Today, we have the privilege of speaking with Mr. Madhavan Krishnamurthy, a seasoned professional whose career in Non-Destructive Testing (NDT) spans over four decades.
With a wealth of experience across multiple countries and industries, Mr. Krishnamurthy has witnessed firsthand the evolution of NDT technologies and methodologies.
Currently leading the Training & Personal Certification department at Setsco Services in Singapore, he has played a pivotal role in shaping the NDT landscape. From overcoming early career challenges to mentoring the next generation of professionals, his insights offer invaluable perspectives on the growth and future of the NDT industry.
Join us as we delve into his remarkable journey, expertise, and the lessons he's learned along the way.
Mr. Krishnamurthy, welcome to OnestopNDT! It’s truly an honour to have you with us today. Could you please introduce yourself to our wonderful readers?
Hi, I am a professional actively involved in the NDT field since February 1981. Over the past 44 years, I have worked with various national and multinational organizations, ranging from NDT Inspector to NDT Consultant. During this time, I have earned relevant credentials in the NDT and Welding fields from various international certification agencies. Currently, I lead the Training & Personnel Certification department at Setsco Services Pte Ltd in Singapore.
I am qualified and certified with continuing validity under the following:
- Level 3 - ASNT 5 methods: PT, MT, RT, UT, & VT
- Level 3 - BINDT/PCN – GEN: EN 9712: UT & PAUT
- Level 3 - BINDT/PCN - Aero: EN 4179: ET & UT
- Level 3 - NAS 410: UT
- Level 3 - ISO 9712: RT
- Level 2 - ISO 9712: RT-D
- AWS Certified Welding Inspector
- API 510: Pressure Vessel Inspector
With a career spanning over four decades in NDT and engineering, what has been the secret to maintaining your passion for this field all these years?
I began my career as a graduate trainee with M/S Southern Structurals Pte Ltd, an esteemed organization under the Tamil Nadu Government. My first major training involved a large project on the fabrication and erection of Giant Bucket Wheel Excavators, in collaboration with a German company specializing in constructing mining equipment. As an Applied Science graduate from a technical university, I was equipped with the knowledge to understand the different testing methods involved. Working on such large projects exposed me to a variety of weld joints and material thicknesses, which required special precautions to ensure testing accuracy.
There were many challenging situations with the production team, especially when repairing critical welds. I vividly recall witnessing top executives and project managers scrutinizing the testing reports during these repairs. This process earned me recognition from both my management and the collaboration company’s project managers. Such challenges honed my ability to evaluate discontinuities accurately, particularly with conventional ultrasonic testing methods, back in the 1980s. I often check the performance of the equipment at NLC (Neyveli, Tamil Nadu), and I am proud that its smooth operation validates the credibility of our profession and fuels my passion for NDT.
You've managed large-scale NDT projects across several countries. What were some of the most unexpected challenges you encountered, and how did you turn them into learning experiences?
As mentioned, my first project laid the foundation for my professional career, helping me build the expertise I now share with my trainees. The experiences from that time gave me the confidence to manage large-scale NDT projects and navigate the many challenges they bring.
Balancing technical expertise with leadership must be an interesting challenge. How do you manage to stay grounded in the details while overseeing such complex operations?
To me, both the technology behind testing and the performance of the testing team are like the eyes of a human being. If one is not perfect, the whole process fails. Dedication to the profession leads to high precision and ensures the quality required for every task.
Can you share a project at Setsco Services that really stands out to you as a career highlight, and why it was so fulfilling for you?
Two major projects stand out:
- Since 2003, I have handled NDT training and certification for contractors working in Brunei Shell Petroleum (BSP) process plants. Over the years, I’ve made numerous trips to Brunei to certify NDT personnel in various methods (VT, PT, MT, UT, RT, and ET).
- I have also been engaged in process plant shutdown maintenance, specifically handling tube testing. I gained extensive experience in tube testing, starting with conventional equipment and moving to modern software-based systems.
Over the years, you've seen NDT evolve. What emerging technique or technology within NDT excites you the most, and why do you think it has such potential?
Since 1981, I’ve closely monitored the growth of Ultrasonic Testing, especially advancements in PAUT and TOFD. These two advanced UT techniques have significantly improved flaw detectability, particularly in the oil and gas industry. PAUT has replaced traditional UT methods for applications such as corrosion mapping, providing more data on corrosion. Additionally, TOFD has resolved the issue of identifying through-thickness defects, such as cracks. Software developments in techniques like TFM and PCI also promise better clarity and more accurate test results.
The digitalization of radiography has also been a game-changer, replacing film with image plates for immediate results. The development of flexible image plates is a significant step forward in catering to the industry's demands.
