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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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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Texas data center boom could strain water supply, new report warns

thirst for data

As data centers continue to boom throughout Texas, a new report from the Houston Advanced Research Center (HARC) warns that the trend could strain the state’s water supply.

HARC estimates Texas data centers used 25 billion gallons of water in 2025—and that the demand for water will continue to rise to meet the needs of the 464 data centers currently in Texas, as well as 70 additional sites currently under development.

In the report, titled “Thirsty Data and the Lone Star State: The Impact of Data Center Growth on Texas’ Water Supply,” The Woodlands-based nonprofit says that water use for cooling data centers is expected to double or triple by 2028 on the national level. If projections hold, the total annual water use for data centers in Texas will increase by 0.5 percent to 2.7 percent by 2030, or to between 29 billion and 161 billion gallons of water consumed.

Data centers often use water for cooling, though water demand is dependent on the type of cooling used, the size and type of the data center. Although used water can be reused, some new water withdrawals are always needed to replace evaporated water and other systems’ water losses. Water is also used to cool the power plants that generate electricity used by the data centers.

The HARC report offers guidance to address the overall concerns of water demands by data centers, including:

Dry cooling methods
Increased reliance on wind and solar energy sources
Alternative water supplies, like treated wastewater or brackish water for cooling
Adjusted operating schedules to accommodate water usage
Partnering with local companies to develop projects that reduce water leaks
Companies creating their own water infrastructure investments

The report goes on to explain that the Texas State Water Plan, produced by the Texas Water Development Board, projects shortages of 1.6 trillion gallons by 2030 and 2.3 trillion gallons by 2070. HARC posits that the recent surge in water demand from AI data centers is not fully reflected in those projections.

"Texas water plans always look backward, not forward," the report reads. "That means the 2027 water plan, which is in development now, will be based on 2026 regional water plans that do not include forecasted data center water use. Data centers that began operation in 2025 will not be added to the State Water Plan until 2032."

Currently, there are no state regulations that require data centers to report how much water they use. However, the Public Utility Commission of Texas (PUC) plans to survey operators of data centers and cryptocurrency mining facilities on their water consumption, cooling methods and electricity sources this spring. It is expected to release the results by the end of the year. The companies will have six weeks to respond. The Texas Water Development Board will assist the PUCT on the questions.

“I think we all recognize the importance of data centers and the technology they support and what they give to our modern-day life,” PUC Commissioner Courtney Hjaltman said during the last commission meeting. “Texans, regulators and the legislature really need that understanding of data centers, really need to understand the water they’re using so that we can plan and create the Texas we want.”

See the full HARC report here.

Houston cleantech startup seeks $200M for superhot geothermal plant

seeing green

Houston-based Quaise Energy is looking to raise $200 million to support the development of a 50-megawatt superhot geothermal plant in Oregon.

The company is seeking $100 million in Series B funding, plus an additional $100 million from grants, debt and project-level finance, a representative from the company tells Energy Capital. Axios first reported the news late last month.

Quaise specializes in terawatt-scale geothermal power. It is known for its millimeter-wave drilling technology, which was developed at MIT.

The company's Project Obsidian development in central Oregon will combine conventional drilling with its millimeter-wave technology. Quaise says the project, targeted to come online in 2030, could be the first commercial plant to operate in superhot rock, a more efficient and abundant resource, but one that requires more advanced and durable drilling technology.

Quaise says Obsidian would initially generate 50 megawatts of "always-on" power and would be designed to add 200 megawatts as additional wells are developed. A power-purchase deal has already been signed for the initial 50 megawatts with an undisclosed customer.

A representative from the company says Quaise would also use the funding to continue advancing its millimeter-wave technology and prepare it for commercialization.

Last year, the company drilled to a depth of about 330 feet using its millimeter-wave technology at its field site in Central Texas.

“Our progress this year has exceeded all expectations,” Carlos Araque, CEO and president of Quaise Energy, said at the time. “We’re drilling faster and deeper at this point than anyone believed possible, proving that millimeter-wave technology is the only tool capable of reaching the superhot rock needed for next-generation geothermal power. We are opening up a path to a new energy frontier.”

Canary Media reports that Quaise plans to drill to nearly 3,300 feet later this year and to deploy its millimeter-wave technology at its power plant in 2027.

Quaise raised $21 million in a Series A1 financing round in 2024 and a $52 million Series A in 2022. Major investors include Prelude Ventures, Safar Partners, Mitsubishi Corporation, Nabors Industries, TechEnergy and others.

Quaise was one of eight Houston-area companies to appear on Time magazine and Statista’s list of America’s Top GreenTech Companies of 2025.

Houston positioned to lead in Carbon Capture Utilization (CCU), study shows

The View From HETI

With global demand for energy production while lowering emissions continues to grow, Houston and the Gulf Coast region are uniquely positioned to lead with carbon capture, utilization and sequestration (CCUS). A new study developed by the Houston Energy Transition Initiative (HETI) in collaboration with Deloitte Consulting explores how the region can transform captured CO₂ into valuable products while supporting continued economic growth and industrial competitiveness.

Key takeaways from the report include:

Houston and the Gulf Coast are uniquely advantaged to utilize and store carbon.As a global hub for chemicals and refining industries, Houston has access to world-class infrastructure, a skilled workforce, and access to global markets. The region also has one of the nation’s highest concentrations of industrial CO₂ and creates the opportunity to capture waste material streams to deliver lower carbon intensity products that continue to deliver economic benefits to the region.

While carbon capture and sequestration (CCS) projects continue to advance, CCU requires coordinated action across policy, infrastructure, technology and market demand to scale successfully. Utilization and sequestration are complementary strategies that support and protect investment deployments. CCS acts as an early foundation while markets and infrastructure evolve toward broader CO₂ utilization, and CCU is essential to developing low-carbon-intensity value chains and products.

“Our collaboration with Deloitte highlights how Houston and the Gulf Coast continue to build on the strengths that have long made our region an energy leader. Houston’s infrastructure, workforce, and industrial ecosystem uniquely position the region to scale CCU,” said Jane Stricker, Senior Vice President, Energy Transition, and Executive Director of HETI. “With supportive policy, continued innovation, and strong industry partnerships, we can accelerate CCU deployment, create new low-carbon value chains, and ensure Houston remains at the forefront of the global energy transition.”

Download the full report here.

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This article originally appeared on the Greater Houston Partnership's Houston Energy Transition Initiative blog . HETI exists to support Houston's future as an energy leader. For more information about the Houston Energy Transition Initiative, EnergyCapitalHTX's presenting sponsor, visit htxenergytransition.org.

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