The case for smarter CUI inspections in the energy sector

Guest Column

A new generation of technology is making it faster, safer, and more cost-effective to identify CUI. Courtesy photo

Corrosion under insulation (CUI) accounts for roughly 60% of pipeline leaks in the U.S. oil and gas sector. Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.

This year, widespread budget cuts and layoffs across the sector are forcing refineries to do more with less. Efficiency is no longer a goal; it’s a mandate. The challenge: how to maintain safety and reliability without overextending resources?

Fortunately, a new generation of technologies is gaining traction in the oil and gas industry, offering operators faster, safer, and more cost-effective ways to identify and mitigate CUI.

Hidden cost of corrosion

Corrosion is a pervasive threat, with CUI posing the greatest risk to refinery operations. Insulation conceals damage until it becomes severe, making detection difficult and ultimately leading to failure. NACE International estimates the annual cost of corrosion in the U.S. at $276 billion.

Compounding the issue is aging infrastructure: roughly half of the nation’s 2.6 million miles of pipeline are over 50 years old. Aging infrastructure increases the urgency and the cost of inspections.

So, the question is: Are we at a breaking point or an inflection point? The answer depends largely on how quickly the industry can move beyond inspection methods that no longer match today's operational or economic realities.

Legacy methods such as insulation stripping, scaffolding, and manual NDT are slow, hazardous, and offer incomplete coverage. With maintenance budgets tightening, these methods are no longer viable.

Why traditional inspection falls short

Without question, what worked 50 years ago no longer works today. Traditional inspection methods are slow, siloed, and dangerously incomplete.

Insulation removal:

Disruptive and expensive.
Labor-intensive and time-consuming, with a high risk of process upsets and insulation damage.
Limited coverage. Often targets a small percentage of piping, leaving large areas unchecked.
Health risks: Exposes workers to hazardous materials such as asbestos or fiberglass.

Rope access and scaffolding:

Safety hazards. Falls from height remain a leading cause of injury.
Restricted time and access. Weather, fatigue, and complex layouts limit coverage and effectiveness.
High coordination costs. Multiple contractors, complex scheduling, and oversight, which require continuous monitoring, documentation, and compliance assurance across vendors and protocols drive up costs.

Spot checks:

Low detection probability. Random sampling often fails to detect localized corrosion.
Data gaps. Paper records and inconsistent methods hinder lifecycle asset planning.
Reactive, not proactive: Problems are often discovered late after damage has already occurred.

A smarter way forward

While traditional NDT methods for CUI like Pulsed Eddy Current (PEC) and Real-Time Radiography (RTR) remain valuable, the addition of robotic systems, sensors, and AI are transforming CUI inspection.

Robotic systems, sensors, and AI are reshaping how CUI inspections are conducted, reducing reliance on manual labor and enabling broader, data-rich asset visibility for better planning and decision-making.

ARIX Technologies, for example, introduced pipe-climbing robotic systems capable of full-coverage inspections of insulated pipes without the need for insulation removal. Venus, ARIX’s pipe-climbing robot, delivers full 360° CUI data across both vertical and horizontal pipe circuits — without magnets, scaffolding, or insulation removal. It captures high-resolution visuals and Pulsed Eddy Current (PEC) data simultaneously, allowing operators to review inspection video and analyze corrosion insights in one integrated workflow. This streamlines data collection, speeds up analysis, and keeps personnel out of hazardous zones — making inspections faster, safer, and far more actionable.

These integrated technology platforms are driving measurable gains:

Autonomous grid scanning: Delivers structured, repeatable coverage across pipe surfaces for greater inspection consistency.
Integrated inspection portal: Combines PEC, RTR, and video into a unified 3D visualization, streamlining analysis across inspection teams.
Actionable insights: Enables more confident planning and risk forecasting through digital, shareable data—not siloed or static.

Real-world results

Petromax Refining adopted ARIX’s robotic inspection systems to modernize its CUI inspections, and its results were substantial and measurable:

Inspection time dropped from nine months to 39 days.
Costs were cut by 63% compared to traditional methods.
Scaffolding was minimized 99%, reducing hazardous risks and labor demands.
Data accuracy improved, supporting more innovative maintenance planning.

