Specialized robotic inspection in Oil & Gas: Optimized efficiency

The integration of autonomous systems with automated NDT capabilities strengthens operational continuity in complex environments in the energy industry. Specialized robotic inspection operates in critical contexts—the seafloor, the interior of tanks in service, confined spaces—maximizing accuracy in defect detection and collecting high-resolution data. The implementation of terrestrial, aerial, and underwater robots allows robotic inspection companies to apply predictive models, optimizing technical resources and reducing environmental impact.

In Oil & Gas, these semi- and fully autonomous systems integrate NDT sensors (ultrasound, eddy currents, optical vision), SLAM navigation, and AI algorithms to monitor tanks, pipelines, platforms, and inspect confined spaces. By automating inspection routes, uninterrupted and in ATEX zones, human risks are reduced, data density is increased, and predictive maintenance decisions are enabled.

What is specialized robotic inspection?

Specialized robotic inspection integrates autonomous or semi-autonomous robots to examine industrial assets using visual, ultrasonic, LIDAR, NDT (non-destructive testing), and other technologies. It is geared toward aggressive, inaccessible, or dangerous environments where manual inspection is risky. These systems can operate on platforms, tanks, pipelines, confined spaces, or underwater. Thanks to robotics, the data collected is more consistent, repeatable, and allows for continuous monitoring.

The global market and demand for automated NDT

Implementing inspection robots is not just a trend: it responds to real market and efficiency needs. The robotic inspection market in Oil & Gas is already estimated at hundreds of millions of dollars (USD 747.47 million in 2024) and is projected to grow steadily (Fortune Business Insights). These solutions reduce unplanned downtime, anticipate failures, decrease human risks, prevent environmental disasters, and aid in regulatory compliance. In sensitive sectors, timely detection can prevent catastrophic events and economic losses, among other benefits.

Listings of leading companies in robotic inspection

The industrial robotic inspection sector is dominated by companies that offer not only hardware, but also complete integrated solutions: robots, sensors, analytical software, and maintenance. These robotic inspection companies have accumulated experience in real-world conditions, allowing them to adapt their technologies to standards, regulations, and safety requirements.

Below is a selection of leading robotic inspection companies:

Waygate Technologies (Baker Hughes): Waygate leads in automated NDT with certified crawler robots and 3DLOC software that automatically georeferences data in confined spaces. Its platforms enable inspection playback, 3D asset mapping, and integrated analysis with digital asset models.

Gecko Robotics: Gecko develops climbing robots equipped with ultrasound, high-resolution cameras, and magnetic sensors to adhere to cylindrical structures. Its Cantilever platform merges this data to generate continuous visualizations of corrosion, pitting, and wear.

In the following video, Gecko Robotics CEO Jake Loosararian explains how his climbing robots collect high-resolution integrity data from multiple industrial infrastructures. This is important for the entire industry: specialized robotic inspection uses advanced NDT to eliminate human risk in confined spaces, ensuring operational continuity and fueling predictive maintenance globally.

Pike Robotics: Created the Wall-Eye robot, a climber designed for in-service inspection of floating roof tanks. It operates in explosive atmospheres thanks to magnetic traction, LIDAR sensors, and depth cameras. Its design eliminates the need for human entry into confined spaces, provides real-time diagnostics on seals and structural defects, and allows for continuous integrity data generation without operational interruptions.

Energy Robotics: This company offers a software-agnostic platform that integrates various robots and drones for autonomous inspection. Its system converts data into actionable analytics: maps, alerts, reports, and predictive analytics. The platform allows you to control a mixed fleet (ground robots, drones, units in ATEX zones) from a centralized web interface, with 24/7 monitoring, API access to cloud data, and integrity alarms.

Flyability: With its Elios line of drones, Flyability tackles inspections in confined spaces that are inaccessible to traditional machinery. The Elios 3 incorporates modular LiDAR and FlyAware™ SLAM engine, generating 3D maps even in environments without GPS, thanks to its collision-tolerant structure.

The following visual application illustrates how robotic drone inspection has transformed safety and logistics in the assessment of critical assets, such as fuel storage tanks.

Acuren: Combines drones and robots with its expertise in NDT/NDE for non-intrusive industrial inspections. It offers inspection in confined spaces, visual surveys with LiDAR and HD cameras, and online UT measurements. Noteworthy is the use of wheeled magnetic scanners that operate at up to 400°C for vessels and pipes in service, minimizing human entry. Its internal software tools facilitate the design of FMC/TFM techniques and the generation of accurate geospatial reports.

Real-world use cases or implemented technologies

Elios 3 drones for atmospheric tank inspection

In 2025, an energy company in the United Kingdom used the Elios 3 drone for internal inspection of atmospheric tanks, eliminating the need to erect scaffolding or enter the space. The equipment combined LiDAR, 3D vision, and UT payload to capture structural data, generating 3D models and anomaly maps with high visual resolution. Its collision-tolerant navigation allowed flights very close to internal surfaces, even in the presence of obstacles, offering safety and operational efficiency.

