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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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


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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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UH lands $8M in federal funding for fusion energy research

fusion funding

The University of Houston will receive $8 million in federal funding from the U.S. Department of Energy for its work on fusion technology to help power data centers and medical work.

Venkat Selvamanickam, professor at UH’s Cullen College of Mechanical and Aerospace Engineering and director of the Advanced Manufacturing Institute, has been tasked to lead the research on superconducting magnets that he said will make compact fusion reactors possible.

“Beyond fusion, superconductors can transform how we deliver power to data centers, enable highly efficient motors and generators and improve electric power devices,” Selvamanickam said in a news release. “They also enable critical applications such as MRI and proton beam therapy for cancer treatment. I want society to experience the broad benefits this remarkable technology can provide.”

UH is one of 23 institutions selected to share part of $134 million from the DOE’s Fusion Energy Sciences division. The total funding is split across two initiatives: $128 million for the Fusion Innovation Research Engine (FIRE) and $6.1 million for the Innovation Network for Fusion Energy program, according to the university.

UH will partner with the FIRE Collaborative for the research, which looks to understand why superconducting magnets in fusion reactors break down and work on developing solutions to make them more resilient.

“The advantage of fusion is it’s clean and it does not require storage. Solar energy can’t be used at night, and wind energy depends on wind conditions,” Selvamanickam added in the release. “Our goal is to make fusion a truly viable energy source.”

Energy expert on Houston's advantage: Building affordability and reliability for all

Guest Column

As the energy capital of the world, Houston has been at the forefront of innovation, powering industries and communities for generations. Many Houston families, however, are facing a reality that undermines our leadership: high energy bills and ongoing concerns about grid reliability.

Affordability and reliability are not just technical issues; they’re equity issues. To remain the world leader in energy, we must ensure that every household has access to affordable and dependable power.

Affordability: The First Step Toward Equity

According to the recent 2025 study by The Texas Energy Poverty Research Institute, nearly 80% of low- to moderate-income Houstonians scaled back on basic needs to cover electric bills. Rising costs mean some Houstonians are forced to choose between paying their utility bill or paying for groceries.

Additionally, Houston now has the highest poverty rate among America’s most populous cities. Energy should not be a privilege for only half of our city’s population. That’s why affordability needs to be at the center of Houston’s energy conversation.

Several practical solutions exist to help address this inequity:

  • We can increase transparency in electricity pricing and help families better understand their electricity facts labels to make smarter choices.
  • We can expand energy efficiency programs, like weatherizing homes and apartments, swapping out old light bulbs for LEDs, and adopting smart thermostats.
  • Incentives to help families invest in these changes can deliver long-term benefits for both them and apartment complex owners.

Many small changes, when combined, can add up to significant savings for families while reducing overall demand on the grid.

Reliability: A Shared Community Priority

The memories of Hurricane Beryl, Derecho, and Winter Storm Uri are still fresh in the minds of Texans. We saw firsthand the fragility of our grid and how devastating outages are to families, especially those without resources to handle extreme weather. Reliability of the grid is an issue of public health, economic stability, and community safety.

Houston has an opportunity to lead by embracing innovation. Grid modernization, from deploying microgrids to expanding battery storage, can provide stability when the system is under stress. Partnerships between utilities, businesses, and community organizations are key to building resilience. With Houston’s innovation ecosystem, we can pilot solutions here that other regions will look to replicate.

Energy Equity in Action

Reliable, affordable energy strengthens equity in tangible ways. When households spend less on utilities, they have more to invest in their children’s education or save for the future. When power is stable, schools remain open, businesses continue to operate, and communities thrive. Extending energy efficiency programs across all neighborhoods creates a fairer, more balanced system, breaking down inequities tied to income and geography.

Studies show that expanding urban green spaces such as community gardens and tree-planting programs can lower neighborhood temperatures, reduce energy use for cooling, and improve air quality in disadvantaged areas, directly reducing household utility burdens.

In Houston, for example, the median energy burden for low-income households is 7.1% of income, more than twice that of the general population, with over 20% of households having energy burdens above 6%.

Research also demonstrates that community solar programs and urban cooling investments deliver clean, affordable power, helping to mitigate heat stress and making them high-impact strategies for energy equity and climate resilience in vulnerable neighborhoods.

