This paper describes the design method of a magnetic system to maximize the magnetic flux leakage (MFL) in a non-destructive testing (NDT) system. The defect signals in a MFL type NDT system mainly depend on the change of the magnetic leakage flux in the region of a defect. The characteristics of the B-H curves are analysed and a design method to define the operating point on B-H curves for maximum leakage is performed. The computed MFL signal by a nonlinear finite element method is verified by measurement using Hall sensors mounted on the 6 legs PIG, the traveling detector unit in gas pipe, in an 8 inch test tube with defects. The rhombic defects could be successfully identified from the defect signals.