Taurob Inspector in offshore environments

Taurob’s Inspector robot has been deployed offshore; between October 2024 and May 2025, two units reportedly operated on TotalEnergies platforms. On its official LinkedIn site, Taurob states that the Inspector can carry out missions lasting up to 4 hours, is ATEX-certified, and captures ultra-HD photos, videos, thermography, sounds, and 3D LiDAR maps.

Hybrid inspections: NDT + robotics

The combined use of ultrasound (UT), eddy currents (ECT), and climbing or crawler robotics is a growing trend. Hybrid robots allow for the simultaneous detection of corrosion, cracks, and defects with less downtime. Recent designs integrate UT probes with visual and magnetic modules for tank inspection without human intervention.

Underwater inspection: SmartTouch prototype

Researchers at the University of Houston are developing SmartTouch, an ROV with intelligent touch sensors, sonar, and a camera for inspecting underwater pipelines. The prototype has been tested in controlled environments, representing the next frontier in underwater robotics.

Differentiators: Drones vs. ground robots and sensors

The effectiveness of specialized robotic inspection lies in selecting the right platform and the right sensors for each critical task.

Aerial, ground, and aquatic platforms

UAVs (drones) are unmatched for Remote Visual Inspection (RVI) at height (torches, chimneys) and pipeline mapping, providing speed and safety. Ground robots (crawlers, magnetic climbers) are necessary for contact Non-Destructive Testing (NDT), such as ultrasonic testing robotics on tank walls or inside conduits. ROVs and AUVs, on the other hand, differ in their degree of autonomy for underwater missions.

High-precision sensors and data fusion

Advanced robotics integrates a variety of sensors that go beyond HD cameras. Laser scanners are used to create high-density 3D models, gas sensors for real-time leak detection, and phased array (PAUT) for automated NDT. The fusion of this data enables a more comprehensive and reliable integrity assessment, which feeds into predictive maintenance systems.

Applications in the Oil & Gas industry

In the Oil & Gas sector, specialized robotic inspection tackles essential tasks with precision and safety:

• Early detection of gas leaks with sensors on board mobile robots, both in onshore facilities and offshore platforms.
• Inspection of storage tanks and internal membranes, allowing scanning without emptying the tank, using internally motorized robots.
• Continuous inspection of oil pipelines or pipes using crawler or in-line robots that travel inside and detect corrosion, wall leaks, or structural failures.
• Surveillance of overhead structures: platforms, towers, elevated or hard-to-reach parts, thanks to drones and ground robots in ATEX/Ex zones to minimize human risk.
• Underwater operations with ROVs (remotely operated vehicles) for inspection of solids, joints, submerged pipes, and offshore connections.

Other industrial applications: mining, energy, and infrastructure

Beyond Oil & Gas, inspection robotics is already being applied in:

• Mining: autonomous robots for inspecting underground tunnels, monitoring tailings walls, cameras in galleries, systems that prevent risks to humans.
• Energy/electrical infrastructure: drones and ground robots that check transmission lines, electrical towers, substations, detect thermal faults or structural wear.
• Civil infrastructure: bridges, viaducts, tunnels, buildings, and drainage networks have robots capable of assessing cracks, corrosion, or structural defects, such as the SRI Lab’s developments for structural inspection.

Emerging trends for 2025-2030

• Miniaturized and swarm robots for collaborative inspection.
• Integration of advanced AI and machine learning in robotics for automatic fault detection.
• Use of digital twins connected to robots in real time for predictive monitoring.
• Automatic inspection of confined spaces with visual systems + AI.
• Combination with IoT/molecular communication for drones/pipes in underground pipelines.

Conclusions

The implementation of specialized robotic inspection in Oil & Gas is a process focused on safer, more efficient, and data-driven operations. Robots equipped with NDT sensors, intelligent vision, and autonomous navigation offer more frequent, reproducible inspections in critical areas where human access is risky.

When comparing technologies ( ground robots, drones, ROVs) and exploring industrial applications, it becomes clear that these systems maintain asset integrity, enable predictive maintenance, and improve operability. As the market for NDT robotic systems grows, the industry is moving toward continuous, automated inspection. The constant advancement of robotic solutions is critical for the energy industry to meet its safety and environmental sustainability goals.

References

1. https://www.sciencedirect.com/science/article/pii/S2667143325001039?
2. https://arxiv.org/abs/2404.12785?  
3. https://at.linkedin.com/company/taurob-gmbh?trk=public_post_feed-actor-name
4. https://invertrobotics.com/es/estudio-de-caso/

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