Oil flowlines, the first “pipeline” system connected to the wellhead, are pipelines that are 5 to 30.5 cm (two to twelve inches) in diameter, most susceptible to corrosion, and very difficult to inspect. Herein, an external corrosion detection sensor for oil and gas pipelines, consisting of a semicircular plastic strip, a flat dog-bone-shaped sacrificial metal plate made out of the same pipeline material, and an optical fiber with Fiber Bragg Grating (FBG) sensors, is described. In the actual application, multiple FBG optical fibers are attached to an oil and gas pipeline using straps or strips or very large hose clamps, and, every few meters, our proposed corrosion detection sensor will be glued to the FBG sensors. When the plastic parts are attached to the sacrificial metals, the plastic parts will be deformed and stressed; thus, placing the FBG sensors in tension. When corrosion is severe at any given pipeline location, the sacrificial metal at that location will corrode till failure and the tension strain is relieved at that FBG Sensor location, and therefore, a signal is detected at the interrogator. Herein, the external corrosion detection sensor and its design equations are described, and experimental results, verifying our theory, are presented.

We propose a sensor design for measurement of large strains where direct application of a fiber optic strain gauge is impossible due to the stiffness mismatch between the optical fiber and the structure under test. The sensor design is based on a rhombus type compliant mechanism, which functions to attenuate input strain and transfer it to the ends of the sensing beam with the mounted optical strain gauge. We developed an analytical model of the sensor, which allows us to relate actuation forces, input displacement/strain, and output strain. The analytical model was verified with the finite element analysis and validated against an experimental prototype. The prototype sensor was able to handle input strains exceeding ±2.5 × 10⁵ µε. Potential application areas of the proposed sensor include compliant elastomeric structures, wearables, and soft robotics.