Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02561402 2006-10-16
COMPOSITE SPOOLABLE TUBE WITH SENSOR
Related Applications
This application is filed as a division of Canadian patent application serial
No.
2,305,148 filed 09 October 1998, and which has been submitted as the Canadian
national
phase application of International patent application No. PCT/US98/21493 filed
09 October
1998.
ackground of the Inventlon
The present invention relates generally to spoolable tubing suitable for use
in the
oil industry, and more particularly to spoolable tubing consisting of a
composite
material.
Spoolable tubing, that is tubing capable of being spooled upon a reel, is
commonly used in numerous oil well operations. Typical oil well operations
include
running wire line cable down hole with well tools, working over wells by
delivering
various chemicals down hole, and performing operations on the interior surface
of the
drill hole. The tubes used are required to be spoolable so that the tube can
be used in
conjunction with one well and then transported on a reel to another well
location. Steel
coiled tubing is typically capable of being spooled because the steel used in
the product
exhibits high ductility (i.e. the ability to plastically deform).
Unfortunately, the repeated
spooling and use of steel coiled tubing causes fatigue damage that can
suddenly cause
the steel coiled tubing to fracture and fail. The hazards of operating steel
coiled tubing,
i.e. risk to personnel and high economic cost resulting from down time needed
to
retrieve the broken tubing sections, forces steel coiled tubing to be retired
after a
relatively few number of trips into a well.
Steel coiled tubing has also proven to be subject to expansion after repeated
uses.
Tube expansion results in reduced wall thickness with the associated reduction
in the
pressure carrying capability of the steel coiled tubing. Steel coiled tubing
known in the
art is typically limited to an internal pressure up to about 5,000 psi.
Accordingly, higher
pressure and continuous flexing typically reduces the steel tube's integrity
and service
life.
For example, the present accepted industry standard for steel coiled tube is
an A-
606 type 4 modified HSLA steel with yield strengths ranging from 70 ksi to 80
ksi. The
HSLA steel tubing typically undergoes bending, during the deployment and
retrieval of
the tubing, over radii significantly less than the minimum bending radii
needed for the
material to remain in an elastic state. The repeated bending of steel coiled
tubing into
and out of plastic deformation induces irrepamble damage to the steel tube
body leading
to low-cycle fatigue failure.
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la
Additionally, when steel coiled tubing is exposed to high internal pressures
and
bending loads, the isotropic steel is subjected to high triaxial stresses
imposed by the added
pressure and bending loads. The high triaxial stresses result in significant
plastic
deformation of the tube and diametral growth of the tube body, commonly
referred to as
"ballooning". When the steel coiled tube experiences ballooning, the average
wall thickness
of the tube is reduced, and often causes a bursting of the steel tube in the
area of decreased
thickness.
Steel coiled tubes also experience thinning of the tube walls due to the
corrosive
effect of materials used in the process of working over the well and due to
materials located
on the inner surface of the well bore. The thinning resulting from corrosive
effects of
various materials causes a decrease in the pressure and the tensile load
rating of the steel
coiled tubing.
It is, therefore, desirable to provide a non-steel coil tubing which is
capable of being
deployed and spooled under borehole conditions, which does not suffer from the
limitations
of steel tubing and is highly resistant to chemicals.
For the most part, prior art non-metallic tubular structures that are designed
for
being spooled and also for transporting fluids. are made as a hose whether or
not they are
called a hose. An example of such a hose is the Feucht structure in U.S.
Patent 3,856,052
which has longitudinal reinforcement in the side walls to permit a flexible
hose to collapse
preferentially in one plane. However, the structure is a classic hose with
vulcanized
polyester cord plies which are not capable of carrying compression loads or
high external
pressure loads. Hoses typically use an elastomer such as rubber to hold fiber
together but
do not use a high modulus plastic binder such as epoxy. Hoses are designed to
bend and
carry internal pressure but are not normally subjected to
external pressure or high axial compression or tension loads.