Why the time is now

Energy operators face mounting pressure from all sides: aging infrastructure, constrained budgets, rising safety risks, and growing ESG expectations.

In the U.S., downstream operators are increasingly piloting drone and crawler solutions to automate inspection rounds in refineries, tank farms, and pipelines. Over 92% of oil and gas companies report that they are investing in AI or robotic technologies or have plans to invest soon to modernize operations.

The tools are here. The data is here. Smarter inspection is no longer aspirational — it’s operational. The case has been made. Petromax and others are showing what’s possible. Smarter inspection is no longer a leap but a step forward.

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Tyler Flanagan is director of service & operations at Houston-based ARIX Technologies.

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Pipeline robotics: How this Houston startup is revolutionizing corrosion monitoring ›

Dianna Liu of ARIX Technologies joins the Houston Innovators Podcast to share her entrepreneurial journey — and why Houston was the right place to start her company. Photo courtesy of ARIX

Pipeline robotics: How this Houston startup is revolutionizing corrosion monitoring

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After working for years in the downstream energy industry where safety and efficiency were top priorities, Dianna Liu thought there was a way technology could make a huge difference.

Despite loving her company and her job, she took a leap of faith to start a robotics company to create technology to more safely and efficiently monitor corrosion in pipelines. ARIX Technologies has developed software and hardware solutions for its customers with pipelines in downstream and beyond.

"Overall, this industry is an industry that really harps on doing things safely, doing things well, and having all the data to make really informed decisions," Liu says on the Houston Innovators Podcast. "Because these are huge companies with huge problems, it takes a lot of time to set up the right systems, adopt new things, and make changes."

But it's an industry Liu knows well, so she founded ARIX in 2017 and created a team of engineers to create the first iteration of the ARIX robot, which was at first made of wood, she says. Now, years later, the much-evolved robot moves up and down the exterior of the pipe, using its technology to scan the interior to evaluate corrosion. The technology works with ARIX's software to provide key data analysis.

With customers across the country and the world, ARIX has a strong foothold in downstream, but has garnered interest from other verticals as well — even working with NASA at one point, Liu says.

"Staying in downstream would be nice and safe for us, but we've been very lucky and have had customers in midstream, upstream, and even outside oil and gas and chemicals," she says. "We've gotten inquiries ranging from cosmetics plants to water or wastewater — essentially anything that's round or a pipe that can corrode, we can help with."

Liu, who goes into detail on the show about how critical establishing a positive company culture has been for ARIX, shares a bit about what it's been like growing her company in Houston.

"Houston being the Energy Capital of the World opens a lot of doors to both customers, investors, and employees in a way that's unparalleled. It is a great place to build a company because of that — you have all this expertise in this city and the surrounding areas that's hard to find elsewhere," she says. "Being such a hub — not only for energy, but in terms transportation — means it's easy for us to get to our customers from around the world."

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This article originally ran on InnovationMap.

Nearly 20 Houston startups and innovators were named finalists for the 2024 Houston Innovation Awards this week. Photo via Getty Images

Houston energy transition innovators named finalists for annual awards program

best of the rest

The Houston Innovation Awards have named its honorees for its 2024 awards event, and several clean energy innovators have made the cut.

The finalists, which were named on EnergyCapital's sister site InnovationMap this week, were decided by this year's judges after they reviewed over 130 applications. More 50 finalists will be recognized in particular for their achievements across 13 categories, which includes the 2024 Trailblazer Legacy Awards that were announced earlier this month.

All of the honorees will be recognized at the event on November 14 and the winners will be named. Registration is open online.

