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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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

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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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8+ must-attend Houston energy transition events in October 2026

Must-Attend Meetings

Editor's note: October is here, and there are many energy events to plug into in Houston this month. From summits and forums to exhibitions and networking opportunities, these are the top events to put on your calendar. Learn more below, and register now.

Oct. 6-7: Hydrogen Americas Summit and Exhibition

Hydrogen Americas delivers an unparalleled opportunity to explore how hydrogen integrates with CCUS and other energy solutions under the new U.S. and Americas energy paradigm. This event moves to Houston in 2026, providing unmatched access to industry leaders and opportunities. The summit will include CCUS dedicated sessions integrated directly into the conference programming, providing deeper insights into carbon capture, utilization, and storage. Look forward to networking opportunities to connect with global suppliers, regional developers, and key policymakers.

This event begins Oct. 6 at George R. Brown Convention Center. Register here.

Oct. 6-7: Annual Energy Summit — Energy, Risk, and Geopolitics

The 10th annual energy summit is co-hosted by Baker Botts and the Center for Energy Studies at Rice University's Baker Institute. This year's summit, “Energy, Risk, and Geopolitics,” will explore how a changing geopolitical landscape and shifts in supply chain risks are impacting investment, innovation, and market dynamics. The two-day program will include discussions spanning petroleum and LNG markets, critical minerals, electricity reliability, AI, and power demand.

This event begins Oct. 6 at 7:30 am at James A Baker III Hall. The event will also be livestreamed. Register here.

Oct. 7: Industrial Data Forward Forum 2026

Houston continues to sit at the intersection of energy, chemical production, and advanced manufacturing. Industrial data experts, automation engineers, and enterprise architects will gather for this one-day forum to address one of the region's biggest operational challenges: modernizing massive, legacy industrial plants without incurring high costs.

This event takes place Oct. 7 at Norris Conference Center. Register here.

Oct. 14: Houston Engineering, Energy & Transportation Networking Event

Connect with leading engineers, energy experts, environmental innovators, and transportation professionals during an evening of collaboration, insight, and opportunity. This exclusive event is designed for engineers, project developers, renewable energy specialists, urban planners, environmental consultants, and infrastructure leaders eager to expand their networks, exchange ideas, and explore solutions driving the future of sustainable development.

This event takes place on Oct. 14 at 7 pm at SOHO Garden. Get tickets here.

Oct. 14: Future of Global Energy Conference

This October, the sixth annual Future of Global Energy Conference kicks off, convening influential leaders from across energy, technology, finance and public policy who will come together to explore the forces defining the next era of global energy and Houston’s role in shaping it. Ryan Lance, Executive Chairman of ConocoPhillips and 2027 Chair of the Greater Houston Partnership’s Board of Directors, is the keynote speaker, bringing a global perspective on rising demand, market volatility and Houston’s role in the next era of energy growth.

This event takes place Oct. 14 at Marriott Marquis. Register here.

Oct. 17: Energy Day 2026

Energy Day Houston is the nation’s largest free, family-friendly STEM festival. It features over 50 interactive exhibits and live demonstrations focused on traditional and emerging energy career paths to power up your curiosity.

This event begins at 11 am on Oct. 17 at Sam Houston Park. Get details here.

Oct. 22: Geophysical Society of Houston Fall Forum

This one-day event will explore how geophysics continues to drive value in hydrocarbon development while opening new opportunities in geothermal, critical minerals, mining, microseismic monitoring, and other emerging subsurface applications. The forum will highlight both the technologies and business strategies needed to succeed in a rapidly evolving energy landscape.

This event begins at 7 am on Oct. 22 at SLB. Get details here.

Oct. 28-29: Energy Council Houston 2026

Energy Council Houston is a private executive forum for leaders across the U.S. upstream oil and gas sector. Over two days, operators, investors, financiers, and strategic partners will come together to discuss the issues shaping capital allocation, energy security, M&A activity, and energy investment across North America.

This event begins Oct. 28 at the Four Seasons Hotel Houston. Register here.

Houston geothermal company picks Nevada site for commercial-scale project

coming soon

Sage Geosystems, a Houston-based developer of geothermal power systems, has chosen a site in Nevada for its commercial-scale Project Vector facility.

The company’s two-well enhanced geothermal system (EGS) will deliver around-the-clock geothermal heat to Ormat Technologies’ Blue Mountain geothermal power plant in Winnemucca, Nevada.

The startup expects to begin drilling the first well later this year, with the first electricity to be generated in 2027 and full-scale production to start in 2028.

In the Nevada system, fluid will circulate through an engineered subsurface reservoir, absorb heat from the surrounding rock and return heat to the surface. The heat will be delivered to the Blue Mountain plant for conversion into electricity.

Project Vector builds on the performance of Sage’s SMECI facility in South Texas. That facility’s results, combined with Sage’s digital twin platform, will be used to shape to the design and development of Project Vector.

Project Vector supports Sage’s growing commercial pipeline, including a 150-megawatt geothermal power agreement with Meta Platforms, the parent company of Facebook and Instagram.

