US 7428350 B1
A technique is provided for utilizing an optical fiber in a variety of sensing applications and environments by beneficially routing the optical fiber. A continuous optical fiber is created to provide optical continuity between two ends of the optical fiber. The optical continuity is created with the assistance of an optical turnaround constructed in a simple, dependable form able to control the bend of the optical fiber as it extends through the optical turnaround.
1. A method of utilizing an optical fiber, comprising:
placing an insert within a tube sized to receive an optical fiber;
deforming the tube in the region of the insert to create an optical fiber turnaround region in the tube having a span greater than the internal diameter of the tube; and
routing an optical fiber through the tube and around at least a portion of the insert to create an optical fiber loop having a diameter greater than the internal diameter of the tube.
2. The method as recited in
3. The method as recited in
4. The method as recited in
5. The method as recited in
Optical fibers are used in a variety of sensing and other applications. For example, optical fiber has been used as a distributed temperature sensor in oilfield applications where the temperature profile can be applied in, for example, detection of water breakthrough, detection of leaks, and gas lift monitoring and optimization. The optical fiber is utilized by injecting light into the fiber, measuring the backscattered light, and then processing the results to determine temperature along the length of the fiber.
Research has shown that distributed temperature sensor measurements are more accurate when performed in a double-ended configuration such that optical continuity exists between two optical fiber ends connected to a distributed temperature sensor control system. By preparing this double-ended configuration, light can be sent through the complete length of optical fiber from both directions and measurement correction is facilitated. However, the double-ended configuration requires that a continuous optical fiber extend down into a wellbore for the desired interval to be sensed, turnaround, and return to the surface.
Attempts have been made to create turnarounds that route the optical fiber back to the surface. In one example, the turnaround has been formed with a metal tube doubled back on itself with both ends connected to additional tubing. The optical fiber is then routed through the tubing. This technique, however, requires many tubing connections that reduce system reliability while increasing deployment time. Many applications also are subject to space constraints which can create problems in properly controlling the bend of the optical fiber when routed through a turnaround. Exceeding the minimum bend radius of an optical fiber increases optical attenuation and can ultimately result in fiber breakage.
In general, the present invention provides a system and method for routing an optical fiber that can be used in a variety of sensing applications and environments. A continuous optical fiber is created such that optical continuity exists between two ends of the optical fiber. The optical continuity is created with the assistance of an optical turnaround constructed in a simple, dependable form able to control the bend of the optical fiber as it extends through the optical turnaround.
Certain embodiments of the invention will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements, and:
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those of ordinary skill in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
The present invention generally relates to a fiber optic system that utilizes an optical fiber in parameter sensing applications. The system utilizes optical fiber arranged in a double-ended configuration to provide optical continuity between two fiber ends that are connected to an appropriate control unit. The configuration facilitates sensing of the desired parameter by, for example, allowing light to be sent through the complete length of the optical fiber from both directions. The arrangement also facilitates measurement correction to provide for more accurate measurement of the desired parameter. In one embodiment, the fiber optic system is utilized in a well environment and the optical fiber is deployed in a wellbore drilled into a geological formation holding desired production fluids, such as hydrocarbon based fluids.
Referring generally to
In the embodiment illustrated in
Optical fiber sensor 22 may be routed along wellbore equipment 40, e.g. a tubing string, deployed in wellbore 28. The wellbore equipment 40 may comprise a variety of wellbore completions, servicing tools or other equipment depending on the well related operation to be performed. Furthermore, the optical fiber sensor 22 can be routed within wellbore equipment 40, along the exterior of wellbore equipment 40, along the interior or exterior of wellbore casing 32, or along a combination of regions. The optical fiber sensor 22 is designed to sense the desired parameter, e.g. temperature, along wellbore 28 or along a specific section of wellbore 28.
