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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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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Nominations close Aug. 31 for Houston Innovation Awards — submit today

Awards Season

Calling all Houston energy innovators: The Houston Innovation Awards return this fall to celebrate the best and brightest in the Houston innovation ecosystem, and that includes those leading the energy transition.

Presented by InnovationMap, the fifth annual Houston Innovation Awards will take place November 5 at TMC Helix Park.

The awards program will honor the top startups and innovators in Houston across 10 categories, and we're asking you to nominate the most deserving Houston innovators and innovative companies, including those in the energy transition sector.

This year's categories are:

  • Minority-founded Business, honoring an innovative startup founded or co-founded by BIPOC or LGBTQ+ representation.
  • Female-founded Business, honoring an innovative startup founded or co-founded by a woman.
  • Energy Transition Business, honoring an innovative startup providing a solution within renewables, climatetech, clean energy, alternative materials, circular economy, and beyond.
  • Health Tech Business, honoring an innovative startup within the health and medical technology sectors.
  • Deep Tech Business, honoring an innovative startup providing technology solutions based on substantial scientific or engineering challenges, including those in the AI, robotics, and space sectors.
  • Startup of the Year (People's Choice), honoring a startup celebrating a recent milestone or success. The winner will be selected by the community via an interactive voting experience.
  • Scaleup of the Year, honoring an innovative later-stage startup that's recently reached a significant milestone in company growth.
  • Incubator/Accelerator of the Year, honoring a local incubator or accelerator that is championing and fueling the growth of Houston startups.
  • Mentor of the Year, presented by Houston Community College, honoring an individual who dedicates their time and expertise to guide and support budding entrepreneurs.
  • Trailblazer, honoring an innovator who's made a lasting impact on the Houston innovation community.

Nominations may be made on behalf of yourself, your organization, and other leaders and institutions in the local innovation scene. The nomination period closes on August 31, so don't delay — nominate today at this link, or fill out the embedded form below.

A panel of esteemed judges will review the nominations, and determine the finalists and winners. Finalists will be unveiled on InnovationMap.com on September 30, and the 2025 Houston Innovation Awards winners will be announced live at an event on November 5.

Tickets will go on sale this fall. Stay tuned for that announcement.

Interested in Innovation Awards sponsorship opportunities? Please contact sales@innovationmap.com.

Greentown Labs names first head of philanthropy

new hire

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

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

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

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

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

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

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

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

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

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

float on

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

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

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

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

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

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

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