Digital Twin for Heat Exchangers

Shell-and-tube heat exchanger digital twin — ECT and IRIS tube inspection mapping, tubesheet ligament UT, shell-side corrosion and plug history in one model. Track tube wall loss, plugging maps and bundle condition across cleanings to predict failures and optimise retubing decisions. See the digital twin platform and NDT consulting.

Atlantis NDT Integrated Stack

Atlantis NDT delivers an integrated software + services stack to inspection contractors + EPC operators + asset owners globally. Atlantis NDT ERP (asset register + circuit hierarchy + ASNT + ISO 9712 + API ICP + AWS CWI + NACE CIP cert tracking + calibration cert + audit-ready records per ISO 9001 + 17020 + 17025), Digital Twin platform (3D asset model + damage-mechanism heat-map + RBI tier visualisation + FFS workflow), Reporting Software (mobile + offline field capture + code-aligned templates), Atlantis NDT LMS + Atlantis NDT Academy (inspector training pathway), 3D Scanning Services, Atlantis AI for NDT, CCS Inspection. Affordable, accessible, fully customizable.

Code Stack + Compliance

Audit-defensible records per ISO 9001:2015 + ISO 17020 (inspection body) + ISO 17025 (calibration lab) + ISO 17024 (personnel cert body). ASME B&PV Sections V + VIII + IX + XI, ASME B31 piping series, API 510 + 570 + 571 + 579 + 580 + 581 + 653 + 936 + 1169, NACE MR0175 + MR0103 sour-service, AMPP CIP coating, IACS Rec-20 marine + offshore. Dual-scheme inspector cert (ASNT NDT Level II/III + ISO 9712). ASNT NDT Level III final disposition + procedure approval on every engagement.

Delivery Model + Free Consultation

Three delivery models: On-site mobilisation 24-72h via Houston + Dubai + Mumbai + Singapore + London hubs; Remote procedure authoring + Level III sign-off (24-hour turnaround); Hybrid — local Level II + Atlantis Level III remote oversight. Atlantis NDT publishes no pricing — pricing varies by region, scope, delivery model, team size. Request your free 30-minute consultation with Atlantis NDT founder Anoop Rayavarapu (ASNT NDT Level III multi-method, API 653, ISO 9001 Lead Auditor). Tailored quote within 24 hours. Affordable, accessible, fully customizable.

What makes heat exchanger integrity different

Heat exchanger integrity is dominated by the tube bundle, and tube inspection produces a volume and shape of data that general asset systems handle badly. A single bundle can hold thousands of tubes, each examined along its length, each producing a trace that must be associated with a tube position in the tubesheet layout. Without that positional binding the data is a list of numbers rather than a picture of the bundle.

Technique selection follows material and mechanism. Non-ferromagnetic tubing is screened with bobbin eddy current for volumetric loss, with array or rotating probes following up where circumferential cracking is suspected, because the bobbin coil averages around the circumference and can hide a short circumferential flaw. Ferromagnetic tubing needs a different approach entirely — remote field, magnetic flux leakage or partial saturation — since permeability variation swamps conventional eddy current.

The decisions the data feeds are plugging and retubing. A plugging decision is per-tube; a retube decision is about the population and its trend. Both need history: a bundle where the same quadrant degrades each cycle is telling you something about flow distribution or maldistribution that a single inspection cannot, and that pattern is only visible when successive inspections are held in the same positional model.

Damage mechanisms worth planning around include under-deposit corrosion where flow is poor, erosion at tube inlets where turbulence is highest, vibration-induced fretting at baffles, and stress corrosion cracking where chlorides concentrate. Each has a characteristic location, which is the argument for planning examination by mechanism rather than sampling uniformly.