A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0
Abstract
:1. Introduction
2. Methodology
2.1. Research Questions
2.2. Document Search
2.3. Paper Selection
3. Results
3.1. Literature Review
3.2. Paper Data
- There is no significant difference between the time optimization means of preventive maintenance and predictive maintenance.
- There is a significant difference between the time optimization means of preventive maintenance and predictive maintenance.
4. Discussion
4.1. Research Questions
- RQ1The technologies inherent to Industry 4.0 allow several changes with resource optimization, improving the productivity of companies and industries. Among the main characteristics, we can mention the following: (i) Production can be made more flexible to achieve efficient customization; (ii) Devices, machines, and facilities can be monitored remotely or in situ in real-time, thus facilitating the rapid detection of failures and problem-solving; (iii) In hazardous environments or environments that generate a risk for human beings, processes can be virtualized, safeguarding the integrity of human resources; (iv) By placing flexible technologies, these can be adapted to the company’s needs, freeing up human personnel to perform other types of tasks; and (v) Intercommunication between devices and operators [57,58].Within the results shown in the previous section, it can be understood that AI and cobots, as core technologies, are the backbone of predictive maintenance and, in part, preventive maintenance. Through AI and its underlying technologies, real-time data can be collected from different sites and devices, which are the basis for generating intelligent algorithms to anticipate pipeline failures. The IoT supports them, a technology that allows the intercommunication of devices and the storage of the information generated. In general, the exemplified case studies are adapted to the following steps for implementing this new tool: (i) Data collection is necessary to generate relevant data, i.e., quality information, to build optimal models with small margins of error. Here, the equipment configuration is essential since external factors must also be considered to obtain clean information. (ii) Data cleaning—having as much data as possible can be considered an advantage. However, it is always necessary to analyze the value of the data, filter, and classify them.(iii) Interpret prediction needs, i.e., combine and complement data obtained from devices, machinery or facilities to generate robust and accurate models. What must be taken into account is the error history so that the algorithm includes normal and failure patterns, maintenance history, a critical factor to know where and when to work, operating conditions, to determine the environment in which it is working and verification if the life of each equipment is dynamic to those conditions. (iv) View the results critically to culminate the feedback process. This allows the maintenance personnel to correct any biases found. (v) Implementation, working with the models generated and data obtained in real-time [59,60].On the other hand, the use of collaborative robots in hazardous environments has become popular in recent years. This is because they can work with humans to perform dynamic tasks, they are easy to program, and most have safety protocols that allow them to interact with processes and operators without putting human life at risk. Its purpose is to increase the accuracy of tasks and reduce both mental and physical fatigue of maintenance personnel.
- RQ2Maintenance is one of the most critical and undervalued processes in any industry. It guarantees the optimal operation of both machinery and facilities. Thanks to this process, it is possible to reduce costs, optimize quality, reduce time, and avoid occupational accidents. There are three types of industrial maintenance: (i) corrective maintenance, (ii) preventive maintenance, and (iii) predictive maintenance. In the past industrial revolution, corrective maintenance was predominant. However, with technological evolution and digitalization, this has become a thing of the past, giving way to preventive and predictive maintenance [61].The information gathered showed that Industry 4.0 focuses more on predictive and preventive maintenance, specializing in the former. One of the reasons for not finding corrective maintenance within this field is the high cost generated once an installation or oil machinery fails. Furthermore, the unplanned stoppage of the tasks also entails mechanical collateral damage, loss of time, and non-compliance with the demand. In addition to these reasons, the environmental damage that a simple oil leak can generate must be taken into account, considering that most of these industries are located in priceless natural resources.Predictive maintenance allows for taking care of the heart of modern industries and factories, i.e., machinery and facilities. Furthermore, combining the human factor with technologies such as the IoT, big data, cobots, and AI allows for communicating data efficiently and constantly, warning of any anomaly, thus optimizing the production cycle. In addition, it can be mentioned that, in the last five years, this maintenance has gained strength since the top management of industries has realized its value and the benefits it represents. In fact, at the general industry level, it is estimated that this maintenance represents forty percent savings in maintenance costs [62].
