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The purpose of this paper is to introduce an in line non‐destructive inspection tool instrumented pipeline inspection gauge (IPIG) and the need for secondary sensors in it; and to design a proper configuration of eddy current based secondary sensor under given design constraints.

The objective is achieved by designing a simple configuration, testing it experimentally and modifying it as per requirements.

An optimized configuration is arrived at under given set of constraints.

This paper presents a novel method to design an eddy current sensor, and especially addresses electromagnetic experts involved in coil based sensor designs.

The purpose of this paper is to describe how to improve magnetic pick up sensor for detection of weak magnetic field. A magnetic marker detection system, built using hall sensors is improved by providing ferrite cores as back yoke to obtain benchmarked performance with reduced number of hall sensors in an equipment for pipeline inspection called caliper tool.

The paper opts for an exploratory study by making various configurations of sensors possible under given constraints, analyzing results of each one of them and correcting the configuration.

Instead of using highly sensitive hall sensors, one can increase the sensitivity of sensor by putting simple ferrite core as back yoke in order to detect weak magnetic field.

This paper fulfils the need of detection of weak magnetic field by changing field direction and maximizing field component in direction of sensitive axis of magnetic sensor.