Non-destructive testing (NDT) training is essential for developing a skilled workforce, whether for new employees with little to no NDT experience or for enhancing the skills of existing NDT personnel. Virtual, remote, or online NDT training provides an economical option for both employers and students to gain foundational knowledge, while also confirming the necessary aptitude through general, specific, and practical exams. This article explores the feasibility of completing Ultrasonic Testing (UT) Level 1 Training in a fully virtual environment, including all practical aspects.
Introduction to Virtual Non-destructive testing (NDT) Virtual training
The structure, duration, and assessment requirements for non-destructive testing (NDT) training programs are defined by recognized standards such as ISO-9712, NAS-410, SNT-TC-1A, and CP-105 [1-4]. These standards establish a framework encompassing theoretical knowledge, practical competencies, and the general, specific, and practical examinations necessary for certification. Each NDT training program typically includes both theoretical and practical components, with the theoretical curriculum outlined in detail for each method under CP-105. Practical training, on the other hand, emphasizes hands-on experience with NDT equipment, data interpretation, and reporting.
Certain NDT methods are more adaptable to remote or virtual delivery than others. For example, Level 1 magnetic particle testing, an enhanced visual inspection technique, relies on applying magnetic fields and visualizing defect indications through accumulations of magnetic particles. Since it requires minimal digital data analysis and is largely observational, the technique is less amenable to virtual training. Minimal no post-inspection data analysis is performed and therefore minimal opportunities for knowledge advancement in the field of magnetic particle testing are plausible in a virtual training environment.
Ultrasonic testing, however, presents unique a unique environment for 100% virtual training due to its delivery through complex instrumentation and the acquisition of digital data. Ultrasonic methods generate A-scan, B-scan, and C-scan data, which require real-time analysis, post-inspection interpretation, and thorough understanding of equipment calibration and controls. This data not only enables students to assess actual inspection results but also facilitates calibration exercises, flaw detection, sizing and characterization repetitions, Downstream of data analysis, a virtual classroom offers the student an opportunity to create industry standard reports. In addition to supporting theoretical instruction, digital platforms offer potential for delivering certain practical elements of ultrasonic training in a virtual environment.
This document explores the feasibility of implementing Ultrasonic Testing (UT) Level 1 training in a virtual format, analyzing the potential for adapting both theoretical and practical components of the curriculum to a remote learning environment while maintaining industry-standard rigor.
Challenges in Virtual Ultrasonic Testing Training
Delivering ultrasonic testing (UT) training in a virtual environment poses significant challenges, particularly in developing hands-on equipment proficiency. UT relies on practical skills for handling specialized equipment, such as transducers and pulse-echo devices, where students gain familiarity with probe positioning, coupling application, and sensitivity adjustments in a traditional lab setting. Without direct interaction, students miss essential tactile feedback, potentially impacting their ability to operate equipment effectively in the field. The complexity of calibration exercises and real-time interpretation of A-scan, B-scan, and C-scan data further complicates virtual training, as students may struggle to understand the nuances of signal responses and timing, both critical for precise flaw detection and analysis.
Student engagement and skill assessment present additional challenges. In-person training allows instructors to actively monitor and guide student progress, helping them retain complex theoretical principles like acoustic wave mechanics while mastering practical techniques. Virtual learning lacks this immediate oversight, making it harder to maintain focus and comprehension, especially during practical demonstrations. Furthermore, assessing practical skills virtually, whether through video submissions or simulations, may not fully capture a student’s proficiency in setup, calibration, and flaw identification, limiting the assessment’s rigor and effectiveness.
Finally, ensuring compliance with industry standards, such as ISO-9712 and SNT-TC-1A, in a virtual format is essential but challenging. These standards require specific practical competencies that are difficult to fulfill remotely. While simulations and interactive models can replicate some aspects of UT, they often lack the depth and variability of real-world testing environments, including irregular surface conditions and material complexities. Maintaining standard compliance without in-person training is a significant obstacle for virtual UT programs, as certification must remain credible and consistent with the high standards set by industry norms.
Figure 3: Example practical training in a virtual environment. Student is provided real NDT data to analyze and report on.
Key Components in UT Level 1 Training
Ultrasonic Testing (UT) Level 1 training covers foundational principles and skills necessary for accurate non-destructive testing (NDT). This training includes both theoretical knowledge and practical skills, preparing trainees to interpret ultrasonic data and operate essential equipment. The training aligns with industry standards such as ISO-9712 and SNT-TC-1A, which define the core components of NDT certification programs, including theoretical instruction, practical exercises, and proficiency assessments.
