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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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


Under its deal with Occidental, pipeline company Enterprise Products Partners will create a carbon dioxide pipeline system for 1PointFive’s Bluebonnet Sequestration Hub. Photo via 1pointfive.com

Oxy, Enterprise Products Partners to collaborate on carbon dioxide pipeline system for Texas project

coming soon

Occidental Petroleum’s carbon capture, utilization, and sequestration (CCUS) subsidiary has tapped another Houston-based company to develop a carbon dioxide pipeline and transportation network for one of its CCUS hubs.

Under its deal with Occidental, pipeline company Enterprise Products Partners will create a carbon dioxide pipeline system for 1PointFive’s Bluebonnet Sequestration Hub, which will span more than 55,000 acres in Chambers, Liberty, and Jefferson counties. The hub will be able to hold about 1.2 billion metric tons of carbon dioxide. The new pipeline network will be co-located with existing pipelines.

Enterprise Products Partners also will supply fee-based services for transporting CO2 emissions from industrial facilities near the Houston Ship Channel to the Bluebonnet hub.

“This agreement pairs our expertise managing large volumes of CO2 with Enterprise’s decades of midstream experience to bring confidence to industrial customers seeking a decarbonization solution,” Jeff Alvarez, president of 1PointFive’s sequestration business, says in a news release.

The Bluebonnet Sequestration Hub recently received funding from the U.S. Department of Energy (DOE) to help cover development costs.

“This hub is located between two of the largest industrial corridors in Texas so captured CO2 can be efficiently transported and safely sequestered,” Alvarez said in 2023. “Rather than starting from scratch with individual capture and sequestration projects, companies can plug into this hub for access to shared carbon infrastructure.”

Here are some things to know about the situation with the pipeline fire burning just outside of Houston. Photo via Getty Images

What to know about the Houston pipeline fire — how it started, pollution impact, and more

latest update

A pipeline fire that forced hundreds of people to flee their homes in the Houston suburbs burned for a third day Wednesday, with officials saying they don't expect it to be extinguished until sometime Thursday evening.

Officials said residents who had to evacuate would be allowed to return to their homes starting Wednesday evening.

Authorities have offered few details about what prompted the driver of an SUV to hit an aboveground valve on the pipeline on Monday, sparking the blaze.

Here are some things to know about the situation with the pipeline fire:

What caused the fire?

Officials say the underground pipeline, which runs under high-voltage power lines in a grassy corridor between a Walmart and a residential neighborhood in Deer Park, was damaged when the SUV driver left the store's parking lot, entered the wide grassy area and went through a fence surrounding the valve equipment.

Authorities have offered few details on what caused the vehicle to hit the pipeline valve, the identity of the driver or what happened to them. The pipeline company on Wednesday called it an accident. Deer Park officials said preliminary investigations by police and FBI agents found no evidence of a terrorist attack.

Deer Park police won't be able to reach the burned-out vehicle until the flame has been extinguished. Once the area is safe, the department will be able to continue its investigation and confirm specifics, city spokesperson Kaitlyn Bluejacket said in an email Wednesday.

The valve equipment appears to have been protected by a chain-link fence topped with barbed wire. The pipeline's operator has not responded to questions about any other safety protections that were in place.

Who is responsible for the pipeline?

Energy Transfer is the Dallas-based owner of the pipeline, a 20-inch-wide (50-centemeter-wide) conduit that runs for miles through the Houston area.

It carries natural gas liquids through the suburbs of Deer Park and La Porte, both of which are southeast of Houston. Energy Transfer said the fire had diminished overnight and was continuing to “safely burn itself out” on Wednesday.

Energy Transfer also built the Dakota Access Pipeline, which has been at the center of protests and legal battles. The company’s executive chairman, Kelcy Warren, has given millions of dollars in campaign contributions to Republican Texas Gov. Greg Abbott.

What's being done to extinguish the fire?

Energy Transfer said its crews were working Wednesday to install specialized isolation equipment on both sides of the damaged section that will help extinguish the fire.

Once the equipment is installed, which could take several hours of welding, the isolated section of the pipeline will be purged with nitrogen, which will extinguish the fire, company and local officials said. After that, damaged components can be repaired.

“The safest way to manage this process is to let the products burn off,” Energy Transfer said.

Late Wednesday afternoon, Deer Park officials said repair work on the pipeline to help speed up the process to put out the fire wasn't expected to be completed until 6 p.m. on Thursday. Once finished, the fire was anticipated to be extinguished within two to three hours.

How have residents been impacted?

