to evaluate oil and gas pipelines for integrity/safety. One way is using hydrostatic or pressure testing. Hydrostatic testing or pressure testing has been an accepted pipeline industry method for the verification of the integrity of pipes, vessels, and pipelines both inside and outside the fence line of pump and compressor stations. In Line inspection or (Smart Pigs) is another way through the use magnetic flux leakage or ultrasonic tools that measure metal loss and or cracking to assess for the integrity of the pipeline from station to station. For local inspections or investigative digs, the use of Non-Destructive Testing (NDT) is also referred to as non-destructive evaluation (NDE) or non-destructive inspection (NDI), NDT is used for verification for pipeline direct examinations. 
NDT allows technicians to check for cracking and or metal loss – through ultrasonic and electrical (eddy) currents. Ultrasonic and eddy currents can find metal loss and or stress corrosion cracking (SCC) through electromagnetic or ultrasonic field tools to find the location and severity of the body of the pipe and welds.
Using NDT inspection techniques to investigate can improve the integrity of the pipeline and lower the risk of failure while increasing ROI but more importantly the safety of the public, employees, and company stakeholders.
Level 1, 2 or 3 training for technicians on eddy current, phased array, short- or long-range ultrasonic, 3D laser, testing, etc. requires a high learning curve on these tools. This also applies to in-line inspection tools that perform the similar type of functions but on a larger scale. Because of the complexities to train technicians needed in gaining the required experience in these tasks, it can take upwards of two years or more to train new inspectors on these specific tools.
The second barrier to successful NDT is that even with the best of inspection equipment, investigative pipeline digs, and local inspection results are more often subjective because the NDT process itself is highly manual and laborious. This also applies to inside the station fence line where tanks, pipes, and vessels come under API 653, 510, and 570 recommended practices.
These barriers to success are significantly alleviated with Augmented Reality (AR). By enabling the inspector to visualize in 3D, AR significantly reduces the learning curve and improves accuracy for many types of ultrasonic and eddy current inspection. AR also enforces standards and parameters, which in turn removes subjectivity from the analysis.
It should be noted that AR can be easily transferred and integrated into the oil and gas industry or with any individual using this process. It allows the user to be quicky trained regardless of the material, industry, tool, or experience level in prompt, automated, and documented way.
AR for NDT Best Practice #1: Implement a Single System for Training and Inspection
The first step to success is designing the AR application in dual use mode. Dual use means that you can use one solution for both inspection training, and as a real-time job aid during the inspection itself.
Open Space or Offsite Mode
If the technician does not have equipment to train on, they will use AR in open space, also known as offsite mode. In open space, the pipeline inspector can pre-train, train, and re-train on the processes and equipment as many times as needed by industry standards such API, AMPP, ASNT, ASME, PRCI, etc. This is good “reps and sets” type training to embed knowledge base into the inspector prior to even touching these components which should meet Operator Qualified (OQ) Training under US Code of Federal Regulations such as 192 and 195.
Traditional NDT classroom training involves PowerPoint slides and other 2D training and reading materials. A game-changing benefit of AR is its ability to teach complex physics concepts, through 3D representation in the real world. The technician not only needs to learn the concepts, but also how to find and show invisible cracks in a large structure using invisible sound and eddy current.
AR makes the unseen visible. It is easier to understand and apply the physics of sound and electrical current when in real time and space, as opposed to understanding these concepts from books and flat images. AR supplies inspectors an intuitive visualization of electrical current and/or ultrasonic sound while inspecting pipelines – making it immensely easier to show degradation.
The second constraint of traditional NDT type training is classroom equipment. During training, the NDT trainee uses an inspection unit along with a physical block that mimics pipelines, tanks, vessels, welds, etc. – this block has a finite number and type of defects built into it. When the trainee places the inspection probe into a crack, different shapes are displayed that allow the inspector to decide information about the defect. The trainee learns about both the inspection tool and the way to assess cracks. The issue with learning this way is that the block is limited in its number of defects, and changing the physical block is time intensive.
AR virtualizes this effort, which in turn expands the training experience and comprehension. With AR, the trainee can have a virtualized system with an unlimited number of defects to evaluate and practice against, without needing a physical training tool. This supports training anywhere and enables a broader and more comprehensive interactive training by using a digital representation of the equipment and error. In AR offsite mode, the inspector can place the inspection probe (or a virtual representative) into a virtual hole with a virtual defect.
