TMK Develops VR Simulator for Non-Destructive Testing Training

The Tubular Metallurgical Company (TMK) has developed a VR simulator for training and certifying skills in manual quality inspection of tubular products and coatings using ultrasonic thickness testing methods. Pilot testing of the virtual simulator was conducted at the Chelyabinsk Tube-Rolling Plant (ChTPZ), a branch of TMK. The project launch is overseen by the Corporate University TMK2U, TMK++, and the TMK Accelerator.

The VR simulator integrates algorithms for six of the most commonly used thickness gauge models at TMK enterprises — ultrasonic devices that measure the thickness of finished tubular products. The simulator allows users to select the desired tool and inspection object. The software complex features three operating modes: training, testing, and examination. Virtual reality headsets create work conditions closely approximating real production, enabling practice in proper equipment setup and detection of areas with insufficient wall thickness in pipes, elbows, and split tees.

The simulator was developed by a team of specialists from TMK«s IT division (TMK++), the Corporate University TMK2U, the Scientific and Technical Center (STC) of TMK, TMK»s quality unit, and a partner company that is a graduate of the corporate TMK Accelerator. During the creation of the virtual trainer, company experts modeled a universal image of a production workshop, developed technical specifications, and scripted its execution. A distinctive feature of the simulator is the ability to input measurements into the system using voice commands, a first for such equipment. Thanks to the universal training program, the simulator is ready for rollout at all TMK enterprises.

— TMK is actively implementing digital and VR technologies across all areas of activity. The new simulator will reduce the time for employee preparation for real production work while maintaining training quality, effectively assess their competencies, and optimize the certification process. Such solutions are particularly important as young specialists who have grown up in a digital environment and are accustomed to interactive formats are joining the company. We are developing training tools to align with their information perception model, — said Elena Pozolotina, Deputy General Director for Human Resources Management at TMK.

At ChTPZ, 16 employees participated in testing the simulator: process engineers, flaw detectors, and controllers. Their task was to complete the three modes of the virtual simulator: training, testing, and examination, as well as inspect a pipe and input data into the system. Flaw detector Marina Kadnikova noted that this training format will be interesting to young employees accustomed to a digital environment.

Marina Kadnikova, a flaw detector for magnetic and ultrasonic control at ChTPZ, said she encountered this training format for the first time.

— I found it very interesting. You get used to working with the joystick quickly; if you understand it and practice well, it will be convenient. VR technologies can engage young specialists and visually show how to work with instruments in production, — says Marina Kadnikova.

The new simulator will become the tenth simulator in the company for personnel training. In particular, a similar simulator is used for practicing and confirming professional skills by tube-rolling mill operators.