Description:FIELD OF THE INVENTION

[0001] The present invention relates to a refinery pipeline structural integrity and maintenance system designed for monitoring, maintenance, and protection of refinery pipelines, focusing on real-time fault detection, structural integrity assessment, flow control, internal cleaning, and early identification of defects to enhance safety, reliability, and operational efficiency in refinery operations.

BACKGROUND OF THE INVENTION

[0002] Refinery pipelines are critical infrastructure for transporting crude oil, gas, and refined products across industrial plants. Continuous monitoring of their operational condition is essential to prevent unexpected failures, environmental hazards, and costly downtime. Early detection of structural degradation such as cracks, corrosion, or wall thinning is crucial for safety and longevity. Furthermore, maintaining pipeline cleanliness and tracking inspection activities ensures efficient operation. Refinery pipeline structural integrity and maintenance face several critical challenges.

[0003] Corrosion, cracking, and wall thinning due to chemical reactions, high pressure, and temperature fluctuations can cause leaks or catastrophic failures. Detecting these defects early is difficult as traditional inspections are periodic and manual, often missing developing issues. Internal cleaning is inefficient without real-time tracking, leading to incomplete maintenance or undetected blockages. Repairing minor structural defects typically requires shutdowns, causing production losses. Flow instability due to sudden faults complicates safe operation. Furthermore, reliance on manual inspection and local control limits responsiveness, increases labor costs, and elevates the risk of human error, compromising pipeline safety and reliability.

[0004] Traditionally, refinery pipeline monitoring relied on periodic manual inspections using visual assessment, ultrasonic testing, or magnetic flux leakage techniques. Structural degradation detection involved scheduled shutdowns and physical examination, which were labor-intensive and time-consuming. Internal cleaning was performed by inserting mechanical pigs or chemical agents, often requiring halting the flow and dismantling sections of the pipeline. Defect restoration typically involved manual repair procedures during maintenance shutdowns. Fluid flow control relied on mechanical valves operated by local controllers without dynamic real-time adjustment. Remote monitoring solutions were rudimentary, involving simple pressure and temperature sensors, with limited fault detection capability and no real-time fault localization or automated remediation features.

[0005] US20060129338A1 discloses a method for reducing the consequences and risks of failure in a hydrocarbon pipeline system includes identifying specific segments of pipelines the leakage of which could have an adverse impact on environment or safety, particularly in areas of high consequence, developing a baseline assessment plan for such segments by analysing information including age, corrosion, and types of seams and joints and then establishing preventive and migitative measures including, where necessary, positioning emergency flow restricting devices in one or more pipeline segments.

[0006] EP1819960A1 discloses a system and method of repairing a pipe including securing a reinforcing material, such as a dry fibre structure (e.g., a carbon fibres) to the surface of the pipe. A polymeric material is placed on top of the reinforcing material, self-penetrating the dry fibre structure. The polymeric material substantially saturates the reinforcing material and cures to form a reinforced polymeric composite which may increase or restore the pressure rating or operating pressure capacity of the pipe. Optionally, an outer containment component, such as a sleeve, shell, box, wall, outer pipe, and so on, may be installed around the reinforcing material prior to introduction of the polymeric material. In this case, the polymeric material may be placed (i.e., poured) into the interior of the containment component on top of the reinforcing material.

[0007] Conventionally, many systems have been developed to facilitate pipeline monitoring, however systems mentioned in prior arts have limitations pertaining to providing isolated measurements and required manual interpretation, and fail to detect fault to analyze real-time data for structural defects or abnormal flow conditions. Additionally, the existing system lack real-time monitoring, leading to poor tracking of cleaning progress, and requiring full shutdowns for repairs.

[0008] In order to overcome the aforementioned drawbacks, there exists a need in the art to develop a system that is capable of continuous real-time monitoring of refinery pipeline conditions, and detecting and identifying structural degradation such as corrosion, cracks, or wall thinning at early stages. Additionally, the system is capable of enabling automatic internal cleaning while tracking cleaning and inspection activities in real time, and repair micro-cracks during operation without disassembly.

OBJECTS OF THE INVENTION

[0009] The principal object of the present invention is to overcome the disadvantages of the prior art.

[0010] An object of the present invention is to develop a system that is capable of continuously monitoring the operational condition of refinery pipelines and detecting faults in real time to ensure safe and reliable operation.

