How Robotics Is Transforming the Inspection of Difficult-to-Inspect Pipelines

Key insights from the Pipeline Things podcast episode with Intero CEO Rienk de Vries

Pipelines once considered impossible to inspect are becoming accessible thanks to rapid advancements in robotic inspection technology.

In a recent episode of the Pipeline Things podcast, our CEO Rienk de Vries joined hosts Rhett Dotson and Christopher DeLeon shortly after the Pipeline Pigging and Integrity Management Conference (PPIM) 2026 to discuss how robotics is pushing the boundaries of inline inspection (ILI), the evolution of robotic inspection tools, collaboration with operators, and the future of pipeline integrity technology.

Tackling the “Difficult-to-Inspect” Pipeline Challenge

Many pipelines remain challenging for conventional inline inspection tools, including urban segments with limited access, older lines with complex geometry, and sections without traditional pigging facilities. Robotic inspection technology was developed to address these hurdles. Unlike traditional free-swimming tools, robotic systems can enter pipelines without launchers or receivers, navigate complex configurations, and collect multiple datasets in a single run.

Over the past 15–20 years, innovation in this space has been driven by close collaboration between technology providers and operators. Organizations such as NYSEARCH support research and development, while operators provide real-world insights, ensuring new technologies focus on delivering maximum impact for pipeline safety and integrity.

A New Long Seam Inspection Capability

One of Intero's latest advancements discussed on the podcast is a long seam inspection module developed in collaboration with Pacific Gas and Electric Company (PG&E) for a 10-inch robotic tool.

Rather than building an entirely new system to address integrity concerns related to long seam areas in certain vintage pipelines, engineers adapted the modular architecture of the robotic platform, allowing the central inspection module to be replaced depending on the inspection objective.

For this application, a circumferential magnetic flux leakage (CMFL) module was designed to inspect pipeline seams. The development journey highlights the evolution of innovation: the initial prototype was built in 2022 for a 20-inch pipeline, later adapted for a 16-inch line, and now scaled down to 10 inches. While scaling introduces engineering challenges due to space constraints, once core technology is proven, development cycles accelerate rapidly.

Combining Multiple Data Sets in One Inspection

Modern robotic pipeline inspection provides more than just a single measurement technique. During an inspection run, the robotic platform can collect multiple types of data simultaneously, including visual inspection through onboard cameras, laser profiling to detect dents and geometry changes, axial magnetic flux leakage (MFL) for corrosion detection, circumferential MFL for seam inspection, and inertial measurement unit (IMU) data for precise positioning.

By integrating these datasets, operators gain a complete view of pipeline integrity, minimizing guesswork and costly excavation. IMU technology further enhances precision by providing exact XYZ coordinates for detected anomalies, allowing repairs to be targeted accurately.

In densely populated or urban areas, this capability reduces unnecessary digs and ensures maintenance resources are focused where they matter most.

Extending the Range of Robotic Inspection

Operators consistently ask for longer inspection ranges. Current robotic systems typically cover up to half a mile before requiring a recharge. To extend this, Intero is exploring several innovations, including autonomous navigation that allows the robot to recognize pipe geometry and move more efficiently, turbine-based energy harvesting that generates power from pipeline flow during inspection, and scaling high-accuracy IMU technology for smaller robotic tools to improve anomaly positioning.

Together, these innovations could dramatically expand the capabilities of robotic inspection tools.

Reliability Remains Critical

Despite rapid innovation, reliability remains the most important requirement. Unlike traditional inline inspection tools, robotic systems operate untethered, with no fallback if a failure occurs. Development cycles therefore include extensive testing, rigorous operational procedures, and redundant system design to ensure safe deployment.

As robotic inspection technology continues to evolve, Intero remains focused on expanding what’s possible in pipeline inspection. Pipelines once considered impossible to assess are now within reach, giving operators the confidence and precision needed to maintain critical infrastructure safely and efficiently.

Listen to the full conversation on the Pipeline Things podcast.