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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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.


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

listen now

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."

———

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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Greentown Labs names first head of philanthropy

new hire

Greentown Labs has named its first-ever head of philanthropy in an "all hands on deck" move to advance philanthropic support for climatetech ventures.

Stacey Harris will join the clean energy incubator and brings more than 15 years of experience to the role, having led major partnerships at organizations like Make-A-Wish International, Movember, Net Impact and the Greater Phoenix Economic Council, according to a release from Greentown.

Harris will be based out of Greentown's Boston-area incubator but will support both its Texas and Massachusetts locations. Greentown maintains headquarters in Houston and Somerville, Massachusetts.

“Stacey brings national reach, local roots, and the entrepreneurial spirit we need,” Georgina Campbell Flatter, CEO of Greentown, said in the release. “She understands that philanthropy isn’t just about raising funds—it’s about building a movement, sustaining an ecosystem, and accelerating change together.”

In her new role, Harris will be tasked with designing and leading a philanthropic strategy that aligns with Greentown's corporate partnerships.

The incubator said in the release that Harris's hire is coming at a "pivotal moment," and the organization is "calling for all hands on deck" to support the clean energy space. "This includes inspiring states and local governments to lean in, individuals and family offices to step up, foundations to mobilize resources, and industry to invest boldly," the release states.

"Philanthropy has the unique power to accelerate innovation where it matters most—by backing the people and ideas that can change the world,” Harris added in the release. “At Greentown, I see an incredible opportunity to partner with local communities in Massachusetts and Texas, while also mobilizing catalytic funds that fuel entrepreneurs globally. I’m energized to work across donors, foundations, and industry to ensure these founders have what they need to go further, faster—together.”

Harris is the latest in a series of new hires for Greentown.

Lawson Gow, founder of The Cannon co-working space and former managing partner at Helium Capital, was named Greentown's Head of Houston in July. Flatter was also named as the organization's new CEO in February, after Naheed Malik was named its new CFO in January.

Houston companies team up on $700M floating solar projects in Texas

float on

Diamond Infrastructure Solutions has given Third Pillar Solar exclusive rights to access Diamond’s Texas reservoirs for the possible launch of utility-scale floating solar installations. Both companies are based in the Houston area.

The potential investment in the floating solar project exceeds $700 million, and the project is expected to generate up to 500 megawatts of solar energy.

“Our agreement with Third Pillar marks a bold step forward in how we think about infrastructure and sustainability. By transforming underutilized water surfaces into clean energy assets, Diamond is advancing its commitment to innovation while delivering long-term value,” Ed Noack, CEO of Diamond Infrastructure Solutions, said in the release.

Dow Chemical Co. and a fund directed by Macquarie Asset Management announced the formation of Diamond in 2024. Dow holds a majority stake in Diamond, which owns Gulf Coast infrastructure used by Dow and other industrial customers at five locations in Texas and Louisiana.

The solar installations are scheduled to be built and in operation by the end of the decade.

The agreement between Diamond and Three Pillar “demonstrates the growing appetite for utility-scale energy solutions and highlights how floating solar can enhance and transform the value of existing infrastructure, all while providing cost-competitive energy, preserving agricultural land, reducing evaporation losses, and existing out of public view,” Jaimeet Gulati, CEO of Third Pillar, added in the realease.

Founded in 2022 and majority-owned by renewable energy investor Glentra Capital, Third Pillar develops, owns and operates floating photovoltaic solar installations. The installations are designed to float in places such as wastewater lagoons, reclaimed sand and gravel pits and industrial reservoirs. Third Pillar’s development pipeline contains more than 60 projects.

Rice Alliance names participants in 22th annual energy forum

where to be

The Rice Alliance for Technology and Entrepreneurship has named the 100 energy technology ventures that will convene next month at the 22nd annual Rice Alliance Energy Tech Venture Forum, as part of the second annual Houston Energy and Climate Startup Week.

Half of the startups, which hail from nine countries and 19 states, will pitch during the event, which culminates in the annual recognition of the “Most Promising Companies." The 12 companies that were named to Class 5 of the Rice Alliance Clean Energy Accelerator will present during Demo Day to wrap up their 10-week program.

In addition to pitches, the event will also host keynotes from Arjun Murti, partner of energy macro and policy at Veriten, and Susan Schofer, partner at HAX and chief science officer at SOSV. Panels will focus on corporate innovation and institutional venture capital. Attendees can also participate in one-on-one office hours with founders and investors.

The forum will take place Sept. 18 at Rice University’s Jones Graduate School of Business.

The 2025 presenting companies include:

  • Aeromine Technologies
  • AlumaPower
  • Ammobia
  • Aqua-Cell Energy
  • Aquafortus
  • Aquora Biosystems
  • Arculus Solutions
  • Artemis Production Solutions
  • AtmoSpark Technologies
  • AtoMe
  • Badwater Alchemy
  • C+UP
  • Carbon Blade
  • Circul8 Energy & Environment
  • CO2 Lock
  • Direct C
  • DirectH2
  • Ekona Power
  • Exum Instruments
  • Fathom Storage
  • Flyscan Systems
  • Geokiln Energy Innovation
  • Glint Solar
  • Hive Autonomy
  • Horne Technologies
  • Hydrogenious LOHC Maritime
  • Innowind Energy Solutions
  • Iron IQ
  • Kewazo
  • LiNova Energy
  • Lukera Energy
  • Lydian
  • Mcatalysis
  • Metal Light
  • Mithril Minerals
  • Moment Energy
  • Moonshot Hydrogen
  • Muon Vision
  • PolyQor
  • Polystyvert dba UpSolv
  • Precision Additive
  • RapiCure Solutions
  • Resollant
  • SiriNor
  • Skyven Technologies
  • Sperra
  • SpiroPak
  • Sweetch Energy
  • Teverra
  • Utility Global
  • Xplorobot

Companies participating in office hours include:

  • Active Surfaces
  • Advanced Reactor Technologies
  • Advanced Thermovoltaic Systems
  • Ai Driller
  • Airbridge
  • Airworks Compressors
  • Austere Environmental
  • Brint Tech
  • CarbonX Solutions
  • Cavern Energy Storage
  • Celadyne Technologies
  • CERT Systems
  • CubeNexus
  • Deep Anchor Solutions
  • Ellexco
  • Emerald Battery Labs
  • Equipt.ai
  • FAST Metals
  • FieldMesh
  • FlowCellutions
  • Fluidsdata
  • GrapheneTX
  • GS VORTEX SYSTEMS
  • Installer
  • Kanin Energy
  • MacroCycle Technologies
  • Modular MOPU
  • NANOBORNE
  • NetForwards
  • Oxylus Energy
  • PetroBricks
  • PHNXX
  • RASMAG Energy
  • RedShift Energy
  • RENASYS
  • RenewCO2
  • Resonantia Diagnostics
  • Respire Energy
  • Safety Radar
  • SeaStock
  • Secant Fuel
  • SolGrapH
  • Stratos Perception
  • Terraflow Energy
  • Think Energy Holdings
  • Turnover Labs
  • Utiltyx
  • Zenthos Energy

Find information about the full day of events here, or click here to register.