Boilers are very important process in power plants and also in many chemical and refinery industries. These boilers work for an extended period of time and cause leakage in its boiler tubes due to aging and also due to corrosion. Due to some unwanted chemical reaction some toxic gases are also released. In order to avoid unwanted power plant accidents continuous monitoring of boiler tubes is necessary. Nowadays there are many methods available to detect these leakages. But all these methods are of complex. Hence we propose a novel system to detect and control boiler tube leakages. In our system a air quality sensor, temperature and humidity sensors are used to detect the leakages. When there is a variation in the set point of the above parameters, we can think of some leakages in the boiler tubes. A zigbee technology is used to transmit the sensor’s data to the remote center from where the power plant is monitored and controlled. This is all about detector unit. At the controller unit, two fans are used to control the leakage. One fan is used to cool when there is a temperature rise and the other is an exhaust fan which is used to remove the toxic gases from the boilers and stores it in a container which will be discarded safely. The aim of this paper is to build a prototype to check the principle explained above.

Keywords : Boiler Tube Leakage, DHT11,MQ-135, Arduino (Microcontroller) , Zigbee.