Inspection tools help inspectors collect the data they need to ensure the proper maintenance of the assets they're inspecting—Read this guide for an overview of the different types of inspection tools they use.

Inspection tools are essential for inspectors to gather critical data. Whether it's visual, thermal, or thickness-related, the right tool can make all the difference in ensuring accurate and reliable results. The specific type of data required for an inspection determines the tools used, which can vary significantly depending on the asset being inspected and the industry involved.

Once the data is collected, inspectors analyze it to assess the condition of the asset and determine if any maintenance is needed. This process is crucial in preventing failures and ensuring safety, especially in industrial environments where even small issues can lead to major problems.

Inspection Tools vs. Inspection Equipment

In this article, inspection tools refer to the actual devices and instruments that inspectors use to gather data. These can include sensors, cameras, drones, or other specialized equipment designed to capture specific types of information. For example, a thickness measuring sensor might be used to evaluate the integrity of a wall inside a coke drum, while a drone equipped with a camera could provide remote visual access to a boiler.

Inspection equipment, on the other hand, includes everything that helps inspectors access the data or supports their work during the inspection. This might be a toolbelt, scaffolding, ropes, or even protective gear. While these items don’t directly collect data, they play a vital role in enabling inspectors to perform their tasks safely and efficiently.

[Related read: Confined Space Equipment: A Guide]

Whether inspecting a large industrial boiler or a home HVAC unit, the core process remains the same:

• Inspectors collect data using inspection tools
• They analyze the data using industry-specific methods
• Based on the analysis, maintenance decisions are made

While the general approach is straightforward, the tools used can vary widely depending on the inspection needs. Some tools are organized by the type of data they collect, while others are categorized by their method of operation, such as aerial or ground-based robotics.

Now let’s take a closer look at each category of inspection tool.

 

Cameras and Other Visual Data Collection Tools

Visual data is one of the most common types of information inspectors need. Cameras are the go-to tool for capturing this data, but not all cameras are suitable for every inspection. The choice of camera depends on the specific requirements of the job, such as image quality, lighting conditions, and the need for color accuracy.

Here are some common visual data collection tools:

• Digital cameras: Available in various levels of quality and cost, digital cameras are essential for capturing high-resolution images. They are often used in inspections where clarity and detail are important.
• Borescopes: These tools allow inspectors to see into areas that are otherwise inaccessible. A borescope consists of a flexible tube with a lens at one end and an eyepiece at the other.
• Video and digital microscopes: These tools magnify images using digital technology, allowing for detailed close-up views of small objects or surfaces.
• Videoscopes: Similar to borescopes, videoscopes have a camera embedded in the tip, making them ideal for remote inspections of tight spaces.
• CCTV: Closed-circuit television systems are commonly used for inspecting pipes, especially in sewer systems, allowing inspectors to view the inside of drains remotely.

A borescope being used to inspect a car engine

Other NDT Sensors and Testing Methods

While visual data is the most common type of information collected, there are many other forms of data that may be required. These often require specialized sensors or Non-Destructive Testing (NDT) methods to gather the necessary information.

Ropes and Drones Case Study

A recent inspection conducted by Premium Inspection & Testing in Baton Rouge, Louisiana, showcases how inspectors combine multiple tools and NDT methods to gather comprehensive data. In this case, the team used a combination of drones and rope access to inspect a coke drum without building scaffolding, saving the client $250,000 in the process.

Photo credit: Premium Inspection & Testing

Here’s how the inspection was carried out:

1. Visual data collected by drone

Using Flyability’s Elios 2 drone, the team captured visual data inside the coker to identify areas that needed further attention.

2. Corrosion, pitting, and other data collected by rope access

Inspectors then used rope access to perform additional tests, including 3D scanning, phased array testing, and liquid penetrant testing.

This case study highlights the importance of combining multiple tools and techniques to meet inspection requirements effectively.

NDT Sensors and Testing Methods

Some examples of data that may require specific NDT methods include:

• Thermal data: Collected using thermal or infrared sensors to detect heat leaks or internal hot spots.
• Ultrasonic data: Captured with ultrasonic sensors to detect surface defects using sound waves.
• Radiography data: Obtained through X-ray or gamma radiation to identify imperfections in materials.
• Eddy current data: Gathered using electromagnetic testing to detect flaws in conductive materials.

