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How to Inspect the Internal of a Pipe Using Crawlers (pipe inspection robots)

Inspecting the internal conditions of pipelines is a critical task in ensuring the safety, efficiency, and longevity of these essential infrastructures. Traditionally, this has been a challenging and labor-intensive process. However, the advent of crawler robots has revolutionized internal pipe inspections. These versatile devices can navigate through pipelines, equipped with various sensors and tools to provide comprehensive assessments. This blog will explore how to inspect the internal of pipes using crawlers, focusing on visual inspection, Magnetic Flux Leakage (MFL), Dry Film Thickness (DFT) measurement, and the different types of crawlers: wired and wireless.

Visual Inspection (pipe inspection robot camera)

Visual inspection is the cornerstone of internal pipe assessments. Crawler robots are equipped with high-resolution cameras that capture detailed images and videos of the pipe’s interior.

Key Features:

  • High-Resolution Cameras: These provide clear visuals, allowing inspectors to identify surface anomalies such as cracks, pitting, and weld defects.

  • Real-Time Monitoring: The live feed enables immediate detection of issues as the crawler moves through the pipe.

  • Illumination: Built-in LED lights illuminate the dark interiors of pipes, ensuring visibility even in low-light conditions.

  • Documentation: The captured images and videos can be stored for detailed post-inspection analysis and record-keeping.

Visual inspection helps in the early detection of potential problems, which can be addressed before they escalate into significant issues.

Inspection of internal pipe
Inspection Video by Binary Robotics

Magnetic Flux Leakage (MFL)

MFL is a powerful technique used to detect corrosion and metal loss in pipelines. Crawler robots equipped with MFL sensors can effectively identify these issues.

How MFL Works:

  • Magnetization: The crawler magnetizes the pipe wall as it moves through the pipeline.

  • Detection: Sensors measure changes in the magnetic field caused by corrosion or metal loss.

  • Analysis: Variations in the magnetic field indicate areas of concern, which are then analyzed to determine the extent and severity of the damage.

MFL is particularly useful in detecting and quantifying corrosion, helping to prevent leaks and structural failures.

Dry Film Thickness (DFT) Measurement

DFT measurement is crucial for assessing the effectiveness of protective coatings inside pipes. Crawler robots use ultrasonic sensors to measure the thickness of these coatings.

Why DFT is Important:

  • Corrosion Protection: Ensuring the coating is of the correct thickness prevents corrosion and extends the pipeline's lifespan.

  • Regulatory Compliance: Many industries have specific standards for coating thickness that must be adhered to.

  • Quality Control: Regular measurement ensures that coatings are applied uniformly and meet quality specifications.

By providing accurate DFT measurements, crawler robots help maintain the integrity of pipeline coatings, ensuring long-term protection against corrosion.

Types of Crawlers: Wired and Wireless

Crawler robots come in two main types: wired and wireless, each with its own set of advantages and applications.

Wired Crawlers:

A pipe coating robot/Crawler for sale
Tethered Crawler for Pipe Coating


  • Tethered Connection: Wired crawlers are connected to a control unit via a cable, which supplies power and transmits data.

  • Real-Time Data Transmission: The tether allows for real-time data transmission, enabling immediate analysis and decision-making.

  • Power Supply: The cable provides a continuous power supply, allowing the crawler to operate for extended periods.


  • Reliable Data Transmission: The tether ensures consistent and reliable data transmission, crucial for detailed inspections.

  • Extended Operation: Continuous power supply means longer inspection times without the need for battery changes.


  • Complex Geometries: Wired crawlers are ideal for pipelines with complex geometries, including bends and welds.

  • Critical Inspections: They are suitable for inspections that require immediate data analysis and decision-making.

Wireless Crawlers:


  • Autonomous Operation: Wireless crawlers operate independently, using onboard batteries for power.

  • Data Storage: Data collected during the inspection is stored onboard and retrieved post-inspection.


  • Flexibility: Free from cables, wireless crawlers can navigate long distances and complex pipelines.

  • Ease of Use: They are easier to deploy in remote or hard-to-reach areas where tethered cables might be impractical.


  • Remote Locations: Wireless crawlers are ideal for inspecting pipelines in remote or inaccessible areas.

  • Long-Distance Inspections: They are suitable for long pipelines where tethered connections would be impractical.


Crawler robots have transformed the way internal pipe inspections are conducted. With advanced capabilities such as visual inspection, Magnetic Flux Leakage (MFL), and Dry Film Thickness (DFT) measurement, these devices provide comprehensive assessments of pipeline conditions. The choice between wired and wireless crawlers depends on the specific requirements of the inspection, with each type offering unique advantages. By leveraging the power of crawler robots, industries can ensure the safety, efficiency, and longevity of their critical pipeline infrastructure, ultimately leading to better resource management and reduced operational risks.

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