There is no doubt that accurate, reliable, and frequent industrial inspection is essential to maintain efficiency and boost productivity in capital-intensive industries, such as oil, gas, and chemical manufacturing. However, manual inspections are ridden with many challenges surrounding the remoteness of locations, dangerous work environments, and rising deployment costs with the looming demographic crisis. Additionally, these methods are often prone to errors from human factors, such as reduced attention spans during repetitive tasks, and the need for more comprehensiveness and accuracy for effective inspections.
Autonoumous Inspection Robots, robots equipped with advanced vision sensors, and powered by AI offer a compelling solution to these challenges. Unlike traditional methods, robots can safely navigate hazardous environments and perform detailed inspections of critical and high-value infrastructure, even in remote locations. This enhances safety for human personnel and enables the collection of richer data for condition monitoring and predictive maintenance.
Choosing the right robot for automated industrial inspection is crucial for maximizing its effectiveness and reducing operational costs. Diverse types of robots, such as wheeled, tracked, and aerial drones, are better suited for different environments and inspection tasks based on their functionalities. Selecting the ideal type not only ensures operational efficiency but also plays a key role in realizing the economic benefits of robotic inspection. So, how do you choose the ideal inspection robot for your facility?
Step 1: Identify Automation Opportunities
To maximize the effectiveness of robotic inspection technology, it is critical to first create a strategic plan. This strategy should focus on understanding your facility's specific needs, identifying present inefficiencies, and establishing clear objectives and goals.
A well-thought-out strategy ensures that your automation investment is aligned with your organization's priorities, resulting in the greatest impact. By evaluating existing challenges such as safety risks, cost implications, and downtime, and determining how automated inspections can address these issues, you can lay the groundwork for a successful implementation.
1.1 Understanding the Needs of Your Facility:
The first step in identifying automation opportunities is to thoroughly understand the unique requirements and challenges of your facility. This understanding lays the groundwork for selecting the most suitable inspection robot.
1.1.1 Operational Inefficiencies
For a start, it is important to evaluate where your current inspection processes fall short and to recognize the repeated obstacles or recurring errors. Understanding these inefficiencies can reveal where automation might provide improvements.
Manual inspections are often time-consuming and prone to inaccuracies. Inaccessible areas may require costly manual entry. Inspection robots can streamline these processes, reducing the time and resources required for inspections. For example, did you know that 8 hours of tiring manual inspection rounds can be trimmed to just a 30-minute automated drone inspection flight?
Additionally, decisions based on outdated information impede proper decision-making for which automation can be used to gain real-time insight into operations.
1.1.2 Safety concerns
Industrial environments can pose significant safety risks. Hazardous areas, toxic substances, and extreme weather conditions can endanger human inspectors. By identifying these safety concerns, you can pinpoint the areas where robotic inspection can significantly enhance worker safety. Autonomous Inspection Robots and Drones eliminate human exposure to dangerous environments, reducing accident risk and improving compliance with safety regulations.
1.1.3 Labor Shortages
The challenge of recruiting and retaining skilled inspectors can lead to increased costs and reduced operational efficiency. By automating dull, dirty, and dangerous tasks, inspection robots offer a solution that frees up human resources for more complex and strategic activities. This approach does not replace human workers, but rather complements them, allowing them to focus on more rewarding and less tedious responsibilities.
Countries such as Japan and South Korea have proved the efficacy of human-robot collaboration in sustaining a productive and pleased workforce, despite demographic challenges. By leveraging inspection robot capabilities, asset owners can manage labor shortages while improving their facilities’ overall productivity and well-being. Discover more about How Robots Plug Gaps in an Ageing Workforce.
1.2 Defining Objectives and Goals
Enhancing the effectiveness of inspections, minimizing interruptions, and broadening the scope of inspections demand a thoughtful strategy that utilizes contemporary technologies and insights based on data. The subsequent sections will explore a creative solution: using automated inspection robots and drones to enable Operator Rounds by Exception and Predictive Maintenance. These approaches can help your facility achieve objectives like improving operational efficiency, reducing downtime, and enhancing safety.