NDT safety protocols have become more stringent. How have you seen these changes improve the industry, and what role have you played in driving these improvements?
The unsafe incidents across the globe have increased awareness of the importance of radiation safety, particularly in radiography. Many certification schemes now mandate basic radiation safety awareness as a prerequisite for Level 2 and Level 3 certification. This has led to the development of safer radiation source devices and accessories. Over the past two decades, radiation safety has greatly improved, with most companies now using safe devices, even if they come at a higher cost, to minimize radiation exposure to workers.
Working in so many diverse regions must have given you a unique perspective. What cultural or operational differences have you noticed in applying NDT across Singapore, the Philippines, and Saudi Arabia?
One of the most significant differences I’ve observed is the mindset of the operators and inspectors in different regions. In recent years, more highly qualified personnel are taking on roles in radiography, which was rare a few decades ago. The ability to handle software for post-analysis of data now requires a basic understanding of IT, something that was not part of the skill set in the past. In earlier days, supervisors would calculate exposure times by trial and error, which often led to delays in production.
The NDT field is constantly evolving. In your opinion, where do you think the biggest opportunities for innovation lie, and how can professionals capitalize on them?
I believe the biggest opportunities lie in the continued development of advanced technologies like PAUT (TFM, PCI), RT-D, ECT array, and MFL. Software that processes and analyzes data from basic equipment will enable easier and more accurate identification of discontinuities. Training AI systems to automatically test and generate reports according to code compliance is also a major area of growth for the industry.
Could you tell us about a particularly complex inspection you managed? What were the hurdles, and how did you and your team overcome them to ensure success?
The complexity often comes from location and access challenges. We’ve overcome these by employing creative solutions, such as using specialized fixtures or taking calculated risks. In radiation work, we ensure that multiple team members are involved to minimize individual exposure. Shutdown projects also require extensive planning and alternative strategies to meet deadlines.
As someone who has mentored many NDT professionals, what qualities or characteristics do you look for when identifying someone with the potential to excel in this field?
I look for dedication, efficiency, and the ability to work swiftly while maintaining high quality. If any challenge arises in meeting quality or deadlines, I focus on convincing the customer that the quality achieved is sufficient, rather than compromising further.
With technology advancing rapidly, how important do you think it is for NDT professionals to stay updated with innovations like AI? How do you encourage your team to embrace these new tools?
AI is essential for mass production non-destructive testing. However, AI requires careful calibration, setting sensitivity levels, and handling specimens according to established procedures. To ensure the effective use of AI tools, I encourage my team to undergo rigorous training and closely monitor AI actions during the testing process.
You've led teams in both technical and managerial capacities. How would you describe your leadership style, and what key values or principles guide your decisions and actions?
I ensure that all team members are qualified and certified in the relevant methods. They must follow strict procedures, regularly verify calibration, and be aware of environmental factors affecting test settings. In special cases, they must consult with Level 3 professionals. Above all, safety is paramount; if any situation poses a threat, testing should not continue.
Building a successful team is often one of the toughest tasks. What do you believe is the secret to creating a cohesive and high-performing NDT team, especially when working on critical projects?
A cohesive team is essential to meeting deadlines and overcoming challenges, especially during shutdowns. Our success in past projects, such as the Udhalia project in Saudi Arabia in 1996, is a testament to the power of cooperation. Without a committed team, we wouldn’t have been able to deliver high-quality results in extreme conditions.
Managing a team and overseeing high-stakes projects require a lot of responsibility. Looking back, what's one of the most important leadership lessons you’ve learned throughout your career?
The most important lesson I’ve learned is that with a strong, dedicated team, any challenge can be overcome. The key is unity and focus, which will help us successfully tackle even the most complex tasks.
You've traveled to over 50 countries and enjoy classical music and theater. Is there one place or experience you've had that’s particularly shaped your outlook on both life and your work?
I do not have any specific experience that shaped my outlook.
The NDT industry is not without its challenges. What do you see as the major hurdles facing the industry today, and how can we collectively overcome them to drive progress?
In my experience, one major challenge is the lack of unity among NDT service providers, leading to price wars at the cost of quality. I believe that all agencies should have a common goal of delivering quality work at reasonable prices.
Finally, what are your thoughts on OnestopNDT? Do you think our efforts to provide real, authentic, and accurate content are helping the industry? Also, do you think our platform helps the community connect with like-minded people?
Your efforts have provided invaluable insight to the NDT community, inspiring and guiding professionals and companies alike. Your platform helps share the experiences of seasoned professionals, which is critical for fostering knowledge exchange within the industry.
