Solution Spotlight: Snowcat FOD Vacuum Crawler
Foreign Object Debris (FOD) has become one of the most costly and disruptive challenges in asset-intensive industries. From loose fasteners in pipelines to scale, or stray debris in tanks and vessels, even small fragments can lead to contamination, flow blockages, or damage to processing equipment.
For industries like oil & gas, mining, and energy generation, these issues don’t just create repair bills, they translate into millions of dollars in downtime, reduced productivity, and equipment faults.
Traditional methods for debris removal, such as manual clean-outs or flushing systems, often fall short when dealing with complex geometries or vertical surfaces. This is where a purpose-built robotic solution becomes critical.
Engineering a Purpose-Built Solution
After extensive R&D, Nexxis engineered a custom Snowcat Vacuum Crawler that merges inspection-grade robotics with powerful suction technology. Built on our proven Snowcat platform – trusted for its performance in confined and hazardous spaces, the system adds a front-mounted industrial vacuum head capable of removing more than just dust or residue.
Rated at 223 mbar (22.3 kPa) and tested using steel and calcium chloride pellets, the vacuum delivers reliable debris removal even under heavy conditions. The head is mounted on a mechanical raise-and-lower platform, enabling operators to precisely target problem areas. With a 300m tether and full control via our Juicebox system, the crawler offers consistent, supervised operations without the need for personnel entry into hazardous or confined environments.
Magnetic Mobility for Any Angle
What makes this crawler unique is its ability to perform on any surface, regardless of orientation. Outfitted with four X-Trax Omni modules and twelve magnetic plates, the platform adheres securely to most steel surfaces and maintains traction while travelling vertically, horizontally, or even across inverted surfaces. This mobility means that pipelines, risers, vessel walls, and storage tanks can all be vacuumed without scaffolding, rope access, or complex rigging. By removing those costly setup requirements and enabling robots to tackle vertical debris removal, operators save significant time and money. The crawler’s robust design ensures it can maintain adhesion and maneuverability even in challenging real-world conditions where other systems may struggle.
Visual Assurance Every Step of the Way
Of course, removing debris is only half of the equation: knowing that it’s gone is just as important. That’s why the system integrates advanced visual inspection tools, including our Qube 360° tilt camera with HD video and ultra-bright LEDs mounted at the front, alongside a rear-facing Monic HD camera. This dual-camera setup provides complete situational awareness for operators, ensuring they can visually confirm debris removal in real time and capture a clear record of every sweep. By pairing inspection-grade visuals with cleaning capability, the Snowcat Vacuum Crawler helps eliminate guesswork, reduces the chance of missed debris, and ensures operators don’t need to return for repeat inspections. Each deployment provides not just a cleaner pipeline or vessel, but also a documented trail.
A Smarter Way to Manage FOD
This solution showcases how robotic platforms can fundamentally change the way industries deal with foreign object debris. Rather than relying on slow, inconsistent manual processes, the Snowcat Vacuum Crawler makes FOD removal fast, precise, and cost-effective: even in areas that were previously considered difficult or impossible to access. By preventing debris-related failures and reducing the need for costly shutdown periods, this system delivers measurable operational savings.
For sectors like oil & gas, mining, and power generation, it represents a smarter way to keep assets in peak condition and avoid the risks of unplanned downtime.
The result is a safer, more reliable, and more predictable approach to one of the industry’s most stubborn challenges.
Want to remove FOD from your problem areas?
Get in touch with our helpful team about tailoring the Snowcat Vacuum Crawler to your pipes and assets.
