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 Yet many operators still rely on outdated inspection methods that are slow, risky, and economically unsustainable.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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Houston's KBR tapped to provide tech for first SAF plant in Kazakhstan

clean deals

Houston-based engineering and technology firm KBR Inc. has been tapped to provide technology for Kazakhstan's first sustainable aviation fuel (SAF) production plant.

KazMunayGas-Aero LLP (KMG-Aero), a subsidiary of Kazakhstan’s national oil and gas company KazMunayGas, and KazFoodProducts awarded the contract to KBR for the project. The plant will use the alcohol-to-jet (AtJ) process for producing aviation fuel and aims to support President Kassym-Jomart Kemeluly Tokayev’s goal of boosting Kazakhstan's profile as a global aviation player, according to a news release from KBR.

"We are honored to support KMG-Aero and KFP in advancing the national commitment to reduce greenhouse gas emissions, recognizing the pivotal role of aviation decarbonization in achieving these strategic objectives,” Jay Ibrahim, president of KBR Sustainable Technology Solutions, said in the release.

KBR will provide its PureSAF technology and engineering design for the project. Invented and developed by Swedish Biofuels AB, the PureSAF tech will be used to convert alcohol-based feedstocks into SAF. The PureSAF Technology can process multiple feedstocks—like bioethanol, syngas, carbon dioxide and hydrogen—and convert them to SAF, diesel and gasoline, according to KBR.

"KBR’s PureSAF is a feed-flexible, bankable technology that is designed to deliver high SAF yields and supports the project across the full lifecycle,” Ibrahim added in the release. “We look forward to closely collaborating and supporting the successful execution of this landmark SAF project.”

Earlier this summer, KBR was also chosen to provide technology for what’s expected to be Asia's first commercial-scale ethanol-to-jet (SAF) plant. The plant has a planned production capacity of up to 100,000 tons of SAF per year.

In addition to the SAF projects, KBR also announced this month that it has been selected by ORNX Green Hydrogen to provide proprietary ammonia technologies for a low-cost green ammonia project in Morocco.

The commitments come as KBR shifts its focus solely toward sustainability technology and services. The company is in the process of spinning off its Mission Technology Solutions business, which KBR recently announced will be named Trinzic. The remaining company, "New KBR," will serve the ammonia and syngas, chemical and petrochemicals, clean refining and circular economy markets.

Army to build nuclear microreactors at 5 U.S. bases, including Texas

Nuclear News

The U.S. Army announced Wednesday that it plans to add nuclear microreactors at five military bases from New York to Texas as a reliable source of energy independent of the commercial electric grid.

The announcement comes as the Trump administration pushes hard to develop the next generation of nuclear power, including billions in loans for large nuclear reactors to meet skyrocketing power demand from data centers and a pilot program to boost advanced reactor designs and projects for military and civilian use. No nuclear microreactors are supplying power to the commercial electric grid in the United States today.

Five companies selected by the Army will be awarded up to $2.2 billion in total over five years to own, construct and operate the microreactors, if they hit set milestones along the way for their performance. The Army expects that more than 20 nuclear microreactors will be built and operated.

Army and industry officials say microreactors offer a resilient power source for critical infrastructure at military installations in case the grid fails. Reactors can run for years without refueling.

Army Secretary Dan Driscoll said the awards will accelerate the military’s ability “to deliver safe, reliable baseload power directly to our installations. We are building the energy resilience necessary to project combat power globally, without relying on potentially vulnerable external grids,” he said.

The grants are part of the Army's “Janus Program” launched last year to deliver next-generation nuclear energy. Officials hope to push nuclear development forward so that advanced reactor designs move beyond experiments and prototypes to provide power for years to come. This will be the “spear tip,” said Jeff Waksman, principal deputy assistant secretary of the Army for installations, energy and environment.

“That is the transition that we are trying to effect here,” he said on a call with reporters Wednesday. “These are not meant to be Army-specific designs.”

Critics of building more nuclear reactors say they’re too expensive and riskier than other energy sources. The Army program is using the military's “deep pockets to provide a hidden subsidy” to nuclear companies that can't find private-sector customers for their hypothetical and uneconomical reactors, said Alan J. Kuperman, associate professor at the Lyndon B. Johnson School of Public Affairs at the University of Texas at Austin and coordinator of the Nuclear Proliferation Prevention Project.

The reactors will be licensed by the Army, rather than the U.S. Nuclear Regulatory Commission, which licenses commercial nuclear reactors. Kuperman said it's “a dangerous scam on many levels.”

Waksman said these reactors will shut down safely in case of a failure, they're small and the Army wouldn't add them to installations without being certain they are safe. He said the Army is working on a deal with the Energy Department to remove radioactive waste, and there won't be any long-term storage on these installations.

