2018 IEEE Conference on Systems, Process and Control (ICSPC 2018), 14–15 December 2018, Melaka, Malaysia

Design and Development of Pipeline

Inspection Robot for Crack and Corrosion
Detection
M. N. Mohammed1, Vidya Shini Nadarajah1, Nor Fazlina Mohd Lazim1, Nur Shazwany Zamani1,
Omar Ismael Al-Sanjary1, Musab A. M. Ali1, Shahad Al-Youif2

1
Department of Engineering & Technology,
Faculty of Information Sciences and Engineering,
Management & Science University,
40100 Shah Alam, Selangor, Malaysia

2
Department of Computer Technology Engineering
Dijlah University College,
00964, Baghdad Iraq

Abstract—Robots are devised in such way to dispose of
human intervention from labour extensive and hazardous
work environment. At times they are also used to travel to
unreachable workplaces that are typically not possible to
access by human. Pipe inspections fall in the same category
due to the fact that they carry toxic chemicals and fluids.
Furthermore, most of the pipeline segments have tiny
internal diameter or bends which end up unreachable to
human. The complex inner geometry and hazard content
constraints of pipes call for robots for inspection of such
pipes so as to test corrosion, cracks and restoration of usable
parts from pipe interior, sampling of sludge and scale
formation on pipe inner surface. This research aims to
design and develop a pipeline inspection robot using an
autonomous mobile robot with ultrasound sensors and
connected via GSM and GPS. In addition, IP camera was
also used for visual inspection, integration of wireless
capability for easy viewing of acquired data and images. The
improvements achieved by the new-fangled design bring the
ultrasonic inspection of pipeline even more competitive.
Furthermore, the system has the ability to record and
display the view of the atmospheres on the employees
monitor display screen for effective observation, detection,
quick analysis, diagnosis and reliably in confined, darkish
environments.
Keywords— Mobile Robot, In Pipe Inspection Robot
(IPIR), Nondestructive test
1. INTRODUCTION
Robotics has emerged as one of the fastest growing
engineering fields in present day technology and in large
part utilized in manufacturing industries to carry out a
wide assortment of works which include loading and
unloading of hardware and work piece, spot welding and
painting. Robots are designed to get rid of involvement of
humans in labour- intensive and perilous workplace.
Moreover, robots may be utilized in remote workplace
that is inaccessible to human beings [1-6]. Pipelines are
built to transport all types of fluids; some lethal, some
extraordinarily flammable while others are pretty
unreactive. In every case, containment of the transported
fluid within the pipeline and prevention of interaction of
these fluids with the enclosing surroundings underneath
any perfect circumstances are crucial [7-8]. In standard,
metal or plastic tubes with internal diameter ranging from
4 to 48 inches is used to make oil pipelines and most
pipelines are established underground with a depth of 3 to
6 ft. Pump stations positioned along the pipeline secure
consistent flow of the oil at an ordinary speed about 1 to 6
m/s [9-10]. Considering this, a pipeline inspection robot
was built which will flow starting with one factor then
onto the subsequent within the inner diameter of the
pipeline, to have the capability to pick out corrosion
inside the pipe by detecting geometric distortions in the
pipe and be capable of giving an alert once crack, deposit
or corrosion is detected. It turned into imperative to
develop Low Cost Pipeline Inspection robot for crack and
corrosion detection. The complex inner geometry and
hazard content constraints of pipes call for robots for
inspection of such pipes so as to test corrosion, cracks and
restoration of usable parts from pipe interior, sampling of
sludge and scale formation on pipe inner surface. A pipe
inspection robotic is a device that can be inserted into
pipe to check for obstruction, harm, deterioration, and
corrosion. Those robots are on the whole used for
offshore and buried pipes [11]. Despite the fact that, they
also can be used on surface pipes if the cost is not too
excessive. Strategies for pipeline inspection contain of
damaging trying out, non-destructive trying out, direct
assessment and traditional strategies as supplied in
Table 1 [12]. The selection of the proper method is
exceedingly dependent on the goals of the inspection
activity.