When the ends of a hose are subjected to opposing forces, the hose is said to
be
under tension. The tensile stress at any particular cross-section of the hose
is defined as the
ratio of the force exerted on that section by opposing forces to the cross-
sectional area of the
hose. The stress is called a tensile stress, meaning that each portion pulls
on the other.
With further reference to a hose subjected to opposing forces, the term strain
refers
to the relative change in dimensions or shape of the hose that is subjected to
stress. For
instance, when a hose is subjected to opposing forces, a hose whose natural
length is LO
will elongate to a length LI = LO + Delta L, where Delta L is the change in
the length of the
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2
hose caused by opposing forces. The tensile strain of the hose is then defined
as the ration
of Delta L to LO, i.e. the ratio of the increase in length to the natural
length.
The stress required to produce a given strain depends on the nature of the
material
under stress. The ratio of stress to strain, or the stress per unit strain, is
called an elastic
modulus. The larger the elastic modulus, the greater the stress needed for a
given strain.
For an elastomeric type material, such as used in hoses, the elongation at
break is so
high (typically greater than 400 percent) and the stress-strain response so
highly nonlinear;
it is common practice to define a modulus corresponding to a specified
elongation. The
modulus for an elastomeric material corresponding to 200 percent elongation
typically
ranges form 300 psi to 2000 psi. In comparison, the modulus of elasticity for
typical plastic
matrix material used in a composite tube is from 100,000 psi to 500,000 psi or
greater, with
representative strains to failure of from 2 percent to percent. This large
difference in
modulus and strain to failure between rubber and plastics and thus between
hoses and
composite tubes is what permits a hose to be easily collapsed to an
essentially flat condition
under relatively low external pressure. This large difference also eliminates
the hose's
capability to carry high axial tension or compression loads while the higher
modulus
characteristic of the plastic matrix material used in a composite tube is
sufficiently stiff to
transfer loads into the fibers and thus resist high external pressure and
axial tension and
compression without collapse.
The procedure to construct a composite tube to resist high external pressure
and
compressive loads involves using complex composite mechanics engineering
principles to
ensure that the tube has sufficient strength. It has not been previously
considered feasible to
build a truly composite tube capable of being bent to a relatively small
diameter, and be
capable of carrying internal pressure and high tension and compression loads
in
combination with high external pressure requirements. Specifically a hose will
not sustain
high compression and external pressure loads.
Moreover, the spoolable tubing commonly used in the industry does not attempt
to identify the ambient conditions experienced by the spoolable tubing during
oil well
operations. These ambient conditions, such as temperature, pressure and axial
strain can
effect down hole operations.
Accordingly, it is one object of this invention to provide an apparatus for
providing a
substantially non-ferrous spoolable tube that does not suffer from the
structural limitations
of steel tubing and that is capable of being deployed and spooled under bore
hole
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3
conditions.
Another object of the invention includes providing a coiled tubing capable of
repeated spooling and bending without suffering fatigue sufficient to cause
fracturing and
failing of the coiled tube.
A further object of the invention is to provide a spoolable composite tube
that
identifies selected ambient conditions.
These and other objects will be apparent from the description that follows.
Summary of the Invention
The invention attains the foregoing objects by providing a composite tubular
member that offers the potential to exceed the performance limitations of
isotropic metals
currently used in forming coiled tubes and that senses the ambient conditions
of the
composite coiled tube. The composite tubular member is formed of a composite
layer and
pressure barrier layer that allows the composite tube to be repeatedly spooled
and unspooled
from a reel.
The composite tubular member, according to the invention, includes a
substantially
fluid impervious pressure barrier layer and a composite layer that together
constitute a wall
of the composite tube, an energy conductor embedded in the wall and extending
along the
length of the tube, and a sensor mounted with the wall. The composite layer is
formed of a
composite of fibers and matrix material. The sensor is connected with the
energy conductor
such that the sensor can communicate a signal by way of the energy conductor.
The sensor
responds to ambient conditions of the composite tubular member by
communicating a
signal on the energy conductor that is responsive to the ambient conditions.
In one aspect of the invention, the sensor can be integrally formed with the
energy
conductor. Sensors integrally formed with the conductor are called intrinsic
sensors.