The Army is working to align its regulatory processes as much as possible, Waksman said, so that companies won’t need major changes to their designs to be later licensed by the NRC. Along with federal funding, the Army expects billions of dollars in private capital investment.

Army leads the military’s adoption of nuclear energy

President Donald Trump signed executive orders in May 2025 to speed up the development of nuclear power. The Army was tasked with ensuring that an advanced reactor would start operating at a domestic military installation no later than Sept. 30, 2028. The Janus program is named for the ancient Roman god of transitions.

Officials know that delivering nuclear power to a military base will be a challenge, so they picked five companies in case one or more fail, Waksman said. The selected companies are: Antares Nuclear at Fort Bragg in North Carolina; BWXT at Fort Campbell in Kentucky; General Atomics Electromagnetic Systems at Fort Hood in Texas; Radiant Industries at Fort Benning in Georgia; and Westinghouse Government Services at Fort Drum in New York.

Senate Minority Leader Chuck Schumer asked the Army to select Fort Drum. The critical missions Fort Drum supports require secure power generation, the New York Democrat said.

The military installations will remain connected to the grid. The reactors would not completely power them. Each reactor will provide between 1 megawatt to 20 megawatts of power, depending on the company's design. Major bases use as much power as a small city. Antares and Radiant are planning to deliver their reactors in three-packs, Waksman said.

The Army now uses diesel as a primary backup for critical infrastructure. But in a conflict, Waksman said, the Army may not be able to move fossil fuels easily wherever it needs them.

“That makes nuclear energy just a natural game changer,” he said. “It makes sense for the Army to take the lead here.”

A reactor at Fort Belvoir in Virginia, completed in 1957, was the first nuclear power reactor to provide electricity to a commercial power grid in the United States for an extended period, according to the U.S. Army Corps of Engineers.

Companies say this will accelerate US nuclear development

California-based Antares reached a crucial milestone under the U.S. pilot program that could allow it to produce electricity at Idaho National Lab next year. The company said the Army's announcement extends its momentum. Westinghouse Government Services said it’s proud to support the Army’s efforts to strengthen energy security and innovate.

Tori Shivanandan, president and chief operating officer of California-based Radiant, said the Army’s $750 million award “shows confidence in Radiant’s product and ability to manufacture, deploy and safely operate nuclear microreactors for the American military.” The Janus program “will build a stronger and more resilient America,” she said.

General Atomics Electromagnetic Systems said its reactor is designed to operate in remote, off-grid and extreme environments for 40 years. It said it will draw on more than 70 years of nuclear expertise to provide safe, dependable and independent power for the military.

Rex Geveden, BWXT's president and chief executive officer, said, “As we commence work on the Janus program, we are delivering the nation’s most credible and reliable path to deployable nuclear power.”

Energy giant Shell lists Houston HQ for sale for $325 million

asset offload

Energy giant Shell has put its U.S. headquarters in Houston’s Energy Corridor on the market and is exploring the sale of its U.S. chemical business.

Green Street News reported Shell just listed its longtime Energy Corridor campus at 150 N. Dairy Ashford Road. The asking price is $325 million, The Real Deal reported. Shell plans to lease back half of the nearly 1.5 million-square-foot Woodcreek campus for 15 years.

A sale-leaseback deal could transform the 43.6-acre campus into a multitenant hub, CoStar News reported.

“Houston is a critical hub for Shell globally and the headquarters of our U.S. businesses,” a Shell spokesperson told the Houston Business Journal. “We remain committed to Houston and are evaluating opportunities to optimize our Woodcreek campus as part of our ongoing review of workplace needs while maintaining a strong presence in the city.”

Shell occupied its first building at the West Houston campus in 1980. The company employs more than 6,000 people in Texas.

Shell is one of the highest-profile businesses occupying space in the Energy Corridor. It’s home to 67,000 workers, more than 27 million square feet of office and mixed-use space, and 3.8 million square feet of retail and restaurant space.

Shell considers $8B sale of chemical business

As the company seeks to unload its Woodcreek campus, The Financial Times reported Shell is looking into selling its U.S. chemical business. The price tag: $8 billion.

Potential buyers include Spring-based ExxonMobil and Houston-based LyondellBasell.

Shell operates four chemical plants in Texas, Louisiana and Pennsylvania, producing an array of chemicals for use in plastics, detergents and pharmaceuticals.

Shell CEO Wael Sawan said last year that the company had spent $45 billion in capital “that is underperforming for us,” split between its chemical business and renewable energy arm.

Shell also agreed to sell its solar and wind power business in India this summer. Read more here.