For much of the last century, trade publications, industry meetings, and conventions for non-destructive testing (NDT) centered around core principles, practical applications, operational insights, and industry trends. These discussions emphasized fundamentals—understanding different testing methods, refining techniques, and exploring applications of NDT in various materials and scenarios. But in recent years, the role of the NDT technician has expanded as cutting-edge technology reshapes the field. Today, NDT practitioners don’t just handle simple inspections; they use advanced technology to acquire, analyze, monitor, and make decisions based on immense amounts of data.
Rather than eliminating human roles, automation in NDT is empowering professionals to take on more complex, high-impact responsibilities. Robots, drones, and even Boston Dynamics' robotic dogs are finding their way into industrial environments, from warehouses to refineries, performing tasks alongside human teams. In some cases, extended reality (XR) technologies, such as VR headsets, are enhancing the precision of inspections and maintenance tasks. For example, VR can project exact, repeatable grids onto piping, replacing traditional line and chalk markings with digital overlays that are consistent and easy to adjust. These innovations mean fewer repetitive tasks for NDT professionals and a greater focus on critical problem-solving and advanced technical oversight.
This shift is particularly visible in environments like nuclear plants, where steam generator (SG) tube testing in pressurized water reactor systems requires extensive skills beyond just what’s required to pass the NDT written and practical examinations. It’s an example of how modern NDT roles are becoming increasingly specialized, requiring not only technical skills but also the ability to operate sophisticated technology.
Automation in NDT: Enabling Efficiency and Precision
One of the greatest benefits of automation is its ability to reduce the need for repetitive, manual tasks while allowing humans to focus on complex oversight. In steam generator tube testing, for example, ECT-certified operators now manage much more advanced technology than was required in the past. They calibrate and operate robotic fixtures, set up and calibrate machine vision-based independent position verification systems, and configure automated acquisition software to collect data on thousands of tubes, often using dual high-speed probe pushers simultaneously. Level II operators must also be skilled at troubleshooting these systems to minimize avoidable downtime.
A modern SG data acquisition setup includes multiple displays showing everything from robotic fixture movement and probe pusher operation to guide-tube centering and position verification status, allowing technicians to monitor critical components in real time. Automated systems also perform real-time data quality verification using a variety of parameters to help ensure that operators don’t unknowingly accept rejectable data. The data quality software must be configured by the operator to monitor specific, industry-required parameters such as drive voltage, digitization rate, spiking, and coil configuration. While automation handles many of these detailed tasks, technicians still play a critical role in overseeing, troubleshooting, and ensuring that everything runs smoothly. This integration of technology not only improves efficiency but also enhances precision in complex testing environments.
Tackling Data Volume with Array Probes and Automated Analysis
While array probes with integrated bobbin coils have been in use for years, recent advancements in their design have significantly boosted their capabilities. These enhanced probes collect a wealth of data, capturing detailed information that was previously challenging to gather with older designs. However, managing the large volume of data they produce can be overwhelming without assistance. Automated analysis systems address this by efficiently screening the data, filtering out routine signals, and flagging areas of interest for further review. Importantly, before deployment, these systems must pass a rigorous industry qualification and a site-specific performance demonstration to ensure reliable performance within the specific inspection environment. This layered qualification process ensures that the automated analysis tools are both robust and finely tuned to their unique applications.
However, there may be times when automated analysis cannot be performed—whether due to unique data complexities, system limitations, or unforeseen conditions. In such cases, human analysts rely on their expertise to manually evaluate the data, applying their trained judgment to interpret complex patterns and signals. In nuclear steam generator tubing inspections, data analysis is never performed by a single human or a single automated system. Multiple layers of review—both human and automated—help minimize missed signals and ensure that the final results are correct. This blend of human expertise and automated processing underscores the psychological demands of Eddy Current Testing (ECT), where professionals must be prepared to make important decisions that technology alone can’t manage. By combining automated data processing with expert decision-making, this approach enhances inspection accuracy and ensures that complex findings receive the attention they require. For a deeper look into the complexities of eddy current data analysis, see my blog post titled “Eddy Current Psychology 101”.
The groundwork for today’s automated systems has been laid over decades. For more than 50 years, computer modeling of eddy current signals has steadily advanced, refining the algorithms and techniques that underpin modern automated systems. Despite the power of automation, human expertise remains essential. Analysts must undergo rigorous training to interpret flagged signals and make crucial decisions that automated systems alone cannot achieve. Automation can lighten the load, but it cannot replace the nuanced understanding that a skilled human offers. This partnership between human insight and automated efficiency empowers NDT professionals to meet the increasing demands of modern testing environments with both speed and accuracy.
Collaboration Between Humans and Technology: Enhancing Decision-Making
One of the most compelling examples of human-technology collaboration in NDT is the use of auto-analysis systems that support signal disposition. These systems sift through immense data sets, flagging areas of interest for human analysts to review. By overlaying historical data from previous years, analysts can spot trends, identify potential issues, and apply their specialized knowledge to make the most informed decisions possible.
This system effectively says, “Here’s something you might want to check,” allowing human analysts to apply their expertise and context to the flagged signals. The ability to analyze multiple years of data in one view allows for spotting trends and identifying areas that need further investigation. This collaboration between humans and technology improves accuracy and streamlines decision-making, elevating the entire inspection process.
From NDT to Broader Tech Roles: Expanding Career Opportunities
Learning the advanced technologies used in NDT, from robotics to automated analysis, equips technicians with transferable skills that open doors to new career paths. For example, experience in setting up robotic systems for SG inspections can translate into other fields that also rely on automation, such as drone operation or robotics maintenance. Drones are now used for ultrasonic testing (UT) and pulsed eddy current testing, expanding inspection capabilities to remote and hazardous environments. Meanwhile, Boston Dynamics’ robotic dogs are finding applications in industrial settings, showing how robotics and tech skills have applications far beyond traditional NDT.
Industries from logistics to healthcare increasingly rely on tech-savvy professionals who can manage complex automated systems. By mastering NDT technology, technicians aren’t just building careers in testing; they’re gaining competencies that are valuable across a growing landscape of technology-driven fields.
The Future of NDT: Embracing Technology and Building Expertise
As NDT continues to evolve, automation and AI are transforming how technicians work. This doesn’t mean replacing humans but rather creating a more collaborative environment where machines handle repetitive tasks, and human professionals focus on critical problem-solving and decision-making.
For today’s NDT professionals, adapting to these changes means embracing new technologies, learning to work with advanced systems, and continually building expertise. As technology progresses, the demand for skilled, tech-savvy NDT professionals will only grow.
In the end, automation in NDT isn’t about reducing jobs- it’s about elevating them. As technology takes on repetitive tasks, human expertise becomes even more critical, allowing technicians to prioritize what truly matters: ensuring the safety, quality, and accuracy of inspections in increasingly complex environments. The future of NDT is bright, and for those willing to embrace change, it offers opportunities beyond what could have been imagined even a decade ago.
Comments