Kav AI Platform · KAP v3.4
The first platform to close the loop between what sensors see, what process data says, and what engineering codes require — delivering risk decisions in hours, not weeks.
Bridging industrial data silos
To analyze asset integrity, we must connect physical reality, process telemetry, and design bounds. Today, these live in completely isolated system and network silos, forcing engineering teams to spend up to 70% of their time manually compiling spreadsheets.
Information Technology
<10%
Visual Data Silo: Less than 10% of captured visual/drone inspection imagery is ever reviewed by a qualified engineer. Lives on corporate networks, completely isolated from active process contexts.
Operational Technology
$2M
Process Data Silo: Telemetry (pressures, temperatures, flow rates) lives behind secure, air-gapped firewalls. Gaps in historians hide progressive degradation, risking unplanned shutdowns costing up to $2M/day.
Engineering & Design
5–10d
Design Intent Silo: Structural 3D CAD design models and P&IDs live in document repositories. It takes 5 to 10 days of manual data-entry to cross-reference design codes and CMLs against field results.
What Kav AI is
KAP ingests visual inspection data, reads operational data from SCADA and process historians, and reasons across both in a persistent 3D model of the facility — continuously updating risk and recommending action.
What Kav AI is not
Observe · reason · recommend
01
See
Multi-modal capture, normalised into a single photorealistic 3D model.
02
Reason
Multimodal AI correlates visual, thermal and process data against the integrity domain model.
03
Recommend
Decisions surface in minutes via a natural-language interface — every action engineer-confirmed.
Purdue model & data flow
KAP establishes a unidirectional, read-only perimeter. Physical sensor networks, robot fleets, and engineering design databases push up to our secure layer, while recommendations route through strict engineer validation (HITL) before reaching the plant CMMS.
Figure 1 Spec: Outlining the absolute boundary between operators, security zones, and external integrations.
Integrity analytical chain
Normalise
Multi-source data QC'd with ±500 ms timestamp alignment.
IOW check
SCADA scored against API 584 limits by duration × intensity.
DMR
API 571 damage mechanism mapping, enriched with CAD context.
Cross-check
Campaign, patrol and SCADA evidence reconciled at the consistency gate.
Validate
Physical validation against UT, thermal, OGI and robot-sourced NDT.
Act
API 581 risk + P90 life → prioritised inspection plan & CMMS work order.
Result Triage-to-work-order cycle reduced from 5–10 days to under 4 hours.
Container & database schemas
The internal platform topology isolates the 3D world model, process limits (IOW), and corrosion models (DMR) into decoupled containers. It illustrates how the cross-source correlation engine serves as the unified fan-in pre-stage feeding the consistency checks.
Figure 2 Spec: Highlighting the decoupling of the 3DGS photorealistic layer, the multi-source broker, and the core integrity engine.
Competitive position
| Layer | RBI incumbents orKsoft · Meridium |
Data fusion Cognite · Hexagon |
Autonomous capture Percepto · Flyability |
Kav AI |
|---|---|---|---|---|
| Visual inspection (multi-modal) | — | partial | ✓ | ✓ |
| Photorealistic 3D (from drone imagery) | — | needs LiDAR / CAD | — | ✓ 3DGS |
| SCADA/IOW context (API 584) | ✓ | ✓ | — | ✓ |
| Damage mechanism reasoning (API 571) | ✓ | — | — | ✓ |
| Deployment time | 6–18 mo | 6–18 mo | weeks | 90-day pilot |
Equipment & mechanism thresholds
| Equipment Class | Automation Capability | Rationale & Engineering Posture |
|---|---|---|
| Pressure Vessels & Exchangers | Full API 581 Automation | Primary M0/M1 asset focus. Heaviest source of corrosion-under-insulation (CUI) and standard IOW exceedances. |
| Piping Circuits | Full API 581 Automation | Mapped continuously via OPC UA SCADA process historical streams and Corrosion Monitoring Locations (CMLs). |
| Pressure Relief Devices (PRDs) | Flag Only (HITL Required) | PRD-specific methodology, requiring distinct consequence logic and specialized verification pathways. |
| Atmospheric Storage Tanks | Flag Only (HITL Required) | Tank floor inspection governed by unique mechanical standards (API 653) requiring offline manual entry. |
| Pipelines & Rotating Equipment | Out of Scope (v1) | Requires specialized inline inspection (ILI) data and vibration dynamics. Deactivated in standard reasoning modules. |
The noise filter
Drone, robot, and SCADA data are tagged, matches resolved within a 2-meter spatial radius, and scored across independent channels.