1.2.1 Optimizing Inspection Efficiency through Operator Rounds by Exception
Operator Rounds by Exception is an innovative approach to industrial inspections that focuses on efficiency and targeted action. Unlike traditional operator rounds, which are conducted at regular intervals based on a fixed schedule, regardless of the condition of the equipment or facility, rounds by exception leverage real-time data and AI-driven insights delivered by autonomous robots. Only when robots detect anomalies, do the operators need to act.
By utilizing robots equipped with sensors and AI-driven analytics, you can perform targeted inspections only when necessary, and enhance safety, improve operational efficiency, and maximize resource utilization. This goal aligns with the strategic use of automation opportunities to prioritize critical tasks and reduce manual workloads, ultimately contributing to the overall integrity and reliability of your plant operations. Learn more about Operator Rounds by Exception and how they can improve your plant's safety and efficiency.
1.2.2 Reducing Downtime by Enabling Predictive Maintenance
Industrial downtime or factory interruptions can lead to significant economic pressures, frequently exacerbated by the limitations of manual evaluations. Conventional examinations, typically conducted at predetermined intervals, may result in issues being identified too late, allowing malfunctions to worsen and escalate before they are repaired.
This approach often means sudden shutdowns, which adversely impact production and have a crippling effect on profits. Manual inspections can also put workers at risk, increasing the chance of accidents and injuries. Moreover, compliance concerns associated with manual inspections can result in penalties and harm an organization's reputation.
AI-driven robotic inspections further enable predictive maintenance by continuously collecting and analyzing data in real-time. Equipped with sensors and advanced AI algorithms, these robots and drones can detect anomalies and subtle changes in equipment conditions that might go unnoticed by human inspectors. This level of precision and constant monitoring helps fix minor issues before they become major ones.
Switching from a reactive approach to a predictive one based on AI allows businesses to realize significant reductions in expenses, boost safety, and improve the dependability and efficiency of their machinery.
1.2.3 Increasing Inspection Coverage While Reducing Inspection Costs
In capital-intensive industries, increasing inspection coverage is essential to ensure safe and efficient operations by monitoring all critical assets, but it often comes with significant labor and time costs. Manual inspections can be labor-intensive, time-consuming, and may not reach every area, particularly in inaccessible or hazardous zones. Autonomous inspection robots and drones provide a solution by expanding coverage with greater accuracy, speed, and consistency, while also reducing overall inspection costs.
These robots and drones improve the inspection procedures by quickly gathering and examining vast amounts of data to spot trends and patterns that might be overlooked with traditional methods. By complementing human expertise, automated inspection robots and drones can extend inspection reach and improve quality control without increasing costs. The optimal strategy often involves onboarding a mixed fleet of different robots and drones which can cover the entire facility and deliver 360° insights.
Step 2: Align Inspection Robot Technology with Your Operational Goals
In the next step, to successfully match the technology of inspection robots with the aims of operations, it is crucial to precisely outline the specific needs and objectives. This requires grasping the distinct obstacles and necessities of the facility, including the kind of information necessary, how often inspections should occur, and the safety regulations that need to be adhered to.
Organizations should evaluate the diverse types of inspection robots available, such as ground-based robots, ATEX/IECEx-certified robots, and BVLOS-approved drones, to determine which technology best matches their operational requirements. Choosing the appropriate robot technology requires considering factors like mobility, sensor capabilities, network connectivity, and durability to guarantee the robot can execute the required functions effectively and consistently. By matching the robot's features with operational goals, companies can attain increased efficiency, lower expenses, and enhanced safety in their inspection activities.
2.1 Assessing Facility Requirements
Before deploying inspection robots, it is essential to carefully examine the facility's needs to ensure the selected robot is suitable for its intended use. This requires a deep understanding of the facility's layout, the conditions the robot is in, how it needs to operate, and how it connects to the internet. By looking at these aspects, organizations can find the best robot system to carry out inspections and gather data safely and reliably.
