Hazardous-location robotics uses certified industrial robots and autonomous systems to perform inspections and routine tasks in areas with a risk of gas, vapour, or dust explosions. These robots help oil and gas facilities improve process safety by removing people from high‑risk zones while still collecting critical inspection and monitoring data.
We support operators in deploying hazardous-location robotics and autonomous inspection systems that integrate with existing gas detection, safety systems, and control infrastructure.
What Is Hazardous Location Robotics?
Hazardous location robotics refers to mobile or stationary robots designed and certified to operate in classified areas where flammable gases, vapours or combustible dusts may be present. These robots are engineered to minimize ignition sources and withstand industrial conditions while carrying sensors and cameras for inspection and monitoring.
In oil and gas and process industries, hazardous location robots are used for:
Routine autonomous inspections in process units and tank farms
Visual, thermal and gas detection checks in classified areas
Remote confirmation of alarms and suspected leaks
Why Hazardous Location Robotics Matters for Process Safety
In many facilities, process safety has traditionally relied on manual rounds, confined space entries and physical presence in hazardous areas. Even with strong procedures, this approach exposes personnel to flammable atmospheres, elevated structures and abnormal operating conditions.
Hazardous location robotics helps process safety programs by:
Reducing the need for personnel to enter hazardous zones for routine inspections
Providing consistent inspection data to support risk‑based inspection (RBI), asset integrity and LDAR programs
Enabling remote assessment of abnormal situations before sending in response teams
How Hazardous Location Robots Work
Modern hazardous location robots combine industrial‑grade hardware with autonomous navigation and integrated sensing.
Typical capabilities include:
Certified design for operation in explosive or combustible atmospheres
Autonomous or semi‑autonomous navigation along defined inspection routes
Onboard sensors such as gas detectors, thermal cameras, HD video and acoustic or vibration sensors
Connectivity to plant DCS, safety instrumented systems and historians for alarms and data logging
These capabilities turn robots into mobile sensing platforms that complement fixed detectors and process instrumentation.
Hazardous Location Robotics in Oil and Gas
Oil and gas facilities have many areas where hazardous location robotics can deliver value.
Common use cases include:
Tank farm patrols for gas leaks, overfill risks and perimeter checks
Process unit inspections for hotspots, abnormal noise or visible anomalies
Compressor building and pump area monitoring where gas accumulation is possible
Support for LDAR and emissions monitoring with repeatable routes and documented readings
By automating these inspections, hazardous location robots help operators increase inspection frequency and coverage without adding personnel exposure.
Hazardous Location Robotics and Autonomous Inspections
Autonomous inspections use hazardous location robots to perform repeatable, scheduled or on‑demand inspection routes. The robot captures data at the same locations and angles over time, creating a consistent record that supports trend analysis and early detection of changes.
Benefits of autonomous inspections include:
Higher‑frequency data for RBI and integrity assessments
Time‑stamped visual, thermal and gas concentration records for LDAR and compliance
Faster situational awareness during alarms or abnormal conditions
Design Considerations for Hazardous Location Robotics
Deploying hazardous location robotics requires attention to both certification and system design.
Key considerations include:
Suitability for the applicable hazardous area classification and standards
Mechanical and electrical design that minimizes ignition sources and handles dust, moisture and temperature extremes
Integration with existing work procedures, permits and emergency response plans
Risk assessments are recommended at both the system design and facility integration stages to ensure safe operation.
Harsh Weather and Remote Industrial Sites
Many Canadian and North American facilities operate in harsh climates and remote locations. Robots used in hazardous locations must be able to function reliably in cold, snow, ice and temperature swings while maintaining their hazardous‑location protection.
Hazardous location robotics solutions can be selected and configured to:
Operate in outdoor tank farms and process areas in winter conditions
Navigate uneven terrain, snow and ice at remote sites
Maintain protection ratings and certification under environmental stress
Visit Microwatt at the Energy Drone & Robotics Summit
We will be on site at the 10th Annual Energy Drone & Robotics Summit in The Woodlands, Texas, the largest event focused on UAVs, robotics and data/AI for energy and industrial operations. The team will be showcasing hazardous location robotics and autonomous inspection capabilities and participating in a technical session on certified robotics in industrial environments.
If hazardous location robotics or autonomous inspections are on your roadmap, visit us at Booth 816, where ExRobotics will be with us to discuss everything from hardware and payload options to deployment approaches and real‑world use cases. Be sure to also join our technical session, “Redefining Safety: The Future of Certified Robotics in Industrial Environments,” on Tuesday, June 23 at 1:00 p.m. to see how these technologies are being applied in operating facilities today.
How Microwatt Supports Hazardous Location Robotics
Microwatt works with operators to evaluate, deploy and support hazardous location robotics and autonomous inspection systems for oil and gas and other process industries.
Microwatt can help with:
Identifying high‑value use cases for hazardous location robotics in existing facilities
Selecting suitable robot platforms designed and certified for hazardous areas
Integrating robots with gas detection, DCS, safety systems and data infrastructure
Supporting commissioning, training and lifecycle service for deployed systems