>98%
True Positive Rate (TPR) targets for multi-source confirmed insights.
<2%
False Positive Rate (FPR) targets achieved via cross-source corroboration.
Operational classification schema
Single-Source Detection
Vulnerable to transient environmental noise. Routed to standard severity-based triage.
Corroborated Finding (2 Sources)
Elevated priority with explicit evidence linking. Promoted to top of triage queue.
Multi-Source Confirmed (3+ Sources)
Bypasses manual verification queue for non-Critical severity items. Critical severity and Remaining Life changes always require engineer sign-off (v3.4 Canonical Rule).
Hallucination mitigation
Given the high stakes of asset integrity, Kav AI rejects black-box LLM predictions. A strict multi-layered validation logic wraps the reasoning engine.
OOD Detection Cadence: The OOD detector identifies out-of-distribution inputs (sensor noise, physical layouts). Onboarded facilities run baseline campaigns during weeks 1-4 to calibrate the model, before production alerting is activated.
Three lines of defense
Beyond intermittent campaigns
Rather than relying solely on high-cost per-robot onboard SLAM modules which degrade in repetitive piping systems, Kav AI pivots navigation to a site-amortized sensor mesh.
>= 20 h/day
Continuous, fleet-wide coverage across equipped site zones, delivering persistent physical tracking.
Localisation: SLAM vs. Fixed Mesh
| Dimension | Onboard SLAM | Fixed Infrastructure |
|---|---|---|
| Reliability | Degrades in piping | Absolute (No drift) |
| ~5cm with drift | ~2cm anchored | |
| Scaling Cost | High (per-robot stack) | Low (amortized across site) |
| Varies by fleet | 5–15ms (Private 5G) |
Physical meets design intent
Rather than treating inspection data as isolated pixels, Kav AI overlays the live photorealistic 3D world against engineering design files.
As-Built vs. As-Designed: Digital Twin Sync Service overlays 3DGS-derived as-built geometry against CAD design geometry, raising automatic notifications for pipe sags and structural shifts exceeding millimeter thresholds.
Per-format ingestion pipelines
Enterprise deployment models
01 / Cloud SaaS
Multi-tenant deployment managed on Kav AI's Google Cloud tenant.
02 / Customer Tenant
Containerized package inside customer Azure or AWS virtual private clouds.
03 / Air-Gapped On-Prem
Fully on-premise inside the local LAN or OT/IT DMZ network.
Work processes
Kav AI fits directly into standard maintenance schedules. It pulls RBI baselines, updates operational corrosion rates, and writes rich evidence back to CMMS systems.
orKsoft Coexistence: orKsoft retains ownership of compliance records, CML thickness logs, and the master RBI plans. Kav AI digests those baselines as Stage 5 corrosion rate inputs, returning predictive risk adjustments.
Certified connector roadmap
MVP v0.1 · Platform Core & Web Workspace
The initial release established Next.js 15 app scaffolding, multi-tenant organizations, secure credentials configuration, and seamless user onboarding.
Timeline boundary
App Start
May 12, 2025 · commit 835074a2 introduced Next.js app scaffolding and Supabase auth setup.
App Finalization
Oct 6, 2025 · commit d81a9ca6 marked complete web workspace finalization before agentic layers.
M0 boundary: web application only — no agentic CrewAI release scope.
01 · Identity
Auth & Tenant Shell
Public landing, login/signup, auth callbacks, protected app shell, org selection, invite flows, and membership checks.
