Low-Cost Sensor Node for Crack Monitoring of Out Pipes Using Non-Destructive Testing for Process Industries

In process industries, non-destructive evaluation is an appropriate method of health monitoring. Due to the manual health monitoring system, catastrophic accidents occur at petrochemical plants. Humans lacked the requisite experience to properly generate fresh materials and operate diverse machinery and modes of transportation in the early industrial days, which led to serious accidents. The use of damage detection to detect potential material flaws resulted in a significant boost in machine reliability. By identifying the potential development and manufacturing improvements with extra knowledge, NDT became a fundamental part of early day complex systems. Oil refineries and petrochemical plants have millions of pipes forming a network. These pipes are monitored annually during plant shutdown. The maintenance has been carried out traditionally, therefore it has become a very hazardous, as well as a tedious task. In the present article, we have tested a low-cost crack monitoring device. For this, an Arduino-based system has been developed for crack monitoring of pipelines from outside. The concept of magnetic flux leakage is used to trace any defect in the internal structure of ferromagnetic pipelines. Using the Hall effect sensor, a change in the magnetic field intensity has been located and captured. The current research reduces the limitations of the health monitoring system of process industries. This will promote a safe atmosphere for workers, as well as for society and the environment.