Overcoming Contractor Challenges in Industrial Inspections with PACS and AI

Introduction

Industrial inspections are essential for keeping operations safe and efficient. However, these inspections often have challenges, particularly when relying on contractors. Issues such as a lack of skilled workers, human errors in test data evaluation and processing, and analog communication with contractors can all compromise the inspection process. Fortunately, Picture Archiving and Communication Systems (PACS) and Artificial Intelligence (AI) can help solve these problems. This article will discuss how PACS and AI can improve industrial inspections by addressing key contractor challenges.

Understanding Contractor Challenges

Industrial inspections require skilled contractors to ensure everything is functioning correctly. However, several challenges can hinder their effectiveness:

1. The Scarcity of skilled contractors. There are often not enough skilled contractors available, which leads to delays and mistakes. Finding qualified professionals to conduct thorough inspections can be difficult for many industries.
2. Manual data transfer with data assigned to wrong inspection points. Many contractors still manually enter data and transfer it through spreadsheets and USB thumb drives. This method is time-consuming and prone to errors. Mistakes during data transfer and assigning data to the correct inspection points can result in inaccurate reports.
3. Receiving reports without test images. Contractors often provide reports without the corresponding test images. As a result, it is difficult for plant operators to double-check the results and have historical comparison images for the next inspection.
4. Poor quality of received test images. When test images are provided, they are sometimes of poor quality, making accurate analysis (e.g., residual wall thickness measurement) really difficult. Accordingly, standards stipulate the necessary image quality for radiographic images, for example, but these are not verified adequately.

Leveraging PACS and AI for Enhanced Inspection Processes

PACS and AI can greatly reduce these challenges and improve the inspection process.

PACS Automates Routine Inspection Tasks

PACS can streamline the inspection process by automating routine tasks. Measurements are automatically transferred to the inspection management system and correctly assigned to the appropriate inspection points. Each inspection is also accompanied by high-quality test images, which are stored systematically for easy retrieval and analysis. This automation reduces the inspection time and improves data availability for better decision-making.

Error Reduction with Artificial Intelligence (AI)

AI helps minimize human errors through advanced image recognition and analysis. AI algorithms can quickly and accurately identify defects and anomalies in test images, ensuring no critical issue is missed. This precision reduces the likelihood of data being assigned to the wrong inspection points and improves the reliability of the inspection process.

Case Study Illustrating the Benefits

To show how PACS and AI can benefit industrial inspections, here’s an example of a worldwide asset operator who successfully enhanced their inspection processes for numerous refineries.

Time Savings and Cost Reduction

By integrating PACS and AI, the operator significantly streamlined their inspection processes. Automated data transfer and accurate assignment of inspection points reduced integrity checks of CML data by 2,000 hours per year. As a result, approximately 2-3 million Euros were saved per turnaround and more than 300,000 Euros for on-stream inspections per year.

Improved Accuracy and Reliability

The operator saw a marked improvement in the accuracy and reliability of their inspections and data. The advanced image analysis capabilities ensured that all defects were detected and accurately reported. This improvement in inspection quality resulted in higher plant integrity and lower maintenance costs.

Conclusion

Integrating PACS and AI in NDT inspections can effectively address many challenges associated with contractor-based inspections. By automating routine tasks and reducing human errors, these technologies can provide a robust solution for improving the efficiency, accuracy, and reliability of industrial inspections. As industries continue to adopt digital solutions, using PACS and AI can be a valuable combination of tools to assist with overcoming contractor challenges and ensuring high standards of operation.