02 · Data model
Dashboard & Datasets
Dashboard content, dataset creation, dataset tables/grids, detail pages, loading states, and error handling.
03 · Cloud storage & data
Secure Credentials
Custom secure Cloud Credentials form supporting Supabase model definitions, Azure SAS tokens, and Google Cloud Storage buckets.
04 · Settings & Setup
Onboarding & UI shell
Onboarding forms, user profiles, theme toggles, invite member forms, custom-styled Radix UI components, toasts, and alerts.
MVP v0.1 · 3D Spatial & Multi-Sensor Visualization
The core workspace features highly interactive visualization components: photorealistic 3D, COCO imports, side-by-side viewports, and gas mapping.
Multi-Sensor Stack
3DGS Spatial Anchoring
Cesium.js & Three.js loader for photorealistic 3D Gaussian Splatting and Google 3D Tiles.
Cross-Modal Juxtaposition
Synchronized dual-viewport for RGB and radiometric thermal imagery comparison.
Data integration: project COCO schemas and GIS gas sensor feeds onto the same workspace.
01 · Spatial 3D Environment
3DGS & Google Tiles
Navigable 3D Gaussian Splatting (3DGS) viewer using Cesium.js, Three.js, and Google 3D Tiles to render photorealistic facility scans.
02 · Multi-Format Dataset Hub
COCO Import & BBox
Upload and parse COCO JSON files to automatically project bounding boxes (`bbox`) and annotations via a canvas BoundingBoxVisualizer.
03 · side-by-side view
Cross-Modal Gallery
Side-by-side dual-viewport of RGB (visible light) and radiometric thermal imagery with fully synchronized zoom and pan controls.
04 · Multi-Sensor Telemetry
Gas Concentration
Visualize real-time sensor streams (methane, NO2, HCl, Cl2, H2) joined via v_dataset_gas_readings and mapped directly to GIS paths.
M1 · MVP v0.2 · CrewAI Added
M1 ran from October 2025 to March 2026, transitioning from 3D data workflows into the first active, agentic reasoning pipeline.
Boundary evidence
CrewAI Start
Oct 6, 2025 · commit d81a9ca6 introduced CrewAI to backend configuration & MCP testing.
M1 Completion
March 2026 · Concluded M1 development as focus transitioned into Q2 planning and M3 design.
01 · Agent Orchestration
CrewAI Multi-Agent Flows
Deployed the multi-agent cognitive architecture to replace static templates with sequential, task-driven reasoning flows.
02 · Backend Architecture
gRPC Subprocess Router
Ran multiple systems on port 8080 by routing traffic over gRPC loopbacks (:50051, :50052) as subprocesses managed by Supervisord.
03 · Structured Database
Supabase & MCP Context
Integrated backend agents with PostgreSQL tables (images, annotations, gas_readings) using Model Context Protocol (MCP).
04 · Cloud Infrastructure
GCP Multi-Container Run
Deployed Next.js as main app and kavai_server as a localhost sidecar inside a secure, autoscale-enabled GCP Cloud Run environment.
M2 · MVP v0.3 · Retrieval & Reliability
M2 introduced 3D CAD engineering asset alignment with Gaussian splats, alongside better retrieval, contextual chat, and recovery.
3D CAD Alignment
Linked structural 3D CAD models with photorealistic 3D Gaussian Splatting via manual and automated coordinate transforms.
Contextual Chat
Evolved conversation from generic Q&A into facility- and dataset-aware dialogue using strict, firewall-enforced SQL limits.
Modular Workspaces
Partitioned the platform frontend into Data Explorer and Integrity workspaces to separate generic data browsing from active triage.
Failure Recovery
Engineered auto-recovery for missing, empty, or malformed database tool results without disrupting the active, live user streams.
Comprehensive Tests
Built extensive E2E validation suites, multi-turn simulators, and programmatic unit-eval tests to secure pipeline reliability.
M2 outcome: operators can ask contextual questions against inspection data and get recoverable, test-backed answers.