“Blue Mountain is an ideal location for Sage to take the next step in continuing to commercialize our proprietary EGS approach,” Jason Peart, chief operating officer at Sage, said in a release. “By delivering geothermal heat into an existing power plant, Project Vector can demonstrate the model for bringing firm, 24/7 geothermal power to market at scale.”

Project Vector extends Sage’s relationship with Ormat.

In August 2025, Sage and Ormat agreed to accelerate commercialization of Sage’s geothermal technology at an Ormat power plant. This January, Ormat co-led Sage’s $97 million Series B funding round.

Sage, founded in 2020, has raised about $159 million across three funding rounds.

As the startup ramps up its ESG platform, Sage is targeting data centers as customers, among other large-scale users of electricity.

“The energy needs are huge, and they need it now,” CEO Cindy Taff said on Data Center Frontiers’ podcast. “They can’t depend on the grid anymore.”

Houston’s power advantage: Key takeaways from 2026 HETI Power Summit

The view from heti

Power has become a defining economic development issue as electricity demand rises across Texas.

Industrial expansion, advanced manufacturing, AI and data center growth are increasing the importance of reliable, affordable power delivered on the timelines major projects require.

The 2026 HETI Power Summit, titled Houston’s Power Advantage: Competing for Large-Load Growth, brought together leaders from utilities, power producers, large energy customers, technology and infrastructure providers, professional services firms and the public sector to examine how Houston can meet this moment.

Across keynotes, research report-outs, panel discussions and a fireside chat, a consistent theme emerged: Houston’s power advantage comes from the region’s ability to align utilities, customers, infrastructure, flexible demand, emerging solutions and regional partners around reliable, affordable and timely growth.

Reliability and Readiness

Public Utility Commission of Texas Commissioner Kathleen Jackson opened the summit by emphasizing reliability as the foundation for continued growth as Texas electricity demand rises.

Commissioner Jackson underscored the importance of sustained planning and investment to support new industrial, manufacturing and digital demand while maintaining a reliable power system. Remarks framed the morning’s broader discussion of how Houston can pair reliability with speed, affordability and long-term system readiness.

Scott Cockerham of FTI Consulting previewed HETI and FTI’s “Texas Power Market & Industry Assessment”. The research identifies accessibility, reliability, affordability, market flexibility and infrastructure readiness as key dimensions of regional competitiveness.

Leaders from FTI Consulting, Kroll, AWS and Constellation also discussed factors shaping major investment decisions, including reliability, infrastructure timelines, cost certainty, site readiness, community support and regional coordination.

For large customers, these factors must translate into credible project-level execution. Confidence in system performance, energization timelines and infrastructure plans can materially influence major capital commitments.

Building for the Houston We Want to Become

Jason Ryan of CenterPoint Energy challenged participants to plan now for the infrastructure needed to support Houston’s next phase of growth. Drawing on the idea that “what got you here won’t get you there,” Ryan urged the region to build infrastructure for “the Houston we want to become” and stay ahead of large-load demand.

A fireside discussion between CenterPoint Energy and Foxconn brought that challenge to the customer level. The conversation explored how early coordination between utilities and large customers can help advanced manufacturing projects move from site selection and planning to construction and operation.

Long-term growth will require continued investment in generation, transmission and distribution. In the near term, better use of existing infrastructure can create additional capacity.

HETI also shared findings from its Role of Efficiency & Demand Response to Meet Near-Term Regional Power Demand report. Energy efficiency can lower baseline electricity use, while demand response can shift or reduce demand during critical periods. Combined with supply-side investment, these tools can create grid headroom as longer-term infrastructure advances.

The summit’s closing panel, featuring leaders from Amperon, Enchanted Rock, EY and Quanta Services, expanded the discussion to emerging solutions. Panelists explored modular and flexible generation, advanced forecasting, grid intelligence and greater coordination among utilities, customers, infrastructure providers and communities.

Houston’s broader regional power landscape adds another dimension. Entergy Texas President and CEO Eli Viamontes described Southeast Texas as experiencing an “extraordinary trifecta of residential, industrial and data center growth.” His remarks highlighted how the MISO-facing portion of the region complements Houston’s ERCOT strengths through utility planning, generation and infrastructure investment, resource adequacy and coordination with major industrial customers.

Together, these approaches point to a broader strategy: invest for long-term demand while using flexibility, technology and regional coordination to create capacity for growth today.

From Power Advantage to Economic Advantage

Taken together, the Power Summit discussions point to a clear priority for Houston: translating power market and infrastructure strengths into coordinated execution.

Priority areas include earlier infrastructure planning, stronger site and project readiness, clearer pathways from projected demand to reliably served load, expanded efficiency and flexibility, and sustained coordination among utilities, customers, policymakers, communities, technology providers and economic development organizations.

HETI is advancing this work through research and convening efforts focused on Houston’s evolving power needs and economic competitiveness.

The 2026 Power Summit reinforced Houston’s strong foundation for power-intensive growth and the importance of aligning investment, reliability, flexibility and regional coordination around the next generation of economic opportunity.

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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. Gain more insights from HETI’s Energy Efficiency and Demand Response Report.

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