Representing the energy industry, the startup finalists include:

Amperon, an AI platform powering the smart grid of the future, was named a finalist in the Energy Transition Business category.
ARIXTechnologies, an integrated robotics and data analytics company that delivers inspection services through its robotics platforms, was named a finalist in the Energy Transition Business and the AI/Data Science Business categories.
CLS Wind, a self-erection wind turbine tower system provider for the wind energy industry, was named a finalist in the Minority-Founded Business category.
Corrolytics, a technology startup founded to solve microbiologically influenced corrosion problems for industrial assets, was named a finalist in the Minority-Founded Business and People's Choice: Startup of the Year categories.
Elementium Materials, a battery technology with liquid electrolyte solutions, was named a finalist in the Energy Transition Business category.
Enovate Ai, a provider of business and operational process optimization for decarbonization and energy independence, was named a finalist in the AI/Data Science Business category.
FluxWorks, developer and manufacturer of magnetic gears and magnetic gear-integrated motors, was named a finalist in the Deep Tech Business category.
Gold H2, a startup that's transforming depleted oil fields into hydrogen-producing assets utilizing existing infrastructure, was named a finalist in the Minority-Founded Business and the Deep Tech Business categories.
Hertha Metals, developer of a technology that cost-effectively produces steel with fewer carbon emissions, was named a finalist in the Deep Tech Business category.
InnoVentRenewables, a startup with proprietary continuous pyrolysis technology that converts waste tires, plastics, and biomass into valuable fuels and chemicals, was named a finalist in the Energy Transition Business and the People's Choice: Startup of the Year categories.
NanoTech Materials, a chemical manufacturer that integrates novel heat-control technology with thermal insulation, fireproofing, and cool roof coatings to drastically improve efficiency and safety, was named a finalist in the Scaleup of the Year category.
SageGeosystems, an energy company focused on developing and deploying advanced geothermal technologies to provide reliable power and sustainable energy storage solutions regardless of geography, was named a finalist in the Energy Transition Business category.
Square Robot, an advanced robotics company serving the energy industry and beyond by providing submersible robots for storage tank inspections, was named a finalist in the Scaleup of the Year category.
Syzygy Plasmonics, a company that's decarbonizing chemical production with a light-powered reactor platform that electrifies the production of hydrogen, syngas, and fuel with reliable, low-cost solutions, was named a finalist in the Scaleup of the Year category.
TierraClimate, a software provider that helps grid-scale batteries reduce carbon emissions, was named a finalist in the Energy Transition Business category.
Voyager Portal, a software platform that helps commodity traders and manufacturers in the O&G, chemicals, agriculture, mining, and project cargo sectors optimize the voyage management lifecycle, was named a finalist in the AI/Data Science Business category.

In addition to the startup finalists, two energy transition-focused organizations were recognized in the Community Champion Organization category, honoring a corporation, nonprofit, university, or other organization that plays a major role in the Houston innovation community. The two finalists in that category are:

Energy Tech Nexus, a new global energy and carbon tech hub focusing on hard tech solutions that provides mentor, accelerator and educational programs for entrepreneurs and underserved communities.
Greentown Houston, a climatetech incubator and convener for the energy transition community that provides community engagement and programming in partnership with corporations and other organizations.

Lastly, a few energy transition innovators were honored in the individual categories, including Carlos Estrada, growth partner at First Bight Ventures and head of venture acceleration at BioWell; Juliana Garaizar, founding partner of Energy Tech Nexus; and Neal Dikeman, partner at Energy Transition Ventures.

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Fervo Energy leads Time’s top green tech companies of 2026

top spot

The accolades keep coming for Houston-based geothermal energy company Fervo Energy.

Fervo sits atop Time magazine’s and Statista’s 2026 list of America’s Top GreenTech Companies. Fervo ranked No. 6 on the list last year.

The ranking honors 250 companies in the U.S. based on their environmental impact, innovation and financial strength. Fervo joins five other Houston-area companies on the list.

No. 49 Quaise Energy, an MIT Energy Initiative spinout that’s developing a drilling system designed to convert existing power stations for geothermal power production
No. 71 Plus Power, which develops, owns and operates battery energy storage systems
No. 98 Utility Global, whose technology enables industrial decarbonization
No. 199 Solugen, whose technology converts plant-based feedstocks into carbon-negative chemicals
No. 215 Noodoe, which specializes in EV charging stations and software

Fervo says its approach to enhanced geothermal systems (EGS)—including horizontal drilling, AI-enabled drilling and exploration, advanced reservoir engineering, and fiber-optic sensing—demonstrates how validated technology can help deliver reliable zero-emission power.

