Introduction
The Non-Destructive Testing (NDT) industry is being digitalized. Some of the top innovations behind this change are Digital Twin – a virtual representation of a physical asset that allows real-time monitoring, analysis, and predictive maintenance. When combined with color-coded inspection data and combined to the Enterprise Resource Planning (ERP) systems, Digital Twins will change the way we plan and perform, and manage the NDT operations in such industries as oil & gas, power, aerospace, and marine.
What is a Digital Twin?
A Digital Twin is a digital representation of a physical entity, system or process which is in real time and is data-driven. It reflects its actual-world reflection in the use of sensor data, 3D modeling, and operational inputs, thus, enabling engineers and inspectors to:
- Visualize degradation over time
- Simulate inspection intervals
- Predict failures before they occur
In NDT, Digital Twins can be all of the pipelines, pressure vessels, offshore structures, turbines, etc – combining historical inspection data, condition assessments in the present, and predictive analytics.
Applications of DTs in NDT.
1. Inspection Planning
Digital twins help implement better risk-based inspection (RBI) since they can pinpoint the critical area that would need to be monitored regularly.
The technicians can simulate potential degradation paths before deploying for field inspections.
2. Live Monitoring
When the data is continuously feeding from the IoT sensors to the digital twin, operators will be able to spot anomalies such as corrosion growth or weld fatigue on near real-time.
3. Post-Inspection Visualization
Results of NDT (such as UT thickness, RT indications) can be directly mapped on to the 3D model and the same is intuitive for non-technical stakeholders (joint planners).
4. Regulatory & Readiness
Any historical data from the inspection is captured in the digital space, making the audit preparation and regulatory compliance much easier.
Visual 1: Comparison of a conventional spreadsheet report side by side with a digital twin that is color-coded and has mapping of UT thickness.
Color-Coded Data Visualization
Color coding increases the interpretability of NDT data in the context of a digital twin:
- Green: Within acceptable thresholds
- Yellow: Approaching limits (e.g., 80% wall thickness)
- Red: Critical/defect identified
- Blue/Grey: Areas not inspected or inaccessible
Such intuitive visuals allow for quick decision-making by plant operators, engineers, and third-party reviewers without having to rely on complicated tables or report pieces full of words.
Visual 2: Heatmap style depiction of a body of a pressure vessel with mapped NDT results segmented by means of color codes.
The integration of Digital Twins with ERP Systems
However, to get the utmost value out of NDT and asset integrity data, ERP system integration is necessary.
Benefits of ERP Integration:
- Real-time inspection status tracking
- Automated work orders using the results of inspection.
- Inventory and spare part alignment for damaged parts
- Restructuring exam on repair expenditure of assets.
Integration Approaches:
- API based integration to current ERP systems such as SAP, Oracle, or Maximo Asset integrity workflow-based custom-made ERP solutions.
- Plug-and-play modules created by state-of-the-art NDT software systems that connect digital twin data into ERP records
Visual 3: Workflow diagram that depicts data flow from the field inspection to the Digital Twin to ERP.
Conclusion
The integration of Digital Twins, color-coded NDT data, and ERP integration is a paradigm change in the way we do asset integrity and inspections. It enables the asset owners and service providers to shift from reactive maintenance to proactive decision-making, minimizing downtime and enhancing safety.
As digital tools are evolving, organizations investing in these technologies today will be the leaders of the industry tomorrow, with better data, better insights, and better outcomes.
At Atlantis NDT we’re developing seamless integration between Digital twins ERP & its VR applications, to advance NDT towards the Digitalization.
Author: Anoop Rayavarapu