- RQ3By using the digital world in which the industry currently finds itself, it is possible to obtain great benefits, which can be summarized in a single sentence: optimize the fidelity and availability of machinery and facilities at the lowest cost. However, it is necessary to establish in detail the utility that this type of technology can add to the maintenance of oil pipelines: (i) Automatic planning of maintenance, having previous or historical information of maintenance, allows algorithms to determine how often the pipelines should be checked for faults and predict the useful life of its components. (ii) Optimization of overall productivity, by not having unscheduled stops or unnecessary downtime; the value chain of the oil industry improves its times and overall profitability.(iii) Increased profitability of machinery when preventive maintenance is applied, the useful life of machinery and equipment is extended, making them more reliable and increasing their availability exponentially. (iv) Decrease in the loss of product and raw material. Not considering an oil pipeline leak or suffering any breakdown can cause the crude oil to be wasted and useless. (v) Reduction of labor accidents, the fact of having machinery working at its optimum level, is synonymous with efficiency and reliability. Therefore, the flaws that may occur, if they do, are not a threat to the integrity of people. (vi) Reduction of environmental damage. Preventive maintenance focused on the oil industry is based on two essential axes, the prevention of spills in the unloading process and the integrity of assets. With these characteristics, the probability of failure and contamination is very low, allowing pipelines and their environment to coexist [63].Finally, it is necessary to understand that implementing predictive maintenance in the oil industry is a qualitative advantage. This can be achieved as long as the necessary human resources are available to implement systems according to the industry and technological equipment that allows this process to be carried out satisfactorily [64]. Likewise, there must be leaders and senior managers who are interested and deeply involved in the activities of the oil industry so that they understand the cost–benefit of implementing these new technologies.
- RQ4Although significant progress has been made in using 4.0 technologies, there are still things to be corrected and polished. Therefore, one of the significant challenges is to balance human resources work with the integrated intelligent devices so that the coordination between the two is accurate and reduces time even more. Understanding the fundamental role of this evolution for top management is also a challenge, as most see technology as an expense rather than an investment. Changing the mindset of these people can be a much more significant challenge than implementing any system [65].Maintaining current technologies and keeping pace with technological advancement are critical when discussing the automated maintenance process. However, having installed or purchased a predictive system and obtaining encouraging results is not all. It is only the beginning of the technological transformation. For this reason, the oil industry must have highly trained and young personnel who know how to adapt to changes and maintain the maintenance system, i.e., constantly feed it with data and investigate other low-cost technologies that can complement and improve its current architecture.However, this does not mean that older or physically/mentally challenged workers should be left out. It is a difficult and critical decision to be made by the human resources department, who are in charge of ensuring that each work team is diversified and inclusive [66]. For example, the experience of older workers can be used to teach and train new employees about the petroleum industry, supporting and guiding them so that their adaptation to these demanding environments is not exhausting. Finally, people with mild autism, whose visual and spatial skills can be essential in handling large volumes of data, recognizing patterns and anomalies quickly and accurately in the facility, can be hired.
4.2. Paper Selection Analysis
5. Conclusions and Future Research Avenues
Author Contributions
Funding
Acknowledgments
Conflicts of Interest
References
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Code | Research Question |
---|---|
RQ1 | What are the most used 4.0 technologies in pipeline maintenance? |
RQ2 | What types of maintenance are most commonly used by the 4.0 industry? |
RQ3 | What are the benefits of applying 4.0 technologies in pipeline maintenance? |
RQ4 | What are the future challenges for 4.0 maintenance? |
Criteria | Description |
---|---|
Study design | All papers whose main objective was to improve the pipeline maintenance process by applying one or more of the Industry 4.0 technologies were selected. Literature reviews and duplicate studies were discarded. |
Time range | Papers published from 2017 to 2022 were selected; articles that did not meet this criterion were discarded. |
Language | Only articles written in English were selected. |
