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# Inspection Tools: A Comprehensive Guide to the Equipment Used by Inspectors Daily
## Understanding Inspection Tools and Their Importance
Inspection tools are essential for inspectors who aim to gather accurate data to ensure the proper maintenance of assets they assess. Whether it's an industrial boiler, a commercial building, or even a residential property, inspectors rely on a variety of tools to collect crucial information. This data can be visual, thermal, or related to thickness measurements. The specific type of data required depends on the inspection goals, which in turn dictate the tools needed for the job.
After collecting the data, inspectors analyze it to understand the current condition and maintenance status of the assets they inspect. The ability to gather precise data directly impacts the accuracy of their assessments and subsequent maintenance decisions.
## Inspection Tools vs. Inspection Equipment
For clarity, **inspection tools** refer to the actual instruments and devices used to collect data. These could include a thickness-measuring SENSOR used to evaluate the wall thickness of a coke drum, or a drone with a camera to remotely inspect the interior of a boiler.
On the other hand, **inspection equipment** refers to anything that aids inspectors in accessing data or supports their work while collecting data. This could include toolbelts, scaffolding used for manual inspections, or ropes used for climbing or rappelling into hard-to-reach areas.
## The Core Process of Inspections
Regardless of the scale of the asset, the fundamental process of inspections remains consistent:
1. Inspectors collect data using inspection tools.
2. Inspectors analyze the data using techniques specific to their industry.
3. Inspectors and maintenance personnel decide on necessary maintenance actions based on the analysis.
While the overall concept is straightforward, the tools used by inspectors can vary widely depending on the nature of the inspection. These tools can generally be categorized by the type of data they collect.
In the case of robotics solutions, tools are often grouped by their method of operation (aerial or ground-based) rather than the type of data they capture. This means the same robotic tool can be equipped with different sensors to collect various types of data.
Let’s delve deeper into the different types of inspection tools.
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## Cameras and Other Visual Data Collection Tools
Visual data is one of the most common types of information inspectors need to collect. Cameras are the go-to tool for capturing visual data, but not all cameras will suit every inspection scenario. The key factor in selecting a visual inspection tool is the data requirement. If the camera can meet the quality standards and requirements for the inspection, it is the right tool for the job.
### Common Types of Visual Data Collection Tools:
- **Digital Cameras**: These vary greatly in terms of quality and price. Factors such as image resolution, low-light capability, and color accuracy play a role in choosing the right digital camera for inspections.
- **Borescopes**: A borescope is a flexible tube with an eyepiece at one end and a lens at the other. It allows inspectors to view areas that are otherwise inaccessible.
- **Video and Digital Microscopes**: These tools use digital technology to magnify images, allowing inspectors to get close-up visual data, especially for tiny objects.
- **Videoscopes**: These are used to remotely inspect small cavities and other areas. They feature a camera embedded in the tip and use CCD technology to relay images.
- **CCTV**: Often used for inspecting pipes, CCTV allows inspectors to see inside pipes and drains remotely.
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## Other NDT Sensors and Testing Methods
While visual data is common, inspectors also need to collect other types of data depending on the inspection requirements. Each type of data requires a specific sensor or non-destructive testing (NDT) method.
### Example: Ropes and Drones Case Study
A great example of inspectors using various tools and methods can be seen in a recent coke drum inspection by Premium Inspection & Testing. They used drones and rope access to avoid scaffolding, ensuring they collected all necessary data.
1. **Visual Data Collected by Drone**: Using Flyability’s Elios 2 drone, inspectors collected visual data to confirm cleanliness and identify areas requiring further attention.
2. **Corrosion, Pitting, and Other Data Collected by Rope Access**: Inspectors performed additional data collection using rope access, including 3D scanning for surface pitting and corrosion, phased array testing for weld seam integrity, and liquid penetrant testing for seam and shell defects.
This approach not only met the inspection requirements but also saved the client $250,000 by avoiding scaffolding costs.
### Types of NDT Sensors and Testing Methods:
- **Thermal Data**: Collected with thermal or infrared sensors, used to detect heat leaks or excess heat within closed systems.
- **Ultrasonic Data**: Collected with ultrasonic sensors, this NDT method uses sound waves to detect surface defects.
- **Radiography Data**: Uses gamma or X-rays to identify imperfections in surfaces.
- **Eddy Current Data**: Electromagnetic testing that measures the strength of electrical currents in a magnetic field to detect defects.
For more information on NDT methods, check out our comprehensive guide.
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## Robots in Inspection
Robotic solutions are increasingly popular among inspectors, offering three main categories:
1. **Drones/Aerial Solutions**
2. **Ground-Based Robotic Solutions**
3. **Submersible/Underwater Robotic Solutions**
### Drones/Aerial Solutions
Over the past few years, drones have become a staple in industrial inspections. They fall under the umbrella of Remote Visual Inspection (RVI) tools, allowing inspectors to collect data remotely. While drones are mainly used for visual data, they can also be fitted with thermal sensors or custom sensors for other types of data collection.
#### Benefits of Using RVI Tools:
- **Safety**: Reduces the need for workers to enter hazardous areas.
- **Savings**: Can reduce inspection costs by up to 90%.
- **Reduced Downtime**: Speeds up the inspection process, minimizing operational interruptions.
#### Indoor vs. Outdoor Drones
Indoor drones are designed for confined spaces, featuring robust designs to withstand collisions. Examples include Flyability’s Elios 3, which is ideal for boilers, pressure vessels, and tanks.
Outdoor drones, like DJI’s Matrice 300, are built for open environments and lack the same collision-resistant features.
### Ground-Based Robotic Solutions
Ground-based robots offer similar advantages to drones, increasing safety and reducing costs. Here are some notable examples:
- **Inuktun MaggHD**: A magnetic crawler for RVI, eliminating the need for hazardous confined space entry.
- **Deep Trekker DT320**: A mini pipe crawler for sewer inspections.
- **Inuktun Versatrax 150**: A versatile crawler system for long-range inspections.
### Submersible Solutions
Advances in submersible robotics are transforming inspections. These robots increase safety by replacing risky diving operations. The MASKI+ and Intero Tank Explorer are examples of robots used in water-filled environments.
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## Measuring Devices
Measuring devices are critical for gathering dimensional data. Handheld tools like calipers are still prevalent, but digital tools are becoming more sophisticated. Some common measuring devices include:
- **Engineering Squares**
- **Protractors**
- **Levels**
- **Calipers**
- **Gages**
- **Micrometers**
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## Inspection Software
The growing volume of inspection data has led to advancements in software. Key developments include improved data collection and enhanced data management.
### Improved Data Collection Software
Software like Flyability Inspector 3.0 offers 3D modeling capabilities, creating quick models of assets during inspections.
### Data Management Tools
AI and machine learning are revolutionizing data processing, making it faster and more actionable.
Innovations in software ensure safer outcomes for all stakeholders involved in inspections.