Authorities evacuated nearly 1,000 homes at one point and ordered people in nearby schools to shelter in place. Officials said that starting at 6 p.m. on Wednesday, residents in Deer Park and La Porte who had to evacuate would be allowed to return to their homes. A portion of a highway near the pipeline would remain closed, officials said.

Hundreds of customers lost power. Officials said Wednesday afternoon that only two customers remained without electricity in the Deer Park and La Porte area. Repairs to all of the power distribution lines affected by the fire had been completed.

Deer Park's statement said Energy Transfer was “prioritizing the safety of the community and environment as it implements its emergency response plan.”

“We appreciate the patience and understanding of all residents during this ongoing situation,” Deer Park officials said.

By late Tuesday, about 400 evacuees remained, and some expressed frustration over being forced to quickly flee and not being given any timeline for when they will be able to return.

“We literally walked out with the clothes on our backs, the pets, and just left the neighborhood with no idea where we were going,” said Kristina Reff, who lives near the fire. “That was frustrating.”

What about pollution from the fire?

Energy Transfer and Harris County officials have said that air quality monitoring shows no immediate risk to individuals, despite the huge tower of billowing flame that shot hundreds of feet into the air, creating thick black smoke that hovered over the area.

Houston is the nation’s petrochemical heartland and is home to a cluster of refineries and plants and thousands of miles of pipelines. Explosions and fires are a familiar sight, and some have been deadly, raising recurring questions about industry efforts to protect the public and the environment.

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10+ must-attend Houston energy transition events happening in Q3 2025

Must-Attend Meetings

Editor's note: Q3 is here, and with it, a full slate of must-attend events for Houston energy professionals. On the agenda are casual mixers, exciting showcases, week-long happenings, and more. Mark your calendars for these top Houston energy transition events coming up from July to September 2025, and begin registering today. Please note: this article may be updated to include additional events.

July 17 — TEX-E Energy, Innovation, and Entrepreneurship networking mixer

The Texas Exchange for Energy & Climate Entrepreneurship hosts this casual networking event to connect the Houston energy and climate tech ecosystem.

This event takes place Thursday, July 17 at 5 pm at Second Draught. Click here to register.

July 29 — Center for Houston's Future presents Summer Salon

This year's Summer Salon breakfast program is titled "Digital Technology and AI: Challenges and Opportunities for Driving Energy Innovation." Sponsored by bp, it will feature a timely conversation about the intersection of digital technology (including AI) and energy innovation.

This event takes place Tuesday, July 29 at 7:30 am at Junior League of Houston. Click here to register.

August 21 — Transition on Tap

Greentown Labs’ signature networking event returns in August to foster conversations and connections within Houston's climate and energy transition ecosystem. Entrepreneurs, investors, students, philanthropists, and more are invited to attend, meet colleagues, discuss solutions, and engage with the growing community.

This event takes place Thursday, August 21 at 5:30 pm at Greentown Labs. Click here to register.

August 22 – Determined to Lead Women Lunch: Investing Through Market Cycles with Ellen Wilkirson

EnergyTech Nexus hosts a monthly Determined to Lead Women’s Lunch as part of its ongoing efforts to create safe spaces for women leaders in the energy transition to connect, learn, and lead. The August session features Ellen Wilkirson, principal at Rev Innovations. With deep experience across traditional and transition energy sectors, Wilkirson will share how she’s approached investing through multiple market and commodity cycles and what it means to be a clean energy investor in today’s evolving landscape.

This event takes place Friday, August 22 at 1 pm. Click here to register.

August 27-28 — 6th Texas Energy Forum 2025

The 6th Texas Energy Forum will dive deep into the strategies, policies, and innovative solutions that reinforce energy security for the United States and its allies and fuel economic growth — centered on Texas’ pivotal role in the global energy landscape. Key discussions will address the future of regulatory reform, tariffs, and tax incentives; advancements in oil, gas, and LNG markets; the expansion of power generation; and breakthroughs in EVs and charging infrastructure. This year's topic is "Texas: The Energy Innovation Powerhouse."

This event begins Wednesday, August 27 at the Petroleum Club of Houston. Click here to register.

September 3-4 — 11th Annual Digitalization in Oil & Gas Conference

This conference will delve deep into the intersection of digitalization and decarbonization, highlighting the transformation required for the oil and gas sector to stay relevant, resilient, and achieve business value. This year, the focus is on leveraging AI and generative AI, driving sustainability and workforce development, and achieving operational excellence through digitalization. Key objectives include building future-ready facilities, planning for a lower carbon market, and realizing business value through innovative solutions.

This event begins Wednesday, September 3 at Hilton Americas Houston. Click here to register.

