Hybrid Cable Housing Racetrack Tray Fiber Stress
Solution Overview
Problem
In well systems, the thermal expansion mismatch between metal and glass components in splice housings causes stress on optical fibers, potentially leading to breakage and increased machining costs due to the need for longer mandrels with separate Y-splitters.
Innovation Solution
A splice housing assembly that incorporates a hybrid cable with a metal tube housing multiple optical fibers and electrical cables, featuring a racetrack tray to retain excess fiber lengths, reducing stress and eliminating the need for a separate Y-splitter, thus minimizing mandrel length and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a traditional splice housing with separate Y-splitter is used, then fiber connections to multiple sensors can be achieved, but the mandrel length increases and machining costs increase
Solution Approach 1:
The patent combines the Y-splitter functionality directly into the splice housing assembly, merging two previously separate components (splice housing and Y-splitter) into a single integrated unit. This eliminates the need for a separate Y-splitter attachment and reduces the overall mandrel length required, while maintaining the capability to connect fibers to multiple sensors.
2Adaptability or versatility
If a traditional splice housing with separate Y-splitter is used, then fiber connections to multiple sensors can be achieved, but machining costs increase
Solution Approach 1:
The patent combines the Y-splitter functionality directly into the splice housing assembly, merging two previously separate components (splice housing and Y-splitter) into a single integrated unit. This eliminates the need for a separate Y-splitter attachment and reduces the overall mandrel length required, while maintaining the capability to connect fibers to multiple sensors.
3Temperature
If the splice housing and tray expand at high temperature, then thermal expansion occurs, but fiber stress increases and fiber may break
Solution Approach 1:
The patent changes the physical state and arrangement of the fiber within the splice housing by introducing a racetrack tray with circumferential grooves. This allows the fiber to be routed in a loop configuration that can accommodate thermal expansion of the metal housing and tray, preventing stress concentration and potential fiber breakage at high temperatures.
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 effectively mitigates fiber stress and breakage at high temperatures, simplifies installation, and reduces machining costs by allowing for easier splicing and repair, while maintaining reliable connections to downhole sensors and gauges.
Implementation Method 1
The splice housing, including the splice tray, and the fiber can increase in temperature when downhole. The splice housing and splice tray can expand in length much greater than the fiber, for example due to differences in the thermal expansion of metal and glass.
Data Source
AI summary
An assembly can include a barrel housing having an opened end. The barrel housing can also include a barrel port for mounting a first compression fitting. A racetrack tray can be positioned within the barrel housing. The racetrack tray can receive an optical fiber and an electrical cable of a hybrid cable. A cap can be secured to the opened end of the barrel housing. The cap can include a cap port for receiving a second compression fitting. A primary seal can be positioned in a groove on one of the cap or the barrel housing. The primary seal can create a pressure seal between the cap and the barrel housing.