Assessing the facility also means thinking about entry points, possible dangers, defining go and avoid zones and any limitations in how the robot can operate. This thorough review guarantees that the chosen inspection robot is a perfect match for the facility's unique features, enhancing the inspection process's efficiency and success.
2.1.1 Environmental Conditions of Your Facility
To guarantee the best functioning of robots and the precision of the data they collect, it is crucial to align environmental factors with operational goals. This involves pinpointing critical parameters such as terrain, space, lighting, and weather, which might affect the process of inspection, and setting limits for these aspects.
Choosing appropriate robots with sensors and materials capable of operating in these environments is equally important. Environmental protection measures should be employed to shield the robot from harsh conditions, and robust data acquisition and processing algorithms are necessary to counteract environmental effects on sensor data.
For instance, in the oil and gas sector, robots must navigate extreme heat, moisture, flammable gases, and confined spaces. Therefore, selecting technology suited for these challenging conditions and implementing safety precautions is crucial.
IP Ratings and Environmental Readiness of Inspection Robots
The IP rating, also known as the Ingress Protection rating, is a standard established by the IEC (International Electrotechnical Commission) and represents a two-digit code that signifies the degree of defense a device, including robots, possesses against the entry of solid objects and water. This rating is an essential aspect to consider when choosing robots for settings, particularly those with severe conditions such as dust, dirt, or moisture.
The IP rating is composed of two numbers. The first digit indicates protection against solid objects, ranging from 0 (no protection) to 6 (complete protection from solid particles), while the second digit shows the level of water resistance, ranging from 0 (no protection) to 8 (complete waterproofing). A higher IP rating means greater protection against substances like dust, grease, and liquids, making the device suitable for harsher environments.
Inspection robots used in the oil & gas sector are typically advised to have an IP rating of IP67 or above. This rating signifies full defense against dust and the ability to withstand brief submersion in water to a depth of 1 meter for 30 minutes. Consequently, these robots can be effortlessly cleaned and sterilized from dangerous materials without compromising their functionality.
In addition to the IP rating, it is crucial to consider various environmental elements like temperature, and lighting to ensure the robots are properly equipped for the environment they will be working in. Verifying that the robots can handle extreme temperatures, resist corrosion from moisture, and work well in areas with little or a lot of light guarantees their dependability and strength in challenging environments.
2.1.2 Mobility Needs for Inspection Robots
The mobility of inspection robots is a critical factor in their effectiveness across various applications. Different environments, such as multi-floored industrial plants, outdoor facilities with rugged terrains, or hazardous sites, impose unique challenges that require specific mobility features. The robot's skill in maneuvering, avoiding obstacles, and staying steady as it travels through these areas significantly affects the achievement of inspection duties.
Thus, understanding the specific mobility needs of the robot for guaranteeing its ability to carry out inspections efficiently, no matter the surroundings.
Checklist: Mobility Readiness of Inspection Robots
When selecting a robot for a specific application, it is crucial to evaluate the mobility needs in conjunction with the task requirements. For example, a robot designed outdoor inspection should prioritize terrain adaptability and obstacle avoidance.
This checklist provides a comprehensive assessment of key factors related to terrain navigation, maneuverability, obstacle avoidance, and speed and endurance. By carefully considering these aspects, organizations can select robots that are not only capable of traversing difficult terrain but also reliable and efficient in their operations.
Terrain Navigation:
- Rough terrain: Can the robot traverse uneven surfaces, slopes, or obstacles?
- Obstacles: Can it detect and avoid obstacles, including people or equipment?
- Stair Climbing: Is the robot capable of ascending and descending stairs safely and effectively?
Maneuverability:
- Agility: Can it navigate tight corners or change direction quickly?
- Stability: Can it maintain balance on uneven surfaces or slopes?
Obstacle Avoidance:
- Sensor capabilities: Does the robot have sensors to detect and avoid obstacles?