[0011] Another object of the present invention is to develop a system that is capable of enabling automatic detection and identification of structural degradation, such as cracks, corrosion, or thinning of pipeline walls, at an early stage to prevent major failures.

[0012] Another object of the present invention is to develop a system that is capable of allowing internal cleaning of refinery pipelines while maintaining real-time tracking of cleaning and inspection activities for better maintenance management.

[0013] Another object of the present invention is to develop a system that is capable of automatically restoring minor structural defects, such as micro-cracks, by applying sealant directly during operation, thereby avoiding the need for pipeline disassembly.

[0014] Another object of the present invention is to develop a system that is capable of providing precise control of fluid flow within refinery pipelines, enabling diversion and stabilization of flow in case of anomalies or faults.

[0015] Yet another object of the present invention is to develop a system that is capable of facilitating remote monitoring and control of refinery pipeline health and operation, improving operational efficiency and reducing the need for manual inspection.

[0016] The foregoing and other objects, features, and advantages of the present invention will become readily apparent upon further review of the following detailed description of the preferred embodiment as illustrated in the accompanying drawings.

SUMMARY OF THE INVENTION

[0017] The present invention relates to a refinery pipeline structural integrity and maintenance system developed for ensuring the integrity, safe operation, and maintenance of refinery pipelines by enabling continuous fault detection, assessing structural condition, controlling fluid flow, performing internal cleaning, and identifying early defects to improve reliability and operational safety.

[0018] According to an embodiment of the present invention, a refinery pipeline structural integrity and maintenance system comprising of a plurality of sensors strategically installed along pipeline sections, valves, and tanks within a refinery, configured to continuously monitor operational parameters and detect faults in real time, a three-phase butterfly valve installed on the pipeline sections and fluidly connected with a conduit pipe, the conduit pipe connecting main refinery pipelines to spare tanks, the valve operable to divert flow upon detection of structural fatigue, a thermal imaging camera mounted on a motorized ball and socket joint for 360-degree pipeline coverage, coupled with temperature sensors positioned along pipeline exteriors to detect thermal anomalies.

[0019] According to another embodiment of the present invention, the present invention includes a pipeline integrity monitoring arrangement integrated with critical sections of the refinery pipeline, configured to support internal cleaning of the pipes, a structural health monitoring arrangement integrated with the outer surface of the pipeline to detect wall thickness variations and early-stage structural anomalies, and a central processing unit configured to process real-time data from multiple system components and autonomously manage sensing, flow control, structural monitoring, and communication functions within the pipeline structural integrity and maintenance system.

[0020] While the invention has been described and shown with particular reference to the preferred embodiment, it will be apparent that variations might be possible that would fall within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
Figure 1 illustrates an isometric view of a refinery pipeline structural integrity and maintenance system.

DETAILED DESCRIPTION OF THE INVENTION

[0022] The following description includes the preferred best mode of one embodiment of the present invention. It will be clear from this description of the invention that the invention is not limited to these illustrated embodiments but that the invention also includes a variety of modifications and embodiments thereto. Therefore, the present description should be seen as illustrative and not limiting. While the invention is susceptible to various modifications and alternative constructions, it should be understood, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.

[0023] In any embodiment described herein, the open-ended terms "comprising," "comprises,” and the like (which are synonymous with "including," "having” and "characterized by") may be replaced by the respective partially closed phrases "consisting essentially of," consists essentially of," and the like or the respective closed phrases "consisting of," "consists of, the like.

[0024] As used herein, the singular forms “a,” “an,” and “the” designate both the singular and the plural, unless expressly stated to designate the singular only.

[0025] The present invention relates to a refinery pipeline structural integrity and maintenance system developed for improving the safety and reliability of refinery pipelines by continuously monitoring for faults, evaluating structural condition, managing fluid flow, facilitating internal cleaning, and detecting early signs of damage to support effective maintenance and prevent failures.

