ExRobotics has launched a UL Certified autonomous inspection robot for hazardous industrial environments in North America. It says the ExR-2.5 is the only inspection robot with that certification for potentially explosive industrial settings.
The Dutch robotics company introduced the ExR-2.5 to the North American market as oil and gas, LNG and chemical operators seek ways to maintain inspections amid labour shortages, ageing equipment and rising downtime costs.
UL 6260 sets out a safety certification framework for robotic inspection technology used in potentially explosive atmospheres. For operators in hazardous areas, certification addresses a key hurdle because the machine itself must not become an ignition source during routine work.
ExRobotics robots are already in use by Shell, BP and Repsol, and have completed thousands of inspection missions across upstream, downstream, LNG and chemical facilities. The machines can carry out routine inspection rounds autonomously or under the supervision of remote operators.
The ExR-2.5 is designed to gather operational and safety data through acoustic imaging, thermal imaging, high-resolution cameras and environmental sensors. These tools are used to detect gas leaks, mechanical faults, overheating equipment, corrosion, valve positions, gauge readings and site conditions.
Its navigation and obstacle-avoidance systems allow the robot to move through live industrial facilities and return to a docking station at the end of a mission. This is intended to reduce the need for staff to enter hazardous zones for repetitive inspection tasks.
Workforce strain
The launch comes amid staffing pressures in the energy industry. ExRobotics cited projections showing the sector could face a shortage of up to 40,000 competent workers globally by 2025/26, while surveys suggest 62% of Gen Z and Millennials view a career in oil and gas as unappealing.
Operators are also contending with the financial impact of equipment failures and unscheduled shutdowns. Figures cited by the company show unplanned downtime costs the world's largest industrial groups about 11% of total revenue, while 3.5 days of downtime can create losses of more than USD $5 million for a mid-sized oil and gas facility.
That combination of labour shortages and asset integrity demands has increased interest in remote operations, drones and robotic inspection systems. In hazardous process industries, routine monitoring remains essential for safety, compliance and day-to-day production, but traditional inspection regimes often require people to work in difficult or risky environments.
Autonomous inspection systems are being positioned as one response, particularly where rounds need to be frequent, repeatable and consistently recorded over time. By collecting data on fixed routes and sending it to off-site specialists, the technology may also widen the pool of personnel available to oversee inspections.
ExRobotics said the North American launch combines the certified robot with local deployment expertise and customer support. Based in Delft, the company focuses on robots built for hazardous industrial settings and says it has carried out more than 1,000 successful deployments worldwide.
Mark Mildon, Chief Executive Officer, ExRobotics, said: "The inspection challenges facing oil and gas operators are intensifying - skilled labour is harder to find, assets are ageing, and the cost of failure is rising fast. Our sole focus is to build rugged, reliable Ex-certified inspection robots to address these issues.
"This certification marks another industry first for ExRobotics. The ExR-2.5 is the only UL Certified autonomous inspection robot for hazardous locations in North America. Operators now have a recognised and trusted pathway to deploy autonomous inspections at their facilities."