- Obstacle avoidance algorithms: Can it effectively navigate around obstacles?
- Safety features: Are there safety mechanisms to prevent collisions?
Speed and Endurance:
- Inspection speed: How quickly can the robot cover a specified area?
- Battery life: Can it operate for an extended period without needing recharging?
- Endurance: Can it withstand continuous operation without mechanical failures?
2.1.3 Network Connectivity for Inspection Robots
The ability of inspection robots to function properly and perform well is heavily reliant on their network connection, as it plays a crucial role in their data sharing, remote operation, and system integration. In industrial settings, where these robots are deployed across vast and complex environments, reliable network connections ensure that they can communicate effectively with control centers, transmit high-quality data in real time, and operate without interruptions.
The type of network connectivity required depends on the specific operational environment, tasks, and data transmission needs of the robots. Factors like signal strength, and potential interference, must also be considered to ensure uninterrupted communication. By choosing appropriate network options, organizations can enhance the efficiency of their inspection processes, minimize downtime, and improve predictive maintenance capabilities through continuous data flow and analysis.
Checklist: Network Readiness of Inspection Robots
To ensure that inspection robots can effectively communicate and transmit data in various environments, it is essential to evaluate their network connectivity capabilities. This checklist provides a comprehensive assessment of key factors related to wireless connectivity, and integration with other systems.
Wireless Connectivity:
- Wireless Connectivity Suitability: Is a wireless connection sufficient for the robot's tasks and environment?
- Available Wireless Options: What type of wireless connectivity is available (Wi-Fi, cellular, Bluetooth)?
- Wireless Signal Considerations: Are there any concerns about signal strength or interference in the operating area?
Integration with Other Systems:
- IoT: Does the robot need to connect to other IoT devices for data sharing or automation?
- Cloud platforms: Will data be stored and analyzed on a cloud platform?
2.2 Types of Inspection Robots
Inspection robots are specialized robotic systems designed to enhance safety, efficiency, and accuracy in various industrial applications. They are categorized based on their operational environment and capabilities, such as ground-based robots, ATEX/IECEx-certified robots, and BVLOS-ready drones.
Each type of robot serves a unique purpose, from navigating challenging terrains to inspecting hazardous environments or performing automated aerial inspections by leveraging these diverse types of robots, industries can perform inspections more effectively, reduce operational costs, and minimize the risks associated with human intervention in dangerous or hard-to-reach locations. Explore how Shell Rheinland leverages 360° Automated Inspection from both the ground and the air.
2.2.1 Ground-Based Robots
Ground-based robots play a vital role in industrial inspection by navigating various terrains and environments to collect critical data, reduce human risk, and improve operational efficiency. These robots come in different forms, primarily categorized as legged, tracked, and wheeled.
Their design and capabilities determine their suitability for specific applications, such as navigating confined spaces, traversing uneven terrain, or quickly covering large, open areas. Each type has its unique strengths, allowing industries to select the appropriate robot based on the inspection task's particular demands and the environment in which it will operate. This adaptability makes ground-based robots essential tools for ensuring the safety, reliability, and longevity of industrial assets.
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2.2.1.1 Legged Robots
Legged robots or quadruped robots are a type of robotic system designed for navigating and inspecting complex environments, particularly those with multiple floors or uneven terrain.
Equipped with legs, these robots can traverse obstacles and stairs that would be difficult or impossible for wheeled or tracked robots. They can perform complex maneuvers, such as crouching, turning in place, or even jumping, allowing for inspection in cluttered, confined, or unpredictable environments.
2.2.1.2 Tracked & Wheeled Robots
Tracked and wheeled robots are a type of robotic system designed for navigating and inspecting rough terrains. These robots are equipped with either tracks or wheels. Wheels allow robots to be typically faster on flat and semi-flat surfaces, making them ideal for inspections in environments like warehouses, factories, substations, or large-scale facilities.