M3 · PRD-aligned decision impact
The PRD frames Kav AI as decision support, utilizing modular workspaces (Data Explorer and Integrity) to transition smoothly from data browsing to active engineer validation.
PRD workflow path
Automated triage: anomaly, severity, confidence, source type, and asset identity.
Human validation: engineer selects Confirm, Dismiss, or Reclassify.
Escalation & audit: every decision is timestamped in the handover trail.
IDMS/CMMS packet: verified insights become work-order-ready data.
Decision rules from PRD
Kav AI supports decisions; it does not autonomously finalize critical integrity calls.
Critical outputs and Remaining Life adjustments require individual engineer sign-off.
Low-confidence alerts move to review; confirmed findings generate actionable-insight records.
Target: compress triage-to-work-order from 5–10 days to less than 4 hours.
Chronological deployment
MVP v0.1 · Web Application
Web app foundation only: organizations, datasets, image workflows, dashboards, and cloud-backed inspection data.
MVP v0.2 · CrewAI Added
CrewAI-backed Supabase/MCP reasoning introduced the first agentic decision-context layer.
MVP v0.3 · Data Chat Reliability
Improved retrieval, contextual data chat, failure recovery, and comprehensive test coverage.
Decision Impact · PRD Workflow
Triage, engineer decision, audit, and structured IDMS/CMMS handoff.
MVP sequence validation
M0 / MVP v0.1: Web application only. (Delivered)
M1 / MVP v0.2: CrewAI added as the first agentic reasoning layer. (Delivered)
M2 / MVP v0.3: Retrieval, contextual data chat, failure recovery, and tests. (Delivered)
M3 / Decision Impact: PRD decision workflow — triage, HITL validation, audit, and IDMS/CMMS handoff. (Focus)
What the integrity engineer needs
The product job: turn multi-source inspection data into grounded, audit-ready decisions an engineer can act on — and defend.
Architecture · the integrity engineer's assistant
Four living stores the assistant reads and writes — each engagement deposits all four. That is the data flywheel.
Files
File Perception
Typed lenses, not raw bytes — image, document (standards with citations), report, CAD, P&ID.
Code
Code & Execution
SQL today → sandboxed code to compute risk and generate reports. Code saved as the artifact of record.
Skills
Skill Repository
Governed markdown — human-curated, assistant proposes. Institutional knowledge.
Memory
Memory & Learning
Decisions, learned facts, preferences across sessions. Working knowledge — graduates into Skills.
Workspace & Artifact Store — object storage + metadata index the four stores sit on. Reuse, don't reinvent.
Enterprise Governance, Security & Audit — sandbox · RBAC · provenance · human-in-the-loop.
Executing Agent-Generated Code
How do we safely and scalably run code written by an AI assistant?
The Execution Sandbox
Implementing the first principles via hypervisor-level isolation.
Hardware-Level Isolation
Each agent session boots inside a dedicated, lightweight Virtual Machine with its own guest Linux kernel. Host infrastructure remains entirely inaccessible.
Virtual Native Mounts
Petabyte-scale Azure Blob and Google Cloud Storage datasets are virtualized into the MicroVM using FUSE, streaming directly to the agent instantly.
Rapid Lifecycle
Boots a complete Ubuntu environment with auto-injected Supabase and API credentials in under 15 seconds.
Safe by Default
Agents have root access to their MicroVM, allowing them to install required dependencies without risking host nodes or neighboring tenants.
Execution Environments
Separating the orchestrator from the execution sandbox.
Current: Google Cloud Run
The Orchestrator
New: GKE Agent Sandboxes
The Execution Engine
$HOME folders, allowing agents to save work across multiple runs and sessions.The Architecture: Cloud Run hosts the brain (API/Orchestrator). GKE MicroVMs provide the hands (Code Execution & Data Processing).
The data moat
Pillar 1
Mathematical foundation
Twenty years of active-learning science, turned into product. The reasoning core competitors can't shortcut.