[0026] Referring to Figure 1, an isometric view of a refinery pipeline structural integrity and maintenance system is illustrated, comprising of a plurality of sensors 101 strategically installed along pipeline sections 102 within a refinery, a three-phase butterfly valve 103 installed on the pipeline sections 102 and fluidly connected with a conduit pipe 104, the conduit pipe 104 connecting main refinery pipelines to spare tanks 105, a thermal imaging camera 106 mounted on a motorized ball and socket joint, a pipeline integrity monitoring arrangement integrated with critical sections of the refinery pipeline, the pipeline integrity monitoring arrangement includes a pig-access mechanical counter 107 positioned at entry and exit points of the pipeline 102, a set of sealing cups 108, brushes 109, and scrapers 110 integrated with the pig, a dispensing unit 111 integrated within the pig, a plurality of mechanical pingers 112 mounted at regular intervals along the external wall of the pipeline 102, a set of mechanical vibration dampers 113 are mounted near critical joints and support structures of the pipeline 102.

[0027] The disclosed device herein comprises of a plurality of sensors 101 is strategically installed along pipeline sections 102, valves, and tanks within the refinery to continuously monitor operational parameters including pressure, temperature, flow rate, and chemical composition. Each sensor is electronically connected to a central processing unit; wherein real-time data acquisition occurs without interruption. Upon detecting deviations from pre-set operational thresholds, the sensors 101 transmit immediate alerts to the central processing unit.

[0028] The plurality of sensors 101 involves continuous real-time measurement of critical parameters, wherein each sensor converts physical or chemical changes into electrical signals. These signals are transmitted via wireless communication protocols to the central processing unit. The central processing unit processes and analyzes the incoming data, comparing it against defined operational limits. Upon detecting abnormalities, the central processing unit triggers alarms, initiates safety protocols, and logs fault occurrences for record-keeping and maintenance planning.

[0029] A servo-driven micro adjuster is mounted at critical sensor points along the pipeline 102 and integrated with a piezoelectric actuator to provide controlled positional adjustments. Upon receiving signals from the central processing unit, the servo motor rotates its shaft, converting rotational motion into linear displacement. This linear motion enables precise coarse and micro-level adjustments of the sensor’s position along multiple axes. The micro adjuster maintains alignment within predefined tolerances, compensates for mechanical drift or environmental perturbations, and ensures optimal sensor orientation. The piezoelectric actuator provides fine micro-level adjustments.

[0030] When voltage is applied across the piezoelectric material, it undergoes rapid dimensional changes, producing precise linear or angular displacements. The displacements are transmitted to the sensor mounting point to achieve sub-micron positional corrections. The actuator responds to control signals with high speed and accuracy, enabling continuous real-time compensation for thermal expansion, vibration, or mechanical drift. The piezoelectric actuator ensures that sensors 101 remain accurately calibrated by combining with the coarse adjustment of the servo-driven adjuster, maintaining optimal performance throughout pipeline 102 operation and environmental variations.

[0031] A three-phase butterfly valve 103 installed on the pipeline sections 102 and fluidly connected with a conduit pipe 104, automatically responding to detection of structural fatigue in the main pipeline 102. Upon identification of abnormal pressure, temperature, or chemical fluctuations, the valve 103 rotates its metal disc via a shaft to partially or fully obstruct the flow, thereby redirecting the fluid to spare tanks 105. The valve 103 is designed for automatic control and perform sequential operations across three separate phases, ensuring uninterrupted flow management. The valve’s construction provides durability under high-pressure and corrosive environments, maintaining operational reliability throughout fault events.

[0032] The conduit pipes 104 functions as the primary fluid transport channel between main refinery pipelines and the spare tanks 105, providing a controlled passage for fluid flow. The pipe 104 maintains structural integrity under high pressure and temperature, preventing leaks and flow disruptions. The conduit pipes 104 supports installation of the three-phase butterfly valve 103, enabling seamless redirection of fluid upon detection of structural fatigue. The pipe 104 ensures continuous and secure transport of chemicals, maintaining proper alignment, pressure gradients, and flow rates.

[0033] The spare tanks 105 herein serve as auxiliary fluid storage units, receiving diverted flow from the main pipelines when a fault is detected. Each tank 105 is designed to accommodate chemical exposure, high pressure, and temperature fluctuations, ensuring safe containment of diverted material. The tanks 105 function as temporary storage to prevent process interruption, allowing maintenance or corrective measures on the primary pipeline 102. The flow into the spare tanks 105 is regulated via the three-phase butterfly valve 103, and monitored in real-time to maintain operational balance, avoid overfilling, and ensure containment integrity.