“By applying drilling technology from the oil and gas industry, we have proven that we can produce 24/7 carbon-free energy resources in new geographies across the world,” Fervo co-founder and CEO Tim Latimer said last year.

Other recent recognitions for Fervo includes:

The 2025 Houston Innovation Awards named it Scaleup of the Year
MIT Technology Review put Fervo on its 2025 list of the 10 global climatech companies to watch
Time named Fervo one of the 100 Most Influential Companies of 2025
Fervo was hailed as the Global Cleantech Group 100 North American Company of the Year
Fervo was among Congruent Ventures’ and Silicon Valley Bank’s 50 by 2050 companies, all of which are poised to advance global decarbonization over a 25-year span

Just last month, Fervo secured $421 million in debt financing for the construction of its 500-megawatt Cape Station geothermal project in Utah. And in December, the company landed an oversubscribed $462 million Series E round of funding, pushing its valuation to an estimated $1.4 billion. Fervo filed for an IPO earlier this year.

3 strategies to strengthen the Gulf Coast as a global energy hub

The View from HETI

The Texas-Louisiana Gulf Coast is the backbone of America’s energy and chemical economy. Texas produces roughly 43% of U.S. crude oil and 28% of natural gas, while Texas and Louisiana together account for about half of the nation’s refining capacity, processing 9.3 million barrels of crude per day across 50 refineries. The region also produces approximately 80% of the nation’s primary petrochemicals and ships more than $117 billion in chemical products annually from Texas alone.

This unmatched concentration of refining, petrochemical manufacturing, pipelines, ports, and technical talent makes the Gulf Coast one of the most critical energy hubs in the world. But maintaining that leadership in a rapidly evolving global market will require intentional collaboration, faster technology commercialization, and strengthened supply chain resilience.

In fall 2025, the Greater Houston Partnership’s Houston Energy Transition Initiative (HETI) convened national laboratories, Gulf Coast universities, and industry leaders to examine how to reinforce the region’s long-term competitiveness. Participants included Argonne, Oak Ridge, Lawrence Berkeley, the National Energy Technology Laboratory (NETL), and the National Laboratory of the Rockies, alongside Gulf Coast academic institutions and energy and chemical companies. Here are the key findings and takeaways from the workshop.

1. Supply Chain Resilience Requires Structured Industry–Lab Collaboration

Resilience—diversity of supply, operational flexibility, and rapid recovery—was a recurring theme. Recent disruptions exposed vulnerabilities in tightly interconnected energy and manufacturing systems.

National laboratories provide capabilities that complement Gulf Coast industrial scale, particularly at early and mid technology readiness levels (TRLs 1–7), before full commercial deployment. Examples include:

Advanced manufacturing and AI-enabled validation of critical components (Oak Ridge).
Materials scale-up and techno-economic modeling to move from lab discovery to industrial relevance (Argonne).
Pilot-scale testing for severe-service alloys, chemical conversion, and process innovation (NETL).
Integrated energy systems modeling to assess grid resilience and system disruptions (National Laboratory of the Rockies).

Recommendation: Organize targeted Gulf Coast industry missions to national laboratories focused on critical supply chains—power equipment, high-heat industrial processes, novel catalysts, refining, and grid infrastructure—to identify joint development opportunities and reduce time to commercialization.

2. Modeling, AI, and Open-Access Platforms Can Bridge the Technology Gap

A persistent barrier to innovation is the gap between scientific discovery, applied development, and commercial deployment. Universities often operate at TRLs 1–3, national labs at 1–7, and industry at 7–9. Bridging these silos requires shared modeling tools, high-performance computing, and structured feedback loops.

National labs maintain open-access platforms capable of:

Simulating grid expansion, investment, and dispatch decisions.
Modeling cradle-to-gate industrial material flows.
Optimizing complex energy and chemical systems.
De-risking carbon capture, critical mineral recovery, and advanced manufacturing integration.

