Dual-Use Fiber Optic Cable for Wellbore Operations
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fiber optic cables used in coiled tubing for oilwell operations face issues such as increased stiffness, pumpability problems, limited electrical power transmission area, and reduced depth capability due to the metallic tubes, which can lead to optical fiber damage and signal attenuation.
Innovation Solution
The development of dual-use fiber optic cables with polymeric jacketing and segregated, insulated metallic components that form crush-resistant tubes, allowing for both data transmission and electrical power distribution while minimizing internal volume reduction in coiled tubing, using materials like CFR-Fluoropolymer and PEEK for enhanced protection and torque resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic tubes are used to protect optical fibers in coiled tubing, then mechanical strength and crush resistance are improved, but the cable stiffness increases and pumpability deteriorates
Solution Approach 1:
The patent replaces rigid metallic tubes with flexible polymeric jacketing layers that provide protection while maintaining cable flexibility. The polymeric jacketing includes multiple layers (inner jacket, outer jacket) that can flex and bend without creating the stiffness problems associated with metallic tubes, thereby improving pumpability while still providing mechanical protection.
Solution Approach 2:
The patent uses composite material structures combining polymers with embedded strength members (such as aramid fibers, steel wires, or glass fibers) within the polymeric jacketing. This composite approach provides the necessary crush resistance and mechanical strength equivalent to metallic tubes while maintaining the flexibility and pumpability of polymeric materials.
2Strength
If metallic tubes are used to protect optical fibers, then mechanical protection is improved, but the internal area available for electrical power transmission is reduced
Solution Approach 1:
The polymeric jacketing layers can be designed with optimized thicknesses that provide adequate mechanical protection while minimizing the overall cable diameter. This allows more space to be allocated for electrical conductors within the cable structure, increasing the area available for electrical power transmission compared to thicker metallic tube designs.
Solution Approach 2:
By using high-strength composite materials with embedded fibers or wires in the polymeric jacketing, the patent achieves superior mechanical protection with thinner wall sections. This reduces the space consumed by the protective layer, thereby increasing the internal area available for electrical power conductors.
3Strength
If metallic tubes are used in fiber optic cables, then structural strength is improved, but the overall strength-to-weight ratio deteriorates, limiting depth capability
Solution Approach 1:
The patent employs composite materials combining lightweight polymers with high-strength reinforcement fibers (such as aramid, carbon fiber, or glass fiber). This creates a protective structure with superior strength-to-weight ratio compared to metallic tubes, reducing the overall cable weight while maintaining or enhancing structural strength, thereby improving depth capability in wellbore operations.
Solution Approach 2:
The polymeric jacketing structure uses thin-film technology to provide adequate mechanical protection with minimal material thickness. This reduces the overall cable weight while maintaining necessary protective functions, improving the strength-to-weight ratio and enabling deeper wellbore operations.
4Strength
If metallic outer tubes are used, then mechanical protection is improved, but optical fibers become vulnerable to damage from fluids entering through pinholes
Solution Approach 1:
The patent uses polymeric jacketing materials that are inherently resistant to fluid penetration through pinholes. The polymeric layers (inner and outer jackets) provide continuous, pinhole-free barriers that prevent fluid ingress, eliminating the vulnerability associated with metallic tubes that can develop pinhole defects. The polymers also provide the necessary mechanical protection.
Solution Approach 2:
The composite polymeric structure with multiple jacketing layers provides both mechanical strength and fluid barrier properties. The layered polymeric construction creates multiple sealing barriers that prevent fluid penetration, while the embedded reinforcement materials provide the necessary mechanical strength, replacing the metallic tube's protective function without the pinhole vulnerability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides increased protection against fluid penetration and torque stresses, reduces signal attenuation, and allows for effective electrical power transmission without significantly reducing the internal area or volume of the coiled tubing, enhancing the depth capability and reliability of wellbore operations.
Implementation Method 1
at least one longitudinally extending optical fiber... the at least one optical fiber is adapted to transmit data
Implementation Method 2
polymer material layer surrounding and encasing the first metallic component... polymeric jacketing to substantially eliminate optical fiber damage from fluids entering through pinholes
Implementation Method 3
the first metallic component is adapted to transmit at least one of electrical power and data... segregated, insulated metallic components that can be used as electrical conductors
Data Source
AI summary
A dual use cable includes at least one fiber optic cable encased in a metallic component that is encased in a layer of polymer material. The polymer material is surrounded by a tube or armor wire strength members embedded in one or two additional polymer material layers. A final assembly can include an outer metallic component or an outer layer of polymer material. The at least one fiber optic cable transmits data and the armor wire strength members and/or metallic components transmit at least one of electrical power and data.