Development of a Digitalised Remote Monitoring
Device For Predictive Maintenance of Pipeline
Cathodic Protection Systems
Chika Edith Mgbemena David Obike Onuoha
Department ofIndustrial & Production Department ofIndustrial & Production
Engineering Engineering
Nnamdi Azikiwe University Awka, Nnamdi Azikiwe University Awka,
Nigeria Nigeria
ce.mgbemena@unizik.edu.ng d4davike@gmail.com
0000-0002-0298-5347
2023 28th International Conference on Automation and Computing (ICAC) | 979-8-3503-3585-9/23/$31.00 ©2023 IEEE | DOI: 10.1109/ICAC57885.2023.10275263
Martins Obi
School ofMechanical Engineering
Coventry University
United Kingdom
Martins.obi@coventrv.ac.uk
0000-0001-7668-9586
Abstract-Cathodic Protection Systems (CPS) are installed in
oil and gas pipelines to protect them from Corrosion. To assess
the CPS level of protection against Corrosion, specialised staff
must carry out routine inspections, data capture and analysis,
and these are usually done ofDine. This traditional method of
inspection and monitoring is time-consuming, expensive and
often made impossible by insecurities, community clashes and
inaccessibility of pipeline right of way. This paper presents the
development of an intelligent system that can capture the pipe-
to-soil potential (PSP) readings ofthe CPS, analyse the data, and
provide feedback from remote locations, all in real-time, to alert
users on the protection status of CPS in time. The hardware
component of the tool was developed using GSM Sim900 Shield
and Arduino Mega 2560 board. The software component was
developed using Arduino software, Thinkspeak loT server and
MATLAB for validation. The system when implemented on real
test posts of oil and gas facilities showed consistency of measured
data, with real-time feedback to users. The system reported PSP
readings below -0.85Vcse, within 0.85Vcse to -1.25Vcse, and
above -1.25Vcse, as 'unprotected', 'protected', and 'over
protected' status. Comparative analysis with Multimeter
showed a Pearson correlation coefficient of 0.999172. One main
limitation of the developed device is a voltage drop of up to -
0.1V... observed at the point of installation. This is
recommended as further work. The tool is beneficial to facility
owners, industries and government as it helps to reduce the rate
of oil spillage and losses through Corrosion.
Keywords--Corrosion Control, Automation, Internet of
things, Test posts, Cloud Computing
I. INTRODUCTION
Some countries' economy is heavily reliant on the oil and gas
sector. In Nigeria for instance, approximately 65% of
government revenue and 88% of the nation's foreign
exchange come from the oil and gas sector. Underground
pipelines are used to move the substances, which are
dangerous hydrocarbons in gas or liquid form and include
natural gas, crude oil, propane, gasoline or jet fuel, from one
location to another [I]. The extreme environmental
conditions to which these pipelines are constantly exposed
cause corrosion-related damages. Hence, Corrosion on these
XXX-X-XXXX-XXXX-X/XX/$XX.OO l!:>20XX IEEE
Authorized licensed use limited to: Universidad de Concepcion. Downloaded on December 12,2023 at 01:48:11 UTC from IEEE Xplore. Restrictions apply.
Chinedum Ogonna Mgbemena
Department ofMechanical Engineering
Federal University ofPetroleum
Resources, Effurun, Nigeria
mgbemena.ogonna@fupre.edu.ng
0000-0002-9794-1370
pipes' outside surfaces, which is typically not sufficiently
protected during construction, is a major issue in Countries
like Nigeria [2]. One ofthe most popular techniques in the oil
and gas sector to minimise rust and corrosion of structures
and metal pipelines or their related costs is the CPS [3]. CPS
are installed in oil and gas pipelines to protect them from rust
and corrosion. It helps to bring down corrosion to almost
nonexistent levels by keeping the PSP readings suitably
negative [4]. To determine the level of protection of the
pipeline against corrosion, specialised personnel must
conduct periodic inspections, direct measurements of data,
and thorough data analysis. This periodic examination is
often time-consuming, and expensive, and requires
experienced people in addition to the accessibility of the
pipeline right ofway.
Due to problems like insecurities and the COVID-19
pandemic, which places limits on mobility, the oil and gas
business needs effective real-time cooperation between
remotely situated staff in the event of another lockdown or
community conflict making pipelines inaccessible.
Additionally, the facility is in significant danger of corrosion
when the CPS is not adequately protecting it.
Moreover, every pipeline operator is required to perform
consistent CPS monitoring, either manually or with the aid of
a cathodic protection monitoring system. These
measurements are made at rectifiers, solar stations, CP test
points in an impressed current cathodic protection (ICCP)
system, and sacrificial anodes (in galvanic systems).
Therefore, for effective predictive maintenance of
these CPS on pipelines, it is important to inform the facility
owners about the degree of protection provided against
corrosion in time.
An Intelligent System that consists of a remote
monitoring device installed at the CPS test post to measure
the Pipe to Soil Potential (PSP) reading, analyse the data,
transmit it to a web server and then alert the user when the
CPS is experiencing any problems that may need immediate
intervention is needed to solve this problem.
 Past researches indicate that cathodic protection is
the most promising method of protecting pipelines [5]. [6]-