Public-Private Partnerships Make the Difference

The solutions to affordability and reliability challenges must come from cross-sector collaboration. For example, CenterPoint Energy offers incentives through its Residential and Hard-to-Reach Programs, which support contractors and community agencies in delivering energy efficiency upgrades, including weatherization, to low-income households in the greater Houston area.

Nonprofits like the Houston Advanced Research Center (HARC) received a $1.9 million Department of Energy grant to lead a weatherization program tailored for underserved communities in Harris County, helping to lower bills and improve housing safety

Meanwhile, the City of Houston’s Green Office Challenge and Better Buildings Initiative bring private-sector sponsors, nonprofits, and city leadership together to drive energy reductions across millions of square feet of commercial buildings, backed by training and financial incentives. Together, these partnerships can result in real impact that brings more equity and access to affordable energy.

BKV Energy is committed to being part of the solution by promoting practical, consumer-focused strategies that help families save money and use energy more efficiently. We offer a suite of programs designed to provide customers with financial benefits and alleviate the burden of rising electricity bills. Programs like BKV Energy’s demonstrate how utilities can ease financial strain for families while building stronger customer loyalty and trust. Expanding similar initiatives across Houston would not only lower household energy burdens but also set a new standard for how energy companies can invest directly in their communities.

By proactively addressing affordability, energy companies can help ensure that rising costs don’t disproportionately impact vulnerable households. These efforts also contribute to a more resilient and equitable energy future for Houston, where all residents can access reliable power without sacrificing financial stability.

Houston as a Blueprint

Houston has always been a city of leadership and innovation, whether pioneering the space race, driving advancements in medical research at the Texas Medical Center, or anchoring the global energy industry. Today, our challenge is just as urgent: affordability and reliability must become the cornerstones of our energy future. Houston has the expertise and the collaborative spirit to show how it can be done.

By scaling innovative solutions, Houston can make energy more equitable, strengthening our own community while setting a blueprint for the nation. As the energy capital of the world, it is both our responsibility and our opportunity to lead the way to a more equitable future for all.

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Sam Luna is director at BKV Energy, where he oversees brand and go-to-market strategy, customer experience, marketing execution, and more.

Energy startup Base Power raises $1 billion series C round

fresh funding

Austin-based startup Base Power, which offers battery-supported energy in the Houston area and other regions, has raised $1 billion in series C funding—making it one of the largest venture capital deals this year in the U.S.

VC firm Addition led the $1 billion round. All of Base Power’s existing major investors also participated, including Trust Ventures, Valor Equity Partners, Thrive Capital, Lightspeed Venture Partners, Andreessen Horowitz (a16z), Altimeter, StepStone Group, 137 Ventures, Terrain, Waybury Capital, and entrepreneur Elad Gil. New investors include Ribbit Capital, Google-backed CapitalG, Spark Capital, Bond, Lowercarbon Capital, Avenir Growth Capital, Glade Brook Capital Partners, Positive Sum and 1789 Capital Management.

Coupled with the new $1 billion round, Base Power has hauled in more than $1.27 billion in funding since it was founded in 2023.

Base Power supplies power to homeowners and the electric grid through a distributed storage network.

“The chance to reinvent our power system comes once in a generation,” Zach Dell, co-founder and CEO of Base Power, said in a news release. “The challenge ahead requires the best engineers and operators to solve it, and we’re scaling the team to make our abundant energy future a reality.”

Zach Dell is the son of Austin billionaire and Houston native Michael Dell, chairman and CEO of Round Rock-based Dell Technologies.

In less than two years, Base Power has developed more than 100 megawatt-hours of battery-enabled storage capacity. One megawatt-hour represents one hour of energy use at a rate of one million watts.

Base Power recently expanded its service to the city of Houston. It already was delivering energy to several other communities in the Houston area. To serve the Houston region, the startup has opened an office in Katy.

The startup also serves the Dallas-Fort Worth and Austin markets. At some point, Base Power plans to launch a nationwide expansion.

To meet current and future demand, Base Power is building its first energy storage and power electronics factory at the former downtown Austin site of the Austin American-Statesman’s printing presses.

“We’re building domestic manufacturing capacity for fixing the grid,” Justin Lopas, co-founder and chief operating officer of Base Power, added in the release. “The only way to add capacity to the grid is [by] physically deploying hardware, and we need to make that here in the U.S. ... This factory in Austin is our first, and we’re already planning for our second.”

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