1. Introduction
Pipelines are the main choice for long-distance transportation of a large number of petroleum products and natural gas due to their high security, strong transmission capacity, low operating costs, and other advantages [
1]. However, pipelines are faced with various threats, among which inner wall corrosion is one of the serious threats [
2,
3,
4]. Rupture, leakage, and other problems caused by pipeline inner wall corrosion will lead to property loss and environmental pollution, and even endanger human life [
5]. Therefore, it is of great practical significance and economic value to investigate the internal corrosion of pipelines through continuous and regular observations [
6,
7].
Traditional non-destructive testing methods (NDT) for pipeline corrosion include visual inspection, magnetic flux leakage detection, eddy current detection, ultrasonic tomography, and X-ray technology [
8,
9,
10,
11,
12]. Visual inspection relies on the expertise of inspectors, and thus, its reliability of results is not guaranteed. Magnetic flux leakage detection requires magnetization of the pipeline, and far-field eddy current detection depends on the formation of eddy currents in the pipeline, thus, they are only appropriate for detecting ferromagnetic materials and conductive materials. These two detection methods have a limited detection range and are inappropriate for the remote detection of oil and gas transportation pipelines. The radiation method is extremely harmful to human health, and the operation is complex and costly [
13]. The aforementioned NDT technologies usually detect pipelines at regular intervals, which makes it difficult to achieve real-time monitoring of pipelines. Instead of traditional inspection techniques, some sophisticated and efficient methods have been proposed as well. For example, Tan et al. proposed a method for monitoring pipeline corrosion using distributed fiber optic sensors, which can efficiently monitor, locate, visualize, and quantify pipeline corrosion online [
14]. However, the detection process involves a lot of processing, such as additive averaging of signals, scanning of frequencies, and tracking of phases, and hence, it requires a long measurement time. Colvalkar et al. utilized a pipeline inspection robot to detect and identify various pipeline anomalies on the inner surface of the pipeline using Image Processing (I.P) and Machine Vision (M.V). The pipeline anomalies may include blockages, bores, cracks, and corrosion [
15]. The robot provides real-time monitoring of the environment as it moves through the pipeline. Defect detection and identification are carried out through machine vision technology. However, when there are many bends in the pipe, the friction between the cable and the pipe wall becomes substantial, which can seriously affect the maximum travel distance of the robot during operation, and also can pose a series of problems such as reliability. Therefore, it is vital to find a reliable, real-time, simple, widely used, harmless to the human body, and low-cost method for monitoring pipeline internal corrosion.
The active sensing approach using surface-mounted or embedded transducers has displayed great potential for the Structural Health Monitoring (SHM) of mechanical and civil structures in real time [
16,
17,
18]. The principle of this approach is based on measuring the property changes of the propagating wave, occurring due to structural damage, by using a pair of sensor transducers or a deployed sensor network. Lead zirconate titanate (PZT) is a commonly used piezoelectric material with dual drive and sensing capabilities and a wide bandwidth and is usually utilized for stress wave generation [
19,
20] and detection [
21,
22]. PZT is cheap, easy to produce, small, and light, which can be permanently arranged on the structure to collect the feedback information of the structure in real time [
23,
24]. The PZT-enabled active sensing approach provides a basis for real-time health monitoring of pipeline structures [
25,
26,
27]. Du et al. employed a stress-waves-based active sensing method to detect real-time damage location for multi-crack pipes [
28]. Zhu et al. utilized the PZT probe for impact detection and for positioning submarine pipelines [
29]. Zhang et al. put forward a Gaussian Mixture Model–Hidden Markov Model (GMM-HMM) method to detect pipeline leakage and crack depth by extracting the time-domain damage index and frequency-domain damage index from signals collected by PZT sensors [
30]. However, most of the working environments of pipelines are exposed to harsh environments. In this case, the method of real-time monitoring of pipeline structure damage based on PZT active sensing is easily affected by noise.
In recent years, the time reversal technique has been extensively used in many fields due to its self-adaptive focus on the solid and its high signal-to-noise ratio. In the time-reversal approach, the sensor-received responding signal is first reversed in the time domain, and then the reversed signal is sent out as an excitation signal and the focused signal is finally received [
31]. Due to its strong anti-noise capability, the time reversal method has been broadly used in the health monitoring of pipeline structures [
32,
33,
34]. Zhao et al. [
35] explored the pipeline crack monitoring theory and the piezoelectric ultrasonic time reversal method to locate the circumferential position of pipeline defects. Du et al. [
36] examined the feasibility of a pipeline corrosion pit monitoring experiment based on time reversal. They utilized the peak amplitude of the focused signal to quantitatively evaluate pipeline corrosion status. However, the damage information of the structure obtained only by intuitively analyzing the waveform characteristics of the focused signal is very limited, and it is impossible to accurately classify and assess the corrosion degree of the pipeline.