affirm that the use of the cathodic protection technique as a
method of controlling corrosion in oil and gas pipelines is
effective and efficient compared to other methods. Thus,
constant monitoring is needed to achieve optimum efficiency.
The Traditional monitoring of CP systems in
pipelines requires periodic inspection and thorough analysis
of the data from specialized operators. Field inspection is
costly, time-consuming, and prone to human errors if not
done by qualified personnel. This makes remote monitoring
required to continuously check the condition of these
structures and commnnicate the information to where it could
be stored and analysed very important [7], [8].
In recent times, technologies have been developed,
and modem methods applied to replace the traditional
methods of being on the site. Remote corrosion monitoring
systems attached to the pipelines enable companies to collect
accurate corrosion measurement data from the fields and also
detect or predict possible problems. Remote monitoring is a
new development that automates the data collection process
and provides operators with a proactive surveillance system.
A remote corrosion monitoring system consists of sensors, a
power supply, a data acquisition system and a cellular
network for data transfer. Solar panels can be used in the
absence of electrical power grids to supply power.
Sometimes, electrochemical multi-probe instruments with
data collection capabilities are used to measure and record
critical parameters contributing to corrosion.
Hence, it is now possible to digitalize corrosion
monitoring using cloud systems. Pervasive sensing
technologies that help optimise the utilisation of wireless
sensors have also been made available through the Internet of
Things (loT) [9]-[11]. To remotely monitor the CPS, data
obtained is transmitted automatically and wirelessly from the
fields through a software package where it is displayed, saved
and available for expert analysis.
The use of sensors to monitor the effectiveness of
CP is a relatively new technology that has been explored by
researchers [12]. [B]-developed a model that can redirect the
condition of oil and gas pipelines using the artificial neural
network (ANN) technique based on historical inspection
data. and in 2012, a corrosion monitoring system based on the
potential array that receives, stores, processes and analyses
potential data from the monitoring node measurement system
was developed [14]. In 2009 [15] introduced a non-intrusive
online method of monitoring corrosion using a permanently
installed ultrasonic sensor and software to automatically
collect and store data remotely while [16] developed an
intelligent remote monitoring system that collects, transmits
and interprets measurements of potential coming from
different sensors distributed in the field along the pipeline to
have continuous monitoring and assessment of the system.
This system made use of standard communications
technologies such as cellular phones, antennas and GPS
devices to assess readings on remote sensors, therefore
allowing for remote pipeline monitoring.
Most detection systems deployed for monitoring in oil and
gas industries are based on wireless sensor network (WSN)
systems or Supervisory Control and Data Acquisition system
(SCADA) systems with limitations. WSN-based systems are
incompatible, non-homogenous systems that lack
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coordinated communication and transparency among regions
and processes, while the SCADA systems are expensive,
inflexible, not scalable, and provide data with a long delay.
In 2021, [17] designed a SCADA to monitor and
control the corrosion of a pipeline buried underground.
SCADA systems can control the corrosion in pipes,
equipment, and structures by collecting data from CPS
sensors in real time and displaying the obtained data to the
observers. Also, a microcontroller equipped with many
sensors and a communication system is used to control and
monitor the process of an impressed current cathodic
protection (ICCP) process for the Pipeline. Likewise in 2014,
[18] developed a device that remotely transmits the CPS data
of oil and gas pipelines and applies it to the SCADA system
via GMS. Linear wireless sensor networks (LWSNs) were
implemented in the CPS monitoring for oil and natural gas
pipelines positioned in high-rise mountains and deep valleys
or other extreme locations where communication
infrastructure is unavailable, or there is limited or interrupted
access to the infrastructure [19], [20]. CPS online monitoring
systems have been implemented for corrosion control using
the WSN, as well as low Power Wide Area Network
(LPWAN) Communication Systems, to collect potential data
and realise remote data transmission [21], [22]. However,
Finding an adequate synchronization method, developing a
good antenna that can be easily integrated with the mechanics
of the test posts, and acquiring suitable radio propagation
measurements are some of the issues related to the WLN
system [19]. Moreover, [22] discovered that an erratic
internet connection causes delivery delays and consequently,
incorrect measurement data in LPWAN.
When the reading obtained needs to be sent to a
distant server, a remote monitoring device is required. There
are CPS remote monitoring devices available, but they are
costly and are set up to send data with specialised software,
which limits the possibility ofusing data with other real-time
programs. The development of a CPS remote monitoring
device for the research using inexpensive and user-friendly