[0034] The three-phase butterfly valve 103 comprises a metal disc mounted on a rotating shaft within a corrosion-resistant body acts as the principal flow control element of the butterfly valve 103. The disc rotates around the shaft axis to obstruct, partially allow, or fully permit fluid passage through the conduit pipe 104. The disc’s metal composition ensures corrosion resistance and structural integrity under high-pressure, high-temperature, and chemically aggressive environments. The shaft provides mechanical support and rotational stability, transmitting actuation forces to the disc for precise and rapid valve 103 positioning during operation.

[0035] A thermal imaging camera 106 installed on a motorized ball and socket joint configured to capture infrared radiation emitted from the pipeline 102 surface and convert it into real-time thermal images, thereby enabling detection of temperature variations along the pipeline 102. The camera 106 transmits the thermal data to the central processing unit, which continuously monitors, analyzes, and stores temperature readings. The camera 106 operates in synchronization with motion controls to scan target areas, detecting hotspots, leaks, or abnormal thermal gradients.

[0036] The thermal imaging camera 106 functions continuously, providing dynamic thermal mapping, and coupled with temperature sensors positioned along pipeline 102 exteriors to correlate localized thermal anomalies with sensor data, ensuring precise monitoring. The motorized ball and socket joint provides rotational and angular movement to the thermal imaging camera 106, enabling full 360-degree coverage of the pipeline 102. The joint incorporates servo motors controlled by the central processing unit to adjust pitch, yaw, and roll of the camera 106 based on predetermined scanning protocols.

[0037] The joint maintains stable positioning during operation, allowing continuous data capture without disruption from vibrations or external forces. The joint’s actuation is responsive to feedback signals from the central processing unit, permitting dynamic adjustment of camera 106 orientation in real-time. The motorized ball and socket joint ensures comprehensive visual access to all sections 102 of the pipeline 102. The temperature sensors are positioned along the exterior of the pipeline 102 to continuously monitor surface temperatures.

[0038] The sensors convert thermal energy into electrical signals proportional to localized temperature changes. The sensors transmit data to the central processing unit, which analyzes the readings to detect deviations from standard operating temperatures, indicating leaks, blockages, or structural weaknesses. The sensors operate in concert with the thermal imaging camera 106 to validate thermal anomalies, providing redundant detection for enhanced accuracy. The system triggers alerts upon exceeding threshold limits and logs historical temperature profiles for predictive maintenance. The sensors function continuously, ensuring precise real-time thermal monitoring along the entire pipeline 102 length.

[0039] A pipeline integrity monitoring arrangement is deployed along critical sections of the refinery pipeline 102 to enable continuous inspection and internal cleaning without interrupting normal operations. the pipeline integrity monitoring arrangement comprises a pig-access mechanical counter 107 positioned at entry and exit points of the pipeline 102, a set of sealing cups 108, brushes 109, and scrapers 110 integrated with the pig, and an ultrasonic sensor and a dispensing unit 111 integrated within the pig. The arrangement coordinates the insertion, movement, and retrieval of the pipeline inspection gauge (pig), ensuring that cleaning and inspection cycles are tracked.

[0040] Upon detection of structural anomalies, fluid flow is redirected to the spare tank 105, and valves are actuated to isolate the affected section. The arrangement ensures that internal cleaning, crack detection, and sealant application occur during pig transit, thereby maintaining pipeline 102 structural integrity while minimizing downtime. The pig-access mechanical counter 107 herein monitors the movement of the pipeline inspection gauge. Each insertion of the pig triggers the counter 107 to log a cycle, while retrieval similarly updates the counter 107, providing a precise record of inspection and cleaning events.

[0041] The counter 107 operates mechanically, relying on physical interaction with the pig to increment or decrement counts. During transit, the sealing cups 108 maintain close contact with the pipe 104 surface to create a pressure seal that stabilizes fluid movement around the pig. The brushes 109 agitate and remove debris adhering to the inner walls, while the scrapers 110 mechanically dislodge hardened residues or scale buildup. The coordinated action of these elements ensures thorough internal cleaning of the pipeline 102 without manual intervention.

[0042] The accumulated debris is carried along with the pig and expelled at the pipeline 102 exit, preserving operational flow. The ultrasonic sensor mentioned herein operates by emitting high-frequency sound waves into the pipeline 102 walls and measuring the reflection signals. Variations in the reflected waves are analyzed to detect micro-cracks, corrosion, and other structural anomalies in the pipeline 102. During pig transit, the sensor continuously scans the internal surface, creating a detailed map of structural integrity. The sensor triggers an alert when defects are detected, prompting fluid diversion and valve 103 closure.

