CUI Monitoring in the Houston, US Energy Sector
In the heart of the U.S. energy sector, the Houston area stands as a pivotal hub for petrochemical and oil & gas industries. CUI accounts for over 40% of piping failures in the petrochemical industry — a risk magnified in Houston’s Gulf Coast climate. With extensive networks of insulated pipelines, tanks, and reactors, the region faces significant challenges related to Corrosion Under Insulation (CUI). CUI, often concealed beneath insulation layers, can lead to unexpected equipment failures, safety hazards, and substantial economic losses.
The challenge of CUI
CUI remains one of the most elusive and damaging forms of corrosion affecting industrial assets. Hidden beneath layers of insulation and cladding, CUI is often detected too late — only after it has led to significant material degradation, costly downtime, or even catastrophic failure. In Houston’s hot, humid, and industrially active environment, the risk is heightened due to frequent wet-dry cycles, salt exposure, and mechanical damage to insulation systems.
Traditional inspection techniques — ranging from ultrasonic thickness testing to radiography — have served the industry for decades but come with notable limitations: they are periodic, labor-intensive, and inherently reactive. This approach leaves blind spots, particularly in hard-to-access areas or complex piping networks.
A new standard: distributed fiber optic sensing for real-time CUI monitoring
Fluves, a leader in fiber optic technology, is redefining how industrial operators approach CUI. Fluves' Distributed Fiber Optic Sensing (DFOS) platform delivers continuous, real-time monitoring along the full length of insulated assets — without removing the insulation, cladding or interrupting operations.
By installing specialized fiber optic cables on the outer surface of insulation systems, Fluves captures high-resolution temperature and humidity data at every meter along a pipeline, tank, or reactor. Subtle thermal anomalies or localized moisture ingress —early indicators of corrosion — can be detected immediately. These data are analyzed using proprietary algorithms and presented through an intuitive user interface that enables maintenance teams to make targeted, data-driven decisions.
Key advantages for Houston-Based operators
With many Houston-area facilities running continuously year-round and facing extreme weather events, Fluves' monitoring system offers local asset owners a powerful way to stay ahead of corrosion risk. Fluves’ solution is ideally suited for the Gulf Coast’s demanding industrial environment:
- Asset visibility: Monitor entire insulated assets with a single solution, reducing blind spots in inspections.
- Proactive maintenance planning: Identify corrosion long before it manifests at the surface or causes structural compromises.
- Reduced operational risk: Minimize unplanned shutdowns and extend asset life with condition-based maintenance strategies.
- Compliance & traceability: Support regulatory reporting with precise, timestamped corrosion data.
- Inspection cost savings: Targeted inspections and maintenance reduce unnecessary costs associated with blanket insulation removal and repairs.
Why Fluves?
At Fluves, we combine deep expertise in industrial sensing with a practical understanding of asset integrity challenges. Our solutions are engineered to integrate seamlessly with existing operations, offering scalable deployments from single assets to full-site coverage.
With proven deployments in critical infrastructure around the globe — and growing interest from major operators in the Houston region — Fluves is proud to lead the transition from reactive inspection to intelligent monitoring.
Take the next step toward predictive integrity management
Don’t wait for the next unplanned shutdown — contact Fluves today to schedule a demo and see how real-time CUI monitoring can transform your maintenance strategy. Partner with Fluves to gain real-time insights, reduce inspection costs, and protect the long-term performance of your critical assets.
Learn more at www.fluves.com/corrosion or contact our corrosion monitoring experts to schedule a consultation.