microcontrollers and other components was motivated by the
high cost of purchasing a remote monitoring device and the
difficulty with software customisation.
The Paper presents the development of a digitalised
remote monitoring device for predictive maintenance of
pipeline CPS.
The proposed system will be achieved using the
Internet of Things, Cloud Computing and Data Analytics
technologies.
II. DESIGN AND DEVELOPMENT OF THE VARlOUS
COMPONENTS OF THE REMOTE MONITORlNG DEVICE
A. Design and Development ofthe Hardware Component of
the CPS Remote Monitoring Device
CPS monitoring is conventionally carried out on Oil and
Gas pipeline Test Post sites using a multimeter or a voltmeter.
Due to its low cost and availability of free hardware training
software, the Arduino hardware microcontroller was chosen.
The Arduino microcontroller is well suited for research
because it can be programmed using a variety of other
programming languages, including Python, C++, MATLAB,
etc. It is also compatible with a wide range of sensors and
components that may be utilised for research purposes.
 The Arduino Mega 2560 and SIM900 GSMlGPRS Shield
with an MTN Sim is used to develop the CPS Remote
Monitoring Device. Each 9V battery serves as a source of
power for each ofthe devices. Jumper cables are used to make
connections.
The ThingSpeak loT Platform was selected based on low-
cost, and little or no server setup, for data collection from the
CPS Remote Monitoring device and feedback to the users.
Depending on the features ofthe pipeline and the surrounding
environment, the protection potentials must be maintained
within the range of permitted values for cathodic protection
to function properly. These levels would typically range from
-1.2 V upper limit value to -0.85 V lower limit value [23]-
[25]. From the literature, CPS monitoring values are usually
set at less than 2.5V. Hence, for this design, we shall set the
measurement range of the proposed remote CPS monitoring
equipment at 0 to 5V to allow for the supply of electricity
from the Arduino 2560 Board which can deliver up to 5V.
The Arduino microcontroller is trained to measure the voltage
across terminals using Equation 1 below.
I (v o lts x Vs )
vo tap e = Ts (1)
Where: Volts = Value read by Arduino as an analogue input,
Vs = Constant Voltage supplied by Arduino board (5V), Ts
= Max Value of analogue input that can be read (for Arduino
Board, the max analogue value is 1024), Voltage = Calculat
ed voltage output.
The Arduino Mega 2560 is selected based on its capacity. It
has more inputs and outputs (VO) so can accommodate more
peripherals when needed, compared to other boards, 54 VO
pins (where 15 can be used as Pulse Width Modulation
(PWM) outputs), 16 analog inputs, and 4 Universal
Asynchronous Receiver/Transmitter (DARTs). It has more
flash storage and Static Random Access Memory (SRAM)
than most other basic Arduino boards. It is most popular with
open source.
The GPRS mode of transmission is selected for the data
transmission to the loT server due to its capabilities which
include low installation costs, ease ofinstallation, and ease of
data measurement. Hence, the SIM900 GSMlGPRS Shield
was selected.
The components used for the development of the CPS
Remote monitoring device are depicted in Figure 1.
Arduino Mega 2560 SIM900 GSMlGPRS 9VBattery
Shield
Jumper Cable 9V Battery Connector Simcard
with barrel jack
Fig. 1 CPS Remote Monitoring Device Components
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The components are assembled to create the CPS
monitoring device. This assembly method is shown in Figure
2.
Fig. 2 Assembling of the CPS Remote Monitoring Device
The steps taken to assemble and build the device are
described thus:
• Step 1 Jumper cable is connected from TXl (pin
18) of Arduino Mega 2560 to Dl of SIM900
GSMlGPRS Shield for transmitting data from
Arduino Mega 2560 to SIM900 GSMlGPRS Shield
• Step 2 Jumper cable is connected from RXl (pin
19) of Arduino Mega 2560 to DO of SIM900
GSMlGPRS Shield for receiving data from SIM900
GSMlGPRS Shield to Arduino Mega 2560
• Step 3 Jumper cable is connected from the GND
of Arduino Mega 2560 to the GND of SIM900
GSMlGPRS Shield for grounding of the SIM900
GSMlGPRS Shield
• Step 4 Jumper is connected to AO (Analog Pin) of
Arduino Mega 2560 while the other end is open.
Terminal 1 for taking PSP measurements which
connects to the reference electrode cable terminated
at the Test Post
• Step 5 Jumper cable is connected to the GND of
Arduino Mega 2560 while the other end is open.
Terminal 2 for taking PSP Measurement which
connects to the Test cable from pipeline terminated
at the Test Post.
• Step 6 9V Battery is connected to the Arduino
Mega 2560 using a barrel jack to power the Arduino
Mega 2560.
• Step 7 9V Battery is connected to the SIM900
GSMlGPRS Shield using barrel jack to power the
SIM900 GSMlGPRS Shield.
• Step 8 MTN sim cards are inserted into the sim
track of the SIM900 GSMlGPRS Shield for GPRS
internet connection.
B. Development ofthe Software Component ofthe CPS
Remote Monitoring Device
After all the parts were linked and a channel created in
ThingSpeak loT Server, a USB cable was used to connect the
gadget to a computer for training with the Arduino software.
The training involved writing codes that measured readings
between test cables and reference electrode cables as an
analog input, calculated PSPs, checked for GPRS networks,
established connections with ThingSpeak loT servers, sent
captured PSP readings to the ThingSpeak loT servers, closed
connections, and repeated the process.
 CPS Remote Monllor