September 8-10 — SPE Energy Transition Symposium

The SPE Energy Transition Symposium brings together professionals from multiple disciplines across the energy sector, offering a comprehensive platform for learning, networking, and collaboration. Its primary objective is to facilitate the exchange and dissemination of knowledge drawn from the insights of industry leaders, technical experts, academics, practitioners, representatives from the financial community, and environmental, social, and governance (ESG) leaders. This year's symposium is titled "Synergizing Innovation and Collaboration: Transforming Energy for a Sustainable Future."

This event begins Monday, September 8 at Houston Marriott Sugar Land. Click here to register.

September 15-19 — Houston Energy & Climate Week

Houston Energy & Climate Week utilizes Houston's potential to propel global climate action. This gathering welcomes an unparalleled selection of global energy leaders and communities, giving participants opportunities to interact and discuss capital, technology, workforce, and policy needs. It is organized by Allies in Energy, a nonprofit dedicated to building energy and climate literacy and a pathway to the workforce of the future.

Following an invite-only dinner on Sunday, September 14, this event begins with Opening Ceremonies on Monday, September 15. Click here for details.

September 15-19 — Houston Energy + Climate Startup Week

Launched in 2024, the official Houston Energy and Climate Startup Week returns for its second year, showcasing how Houston is developing and scaling real solutions for the dual challenge of meeting growing global energy demand while reducing carbon emissions. Join leading energy and climate venture capital investors, industry leaders, and startups from around the world for this showcase of the most innovative companies and technologies that are transforming the energy industry while driving a sustainable, low-carbon energy future.

This event begins Monday, September 15 with a kickoff event at the Ion Plaza. Click here for details.

September 16 — Pilotathon 2025 & Company Showcase

EnergyTech Nexus hosts its annual Pilotathon — a high-impact event designed to fast-track pilot deployments for climate and energy tech startups. Expect a full day of curated startup pitches, a 50-plus company innovation showcase, and direct engagement with corporate partners, investors, and ecosystem leaders. The afternoon will also feature participants from the ETN CoPilot Accelerator. Startup applications and event registration is now open at www.pilotathon.com.

This event takes place Tuesday, September 16 at 8 am at GreenStreet. Click here to register.

September 18 — ACCEL Year 3 Showcase

As part of Houston Energy and Climate Startup Week, Greentown Labs will celebrate ACCEL, an accelerator program for startups led by BIPOC and other underrepresented founders. The third ACCEL cohort will present a showcase featuring their technologies, what they’ve accomplished in the first six months of the program, and where they’re headed next. Attendees will also have the opportunity to network with industry leaders who are passionate about and building an inclusive and sustainable future.

This event takes place Thursday, September 18 at 5 pm at Greentown Labs. Click here to register.

Greentown Labs adds 6 Texas clean energy startups to Houston incubator

green team

Greentown Labs announced the six startups to join its Houston community in Q2 of 2025.

The companies are among a group of 13 that joined the climatetech incubator, which is co-located in Houston and Boston, in the same time period. The companies that joined the Houston-based lab specialize in a number of clean energy applications, from long-duration energy storage systems to 3D solar towers.

The new Houston members include:

  • Encore CO2, a Louisiana-based company that converts CO2 into ethanol, acetate, ethylene and other sustainable chemicals through its innovative electrolysis technology
  • Janta Power, a Dallas-based company with proprietary 3D-solar-tower technology that deploys solar power vertically rather than flatly, increasing power and energy generation
  • Licube, an Austin-based company focused on sustainable lithium recovery from underutilized sources using its proprietary and patented electrodialysis technology
  • Newfound Materials, a Houston-based company that has developed a predictive engine for materials R&D
  • Pix Force, a Houston-based company that develops AI algorithms to inspect substations, transmission lines and photovoltaic plants using drones
  • Wattsto Energy, a Houston-based manufacturer of a long-duration-energy-storage system with a unique hybrid design that provides fast, safe, sustainable and cost-effective energy storage at the microgrid and grid levels

Seven other companies will join Greentown Boston's incubator. See the full list here.

Greentown Houston also added five startups to its local lab in Q1. Read more about the companies here.

How Planckton Data is building the sustainability label every industry will need

now streaming

There’s a reason “carbon footprint” became a buzzword. It sounds like something we should know. Something we should measure. Something that should be printed next to the calorie count on a label.

But unlike calories, a carbon footprint isn’t universal, standardized, or easy to calculate. In fact, for most companies—especially in energy and heavy industry—it’s still a black box.

That’s the problem Planckton Data is solving.

