Dual-Purpose smart liner system for oil and gas pipelines: Digital twin-enabled rapid monitoring during strike events

This study presents an innovative smart-liner system for real-time monitoring and digital twin-enabled deformation visualization, aiming to enhance the safety and efficiency of oil and gas pipelines. Pipelines are vulnerable to sudden mechanical impacts, such as third-party strikes and ground movements, which can introduce localized dents and hidden structural damage that compromise long-term integrity. To address this challenge, the developed smart-liner integrates a dual-sensor network combining distributed fiber optic sensing and fiber Bragg grating technologies to capture strain responses under both static loading and high-rate impact events. This sensing system is coupled with a computationally efficient hybrid framework that merges finite element modeling with machine learning techniques, enabling accurate and rapid three-dimensional deformation visualization while minimizing computational demands. In addition to deformation and damage, the smart-liner also captures curing-induced strain in the adhesive layer, offering valuable insights for quality control and manufacturing improvement. The results demonstrate the system's effectiveness and scalability, supporting its use in advanced structural health monitoring and predictive maintenance for oil and gas pipelines protected by composite liners.