Codes that control how the CPS Remote Monitoring

Device will function in terms of measuring the Pipe-to-Soil PSP Readll'1g : -a .8I/ cae I 1 4 · F.o-20 23 1 7 :S g :0 3

Potential, collecting the data and transmitting it to the l o wer Lim": -o .8 5Vcse

•
ThingSpeak loT platform in real-time, were written using the Upper Ltm ll: - I .2 5Vcse

programming language provided by the Arduino Software Pr ot ection Stat us: UnProtected

which can be downloaded from www.arduino.cc. The

programme flow chart is depicted in Figure 3.

cp;::::]j
JanDe Ja n 13 . .", 20 J&n21 Fab03 Feb 10 Fe b 11
11
= =;:1
F1Ib 2<1 Ma r03
[ Dale c~rrn 1
Fig. 4 Display screen to users when the CPS is unprotected

CPS Remote Monitor

PSI' Readlrlg : · 1. 2 \1cse I 14 ·hb·2 0 23 17 :58 :15

•
UpperLmit: - l .25\1ClW'

Protection Statu s: Protected

I.()B Plpo·.~So Il PO'.n'''' Reed'n ••

~ .,
·' 2
Jan06 Jan 13 -la n20 Jan 21 FelJ 03 Feb 10 Feb 17 Feb 2"
[ Cm:'7" 1Da te

Fig. S Display screen to users when the CPS is protected

Fig 3 Flowchart of the CPS Remote Monitoring Device

III. THE FEEDBACK SYSTEM

• • CPS R emote Mon itor

The system analyses the PSP reading obtained from the

•
ThingSpeak loT Server using the lower and upper protection Upp«L.... ,, : - '. 2 5 Vcse

limits to determine the facility's protection status and provide

feedback to the user during monitoring.
Figures 4, 5 and 6 show the display screens which show the
PSP reading, the time stamp, and the protection status for
simple visualisation by the users. When the PSP reading falls Pi pe-la-Soli P o t. n Ua l R ....ln g .

below the lower protective limit, a red signal and auditory

feedback are also provided, with an unprotected status
display as shown in Figure 4. When the PSP reading falls
within the range, the indication is green, with a protected
status display as shown in Figure 5. A magenta colour display
means that the PSP reading falls above the range, showing an
overprotected status display on the screen as shown in figure
6.
... re
De,.
Fig. 6 Display screen to users when the CPS is overprotected
IV. TEST AND VALIDATION
The developed system was tested at one of the test
stations of Integrated Corrosion Science Company Limited
(ICSCL), an Oil & Gas Contractor that specialises in
corrosion control and monitoring, located at Port Harcourt,
Nigeria. The consent ofthe Management was obtained before
the test.
The setup for testing the developed system is depicted in
Figure 7. Figure 7a shows the setup ofthe real test post, with
the developed device installed on it, and a multimeter also
connected to measure PSP readings. This setup is further in
Figure 7b.