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 2018 IEEE Conference on Systems, Process and Control (ICSPC 2018), 14–15 December 2018, Melaka, Malaysia

In-Pipe Inspection Robots (IPIRs) are appreciably used and robot actions. The robotic unit is authorized to be
in petrochemical, water deliver and fluid transportation located in a workplace such as road, tunnels or bridges in
industries. Several researchers have shown that the IPIRs which the robot does the crack detecting actions. Actions
has the potential to be used for a varied range of are determined via the sensor unit and the feedback is
processes that are either already patented or under given to the computer. Computer unit is attached to GSM
investigation within research centers all over the world. In unit and the computer gives instructions to the robot. The
spite of some technical and technological differences robot and computer can immediately command the sensor
between the available IPIRs, they can be categorized into unit. All movements are under the manipulation of the
three types as shown in Figure 1. The present research robotic unit while the robot includes the Arduino, sensor
aims to design and develop a pipeline inspection robot unit and computer programs. The sensor unit consists of
using an autonomous mobile robot with ultrasonic crack ultrasonic sensor that emits the radiation and detects the
detection tool. crack and corrosion at the workplace such as roads,
TABLE I bridges and tunnels. The robot acts in the workplace and
PIPELINE INSPECTION TECHNIQUES
sensor unit is activated as soon as the crack is detected.
Inspection Techniques Descriptions
• When pipeline is not in service
The sign is given to the computer unit that's comprised of
Destructive testing • Hydrostatic pressure testing GSM unit programs and activate the GSM to send the
message as “CRACK IS DETECTED”. After the
• Smart pigs (in-line inspection or message is sent to the mobile, it receives reset to the
ILI) original place and makes the robot to move forward via
Non-destructive • Dent deformation and geometry
testing • Corrosion magnetic crack
mobile control.
• Crack ultrasonic/transverse field

• Gas and non-pig able oil

pipeline, corrosion tests
Direct assessment
• External and Internal stress

• Aerial
• Airplanes
• Helicopters
Traditional techniques
• Ground
• Vehicle
• Foot patrols

Figure 2: Block diagram of pipeline inspection robot

The final design of pipe inspection robot is illustrated

in Figure 3. The robotic become connected to two
ultrasonic sensor detectors which were located on the top
and at the lowest of the automobile to detect the crack in
the pipeline. A camera is attached at the front of the robot
to record and display the view of the atmospheres on the
employees monitor display screen for effective
observation, detection and quick analysis. Furthermore,
Figure1: Classification of in pipe inspection robot (IPIR) [13] GPS and GSM were connected to the robot in order to
obtain information, message and pictures by data transfer
and to alert the approximate location of the crack
2. MATERIALS AND METHODS
detected.
Primarily robots are designed in such method that they
reduce human intervention from labor intensive and
dangerous work surroundings. The pipeline examination
robot has 3 main physical sections to its design: an
autonomous mobile robot, a crack and corrosion detector
and alert message system. The hardware needed are:
Arduino ,Camera ,Battery ,GSM module ,Ultrasonic
sensor ,Wheel ,Motor defend ,Bluetooth shield, Blue Bee
,GPS module as shown in Figure 2. There are two
extraordinary models viz. abstract model and physical
version. The abstract model is a pre-processed device in
which the programs are managed. It consists of a
computer in which the sensor program (robot application)
is programmed and controlled. Within the physical
model, actual time actions are made similar to workplace Figure 3: Final design of in pipe inspection robot

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 2018 IEEE Conference on Systems, Process and Control (ICSPC 2018), 14–15 December 2018, Melaka, Malaysia

