Scale Prototype of Pipeline Inspection Gauge for 2D Mapping

The accurate acquisition of pipeline position data is critical for the oil industry, significantly impacting maintenance strategies and operational efficiency. Traditional Pipeline Inspection Gauges (PIGs) often face challenges with data accuracy and realtime transmission, limiting their effectiveness. This study presents the development and evaluation of a PIG designed for precise pipeline mapping under controlled conditions. The PIG features flexible arms and is equipped with an ESP32 microcontroller, integrating an IMU, magnetometer, and incremental encoders. The data is processed using an Extended Kalman Filter (EKF) to enhance positional accuracy. Controlled tests in a PVC pipeline environment confirmed the system's consistency and reliability.The PIG achieved a distance measurement error of 0.34% and an angular error of 4.67%, with 0% data loss and low latency. The implementation of the Message Queuing Telemetry Transport (MQTT) protocol with Quality of Service (QoS) level 2 ensures reliable data transmission, storing messages on the server until receipt is confirmed. Built-in connection maintenance mechanisms and automatic reconnection capabilities minimize data loss, achieving near-zero data loss under optimal conditions. Although the communication protocol was tested in ideal conditions (PVC pipes and short distances), the results demonstrate the system's potential for industrial applications, underscoring the importance of continuous calibration and energy optimization. While the controlled testing environment validates the PIG's efficiency, further testing in more diverse and realistic conditions is necessary to fully assess its reliability and performance.