Publication Status | Articles published in conference proceedings or indexed journals were considered, and it was also verified that they had DOI (Digital Object Identifier). |
Code | Name | Year | Improvement | 4.0 Tech |
---|---|---|---|---|
PVM1 | Robust Visual Localization of a UAV Over a Pipe-Rack Based on the Lie Group SE(3) | 2021 | 32% | Cobots |
PVM2 | Reliability-based preventive maintenance planning for corroded pipelines using a RBF surrogate model | 2021 | 19% | AI |
PVM3 | Development of a Pipeline Inspection Robot for the Standard Oil Pipeline of China National Petroleum Corporation | 2020 | 35% | Cobots |
PVM4 | Application of USCCD on Girth Weld Defect Detection of Oil Pipelines | 2020 | 25% | Big Data |
PVM5 | A Zero Accident Strategy for Oil Pipelines: Enhancing HSE Performance | 2020 | 17% | Big Data |
PVM6 | A Dynamic-Bayesian-Networks-Based Resilience Assessment Approach of Structure Systems: Subsea Oil and Gas Pipelines as A Case Study | 2020 | 30% | AI |
PVM7 | Hierarchical Controller for Autonomous Tracking of Buried Oil and Gas Pipelines and Geotagging of Buried Pipeline Structure | 2019 | 30% | Cobots |
PVM8 | Lightweight, High Performance Detection Method of Pipeline Defects Through Compact Off-Axis Magnetization and Sensing | 2019 | 40% | Cobots |
PVM9 | Improved AHP–TOPSIS model for the comprehensive risk evaluation of oil and gas pipelines | 2019 | 26% | Big Data |
PVM10 | Design of Informationized Operation and Maintenance System for Long-distance Oil and Gas Pipelines | 2019 | 22% | Cobots |
PVM11 | Real time automatic object detection by using template matching for protecting pipelines | 2018 | 18% | Cobots |
PVM12 | Integration of sUAS-enabled sensing for leak identification with oil and gas pipeline maintenance crews | 2017 | 23% | Cobots |
Code | Name | Year | Improvement | 4.0 Tech |
---|---|---|---|---|
PDM1 | A KPCA-BRANN based data-driven approach to model corrosion degradation of subsea oil pipelines | 2022 | 35% | AI |
PDM2 | Approach to weld segmentation and defect classification in radiographic images of pipe welds | 2022 | 63% | AI |
PDM3 | Application of artificial intelligence technologies in intelligent diagnosis of crude oil pipelines | 2022 | 33% | AI |
PDM4 | A Case Study Showcasing the Use of Extreme Learning Machine Based on in-line Inspection Data | 2022 | 37% | AI |
PDM5 | Optimal inspection and maintenance plans for corroded pipelines | 2021 | 45% | AI |
PDM6 | An intelligent model to predict the life condition of crude oil pipelines using artificial neural networks | 2021 | 51% | AI |
PDM7 | A data-driven corrosion prediction model to support digitization of subsea operations | 2021 | 23% | AI |
PDM8 | A semi-empirical model for underground gas storage injection-production string time series remaining useful life analysis in process safety operation | 2021 | 37% | AI |
PDM9 | An Implementation of Fuzzy Logic Technique to Predict Wax Deposition in Crude Oil Pipelines | 2021 | 25% | AI |
PDM10 | Resilient IoT-based Monitoring System for Crude Oil Pipelines | 2020 | 22% | IoT |
PDM11 | Doctor for Machines: A Failure Pattern Analysis Solution for Industry 4.0 | 2020 | 41% | AI |
PDM12 | Residual Stress in Oil and Gas Pipelines with Two Types of Dents during Different Lifecycle Stages | 2020 | 19% | Big Data |
PDM13 | Investigating an assessment model of system oil leakage considering failure dependence | 2020 | 42% | AI |
PDM14 | Integrity assessment of corroded pipelines using dynamic segmentation and clustering | 2019 | 60% | Big data |
PDM15 | Integrated Cloud Cockpit: A viable approach to surveillance and detection of leaks in oil pipelines | 2019 | 48% | Big data |
PDM16 | Study of the acoustic noise in pipelines carrying oil products in a refinery establishment | 2019 | 35% | Cobots |
PDM17 | The Application Research of Internet of Things to Oil Pipeline Leak Detection | 2018 | 15% | IoT |
PDM18 | An intelligent oil and gas well monitoring system based on Internet of Things | 2017 | 25% | IoT |
PDM19 | Inspection and Maintenance Planning of Underground Pipelines Under the Combined Effect of Active Corrosion and Residual Stress | 2017 | 36% | AI |
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Naranjo, J.E.; Caiza, G.; Velastegui, R.; Castro, M.; Alarcon-Ortiz, A.; Garcia, M.V. A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0. Sustainability 2022, 14, 16723. https://doi.org/10.3390/su142416723
Naranjo JE, Caiza G, Velastegui R, Castro M, Alarcon-Ortiz A, Garcia MV. A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0. Sustainability. 2022; 14(24):16723. https://doi.org/10.3390/su142416723
Chicago/Turabian StyleNaranjo, Jose E., Gustavo Caiza, Rommel Velastegui, Maritza Castro, Andrea Alarcon-Ortiz, and Marcelo V. Garcia. 2022. "A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0" Sustainability 14, no. 24: 16723. https://doi.org/10.3390/su142416723
APA StyleNaranjo, J. E., Caiza, G., Velastegui, R., Castro, M., Alarcon-Ortiz, A., & Garcia, M. V. (2022). A Scoping Review of Pipeline Maintenance Methodologies Based on Industry 4.0. Sustainability, 14(24), 16723. https://doi.org/10.3390/su142416723