For more details on these methods, refer to our in-depth guide on Non-Destructive Testing.

Robots

Robotic solutions have become increasingly popular in inspection work, offering safer and more efficient alternatives to traditional methods. There are three main categories of robotic inspection tools:

• Drones / Aerial Robotic Solutions
• Ground-Based Robotic Solutions
• Submersible / Underwater Robotic Solutions

Drones / Aerial Solutions

Drones are now a common tool for remote inspections, particularly in industrial settings. They allow inspectors to collect data without risking personal safety. While many drones are used for visual data, some can also collect thermal or other types of data when equipped with the right sensors.

Why use RVI tools?

There are several advantages to using remote visual inspection (RVI) tools like drones:

• Safety: Reduces the need for inspectors to enter hazardous areas.
• Savings: Can reduce costs by up to 90% by avoiding temporary structures like scaffolding.
• Reduced downtimes: Speeds up the inspection process, minimizing operational downtime.

Indoor vs. outdoor drones

Indoor drones are designed for confined spaces and are often built to withstand collisions. Outdoor drones, on the other hand, are typically used for larger, open-area inspections and lack the same level of collision tolerance.

Flyability’s Elios 3 is an example of an indoor drone that can navigate tight spaces safely. It is commonly used in boilers, pressure vessels, and tanks.

DJI's Matrice 300, an outdoor drone commonly used in inspections

Ground-based Robotic Solutions

Ground-based robots are another type of RVI tool that offer similar benefits to drones, improving safety and reducing costs. Some examples include:

Inuktun MaggHD

The Inuktun MaggHD is a magnetic crawler used for remote visual inspections in hazardous or hard-to-reach areas.

Deep Trekker DT320

The Deep Trekker DT320 is a mini pipe crawler used for inspecting sewers and other narrow spaces.

Inuktun Versatrax 150

The Inuktun Versatrax 150 is a long-range crawler used for inspecting tanks and wastewater infrastructure.

Robots—Submersible Solutions

Submersible robots are also gaining traction in the inspection industry. These tools allow inspectors to collect data in underwater or submerged environments without requiring divers. One example is the MASKI+ ROV, used by HydroQuebec to inspect dams in turbulent waters.

Another example is the Intero Tank Explorer, which can operate in explosive environments, such as petrochemical storage tanks, to detect thickness inconsistencies and provide real-time imaging.

Recent Advances in Robotics

Future inspections will likely involve a wider range of robotic tools, including those equipped with advanced NDT sensors. For instance, robot-mounted ultrasonic testing tools are already being used in various industries. Newer models can even fix detected issues using onboard tools like water-jet cutters or UV-curable patches.

Measuring Devices

Measuring devices are essential for collecting precise dimensional data. These tools help inspectors determine the length, depth, or width of an object. While some are digital and highly sophisticated, many are simple, handheld tools like calipers, which are widely used in inspections.

Common measuring devices include:

• Engineering Square: Used to check perpendicularity and draw straight lines.
• Protractors: Measure angles between two surfaces.
• Levels: Determine the inclination of a surface relative to the earth.
• Calipers: Measure external, internal, and depth dimensions with precision.
• Gages: Compare an object to a standard size for measurements like radius or thickness.
• Micrometer: Measures very small distances using a fine-threaded screw mechanism.

Inspection Software

As inspections become more data-heavy, managing and analyzing the collected information has become a growing challenge. This has led to significant advancements in inspection software, particularly in data collection and management tools.

Improved Data Collection Software

Software like Flyability Inspector 3.0 allows inspectors to create 3D models of assets during drone flights, highlighting defect locations for quick identification. This streamlines the inspection process and improves accuracy.

Data Management Tools

New software solutions leverage artificial intelligence and machine learning to process vast amounts of data quickly. This makes it easier for inspectors to extract actionable insights from complex datasets. For example, sewer inspection software automatically identifies potential defects from uploaded visual data.

Whether through innovation or refinement, improved software continues to enhance the speed, accuracy, and safety of inspections across industries.

Gas Cylinders Caps

Gas Cylinders Caps,Abs Guards,,Lpg Cylinders Caps

Hangzhou Qizheng Trading Co., Ltd. , https://www.gascylindercap.com