A strong emphasis is placed on understanding the basic principles of acoustics, as they form the basis of ultrasonic testing. This includes an introduction to the nature of sound waves, wave propagation modes (longitudinal and shear), and properties such as wavelength, frequency, and velocity. Trainees also study key concepts in wave behavior, such as reflection, refraction, and attenuation, which are critical to interpreting ultrasonic signals accurately. The training further covers the specifics of ultrasonic instrumentation, including types of transducers (e.g., straight, angle, and dual-element), the piezoelectric effect, and the basics of pulse-echo systems used to generate and capture ultrasonic waves.
In UT Level 1 training, practical components focus heavily on calibration procedures, a critical skill for accurate testing. Calibration exercises involve setting up equipment parameters, adjusting signal gains, and using reference blocks to establish benchmarks. These processes ensure that ultrasonic equipment accurately reflects material thickness and detects flaws. Trainees learn to work with A-scan, B-scan, and C-scan displays for visualizing data and are trained to interpret indications related to material defects, such as inclusions and cracks. Proficiency in calibration ensures that Level 1 technicians can verify the reliability of their readings across different test materials and conditions.
Innovative Solution for virtual training
For virtual practice training in ultrasonic testing (UT) Level 1, an innovative solution involves the use of OmniPC software to simulate practical testing scenarios and engage trainees in data analysis. OmniPC allows trainees to gain hands-on experience with ultrasonic data interpretation by working with real data files containing defect information. This approach effectively bridges the gap between theoretical knowledge and practical application in a virtual setting.
OmniPC provides a powerful platform for viewing, analyzing, and interpreting A-scan, B-scan, and C-scan data, which is integral to UT. By uploading data files with embedded defects, such as cracks or inclusions, trainees can practice identifying these flaws as they would in a physical test environment. This hands-on experience with OmniPC reinforces their ability to recognize patterns, interpret signal reflections, and understand the characteristics of different defect types. Moreover, the software includes a range of tools for zooming in on specific data points, adjusting signal parameters, and comparing scans, allowing for a comprehensive examination of ultrasonic signals in a controlled, virtual environment.
In addition to data interpretation, OmniPC enhances the learning experience by allowing instructors to assign specific tasks or scenarios within each data file, guiding students through calibration exercises, defect sizing, and reporting. This level of interactivity and targeted practice ensures that trainees build the necessary skills to operate independently and make accurate assessments, even without direct access to physical equipment. By using OmniPC, virtual UT training not only becomes feasible but also offers trainees a highly interactive and immersive learning experience that builds confidence in data analysis and defect detection—skills critical for UT Level 1 certification.
Summary
The feasibility of virtual Ultrasonic Testing (UT) Level 1 training relies heavily on innovative solutions that can simulate hands-on experiences and meet industry standards for competency evaluation. While OmniPC software provides an effective means for trainees to engage with ultrasonic data interpretation, it is essential to ensure that evaluation and certification processes accurately reflect a trainee’s competency. Virtual training programs must integrate rigorous assessment methods, including simulation-based practical exams and scenario-based evaluations, to validate a student’s understanding of both theoretical and practical components.
Achieving certification through virtual UT Level 1 training demands that all assessment criteria align with the stringent requirements outlined in standards like ISO-9712 and SNT-TC-1A. This includes demonstrating proficiency in equipment calibration, data interpretation, and flaw detection. Virtual training programs, therefore, must incorporate robust feedback mechanisms, allowing instructors to provide real-time guidance and support to ensure that trainees achieve these critical competencies. By combining innovative virtual tools like OmniPC with structured evaluation processes, UT training can be adapted to a remote format without compromising the quality or rigor of the certification process.
In conclusion, while virtual training presents distinct challenges in fields like ultrasonic testing, the careful implementation of digital tools and standards-based assessment frameworks can make a fully remote UT Level 1 training program viable. Through OmniPC, students gain a practical understanding of data analysis and defect detection, bringing virtual training closer to traditional, in-person learning experiences. This approach not only expands access to NDT certification but also has the potential to set new standards for remote learning in technical disciplines, paving the way for a future where UT training can be effectively conducted in both physical and virtual classrooms.
References
ISO 9712:2021 Non-destructive testing — Qualification and certification of NDT
personnel
2. AIA/NAS - NAS410 Certification & Qualification of Nondestructive Testing Test Personnel.
3. ASNT Recommended Practice No. SNT-TC-1A (2024) Personnel Qualification and Certification in Nondestructive Testing
4. NSI/ASNT CP-105: ASNT Standard Topical Outlines for Qualification of Nondestructive Testing Personnel (2020)
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