Smart assurance: Curtiss-Wright leads the digital evolution of tube plugging

Verification and documentation

Heat exchanger tube plugging is a routine but critical maintenance task across power generation, refining, petrochemical processing, and other heavy industries. While the mechanical process of installing a tube plug is well understood, verifying and documenting that the installation was completed correctly has long remained a weak point.

“Installation has always been reliable from a mechanical standpoint,” says Alex. “But the industry has struggled with how to prove, years later, that the plug was installed exactly the way it should have been.” Tube plugging often takes place during tight outage windows, where every hour of downtime matters. Technicians may be working in confined, wet, or poorly lit conditions, sometimes inside large condensers or heat exchangers with limited access. Under these circumstances, documentation has traditionally relied on handwritten notes that are later transferred into spreadsheets or formal reports.

“Those environments are not exactly friendly to paperwork,” Alex adds. “You’re dealing with water, scale, tight spaces. Notes get smudged, pages get lost, and by the time information is transferred, details can be missing.”

The consequences of poor documentation can be serious. A leaking tube can allow cooling water and process media to mix, contaminate product batches, or force an unscheduled shutdown. In critical facilities such as nuclear power plants, the implications extend beyond production losses into regulatory and safety concerns.

“We already put tremendous effort into quality control during manufacturing,” Alex explains. “The logical next step was bringing that same level of confidence directly to the installation site.” The Smart Ram Plus was developed precisely to close this gap between product quality and field verification.

Why digital traceability is now essential

Across the energy and process industries, digital traceability has shifted from being a convenience to a necessity. Plants must now demonstrate not only that maintenance work was performed, but that it followed approved procedures, used qualified components, and stayed within defined operating limits.

“In regulated environments, documentation is just as important as the repair itself,” Alex says. “You need to show what was installed, who installed it, and that every step was done correctly.”
The Smart Ram Plus system creates a direct digital link between the factory and the field. Before installation begins, technicians enter key job data into a rugged, glove-compatible tablet designed for industrial environments. This includes equipment identification, tube and exchanger details, installer credentials, and job location information.

The app guides users through required preparation steps such as tube cleaning and dimensional checks using go/no-go gauges.

“We’re not just recording the result,” Danko explains. “We’re guiding the process. The app reminds technicians of each critical step, so nothing gets overlooked.”

Each plug’s manufacturing lot information is captured by scanning a QR code on the product packaging, instantly linking field installation data with factory material certifications and batch test records.

“That’s a huge benefit,” says Alex. “Ten years from now, if someone asks about a specific tube, we can trace that plug back to its manufacturing data with a click. That level of traceability simply didn’t exist before.”

How the Smart Ram Plus and 640T synergize

At the core of the system is the integration between the Smart Ram 640T installation tool and the Smart Ram Plus tablet application. Traditional hydraulic installation setups often required hoses, external pumps, and multiple pieces of heavy equipment.

“Older systems worked, but they were bulky,” Danko notes. “You had hoses, power units, and a lot of gear to move around inside a heat exchanger.” The Smart Ram 640T simplifies the setup with a compact, battery-powered design and integrated Bluetooth connectivity. This eliminates hoses and external power sources, improving portability and reducing trip hazards in already confined workspaces.

“Ten years from now, if someone asks about a specific
tube, we can trace that plug back to its manufacturing
data with a click. That level of traceability simply didn’t exist
before.”
– Danko Kobzar

As each plug is set, the tool communicates directly with the tablet, capturing real-time installation force and generating an installation graph. “That graph is extremely valuable,” says Danko. “It shows us how the plug expanded and whether the seal formed the way we expect. It’s like a signature of a good installation.”

If irregularities appear, technicians can address them immediately while the exchanger is still open. The app also enables pre- and post-installation photos. “Pictures tell a story,” Danko adds. “You can see tube condition before and confirm plug position after. It removes a lot of guesswork.”

Real-time verification in safety and reliability

Real-time installation verification significantly enhances both safety and long-term reliability. In the past, an improperly installed plug might only be discovered after the exchanger was reassembled and returned to service.

“Finding a problem after startup is the worst-case scenario,” Alex says. “You have to shut down again, drain systems, and reopen equipment. That costs time and money.”

With Smart Ram Plus, installation performance is confirmed instantly. “If something doesn’t look right, you know immediately,” Danko explains. “You can fix it on the spot instead of days later.” From a safety perspective, immediate confirmation reduces the risk of leaks that could expose workers to hazardous fluids or lead to environmental releases. It also minimizes the chance of cross-contamination between cooling and process streams. “In certain applications, mixing fluids is more than a production issue, it’s a safety issue,” Alex emphasizes. “Anything that reduces that risk is extremely valuable.”

“At the end of the day, it’s about giving customers more
confidence in the installation, in the documentation, and the
long-term reliability of their equipment.”
– Alex Kotlyar

Installation data can also be reviewed remotely by Curtiss-Wright specialists. “If a customer wants a second set of eyes, they can send us the graphs,” says Danko. “We can review them and give feedback without being onsite.”

The power of automated documentation

The Smart Ram Plus system replaces traditional handwritten records with automated digital reporting. As soon as the job is complete, the app generates a comprehensive report.
“You push a button and the report is done,” Alex says. “No rewriting notes, no transferring data later.”

Reports include plug location, installation graphs, plug lot numbers, installer identification, timestamps, and captured images. These files can be shared immediately with plant personnel, contractors, or quality departments.

“Because everything is recorded at the source, there’s no data degradation,” Danko explains. “It’s clean, consistent, and complete.”

For contractors, this means faster job closeout. For plant operators, standardized reports simplify audits and long-term recordkeeping.

“It streamlines communication between the field and engineering teams,” Alex adds. “Everyone sees the same information, in the same format, right away.”

Shaping the future of heat exchanger maintenance

Curtiss-Wright views Smart Ram Plus as a digital platform that will continue to evolve. “This is just the beginning,” says Alex. “Because it’s app-based, we can add features over time without changing the hardware.”

One future possibility is digital tube sheet mapping, allowing technicians to create a visual layout of plugged tubes within the app. “Imagine being able to see exactly which tubes are plugged and how that affects performance,” Danko says. “That could help plants plan maintenance much more strategically.”

The platform could also integrate training resources and installation procedures, giving technicians on-demand guidance in the field. “We’re taking something that was traditionally mechanical and bringing it into the digital world,” Alex concludes. “At the end of the day, it’s about giving customers more confidence in the installation, in the documentation, and the long-term reliability of their equipment.” With patented technology, real-time verification, and seamless digital documentation, Curtiss- Wright’s Smart Ram Plus is redefining how tube plugging is performed and proven. In an industry where reliability, accountability, and safety are
paramount, this digital advancement ensures that every installed plug carries not just mechanical strength, but documented assurance.