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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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

From Your Site Articles

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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Chevron inks 20-year deal to power massive Microsoft data center in West Texas

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Chevron and Microsoft have signed a 20-year deal in which Chevron will provide natural-gas-fired power for a future West Texas data center, known as Project Kilby.

The proposed Microsoft data center could be one of the biggest in the U.S. and is expected to deliver 2.67 gigawatts of capacity. It will be built through a “phased, modular approach that enables incremental expansion over time,” according to Chevron.

Chevron expects the facility to be up and running by 2028, though the company won’t make a final investment decision on the project until later this year. The company is collaborating on Project Kilby with investment fund Engine No.1.

Project Kilby is projected to bring in $10 billion in state and local tax revenue and support 2,000 jobs, according to Chevron. The plant will use non-potable, brackish groundwater for power plant operations and aims to find new ways to reuse water produced by oil and gas operations.

The site will use selective catalytic reduction systems to reduce nitrogen oxide emissions and minimize noise and light impacts and will utilize other advanced air emissions control technologies. A majority of the generation will come from large turbines developed by Chevron partner GE Verona with additional capacity from Caterpillar’s solar turbines. The plant will be fed by natural gas from the Permian Basin.

“Chevron is uniquely positioned to deliver power to customers with certainty, speed and at a competitive cost, leveraging Permian natural gas and our proven execution capabilities,” Jeff Gustavson, Chevron president of new energies, said in a news release. “This project links Chevron’s traditional strengths to emerging demand, creating differentiated value for our shareholders and the communities where we operate.”

According to BloombergNEF, the U.S. is expected to increase its data center capacity to 77 gigawatts by 2030. Another report from Bloom Energy predicts Texas will see a 142 percent increase in its market share for data centers from 2025 to 2028.

“The rapid growth we’re experiencing in AI and cloud, driven by customer demand, requires energy infrastructure that can scale quickly and reliably,” Noelle Walsh, Microsoft president of cloud operations and innovation, added in the news release. “Our agreement with Chevron helps ensure we’ll have dedicated, large-scale power to support the evolution and reliability of advanced computers. Through this partnership, we’re delighted to grow with and become a deeper part of the West Texas community.”

Chevron was named No. 21 on the 2026 Fortune 500 list earlier this month.

17 Houston energy sector cos. among most future-ready businesses, says WSJ

More than 20 Houston-area companies reign among the most future-ready in the U.S., based on a first-time ranking of the best S&P 500 companies for the future. The majority of them are part of Houston's booming energy sector.

Published by The Wall Street Journal, the ranking was created by Bendable Labs for the WSJ Leadership Institute. It evaluates how S&P 500 companies stack up in six areas: AI readiness, innovation, talent readiness, financial fitness, resilience and agility. To be ranked, a company had to be part of the S&P 500 as of Dec. 31.

Here are the Houston-area companies in the energy sector included in the ranking of the best companies for the future:

No. 105 SLB
No. 120 Baker Hughes
No. 125 ConocoPhillips
No. 158 NRG Energy
No. 176 Targa Resources
No. 185 Chevron
No. 195 Halliburton
No. 223 Coterra Energy
No. 235 Exxon Mobil
No. 250 Kinder Morgan
No. 257 Quanta Services
No. 276 CenterPoint Energy
No. 313 Occidental Petroleum
No. 333 EOG Resources
No. 365 LyondellBasell Industries
No. 408 Phillips 66
No. 500 APA

Here are the remaining Houston-headquartered businesses that made the list:

No. 72 Hewlett Packard Enterprise
No. 229 Waste Management
No. 285 Sysco
No. 318 Camden Property Trust
No. 373 Comfort Systems USA
No. 401 Crown Castle

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A version of this story first appeared on InnovationMap.com.

Rice, DOE launch new Eastern Mediterranean Energy Center

Energy Diplomacy

Representatives from three countries visited the Rice University Baker Institute for Public Policy this month to establish the Eastern Mediterranean Energy Center, a new partnership promoting energy advancement in the region.

On June 11, Baker played host to delegations from Cyprus, Greece and Israel that included Michael Damianos, Minister of Energy, Commerce and Industry of the Republic of Cyprus; Stavros Papastavrou, Minister of Environment and Energy for Greece; and Yechiel Leiter, Israeli Ambassador to the United States. U.S. Secretary of Energy Chris Wright and Rice University President Reginald DesRoches were also present to sign a declaration of intent (DOI) that officially formed the partnership first envisioned in the Eastern Mediterranean Security and Energy Partnership Act of 2019.

“This is a dynamic field,” David Satterfield, director of the Baker Institute and former U.S. ambassador to Turkey and Lebanon, said in a news release from Rice. “The East Med has enormous further potential, not just for development, for coordination of development. It is a positive thing for energy, it's a positive thing for industry, for all of the three states represented here today. It's good for the region in a geopolitical sense as well. It provides a stabilization based upon the pragmatic and integrated development and distribution of energy resources, and that is a very good thing indeed.”

The new pact will focus on improving grid stability in the region, as well as on developing U.S. liquefied natural gas (LNG) infrastructure and new technologies.

Another goal of the Eastern Mediterranean Energy Center is suppressing conflict in the region. When the Eastern Mediterranean Security and Energy Partnership Act was signed by President Joe Biden in 2019, it lifted the prohibition on arms sales to the Republic of Cyprus, authorized foreign military financing for Greece and increased intelligence gathering on Russian interests in the Mediterranean.

“We need to use commerce to suppress and surpass conflict – that is the way to bring nations together in geopolitical tensions between countries,” Wright said in the release. “You think of it as zero-sum, there's a winner and a loser, and both sides want to be the winner. Ultimately, one side will be the winner, one side will be the loser. Maybe more objectively, both sides lose, but one loses more than the other. In commerce, it's entirely different, and commerce is voluntary exchange. It only happens when there's winners on both sides. So, when you build, you develop energy and you build energy distribution infrastructure, you bring countries, you bring people together. The three founding nations here and their leadership are all friends of mine and passionate in this mission. They not only want to develop energy to bring better opportunities to their people, but they wanted to bring those three nations together, and all of their neighbors as well, and use commerce to suppress and surpass conflict. These are generational investments.”

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