Absolute Tube Accounting
Every tube position receives a permanent matrix address (e.g. Row 06, Column 12). Duplicate frames from video sweeps are consolidated onto a single physical lattice.
MA'ADEN ASSET INTEGRITY · UNEARTH TOMORROWEvery tube.
Every tube.
Precision mapped.
Visual intelligence for critical heat transfer equipment. Convert field capture into calibrated tube lattices, auditable plugging tallies, and engineering compliance sign-offs.
Engineered for Ma'aden Mechanical Reliability Teams
THE HEAT EXCHANGERThe equipment
The equipment
behind the count.
A heat exchanger moves heat between two fluids through hundreds or thousands of small tubes. Every tube end is visible on the tubesheet, the metal plate at the end of the unit. When a tube fails, it is sealed with a plug, and plugged tubes reduce how well the exchanger works.
THE PROBLEMCounting by hand is slow,
Counting by hand is slow,
and mistakes are costly.
Every tube and every plug has to be counted, often by hand and often in poor light. Miss a plug and the equipment looks healthier than it is. Count one that isn't there and you may act on a problem that doesn't exist.
WHAT YOU GETOne photo.
One photo.
A complete picture.
A tube-by-tube map
Every tube located and marked open, plugged or uncertain.
A clear count
Total tubes, open tubes and plugged tubes in one place.
A report ready for review
A record of what was found, ready for an inspector to check.
Counts reflect the tubes visible on the photographed face.
DETECTION CLASSESPhysical tube
Physical tube
classification
Plugged
sealed by a solid metal plug
Open
clearly open and hollow (unplugged)
Uncertain
partly obscured by dust
FIELD CAPTUREPhotos & Video Sweeps
AI & GEOMETRYSub-pixel Lattice Fitting
INSPECTOR CONTROLHuman-in-the-Loop Sign-off
REFERENCETEMA & ASME Sec VIII Reference Framework
FOUR-STAGE WORKFLOWFrom field capture
From field capture
to certified sign-off.
Built specifically around Ma'aden turnaround and maintenance inspection protocols, maintaining an unbroken chain of custody from optical capture to report archive.
01
Capture with confidence
Upload high-resolution photos or a guided video sweep. Immediate quality checks flag blur, glare, and missing coverage.
ENTERPRISE HEAT TRANSFER INTELLIGENCEIndustrial reliability.
Industrial reliability.
Zero guesswork.
Inspectors and reliability managers get unequivocal visibility into tube bundle degradation. Real-time inference routes allow quick turnaround reviews or in-depth accuracy auditing.
01Tubesheet Geometry Calibration
Accounts for perspective distortion, camera tilt, and optical glare in challenging field conditions.
02Automated Drawing Reconciliation
Reconciles detected pitch patterns against vendor TEMA datasheets to confirm missing or phantom tubes.
03Audit Trail & Model Lineage
Every tube classification carries the active model version, reviewer ID, timestamp, and high-res image chip.
ENGINEERING REASSURANCEWhat the system
What the system
delivers to operations.
Certified Plugging Ratio
The platform calculates the exact plugging percentage against each exchanger's thermal and hydraulic limit. Over-threshold alerts are flagged before bundle closure.
Full Traceability For Turnarounds
Inspection certificates can be exported directly for turnaround audits, insurance evaluations, and root-cause analysis with complete reviewer accountability.
WHO IT'S FORBuilt for everyone
Built for everyone
who depends on the count.
Decision-makers
A clear answer to "how many tubes are plugged, and is that acceptable?", backed by evidence.
Field inspectors
A guided way to capture photos and get a quick count on site. Doubtful tubes are flagged, not guessed.
Reviewers and engineers
A review step where every decision is recorded before the final count is signed off.
Reliability and maintenance planners
A plugged-tube count to support repair and replacement decisions.
Site safety
Less time spent counting by hand near the equipment.
Auditors and standards bodies
A traceable record of what was found and who confirmed it.
COMMON QUESTIONSAnswers before
Answers before
you ask.
Clear, straight-on photos in even light, with the whole tubesheet in view.