The optical fiber sensor 22 comprises a plurality of optical fibers 42, as illustrated in
Proper selection of a suitable optical fiber with which to form optical fiber loop 46 can be accomplished by a variety of methods. For example, lengths of optical fiber may be acquired for use in the optical turnaround 50 through a combination of testing and statistical flaw distribution. The optical fiber can be selected so as to have a statistical probability of sufficiently high strength to reliably form the optical fiber loop. In one example, lengths of optical fiber are taken from a batch of select fiber and subdivided into three sections or lengths. One length of fiber is set aside for use as optical fiber loop 46, while the other lengths of optical fiber are tested to determine tensile strength/break load. If the strength of the tested lengths of fiber is sufficient to avoid experiencing damaging stress levels when creating a loop size needed for the optical turnaround, the set aside optical fiber is presumed suitable for use in forming loop 46. Only a statistically insignificant probability exists that the set aside fiber has differing characteristics compared to those of the tested optical fibers. An alternative approach is to select the optical fiber for forming loop 46 from a fiber spool that is batch tested. A single test is performed on a sample of the fiber to verify strength. Additionally, through the use of appropriate optical fiber during manufacture of an optical fiber cable, it is feasible to create optical fiber loop 46 by exposing a sufficient length of optical fiber from the cable so that one of the fibers can be looped and fusion spliced to a second fiber in the cable. It should be noted that in some embodiments optical fiber loop 46 and optical fibers 42 can be formed from one continuous fiber. Use of these analysis and selection methods enables the determination of optical fiber having high strength for use in the optical turnaround. By locating suitable high strength fiber through selective/random testing and/or statistical/historical data, the optical fiber can be bent in a small diameter while still ensuring long-term reliability. The turnarounds discussed herein also can be formed with relatively short optical fiber loops, e.g. one meter or less, which further reduces the probability of defects in the optical fiber turnaround.
The housing 48 is sealed to optical fiber cable 56 to ensure fiber loop 46 and fibers 42 are isolated from direct contact with the surrounding well environment. In the embodiment illustrated, housing 48 and optical fiber cable 56 are sealed together by a suitable cable seal assembly 60, such as an in-line splice. However, other methods of cable sealing can be used. One example of a suitable seal assembly, illustrated in
Construction of fiber loop optical turnaround 50 can be carried out according to several methodologies. One suitable approach involves initially preparing optical fiber cable 56 by stripping back the encapsulation material, straightening the cable, and holding the optical fiber cable via an appropriate assembly fixture or other mechanism. The cable seal assembly 60 is then slid onto optical fiber cable 56, as illustrated in
Formation of the optical fiber turnaround in this manner avoids the addition of a variety of components into the overall tubing string. For example, no mandrels or shrouds are required to mount and protect the optical turnaround. Protection of optical turnaround 50 is achieved through the systems and procedures described above, resulting in significant cost savings.
An alternate embodiment of optical trunaround 50 is illustrated in
As illustrated in
The optical fiber turnaround 50 illustrated in
In creating this embodiment of optical fiber turnaround 50, insert 72 is initially placed within tube 64 at the desired optical fiber turnaround region 66. An appropriate pressing tool is then used to pinch tube 64 from the outside to reduce its dimension in the direction of pinching and to increase its dimension in the opposite or perpendicular direction. The wall of tube 64 is pinched until it touches insert 72 which allows the insert 72 to support tube 64 against further collapse. The extremities of tube 64 on one or both sides of optical fiber turnaround region 66 can remain undeformed to enable connection to other tubes or to enable termination using suitable pipe termination fittings.
As further illustrated in
The optical fiber loop 46 can be formed by allowing a single optical fiber 42 to be routed through passage 74 and around at least a portion of insert 72 until it is allowed to turn around and extend back up through tube 64. The diameter of the optical fiber loop is larger than the inside diameter 70 of tube 64 and may, for example, be in the range of more than 1 and less than 1.57 times the inside diameter 70. In many applications, a suitable diameter for optical fiber loop 46 is in the range of 1.1 to 1.4 times larger than the inside diameter 70 of tube 64.
In some embodiments, optical fiber loop 46 and the optical fiber sections 42 extending from loop 46 can be further protected by an auxiliary sheath or tube 80 disposed around the optical fiber. The auxiliary tube 80 can be made from appropriate, flexible materials including polytetrafluoroethylene (PTFE) or thin-walled metal.
Another embodiment of insert 72 is illustrated in
The embodiments of optical turnaround 50 can be formed from a variety of materials and components. Additionally, the optical turnarounds 50 can be used to facilitate construction of a variety of optical fiber sensor systems that are used in many environments and applications. The optical fiber sensor system and turnaround are suited to well related applications, but the system and methodology also can be applied in other applications.
Accordingly, although only a few embodiments of the present invention have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this invention. Such modifications are intended to be included within the scope of this invention as defined in the claims.