[0043] The sensor allows the dispensing unit 111 by providing real-time detection of micro-cracks, to apply corrective measures immediately, ensuring structural continuity without necessitating pipeline 102 disassembly. The dispensing unit 111 herein restore structural integrity upon detection of cracks by the ultrasonic sensor. Upon receiving a signal indicating a defect, the dispensing unit 111 discharges epoxy-based sealant directly onto the identified cracks. Simultaneously, the main pipeline 102 valve is closed, and fluid is diverted to the spare tank 105 to prevent interference with sealant application.

[0044] The sealant adheres to the inner wall and fills the defect, hardening to restore strength and prevent leakage. The dispensing unit 111 ensures targeted, precise application during pig movement, eliminating the need for pipeline 102 shutdown or disassembly, thereby maintaining continuous refinery operations. A structural health monitoring arrangement is integrated with the outer surface of the pipeline 102 and operates continuously to assess the integrity of the pipeline 102 wall.

[0045] The arrangement generates and receives mechanical pulses through the pipeline 102 material, and the resulting resonance patterns are analyzed to detect deviations indicative of structural anomalies. The arrangement identifies early-stage corrosion, thinning, or other forms of structural degradation by continuously monitoring frequency shifts, amplitude variations, and temporal characteristics of returning signals. The arrangement transmits data to the central processing unit for real-time evaluation, allowing predictive maintenance and timely intervention to prevent catastrophic failure.

[0046] The structural health monitoring arrangement includes a plurality of mechanical pingers 112 is mounted at regular intervals along the external wall of the pipeline 102. Each pingers 112 is configured to emit precise, controlled mechanical pulses that propagate through the pipeline 102 material. The pulses interact with the pipeline’s internal structure, reflecting variations caused by wall thickness differences, corrosion, or other anomalies. The pingers 112 operate in a synchronized sequence to ensure coverage of the entire pipeline 102 surface, generating resonance signals at specific frequencies and amplitudes.

[0047] The emitted pulses are calibrated to penetrate the pipeline 102 wall effectively without damaging the material, enabling accurate detection of structural changes along the pipeline 102 length. A corresponding set of acoustic sensors is paired with each mechanical pingers 112 and mounted adjacent to the pingers 112 locations on the pipeline 102 surface to receives returning resonance signals generated by the interaction of mechanical pulses with the pipeline 102 material. The sensors analyze signal frequency, amplitude, and phase to detect variations indicative of wall thinning, corrosion, or other structural degradation. The sensors convert the acoustic data into electrical signals and transmit them to the central processing unit for evaluation.

[0048] A set of mechanical vibration dampers 113 are mounted proximate to critical joints and support structures of the pipeline 102 and function by engaging with vibrational energy transmitted through the pipeline 102 during operation. Upon generation of vibrations, the mechanical elements of each damper undergo controlled deformation, converting kinetic energy into heat energy, which is subsequently dissipated. This energy absorption mitigates oscillatory motion at joints and supports, thereby minimizing fatigue-induced stress accumulation within the pipeline 102 structure.

[0049] Additionally, the dampers 113 attenuate high-frequency vibrations that could interfere with sensitive monitoring sensors, ensuring operational integrity and accurate data acquisition. The set of mechanical vibration dampers 113 operates through a sequential energy modulation process. Upon detection of vibrational forces within the pipeline 102, the dampers’ internal spring compress proportionally to the amplitude of the vibration. Simultaneously, frictional and viscoelastic elements within the dampers 113 convert the absorbed kinetic energy into thermal energy, which is harmlessly released to the surrounding environment.

[0050] The dampers 113 then restore to their original configuration, ready for subsequent vibration events. Through repetitive cycles of energy absorption and dissipation, the dampers 113 continuously stabilize the pipeline 102, reduce structural fatigue, and prevent vibration-induced anomalies in adjoining sensors, ensuring prolonged operational reliability. A plurality of ultrasonic flow meters is strategically installed at multiple intervals along the pipeline 102 to continuously monitor the volumetric flow rate of the fluid. The ultrasonic flow meters transmit high-frequency sound pulses through the fluid, and the transit time of these pulses between transducers is measured.