Additionally, robots equipped with tracks are better suited for rougher terrains and can handle obstacles like rocks, debris, or uneven surfaces. They can traverse narrow, uneven, or inclined tunnels and pipes, making them ideal for inspecting pipelines, sewers, and underground infrastructure.
2.2.2 ATEX/IECEx-certified robots
Robots that have been approved by ATEX/IECEx standards are made for operation in areas where there is a risk of explosions, like those present in oil and gas sites, chemical manufacturing plants, and other dangerous sectors. These areas are categorized into Zones 0, 1, and 2, depending on how probable an explosive atmosphere is. Zone 0 means there is a steady or ongoing presence of explosive gases, Zone 1 points to a probable event, and Zone 2 indicates a rare or brief occurrence.
For instance, ExR-2 allows for the automation of inspections in areas that could be explosive under ATEX or IECEx Zone 1 regulations, gather detailed information, and carry out predictive plant maintenance through advanced computation. Learn more about EXR-2 for Industrial Inspection.
2.2.3 BVLOS-ready Drones
Beyond Visual Line of Sight (BVLOS) describes the use of a drone or unmanned aerial vehicle (UAV) that operates outside the direct line of sight of the person controlling it. This implies that the drone can be flown remotely with no human presence needed onsite.
Drones used for Beyond Visual Line of Sight (BVLOS) missions are equipped with advanced cameras, thermal imaging technology, offering comprehensive information for a range of inspection activities. These sensors can capture precise data, including size, temperature differences, and the structure condition, aiding in quick detection and fixing of issues, especially during tank roof inspections. Explore how Shell is enhancing the inspection of tank farms through drones and automating processes.
By operating remotely, BVLOS drones minimize the risk of accidents or injuries to human operators in hazardous environments. Difficult-to-access areas can be inspected safely from a distance, reducing the need for human intervention. Learn more about The Advanced Energy Robotics Drone Solution.
Step 3: Choose a Hardware-Agnostic Platform to Manage Different types of Robots and Drones
Given the enormous scope and diversity of inspection tasks and environments, there is no single wheeled, legged, tracked or flying robot that can handle each inspection use case equally well. Selecting a combination of robots and sensor payloads that best fits specific inspection needs will unlock maximum potential in terms of performance and cost.
Therefore, to enhance efficiency and increase adaptability, asset owners should adopt a hardware-agnostic solution capable of managing different types of robots and drones from a single platform. This ensures cost-effectiveness and comprehensive 360-degree inspection coverage, while also providing long-term security for your investment and the flexibility to adapt to new technologies.
Why Choose a Fleet of Different Robots and Drones?
Deploying diverse types of robots and drones tailored to particular tasks can greatly improve operational efficiency and cost-effectiveness. Specialized robots, designed for unique environments or tasks, often outperform generalist solutions in their specific use cases. Employing a range of robots and drones balances usefulness with cost, ensuring minimal needs for one-size-fits-all solutions, which tend to be extremely expensive.
However, many customers begin their journey with a single pilot use case to test robotic solutions. Once they have proven its success, they either scale up its implementation across their operations or explore additional use cases. In such cases, moving to more specialized solutions involves dealing with friction from various suppliers of the robots, which may cause frustration and inefficiencies.
Why Energy Robotics?
Energy Robotics addresses this challenge by providing a hardware-agnostic software platform that unifies diverse robotic systems under a single management interface. Our AI-powered platform enables the integration of diverse fleets of robots and drones, providing a scalable and flexible solution to meet all your inspection needs.
Since 2019, robots deployed with our software have covered over 20,000 kilometers of autonomous inspections across 4 continents, proving its robustness and reliability across various sectors. Discover how Energy Robotics' software is tailored to meet the unique needs of different industries.
Our cutting-edge software features, combined with our expertise in AI, empower you to streamline complex inspection tasks, ensuring the safety of your employees but also enhancing operational efficiency, reducing downtime, and optimizing asset performance.
Ready to transform your inspection processes? Book a demo today to start building your robot fleet or contact us to discuss how we can tailor our technology to meet your facility's needs.