3. RESULT AND DISCUSSION
In order to verify the feasibility of the proposed design,
simulations need to be carried out on the robot. This
would also enable us to verify the reliability of the control
strategies that was discussed above. A simplified model
of the robot was prepared in Proteus software. The circuit
simulation of car motor driver movement was
successfully done as shown in Figure 4(a). Rotation of
two dc motor was set as follows: one motor rotated to left
(-30) and another in (+30) mode. While Figure 4(b)
shows the crack detection procedure where the Arduino
was connected with ultrasonic and the led, once the
cracked detected the led will be light on, and the distance
measurement will be displayed on the monitor screen.
(a)
Figure 5 shows the robot stopped in the section of the
pipeline in which geometric distortions in the inner
diameter of the pipeline. At this location, a message
indicating the presence of crack is displayed on the
computer screen, while an alert is issued by the GSM and
GPS as shown in Figure 6. On the other hand, Figure 7
shows the robot close to the pipe entrance that is
displayed by the Wi-Fi camera, and when the pipe length
is almost completely inspected. The measurements from
the inspection were displayed on the computer screen for
instantaneous monitoring delivered by Wi-Fi camera. It
can be said that, the developed prototype verified the
practicality of the proposed design. As of now the system
is manually controlled. The joint angles and the wheel
velocities are set manually. With proper sensor suite and
software the system can be made to climb autonomously
to a desired height. This could make it easier to use future
versions of the system for various applications like
surveillance, inspection and maintenance.

(b)

Figure 5: The robot stopped at the crack section of the pipeline

(a)

Figure 4: Proteus Circuit Simulation for (a) motor driver movement and
(b) Ultrasonic Sensor Detector.

For experimental authentication, the system was

controlled from base station over Arduino using the
control software. Mobile robot tested for functionally and
found suitable for inspection of defect in pipeline with
camera attach to it, which moves freely in the pipeline.
The pipe inspection robot was tested using a pipeline
model made from 2.0 m sheet of aluminium and wrapped
into a cylinder with 250 mm inner diameter and bounded
with metal strips for solidity. Certain sections of the (b)
pipeline model were tampered with to introduce dents and
geometric distortions within the interior pipelines. These
regions were used to simulate the effect of corrosion or
the presence of deposits within the pipeline. The robot
has a good mobility and ability to pass over small
obstacles. Monitoring the pipe inside was suitable and the
control of different actuators was effectively possible.
Transmitted image and status data like SFR forces and
motor currents help operator to make decision.

Figure 6 : Result of (a) Msg alert and (b) location of cracked detected
inside pipe

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 2018 IEEE Conference on Systems, Process and Control (ICSPC 2018), 14–15 December 2018, Melaka, Malaysia
[9] M. F. Abdul Jalal, K. S. Mohamed Sahari & A. Anuar ,
Development of magnetic wheeled boiler tube inspection robot,
Jurnal Teknologi (Sciences & Engineering) 76:4 (2015) 19–23

[10] Godwin I, Ene DO, Udo I, Awe PE, Barthelomew E, (2015)

Pipeline Inspection for Corrosion using a Mobile Robotic
System. Int J Robot Eng 1:001

[11] Motamedi M, Faramarzi F, Duran O (2012) New concept for

corrosion inspection of urban pipeline networks by digital image
processing. 38th Annual, Conference on IEEE Industrial
Electronics Society, IECON 2012, 1551-1556.

[12] Md Raziq Asyraf Md Zin, Khairul Salleh Mohamed Sahari,

Juniza Md Saad, Adzly Anuar, Abd Talip Zulkarnain (2012)
Development of a Low Cost Small Sized In-Pipe Robot.
International Symposium on Robotics and Intelligent Sensors
2012. Procedia Engineering 41: 1469-1475.
Figure 7: The robot movement in pipe that delivered by the Wi-Fi
camera.
[13] Ankit Nayak, S. K. Pradhan, Design of a New In-Pipe Inspection
Robot, Procedia Engineering 97 ( 2014 ) 2081 – 2091
4. CONCLUSION
A new generation of ultrasonic crack detection tool has
been presented in this research using fully autonomous
pipeline robot. The enhancements accomplished by the
new design that make the In-Pipe Inspection Robots
(IPIRs) with ultrasonic inspection more competitive. An
actual prototype was developed to check the viability of
inspection of this kind of robot. The major advantage is
that the system has ability to record and display the view
of the atmospheres on the employees monitor display
screen for effective observation, detection, quick analysis,
diagnosis and reliably in confined, darkish environments.

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