[0051] The variations in transit time correspond to the velocity of the fluid, which is then converted into real-time flow rate data. The collected data from all ultrasonic flow meters is aggregated and transmitted to the central processing unit. Upon detecting flow irregularities, the central processing unit triggers corrective actions, ensuring continuous and precise flow monitoring across the pipeline 102. A turbine flow meters are mounted along the pipeline 102 in coordination with the ultrasonic flow meters to provide redundant and corroborative flow measurements.

[0052] The fluid passing through the turbine flow meter causes the rotor to rotate at a speed proportional to the volumetric flow rate. The rotational speed is detected using a magnetic sensor, which generates electrical pulses corresponding to the rotor velocity. The pulses are processed to calculate instantaneous and cumulative flow. The turbine flow meters provide high-resolution flow data, which, in combination with ultrasonic measurements, allows the central processing unit to detect anomalies and initiate controlled flushing via the spare tank 105 and butterfly valve 103 to stabilize the pipeline 102 flow.

[0053] An IoT (Internet of Things) module is coupled with the processing unit to establish a wireless communication network among system components. Upon activation, the IoT module continuously collects operational parameters, environmental data, and component status from connected elements of the system. The module converts the acquired data into standardized digital signals and transmits the signals via secure wireless protocols, including but not limited to Wi-Fi, Bluetooth, or LTE, to a centralized platform.

[0054] The centralized platform aggregates, analyzes, and displays the data, thereby enabling authorized personnel to monitor real-time system performance and exercise remote control over system functions. The IoT module involves initializing the wireless interface upon system startup, establishing authenticated connections with each system component, and actuators at predefined intervals. The collected data is encoded into communication packets and transmitted to the centralized platform, where it is decoded and logged.

[0055] The module concurrently receives control commands from the platform, which are parsed and routed to the respective system components to effect operational adjustments. The module maintains continuous synchronization, implements error detection, and ensures secure, low-latency data flow, thereby facilitating real-time monitoring. A plurality of gauge pressure sensors is positioned along interior walls of the pipeline 102 to continuously monitor pressure variations within the conduit.

[0056] Each sensor comprises a sensing diaphragm, a transducer element, and an electronic signal conditioning unit, wherein the diaphragm undergoes deformation proportional to the internal fluid pressure. The transducer converts this mechanical deformation into an electrical signal, which is subsequently processed by the signal conditioning unit to produce a calibrated pressure reading. Upon detection of a deviation from predetermined pressure thresholds, the sensor transmits an alert for enabling timely intervention to prevent operational disruptions, leaks, or structural damage.

[0057] The plurality of gauge pressure sensors involves continuous real-time monitoring of pressure along the pipeline 102 length, wherein each sensor independently measures local pressure. The sensors detect both transient and sustained pressure fluctuations, converting mechanical stress on the diaphragm into proportional electrical signals. These signals are aggregated and analyzed by the central processing unit to identify abnormal pressure profiles. Upon identification of anomalies, the sensors generate alerts. This ensures early detection of overpressure or under pressure conditions, maintaining operational integrity and preventing potential pipeline 102 failure.

[0058] The present invention works best in following manner, where the system comprises the plurality of sensors 101 strategically installed along the pipeline sections 102, valves, and tanks within the refinery, continuously measuring operational parameters such as temperature, pressure, flow rate, and structural conditions. The data collected by the sensors 101 is transmitted to the central processing unit, where the central processing unit processes the information in real time. Upon detection of misalignment or degraded sensor performance, the servo-driven micro adjuster integrated with the piezoelectric actuator performs precision alignment and calibration of the sensors 101 by executing coarse and micro-level adjustments. Simultaneously, the thermal imaging camera 106 mounted on the motorized ball and socket joint performs 360-degree scanning of pipeline 102 exteriors, while temperature sensors detect thermal anomalies. In the event of fault detection, the three-phase butterfly valve 103 is actuated to divert flow towards the spare tank 105, isolating the affected section. The pipeline 102 integrity monitoring arrangement initiates internal cleaning using the pig equipped with mechanical counter 107, sealing cups 108, brushes 109, scrapers 110, ultrasonic sensor, and dispensing unit 111. The ultrasonic sensor identifies micro-cracks, and the dispensing unit 111 releases epoxy-based sealant directly onto the defects. The mechanical pingers 112 and acoustic sensors continuously assess wall thickness and structural degradation. The IoT module enables wireless transmission of system data for remote monitoring, while the vibration dampers 113 mitigate structural fatigue. The system thus operates in a fully autonomous and fault-tolerant manner.

