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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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

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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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Rice, UH join major quantum, nuclear energy initiatives

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Rice University and the University of Houston will be playing a part in the future of energy in Texas and beyond, as Rice has joined the U.S. Department of Energy Quantum Science Center and UH has been added to the Texas Nuclear Alliance.

Rice’s role with the DOE Quantum Science Center will expand the university’s work in helping to develop “fault-tolerant quantum computers capable of solving scientific problems,” according to Rice. Tirthak Patel, an assistant professor of computer science, will develop and evaluate quantum error-correction decoding methods on high-performance computing platforms. Patel’s team will receive $900,000 over 5 years from a DOE-funded center at Oak Ridge National Laboratory.

The Quantum Science Center was established in 2020 under the National Quantum Initiative Act, and brings together national laboratories, universities and industry partners like IBM, AMD, IQM, Quantinuum and Riverlane, and others to advance quantum information science. The Quantum Science Center is one of the DOE’s five National Quantum Information Science Research Centers, and has planned funding of $125 million over 5 years.

“Reliable error correction is one of the biggest challenges in making quantum computing useful for accelerating scientific discovery,” Patel said in a news release. “Our work is focused on developing methods that can scale to future systems and support practical scientific applications.”

Meanwhile, as power demand continues to rise in Texas and North America, the Texas Nuclear Alliance brings industry, academic, and government leaders together to advance nuclear technologies to meet growing energy demands, support economic efforts, bolster domestic manufacturing, and protect overall energy security.

UH brings expertise to the Texas Nuclear Alliance from UH Energy, the Texas Center for Superconductivity at UH (TcSUH), and the Advanced Manufacturing Institute (AMI). UH says that 11 of its 16 colleges will contribute research to the alliance.

“Texas and the University of Houston have long led the nation in energy innovation and research,” Ramanan Krishnamoorti, vice president of energy and innovation, said in a news release. “As demand for reliable, affordable and secure energy continues to grow, advanced nuclear technologies will become increasingly important. The University of Houston is uniquely positioned to contribute through world-class research and deep industry partnerships that help transform breakthrough discoveries into real-world solutions. We look forward to working with the Texas Nuclear Alliance to accelerate technologies that will shape the future of the energy industry.”

Projects from both Rice and UH were selected this week to participate in the DOE's Genesis Mission. Read more here.

4 Houston researchers awarded projects in DOE's Genesis Mission

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The U.S. Department of Energy has named the nearly 300 projects selected under the Trump Administration's Genesis Mission, which aims to address some of the largest science and technology challenges in the country. The group features four projects from Houston universities and companies.

The initiative aims to unite government, industry, academia and philanthropy to lead to breakthroughs in energy, scientific discovery and national security, according to a release.

The selected projects feature 87 led by DOE and National Nuclear Security Administration (NNSA) National Laboratories, 168 led by universities, 19 led by companies and 4 led by nonprofit organizations—totalling 342 participating institutions.

“America has no shortage of bold ideas or talented scientists, and the response to the Genesis Mission proves that,” U.S. Secretary of Energy Chris Wright said in a news release. “The 278 projects selected today represent the very best of our nation’s scientific enterprise. The remarkable number of high-quality proposals we received demonstrates that America’s innovation pipeline is strong, and it points to even greater opportunities for future investment and continued expansion of the Genesis Mission portfolio.”

Twelve Texas-based projects were selected among the 278. The Houston projects and their researchers include:

Caroline Ajo-Franklin

Ajo-Franklin recieved a Phase I grant for her project "Predictive AI to Map Point Mutation Effects on Protein Function: Measurement and Biosynthesis of Isoprenoids." Ajo-Franklin is a professor of biosciences at Rice University, a CPRIT Scholar in Cancer Research and member of the Rice Synthetic Biology Institute. The project aims to accelerate the engineering of microbes that can produce isoprenoids, which are natural compounds that could replace petroleum-derived fuels, solvents and materials.

