Restricted accessResearch articleFirst published online 2025
Data-driven structural health monitoring for early corrosion detection in the oil and gas pipelines: enhancing sensitivity with unsupervised dimensionality reduction
Corrosion presents significant threats to structural integrity within the oil and gas industry, increasing maintenance demands and associated costs. However, traditional inspection techniques often face limitations in detecting early-stage corrosion, particularly under challenging environmental and operational conditions. This study investigates structural health monitoring using low computational cost data-driven approaches, specifically principal component analysis, t-distributed stochastic neighbor embedding, and locally linear embedding to enable early and autonomous corrosion detection capabilities in a scalable manner for embedded systems. Corrosion was induced in a steel pipe using an ionic solution, with nearly 400 GB of guided wave signal data recorded across well-defined corrosion stages via an array of piezoelectric transducers. The results demonstrate that the proposed approach enables the detection of corrosion with a sensitivity of up to 0.39% reduction in the cross-sectional area. Furthermore, the results validate the feasibility of establishing autonomous damage detection thresholds, mitigating the need for periodic inspections. The methodology proved robust, effectively isolating environmental effects without the need for environmental and operational condition compensation techniques. Unsupervised dimensionality reduction effectively detects early structural changes, such as corrosion and transduction loss, with guided waves and optimized parameters, offering strong support for traditional inspection methods.
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