[0059] Although the field of the invention has been described herein with limited reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. , Claims:1) A refinery pipeline structural integrity and maintenance system, comprising:
i) a plurality of sensors 101 strategically installed along pipeline sections 102, valves, and tanks within a refinery, configured to continuously monitor operational parameters and detect faults in real time;
ii) a three-phase butterfly valve 103 installed on the pipeline sections 102 and fluidly connected with a conduit pipe 104, the conduit pipes 104 connecting main refinery pipelines 102 to spare tanks 105, the valve 103 operable to divert flow upon detection of structural fatigue;
iii) a thermal imaging camera 106 mounted on a motorized ball and socket joint for 360-degree pipeline 102 coverage, coupled with temperature sensors positioned along pipeline 102 exteriors to detect thermal anomalies;
iv) a pipeline integrity monitoring arrangement integrated with critical sections of the refinery pipeline 102, configured to support internal cleaning of the pipes;
v) a structural health monitoring arrangement integrated with the outer surface of the pipeline 102 to detect wall thickness variations and early-stage structural anomalies; and
vi) a central processing unit configured to process real-time data from multiple system components and autonomously manage sensing, flow control, structural monitoring, and communication functions within the pipeline 102 structural integrity and maintenance system.

2) The system as claimed in claim 1, wherein the three-phase butterfly valve 103 comprises a metal disc mounted on a rotating shaft within a corrosion-resistant body designed to withstand high pressure, temperature, and chemical exposure, and is automatically controlled to divert flow upon fault detection.

3) The system as claimed in claim 1, wherein a set of mechanical vibration dampers 113 are mounted near critical joints and support structures of the pipeline 102 to absorb and dissipate vibrations, thereby reducing structural fatigue and sensor interference.

4) The system as claimed in claim 1, wherein the pipeline integrity monitoring arrangement includes:
a) a pig-access mechanical counter 107 positioned at entry and exit points of the pipeline 102 to log insertion and retrieval cycles of a pipeline inspection gauge (pig) for tracking inspection and cleaning events,
b) a set of sealing cups 108, brushes 109, and scrapers 110 integrated with the pig to clean inner walls of the pipeline 102 during transit, and
c) an ultrasonic sensor and a dispensing unit 111 integrated within the pig, the sensor is configured to detect cracks and the dispensing unit 111 is configured to release epoxy-based sealant over the cracks after diversion of fluid to a spare tank 105 and closure of the main valve.

5) The system as claimed in claim 1, wherein the structural health monitoring arrangement includes:
a) a plurality of mechanical pingers 112 mounted at regular intervals along the external wall of the pipeline 102, each configured to emit controlled mechanical pulses through the pipeline 102 material, and
b) a corresponding set of acoustic sensors paired with the pingers 112, each configured to receive returning resonance signals and analyze frequency and amplitude to determine wall thickness and detect corrosion, thinning, or other structural degradation.

6) The system as claimed in claim 1, wherein a plurality of ultrasonic flow meters and turbine flow meters are placed at multiple intervals along the pipeline 102 for accurate flow monitoring, and triggering controlled flushing via the spare tank 105 and butterfly valve 103 to stabilize flow.

7) The system as claimed in claim 1, wherein the ultrasonic sensor in the pig identifies micro-cracks, and the dispensing unit 111 discharges sealant directly onto the cracks to restore structural integrity without requiring pipeline 102 disassembly.

8) The system as claimed in claim 1, wherein a servo-driven micro adjuster integrated with a piezoelectric actuator is mounted at critical sensor points along the pipeline 102, configured for precision alignment and calibration of sensors by providing coarse and micro-level adjustments to maintain optimal sensor performance.

9) The system as claimed in claim 1, wherein an IoT (internet of things) module is configured with the processing unit to wirelessly interconnect system components and enable real-time data transmission to a centralized platform for remote monitoring and control.

10) The system as claimed in claim 1, wherein a plurality of gauge pressure sensors is positioned along pipeline 102 interior walls to detect pressure fluctuations and trigger alerts for timely intervention.