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a b
Fig. 7 Setup for Testing of Developed System
A reference electrode is connected to both a Multimeter and
the developed CPS monitoring device at a test post as shown
in figure 7a. The test cable from the pipeline is connected to
one terminal of the CPS remote monitoring device, and the
other terminal is connected to a portable Copper/Copper
Reference Electrode that had been buried beneath the pipeline
in the overlying soil. The multimeter's terminals are
simultaneously attached to the Copper/Copper Reference
Electrode and the test cable from the pipeline, respectively.
The Cathodic Protection (CP) Technician in the field
manually records the PSP reading from the multimeter every
five minutes after setting up the developed system at the test
post location. To view the PSP reading in real-time on the
computer, the ThingSpeak: loT Server is activated to keep
track of the PSP reading's update.
The developed system is validated by comparing the
PSP readings obtained from it with the PSP reading obtained
at the site location using a multimeter.
The two measurements are shown on the same plots for
analysis, and the correlation coefficients are computed using
MATLAB.
The Pearson correlation coefficient which indicates how
strong and in what direction two variables are related, was
employed to statistically analyse the relationship in the
measured data using the developed device and Multimeter.
Pearson correlation coefficient of 1 or -1 indicates a high link
between the variables where a perfect positive correlation is
indicated by 1, and a perfect negative correlation is indicated
by -1, no correlation is indicated by 0 [26], [27]. The Pearson
Correlation Coefficient is obtained using equation 2 in
MATLAB.
r = L(x - mean(x))(y- mean(y))/ (L
(x- mea1l(x))l L
(y- mean(y)l)
Where mean(x) and mean(y) is the means ofthe x and y data,
respectively, and x and y are the data points from the
developed device and multimeter respectively, r is the
Pearson Correlation Coefficient.
MATLAB was employed in the computation of the Pearson
Correlation Coefficient and this yielded a Correlation
Coefficient of r=0.999172.
Figure 8 shows the analysis of the association between the
PSP Reading results from the developed device and the
multimeter using MATLAB.
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I.. -'"---
,
I
[
a. Box plot of the measured data
I:
I
I ! --.. .
,I
:,
"I
b. Time Series plot of the measured data
Fig. 8 Validation plots using MA TLAB
Figure 8a depicts the Box plot of the measured data
while Figure 8b shows the Time Series plot of the measured
data. Figure 8 indicates that there is a strong correlation
between the PSP measurements using the developed device
and the PSP measurements using a multimeter.
V. CONCLUSION
This study presents the design and development of an
intelligent remote monitoring system that can capture the PSP
readings in Oil and Gas pipelines, transmit the measured data
to an loT server, and provide feedback to the user, all in real
time.
The device hardware component was developed using
(2)
GSM Sim900 Shield and Arduino Mega 2560 board, while
its software component was developed using the Arduino
software and Thinkspeak:loT server. MATLAB was used for
validation.
The result ofthe testing and validating the device with an
existing device showed that the developed monitoring device
is consistent and reliable for monitoring the cathodic
protection system since there is a substantial positive
correlation between its measured data and that of the
multimeter. This has established the viability of the
developed CPS Remote Monitoring device and can be
employed for the predictive maintenance of the CPS on
Pipelines.
We recommend that the device should be tested in a wider
range of field conditions to ensure its performance and
reliability under different environments, weather conditions
and soil types. This includes testing in different geographical
locations, temperatures, and humidity levels to ascertain its
suitability for use in a variety of real-world settings. The
developed device was not tested for Compatibility with
different types of CPS such as the impressed current systems,
galvanic systems, and hybrid systems, and made available for
use with a wide range of systems. This test is recommended.
The device was observed to be dropping the voltage at the
point of installation up to -0.1Vcse. This negatively impacts
the accuracy of measurement and is a limitation.
ACKNOWLEDGEMENT
The authors would like to acknowledge the Integrated
Corrosion Science Company Limited (ICSCL), Port Harcourt,
Nigeria for providing their facility for the validation of the
developed device.
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