“This project creates a continuous feedback loop in which AI guides experiments and each experiment generates more detailed data to better hone the AI model,” Ajo-Franklin said in a news release. “In addition, it demonstrates the extraordinary star power Rice has recruited in protein engineering and synthetic biology.”

Anastasios Kyrillidis

Kyrillidis recived a Phase I grant for his project "Cracking the VQA Optimization Bottleneck: AI Methods for Quantum Chemistry and Materials." Kyrillidis is the Noah Harding Associate Professor of Computer Science at Rice and a member of the Ken Kennedy Institute. The project aims to develop AI tools to resolve bottlenecks in quantum computing for chemistry and materials research.

“Our goal is to replace fragile, hand-tuned optimization methods with intelligent systems that can learn from quantum computations while still operating within frameworks that provide strong mathematical guarantees,” Kyrillidis added in the release.

Myoungkyu Lee

Lee received a nearly $750,000 Phase I grant for his project "Physics-Informed AI Surrogates for Turbulent Forced Convection in Energy System." Lee is an assistant professor of mechanical aerospace engineering at the University of Houston. Lee will collaborate with researchers from Lawrence Livermore National Laboratory and University of Pennsylvania on the project and develop artificial intelligence to accelerate the design of materials for advanced nuclear fission and fusion reactors.

“The goal is to develop a tool that runs much faster than today’s most detailed simulations while keeping errors small,” Lee said in a news release. “If successful, the approach could support better heat-transfer predictions for molten-salt reactor design and provide a starting point for studying heat removal in fusion blankets. This is one contribution among many toward reliable, carbon-free energy.”

Amit Padhi

Padhi recieved a grant for his project "Probabilistic Inference of Subsurface Fracture Connectivity for Stimulation Control with Physics-Informed AI." Padhi is a scientific advisor for Halliburton.

The DOE first called for applications for the Genesis Mission in March. At the time, the DOE shared that it would grant approximately $293 million to the selected teams via Phase I awards, ranging from $500,000 to $750,000 for nine-month project periods, and Phase II awards, for $6 million to $15 million over a three-year project period.

Since then, however, the initiative has grown with 15 federal agencies now granting research awards and funding opportunities under the Genesis umbrella. The White House announced this week that it had secured more than $5 billion in federal commitments to expand the initiative.

SLB teams with Liberty Energy on modular power for AI data centers

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Houston-headquartered SLB and Denver-based Liberty Energy Inc. announced a strategic agreement this month to support the rapid growth of new data center capacity.

Under the agreement, SLB will supply modular data center infrastructure and oversee large-scale execution, while Liberty will provide modular power generation systems and behind-the-meter power management technology for developers looking to add capacity. According to Reuters, the power will come from natural gas generation.

“The bottleneck in AI infrastructure is no longer just compute. It is the ability to deliver infrastructure and power on the timelines the market now demands,” Gavin Rennick, president of SLB’s New Energy and Industrial business, said in a news release. “By bringing together complementary infrastructure and power capabilities, we will help developers accelerate deployment of new data center capacity.”

The companies seek to specifically offer the modular technologies in areas without traditional grid connections or where grid capacity is limited.

They also aim to improve the "efficiency, flexibility and environmental performance of future data center energy systems," potentially through solutions like hybrid power systems and digital energy management, according to the news release.

Goldman Sachs estimates that U.S. data center capacity will more than double from 31 gigawatts in 2025 to 66 gigawatts in 2027. Other reports predict that Houston and Texas will be home to a significant portion of the data center boom, with capacity in the city and the state also expected to double in the next few years.

“The scale and complexity of AI energy infrastructure is fundamentally changing how power systems are built and deployed,” Ron Gusek, CEO of Liberty Energy, added in the release. “Liberty’s comprehensive power service platform is engineered to meet this transition, as customers increasingly prioritize tailored, integrated solutions. Building on our long-standing relationship with SLB, we are excited to bring power solutions that address immediate capacity constraints while supporting the next generation of energy systems.”

SLB sold its onshore hydraulic fracturing business in the United States and Canada to Liberty Energy in December 2020 in exchange for a 37 percent equity interest in the company.

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