On this episode of the Energy Tech Startups Podcast, Planckton Data co-founders Robin Goswami and Sandeep Roy sit down to explain how they’re turning complex, inconsistent, and often incomplete emissions data into usable insight. Not for PR. Not for green washing. For real operational and regulatory decisions.

And they’re doing it in a way that turns sustainability from a compliance burden into a competitive advantage.

From calories to carbon: The label analogy that actually works

If you’ve ever picked up two snack bars and compared their calorie counts, you’ve made a decision based on transparency. Robin and Sandeep want that same kind of clarity for industrial products.

Whether it’s a shampoo bottle, a plastic feedstock, or a specialty chemical—there’s now consumer and regulatory pressure to know exactly how sustainable a product is. And to report it.

But that’s where the simplicity ends.

Because unlike food labels, carbon labels can’t be standardized across a single factory. They depend on where and how a product was made, what inputs were used, how far it traveled, and what method was used to calculate the data.

Even two otherwise identical chemicals—one sourced from a refinery in Texas and the other in Europe—can carry very different carbon footprints, depending on logistics, local emission factors, and energy sources.

Planckton’s solution is built to handle exactly this level of complexity.

AI that doesn’t just analyze

For most companies, supply chain emissions data is scattered, outdated, and full of gaps.

That’s where Planckton’s use of AI becomes transformative.

  • It standardizes data from multiple suppliers, geographies, and formats.
  • It uses probabilistic models to fill in the blanks when suppliers don’t provide details.
  • It applies industry-specific product category rules (PCRs) and aligns them with evolving global frameworks like ISO standards and GHG Protocol.
  • It helps companies model decarbonization pathways, not just calculate baselines.

This isn’t generative AI for show. It’s applied machine learning with a purpose: helping large industrial players move from reporting to real action.

And it’s not a side tool. For many of Planckton’s clients, it’s becoming the foundation of their sustainability strategy.

From boardrooms to smokestacks: Where the pressure is coming from

Planckton isn’t just chasing early adopters. They’re helping midstream and upstream industrial suppliers respond to pressure coming from two directions:

  1. Downstream consumer brands—especially in cosmetics, retail, and CPG—are demanding footprint data from every input supplier.
  2. Upstream regulations—especially in Europe—are introducing reporting requirements, carbon taxes, and supply chain disclosure laws.

The team gave a real-world example: a shampoo brand wants to differentiate based on lower emissions. That pressure flows up the value chain to the chemical suppliers. Who, in turn, must track data back to their own suppliers.

It’s a game of carbon traceability—and Planckton helps make it possible.

Why Planckton focused on chemicals first

With backgrounds at Infosys and McKinsey, Robin and Sandeep know how to navigate large-scale digital transformations. They also know that industry specificity matters—especially in sustainability.

So they chose to focus first on the chemicals sector—a space where:

  • Supply chains are complex and often opaque.
  • Product formulations are sensitive.
  • And pressure from cosmetics, packaging, and consumer brands is pushing for measurable, auditable impact data.

It’s a wedge into other verticals like energy, plastics, fertilizers, and industrial manufacturing—but one that’s already showing results.

Carbon accounting needs a financial system

What makes this conversation unique isn’t just the product. It’s the co-founders’ view of the ecosystem.

They see a world where sustainability reporting becomes as robust as financial reporting. Where every company knows its Scope 1, 2, and 3 emissions the way it knows revenue, gross margin, and EBITDA.

But that world doesn’t exist yet. The data infrastructure isn’t there. The standards are still in flux. And the tooling—until recently—was clunky, manual, and impossible to scale.

Planckton is building that infrastructure—starting with the industries that need it most.

Houston as a launchpad (not just a legacy hub)

Though Planckton has global ambitions, its roots in Houston matter.

The city’s legacy in energy and chemicals gives it a unique edge in understanding real-world industrial challenges. And the growing ecosystem around energy transition—investors, incubators, and founders—is helping companies like Planckton move fast.

“We thought we’d have to move to San Francisco,” Robin shares. “But the resources we needed were already here—just waiting to be activated.”

The future of sustainability is measurable—and monetizable

The takeaway from this episode is clear: measuring your carbon footprint isn’t just good PR—it’s increasingly tied to market access, regulatory approval, and bottom-line efficiency.

And the companies that embrace this shift now—using platforms like Planckton—won’t just stay compliant. They’ll gain a competitive edge.

Listen to the full conversation with Planckton Data on the Energy Tech Startups Podcast:

Hosted by Jason Ethier and Nada Ahmed, the Digital Wildcatters’ podcast, Energy Tech Startups, delves into Houston's pivotal role in the energy transition, spotlighting entrepreneurs and industry leaders shaping a low-carbon future.