Recommendation: HETI should convene structured training and feedback sessions on these public modeling platforms—ensuring Gulf Coast industry can apply, improve, and help guide further development of tools critical to regional competitiveness. Federal initiatives such as the Genesis Mission, focused on AI-accelerated scientific discovery, further expand opportunities for Gulf Coast participation.

3. Time to Commercialization Is the Ultimate Competitive Metric

The lithium-ion battery is a cautionary example: while pioneered in U.S. labs, large-scale manufacturing leadership shifted overseas. Without strategic intervention, U.S. firms are projected to capture less than 30% of domestic lithium battery cell value by 2030.

Successful DOE-backed consortium models show that mission-aligned, multi-partner collaboration reduces development timelines and strengthens domestic manufacturing know-how. However, public–private partnership mechanisms such as CRADAs and Strategic Partnership Projects can be time-intensive.

Recommendation: The Gulf Coast should actively engage DOE and national laboratories to streamline public–private partnership pathways, improve intellectual property clarity, and expand industry access to laboratory infrastructure.

The Path Forward: A Gulf Coast Consortium Model
The workshop’s central conclusion was clear: the Gulf Coast should formalize collaboration through a regional industry–academia–laboratory consortium.

Such a model could:

Co-locate national lab researchers within the region.
Share modeling data and analytical capabilities.
Establish open-access pilot facilities that complement lab infrastructure.
Harmonize IP frameworks to accelerate licensing and deployment.

With its dense industrial ecosystem, technical workforce, and decision-making concentration, the Gulf Coast is uniquely positioned to serve as a national demonstration hub for advanced energy and chemical manufacturing.

If industry, universities, and national laboratories align around a shared regional strategy, the Gulf Coast can:

Accelerate commercialization timelines.
Strengthen critical supply chains.
Unleash a world-class technical workforce.
Reinforce U.S. leadership in strategic energy and chemical sectors.

———

This article originally appeared on the Greater Houston Partnership's Houston Energy Transition Initiative blog . A full report on the key learnings and recommendations from the workshop can be found here: https://bit.ly/4uEDEqk.

Houston cleantech company closes $12M seed round

fresh funding

Houston-based Helix Earth Technologies has closed a $12 million Seed 2 funding round to scale manufacturing of its energy-efficient commercial HVAC add-on technology.

Veriten, a Houston-based energy investment firm, led the round. Rua Ventures, Carnrite Ventures, Skywriter LLC and Textbook Ventures also participated.

Helix Earth—which was founded based on NASA technology, spun out of Rice University and has been incubated at Greentown Labs—is developing high-efficiency retrofit dehumidification systems that aim to reduce the energy consumption of commercial HVAC units. The company reports that its technology can lead to "healthier indoor air, lower energy bills, reduced building maintenance, and more comfortable spaces for building owners and occupants."

"Building owners are dealing with rising energy costs, uncontrolled humidity, and aging infrastructure with no viable, cost-effective path forward. We are in the field today solving these problems for commercial customers, and this capital puts us on an aggressive path to scale,” Rawand Rasheed, Helix Earth co-founder and CEO, said in a news release.

“The strength of this round reinforces our team's conviction that we can transform innovation-starved sectors with transformational solutions that deliver order-of-magnitude improvements to owners and operators, for both their bottom line and the environment,” Rasheed added.

Maynard Holt, Veriten’s founder and CEO, said that the investment firm is tripling its investment in Helix Earth.

"The team has built breakthrough technology with real applicability across multiple industries,” Holt said in the release. “Their first product will have an immediate and measurable impact on our energy system, and they are already pursuing adjacent innovations to help heavy industries operate more efficiently and with less waste. This is a well-rounded team with a proven track record of strong execution and disciplined capital management.”

Helix Earth also closed a $5.6 million seed funding round in 2024, led by Veriten.

Last year, the company secured a $1.2 million Small Business Innovation Research (SBIR) Phase II grant and won in the Smart Cities, Transportation & Sustainability contest at the 2025 SXSW Pitch Showcase. Rasheed was also named to the Forbes 30 Under 30 Energy and Green Tech list for 2025.

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