The best AR training in offsite mode incorporates individualized scaffolded learning techniques – or learning hints – that enables a progression of learning aid depending on the trainee’s needs. Gamification is incorporated to improve memory retention. It can involve random algorithms to change location of crack to make it more game based, interactive, and even competitive in a team environment. 
AR furthermore enables real-time and automated user-specific performance assessment, as well as inspection results. This enables twofold benefit. Firstly, a trainer or senior expert can check the technician’s performance both in training and during the actual inspection itself. Secondly, it saves time and potential data entry errors by automating the results electronically, replacing the current method of the inspector needing to stop often and record their findings.
AR for NDT Best Practice #2: Reduce Inspection Subjectivity
A best practice when designing AR is to incorporate Artificial Intelligence (AI) for specific parts of the AR application. It is important to understand how AI produces the best results during NDT. To begin, NDT technicians are highly trained, certified, and proficient in their field of ability. Their career requires utmost integrity and ability that is honed over many years. The best AR applications support the inspector – they cannot remove the critical human decision processes that supply substantial benefits to the pipeline industry and safety to the public.
With this approach in mind, AR best supports NDT when it is combined with AI for two functions: Auto Detect, and Assessment. This functionality must be designed from the viewpoint of how to enhance the user experience and make the inspection process easier, faster, and more effective.
AR Auto Detect
ARinspect™ has a built in Auto Detect feature that uses AI to supply automatic QA and recording of inspection results in the field. This saves time for the inspector, while increasing accuracy. During eddy current bolt hole inspection, for example, AR can automatically find and color code each of the many bolt holes that need to be inspected, ensuring that none go unchecked. As the inspection progresses, AR Auto Detect visually shows the inspector each hole that has been inspected. The results of the inspection are then automatically serialized, found, and logged. This ends the need to manually enter data for each inspection. Not only can the metrics be logged, but photos or inspection equipment graphics can be saved.
This digitally captured information can be used electronically for individual assessment, and for all types of analysis that ensure optimal pipeline, tank, or vessel structural integrity. Information can be shared with key stakeholders in an organization and through its supply chain – at both detail and dashboard level – to improve outcomes for all parties involved.
AR Performance Assessment
AR Performance Assessment is a powerful training and in-field capability that guides the technician to assess errors during the evaluation process itself. For example, during angle-beam inspection (also known as shear-wave inspection) which is used primarily for pipeline, tank or vessel welds, the inspection probe is set at an angle. AI is used to interpret whether the technician has set the probe at the correct angle. Suggestions can be made to the inspector as needed.
Assessment can also be used for defect accuracy. Each defect detected has an original signature – for example, severity, type, and location. These defects can be grouped by category. During Performance Assessment, AI can steer the technician to correctly find the type of defect and make recommendations to the technician for validation. Performance Assessment is a technician “second set of eyes” while working on the job.
AR can take advantage of advanced features in wearable AR devices that use AI to track inspector’s actions, including both eye gazing and detailed hand movement. This data can also allow a supervisor to assess performance, give feedback, and speed the overall learning curve. 
Best practices for implementing Augmented Reality in Non-Destructive testing include dual use mode that concurrently improves on-the-job performance and traditional training methods, along with well- designed AR that incorporates user-centric AI capabilities to support the inspector’s techniques while reducing effort and subjectivity. On the job, AR automatically captures data and supplies information critical to keeping pipeline integrity. AR helps NDT realize significant benefits including decreased training time, reduced time on task, standardized performance, and improved inspection results. Within the sphere of Industry 4.0 and Digital Transformation, AR is a powerful enabler of Industry 4.0 and Digital Transformation, supplying benefits to technician and the many stakeholders.
About the Author
Marlo Brooke is CEO & Founder of simpleAR®, software product provider of ARinspect™, and the simpleAR® enterprise AR authoring platform used widely by industry and government. Brooke is a widely published subject matter expert in augmented reality, digital transformation and supply chain.
Scott Toppel is President of AVATAR Partners®, a Platinum systems integrator of simpleAR® and provider of DoD and Industrial AR solutions. Toppel is a retired Navy CDR, and former combat and test pilot and maintenance officer and based in Virginia Beach, VA.
Joe Pikas has 55 years of experience in pipeline construction, operations, corrosion, risk and integrity in the oil, gas, water, and nuclear industries. After retiring from a large gas company and other engineering companies, he started his own company, Beyond Corrosion Consultants. Now advising for AVATAR Partners software solutions that simplify complex tasks.