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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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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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Texas' oil and gas foundation could boost its geothermal future, UH says

future of geothermal

Equipped with the proper policies and investments, Texas could capitalize on its oil and gas infrastructure and expertise to lead the U.S. in development of advanced geothermal power, a new University of Houston white paper says.

Drilling, reservoir development and subsurface engineering are among the Texas oil and gas industry’s capabilities that could translate to geothermal energy, according to a news release. Furthermore, oil and gas skills, data, technology and supply chains could help make geothermal power more cost-effective.

Up to 80 percent of the investment required for a geothermal project involves capacity and skills that are common in the oil and gas industry, the white paper points out.

Building on its existing oil-and-gas foundation, Texas could help accelerate production of geothermal energy, lower geothermal energy costs and create more jobs in the energy workforce, according to the news release.

The paper also highlights geothermal progress made by Houston-based companies Fervo Energy, Quaise Energy and Sage Geosystems, as well as Canada-based Eavor Technologies Inc.

UH’s Division of Energy published the white paper, Advanced Geothermal: Opportunities and Challenges, in partnership with the C.T. Bauer College of Business’ Gutierrez Energy Management Institute.

“Energy demand, especially electricity demand, is continuing to grow, and we need to develop new low-carbon energy sources to meet those needs,” Greg Bean, executive director of the institute and author of the white paper, said of geothermal’s potential.

HETI leader reflects on four years focused on the energy transition

The View From HETI

It’s hard to believe only four years have passed since I joined the Greater Houston Partnership to lead the Houston Energy Transition Initiative. We talk about COVID years feeling simultaneously like just yesterday and a lifetime ago, and my time at HETI feels quite similar. The energy and climate landscape has evolved dramatically over the last few years, but one constant has endured…Houston remains at the heart of the energy industry.

When I joined HETI at the start of 2022, I could not have imagined the impact we would have over the next four years. Our vision, laid out in 2020 by then Partnership Chair Bobby Tudor, was bold – leverage Houston’s energy leadership to accelerate global solutions for an energy abundant, low-carbon future. Our mission was clear – ensure the long-term economic competitiveness of the Houston region in a changing energy landscape. Our strategy, developed with strong support from McKinsey, was sound – build a coalition of industry, academic and community partners to position Houston as a leading hub for energy and climate innovation, commercialization and economic growth.

And Houston’s energy leaders, across business, academia and community, came together to deliver that strategy. Bobby Tudor’s timely vision created an anchor for Houston’s energy community that allowed us to broaden the energy and climate discussion to one focused on meeting growing energy demand and reducing emissions. That vision was a catalyst for changing the perception of Houston from oil & gas capital to an “all of the above” energy capital with a thriving energy and climate tech innovation ecosystem. Houston is where you can work collaboratively to build new energy value chains and ensure an affordable, secure, and lower emissions energy mix for our region, our country, and the world.

In this fast-moving energy environment, it can be easy to focus on what to do next without taking time to reflect on the work and celebrate the wins. We took the opportunity at the end of 2025 to reflect on five years of impact. As we developed that report, I thought about how fortunate I have been to lead this work for the last four years. HETI’s impact has been incredibly meaningful for our region, our members, and the new companies and founders building the next generation of energy technology and talent. As my time as executive director comes to an end, HETI’s work continues. The need remains clear: more energy, less emissions, and continued collaboration that brings together innovation and infrastructure, policies and markets, and hard tech together with human ingenuity.

As I prepare to hand the reigns to HETI’s new SVP and executive cirector, Sophia Cunningham, at the end of March, I have been reflecting on the impact this role has had on me. Four years ago, I could never have imagined the opportunities, experiences and relationships this role has enabled. I am truly grateful for the support and engagement of Houston’s business and community leaders, the visionary leadership of Bobby Tudor, Scott Nyquist, HETI Members, and the Greater Houston Partnership in creating this initiative at exactly the right moment in time. I am incredibly proud of the HETI and partnership team members who have delivered with purpose and passion, and I greatly appreciate Houston’s energy and climate leaders and champions who have supported my agenda, challenged my thinking, broadened my perspectives, and worked with HETI to demonstrate the power of partnership in developing, innovating and advancing the ideas and technologies needed to meet this challenge for our region and the world.

As excited as I am to see where this next chapter takes me, I am even more excited to see where the work of HETI goes from here. I am still optimistic that the challenge of providing the world with affordable, reliable, and resilient energy while simultaneously reducing emissions is one Houston is uniquely positioned to meet.

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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. For more information about the Houston Energy Transition Initiative, EnergyCapitalHTX's presenting sponsor, visit htxenergytransition.org.

Texas could topple Virginia as biggest data-center market by 2030, JLL report says

data analysis

Everything’s bigger in Texas, they say—and that phrase now applies to the state’s growing data-center presence.

A new report from commercial real estate services provider JLL says Texas could overtake Northern Virginia as the world’s largest data-center market by 2030. Northern Virginia is a longtime holder of that title.

What’s driving Texas’ increasingly larger role in the data-center market? The key factor is artificial intelligence.

Companies like Google and Microsoft need more energy-hungry data centers to power AI innovations. In a 2023 article, Forbes explained that AI models consume a lot of energy because of the massive amount of data used to train them, as well as the complexity of those models and the rising volume of tasks assigned to AI.

“The data-center sector has officially entered hyperdrive,” Andy Cvengros, executive managing director at JLL and co-leader of its U.S. data-center business, said in the report. “Record-low vacancy sustained over two consecutive years provides compelling evidence against bubble concerns, especially when nearly all our massive construction pipeline is already pre-committed by investment-grade tenants.”

Dallas-Fort Worth has long dominated the Texas data-center market. But in recent years, West Texas has emerged as a popular territory for building data-center campuses, thanks in large part to an abundance of land and energy. Nearly two-thirds of data-center construction underway now is happening in “frontier markets” like West Texas, Ohio, Tennessee and Wisconsin, the JLL report says.

Northern Virginia, the current data-center champ in the U.S., boasted a data-center market with 6,315 megawatts of capacity at the end of 2025, the report says. That compares with 2,423 megawatts in Dallas-Fort Worth, 1,700 megawatts in the Austin-San Antonio corridor, 200 megawatts in West Texas, and 164 megawatts in Houston.

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