ExRobotics launches UL-certified inspection robot for hazardous environments

Oil and gas operators face mounting pressure from aging infrastructure, acute workforce shortages, and the escalating cost of unplanned downtime, noted ExRobotics B.V. The company today made the North American launch of its UL-certified ExR-2.5 autonomous inspection robot at the Energy Drone & Robotics Summit in Houston.

“The inspection challenges facing oil and gas operators are intensifying — skilled labor is harder to find, assets are aging, and the cost of failure is rising fast,” stated Mark Mildon, CEO of ExRobotics. “We build rugged, reliable Ex-certified inspection robots because this is not a side capability for us; it’s our sole focus.

“With thousands of robotic missions completed for operators like Shell, Repsol, and BP, the ExR-2.5 delivers smart robotic missions that deliver better data, boost productivity, and keep operations on track – helping reduce personnel exposure to hazardous environments,” he added. “Launching the UL Certified ExR-2.5 at EDRC [Energy Drone & Robotics Coalition’s event] shows that autonomous inspection has moved beyond pilot projects and into real industrial operations.”

ExRobotics responds to oil and gas industry shortfalls

Analysts have predicted that the energy industry will be short by up to 40,000 skilled workers globally this year, while 62% of Gen Z and Millennials reportedly view oil and gas careers as unappealing. This makes the replacement of retiring engineers an active operational risk, said ExRobotics.

At the same time, unplanned downtime now costs the world’s largest industrial companies an estimated 11% of total revenue, according to Siemens. Just 3.5 days of downtime can generate more than $5 million in losses for a midsize oil and gas facility.

Inspection remains fundamental to maintaining a facility’s license to operate, yet traditional inspection regimes increasingly expose people to risk while struggling to keep pace with complex and aging assets, asserted ExRobotics. Founded in 2017, the company said it focuses exclusively on building rugged, reliable inspection robots for hazardous locations with potentially explosive atmospheres.

By automating hazardous inspection rounds, robotic missions allow operators to maintain inspection frequency and consistency, while reducing reliance on hard-to-source specialist labor, ExRobotics said.

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ExR-2.5 listens for leaks

The ExR-2.5 robots can perform safety inspections and collect real-time data across upstream and downstream operations, onshore and offshore, as well as liquefied natural gas (LNG) and chemical facilities worldwide, said ExRobotics.

The Delft, Netherlands-based company claimed that the new system replaces routine human exposure with smart robotic missions that deliver better data, boost productivity, and keep operations on track, ExRobotics claimed. The robots perform safety checks and collect and send back real-time data using a range of built-in tools.

The system’s acoustic imaging sensors detect high-frequency sound signatures from gas leaks and mechanical faults to enable earlier detection than visual or manual inspections.

High-resolution cameras allow visual inspection of assets, corrosion, valves, gauges and structures. A thermal imaging camera can identify overheating equipment and temperature anomalies, and environmental and safety sensors monitor conditions relevant to hazardous locations.

Autonomous navigation with administrative control and built-in obstacle-avoidance systems allow the mobile robot to operate safely in complex, live industrial facilities and be remotely controlled on site or thousands of miles away. Once missions are complete, the robot returns to its docking station to get ready for redeployment, said ExRobotics.

UL Solutions certifies ExRobotics system

UL 6260 establishes a framework for safety certification of the robotic inspection technology in environments where explosive gases, vapors, or combustible dusts may be present, while ensuring that the robot itself does not become an ignition source.

Northbrook, Ill.-based UL Solutions evaluated the ExR-2.5 against risks including fire, explosion, and electrical shock across its intended operating modes and power systems. Testing focused on the safety challenges associated with hazardous-area robotics, including battery systems, electrical controls, and mechanical components operating safely under both normal and fault conditions in explosive atmospheres.

“Hazardous locations present unique safety challenges for remotely operated systems,” said Wesley Kwok, vice president and general manager of energy and industrial automation at UL Solutions. “Certification helps provide operators with confidence that these technologies can be deployed safely and responsibly in hazardous locations.”

ExRobotics added: “As operators increasingly explore automation to address workforce shortages and aging infrastructure, certification is becoming a critical barrier to adoption in hazardous locations.” It said UL 6260 creates a recognized certification pathway for safely deploying inspection robots in these settings.

MicroWatt supports inspection robots in North America

MicroWatt is the ExRobotics’ exclusive partner in North America.

“As the exclusive North America distributor, manufacturer, and service provider, we are proud to support the introduction of certified robotic technology for the oil and gas industry in North America,” said Shawn Coffey, CEO of MicroWatt. “Our role is to help customers access proven solutions with the local expertise, deployment support and operational understanding needed to reduce risk and improve operational safety and efficiency.”

ExRobotics is conducting scheduled live demonstrations of the UL Certified ExR-2.5 at Booth 816 throughout the Energy Drone & Robotics Summit from June 22 to 24 at the Woodlands Waterway Marriott. Visitors can pre-book demos of the ExR-2.5 at MicroWatt’s website.