Pillar 2
Active sensing
The system decides what to sense, when, and where. Live telemetry points the next inspection — sensing with intent, not passive capture.
Pillar 3
Data flywheel
Files, Code, Skills, Memory + SCADA compound per facility — proprietary, continuous, sticky. Irreplicable without the same integration.
The loop that compounds
Inspect → Find → Correlate with live SCADA → Decide → Capture outcome → Sharper models ↻
Backup Slide
While SCADA connection is planned for later phases (Q4), the 6-stage analytical pipeline is pre-designed to connect raw physical telemetry (OPC UA) to automated risk models (API 581) once the datastream becomes active.
Ingestion & QC
Normalizes OPC UA feeds; handles stale tags and gaps inside ±500ms alignment window.
IOW Check
Compares SCADA telemetry against API 584 bounds by duration × intensity.
DMR Mapping
Maps exceedances to API 571 mechanisms, leveraging CAD metadata.
Consistency Gate
Three-way validation of material, predicted corrosion rate, and cross-source evidence.
Validation
Cross-references damage maps with UT scans, OGI leaks, and robot telemetry.
Risk & Action
Applies API 581 Damage Factors to score risk → CMMS work orders.
Backup Slide
Kav AI maintains a strictly read-only OT posture. It intercepts, ingests, and analyzes physical reality, process telemetry, and design bounds inside a persistent 3D model, but it never commands valves, acts, or writes to control networks.
Technical Boundary: Outbound-only connection initiation supported from OT to satisfy strict "no-inbound" firewall architectures.
Read-only technical enforcement
Corrosion Rate (CR) Provenance
Level A (Measured)
Derived from localized ultrasonic testing (UT) trend data at specific Corrosion Monitoring Locations (CMLs).
Level B (Modeled)
Derived from process-specific chemical models (pH, CO₂, H₂S, velocity) if UT data is stale (>12 months) or absent.
Level C (Generic)
Standard API 571 / API 581 material susceptibility guidelines inside nominal operational boundaries.
Backup Slide
Deterministic models fail on safety reviews because they ignore measurement tolerance. Kav AI propagates input variance across the entire analytical loop.
RL = (t_actual - t_min) / CR
Where t_actual carries a ±0.1–0.5mm ultrasonic tolerance, t_min is calculated per ASME B31.3/API 570, and CR uncertainty is scaled by its Level A/B/C provenance.
Backup Reference
Standard engineering acronyms, domain vocabulary, and machine learning terminology utilized across the KAP product architecture.
Operational Networks
IT / OT Subsystems
Information Technology (corporate networks) and Operational Technology (industrial controls, SCADA, PLCs) logically separated per the Purdue model.
IDMZ (Industrial DMZ)
A secure network perimeter subnetwork (Level 3.5) preventing direct traffic exchanges between untrusted corporate IT and highly trusted OT control networks.
CMMS (Work Orders)
Computerized Maintenance Management System (e.g., SAP PM, IBM Maximo) used by facilities to log assets and dispatch official repair work orders.
Integrity & Compliance
IDMS (System of Record)
Inspection Data Management System (e.g., pcMS, Visions) holding historical NDT thickness measurements and mechanical compliance records.
APM (Performance)
Asset Performance Management (e.g., GE APM/Meridium) analyzing asset health scoring, failure prediction, and statistical reliability over time.
RBI (Risk-Based Inspection)
Methodology prioritizing equipment inspections based on computed Probability of Failure (POF) and Consequence of Failure (COF) per API 580/581.
Core KAP Technologies
3DGS (Digital Twins)
3D Gaussian Splatting, a neural rendering technique creating navigable, photorealistic 3D twins directly from standard drone inspection imagery.
OOD (ML Reliability)
Out-of-Distribution detector that flags raw sensor inputs, metals, or operating bounds that fall outside the model's training parameters.
KRSI / OPC UA
Robot telemetry broker normalizer (KRSI) and unified industrial communication standard (OPC UA) used for secure machine-to-machine telemetry feeds.