The manual feature extraction work depends on high expertise and costs too much labor. Moreover, the final obtained features are not always effective when faced with unknown working conditions or application scenarios [
37]. The Convolutional Neural Network (CNN) is one of the representative algorithms of deep learning, which can automatically extract waveform features and can learn inherent features of signals to perform more accurate classification and identification of fault diagnosis [
10]. In recent years, CNNs have shown great potential in structural damage identification. Yang et al. proposed a vision-based automated method for the identification of the surface condition of concrete structures, which consisted of state-of-the-art pre-trained CNNs, transfer learning, and decision-level image fusion [
38]. The proposed method was capable of accurately pinpointing the crack profile with wrong predictions of limited areas. Yang et al. improved the bird swarm algorithm to optimize the two-dimensional CNN, and the improved algorithm exhibited great performance in predicting the torsional strength of reinforced concrete (RC) beams [
39]. Guo et al. developed a hierarchical CNN that extracted features automatically from raw vibration data and diagnosed bearing faults plus severity at the same time [
40]. Peng et al. put forward a deeper residual one-dimensional CNN for adaptively learning fault features of the original vibration signal and obtained very high diagnostic accuracy for the fault diagnosis of wheelset bearings in high-speed trains [
41]. However, if a CNN is used directly to classify original signals, the training of CNNs will become very challenging as the size of the original signal dataset increases. This will also give rise to an increase in training time and a higher requirement for model structure [
42].
In this paper, a novel pipeline corrosion monitoring method based on wavelet packet energy (WPE) and CNN is proposed, which is denoted as WPE-CNN. Compared with other diagnostic methods, wavelet packet transform can continue to decompose the high-frequency components that are not decomposed by wavelet transform and extract the high-frequency features of the signal. Through this approach, the division of the signal in the full frequency band range is realized, and a more refined analysis of the signal is obtained [
43]. The characteristic information of the original signal exists in each sub-band signal, and the signal characteristics can be further extracted by analyzing and determining the energy of each band. By using the sub-band energy obtained after wavelet packet decomposition as the input of the CNN model, the size of the data samples will also be diminished by a large proportion, thus reducing the complexity of the CNN model. Therefore, the WPE-CNN can not only further extract features and improve the accuracy of classification and recognition but also can greatly reduce the complexity of the CNN model and improve the efficiency of model training.
The piezoelectric active sensing with time reversal is utilized in this paper to quantitatively monitor the internal corrosion of pipelines. The specific arrangement of the experiment is as follows: First, the pipeline is corroded to different depths by electrochemical corrosion. After different corrosion depths on the PZT, the focused signal is collected by the time reversal method and is decomposed into sub-band energy by the wavelet packet. Then, a CNN is employed to convolve the wavelet packet energy, and the pipelines with different corrosion degrees are identified according to the output matrix. The rest of this paper is organized as follows:
Section 2 explains the monitoring principle of the time reversal method and the classification principle of pipeline internal corrosion degree based on wavelet packet energy and the CNN model.
Section 3 describes the experimental equipment, procedures, and results.
Section 4 discusses the experimental results and compares them with other identification models.
Section 5 summarizes and assesses the proposed method.
3. Experimental Setup and Procedures
To verify the effectiveness of the proposed method, an experimental study was carried out. The experimental setup consists of a sample pipeline with two PZT patches mounted on the surface as actuator and sensor, respectively, a multifunctional data acquisition device (NIUSB-6361), and a laptop computer. The PZT patch was pasted on both sides of the outer surface of the pipeline sample using a quick-curing epoxy resin (brand name J-B WELD) to protect the pipeline from water corrosion.
To simulate the occurrence and evolution of pipeline internal corrosion,
Figure 4 shows the electrochemical corrosion settings designed in this paper. The main parameters of experimental materials and devices are shown in
Table 2. The graphite rod and sample pipeline were connected to the anode and cathode of an external DC power supply (China Delixi Electric). In addition, the output voltage of the electrochemical DC power supply was 12 V, and the output current was set to a constant value of 3 A. A 10%NaCl solution was used as the electrolytic solution.
The corrosion monitoring test was performed every 5 h after the pipeline corrosion. The total corrosion time was 40 h. Therefore, 9 corrosion states were obtained, including no corrosion (0 h). The corrosion states are shown in
Table 3.
After the corrosion every 5 h, the pipeline was cleaned and the inner diameter of the pipe wall was measured with a gauge caliper 323-134-95 mm (Three quantities, China) with a precision of 0.01 mm. The inner diameter difference between adjacent corrosion periods is the corroded wall thickness per unit of time.
The Control and Data Acquisition (DAQ) program in LabVIEW was run on the computer to generate the pulse signal. The parameters of the pulse signal are shown in
Table 4. The NIUSB-6361 converts the pulse signal into an analog signal to drive the PZT1. Subsequently, the signal propagates along the pipeline wall, and PZT2 acquires the response signal, which is reversed in the time domain. Then, the reversed signal is re-emitted, and the focused signal detected by PZT2 is acquired by the data acquisition (DAQ) program. The focused signals under different corrosion degrees are automatically stored by LabVIEW programming software.