Other aspects of the invention provide for different types of sensors for
identifying
various ambient conditions. The composite tubular member can include,
individually or in
combination: acoustic sensors, optical sensors, mechanical sensors, electrical
sensors,
fluidic sensors, pressure sensors. strain sensors, temperature sensors, and
chemical sensors.
Optical sensors can be classified as interferometric sensors or as optical
intensity
sensor. Optical intensity sensors include light scattering sensors, spectral
transmission
sensors, radiative loss sensors, reflectance sensors, and modal change
sensors. Another type
of optical sensor is the Bragg grating sensor that can be disposed in a fiber
optic cable.
Mechanical sensors include piezoelectric sensors, vibration sensors, position
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sensors, velocity sensors, strain sensors, and acceleration sensors.
Electrical sensors
includes sensors such as current sensors, voltages sensors, resistivity
sensors, electric field
sensors, and magnetic field sensors; and fluidic sensors include flow rate
sensors, fluidic
intensity sensors, and fluidic density sensors. Another type of sensor, the
pressure sensor,
includes absolute pressure sensors and differential pressure sensors. While
temperature
sensors include thermocouples, resistance thermometers, and optical
pyrometers.
The sensors can be positioned throughout the composite tubular member.
Preferably, the sensor is mounted with the wall formed by the composite layer
and the
pressure barrier layer. In particular, the sensor can be embedded in the
composite layer or
the pressure barrier layer, or sensor can be positioned between the pressure
barrier layer and
the composite layer. Additional aspects of the invention provide for mounting
the sensor to
the inner surface of the composite tubular member.
Further features of the invention include additional sensors that communicate
signals by the energy conductor in the composite tubular member. The first
sensor and any
additional sensors can be distributed along the length of a single energy
conductor, thereby
forming a distributed sensor. These distributed sensors can communicate by way
of the
single energy conductor. In addition, the plurality of sensors forming the
distributed sensor
can be positioned at different locations along the composite tubular member.
Another feature of the invention includes a second energy conductor. In one
embodiment, sensors can be connected in parallel between a first energy
conductor and a
second energy conductor. In another embodiment, the first sensor can be solely
connected to
the first energy conductor, while the second sensor can be only connected to
the second
energy conductor.
The energy conductors can be formed from various energy conducting medium,
including hydraulic medium, pneumatic medium, electrical medium, and optical
medium.
The optical medium includes single-mode optical fiber, multimode optical
fiber, and plastic
optical fiber. Furthermore, the energy conductors can be embedded in the
tubular member
in various orientations. For instance, the energy conductor can extend
helically along the
length of the composite tubular member. Alternatively, the energy conductor
can extend
substantially axially along the length of the composite tube. In addition,
multiple energy
conductor can extend helically or axially along the length of the composite
tube.
The composite tubular member can include other layers besides the pressure
barrier
layer and the composite layer. The composite member can include an interface
layer to aid
CA 02561402 2008-06-27
in the bonding between the pressure barrier layer and the composite layer. The
composite
member can include an inner protective layer or an outer protective layer.
Additionally, the
composite member can include an outer pressure barrier layer. Various
embodiments of the
invention exist which include one or more of the layers described above. In
one
5 embodiment, the spoolable composite tube comprises an inner pressure barrier
layer and an
outer composite layer. In all embodiments, the tube can be designed to include
or exclude
an interface layer sandwiched between the inner pressure barrier layer and the
composite
layer. Other embodiments provide for a composite tube including an inner
pressure barrier
layer, a composite layer, and an outer pressure barrier. Further embodiments
include an
inner pressure barrier layer, a composite layer, an external pressure barrier,
and an external
protective layer. While in an additional embodiment, the composite tube might
include only
an inner pressure barrier layer, a composite layer, and an outer protective
layer. A further
aspect includes an inner protective layer, an inner pressure barrier layer, a
composite layer,
an external pressure barrier, and an external protective layer. The invention
also
contemplates a spoolable tube having an inner composite layer surrounded by
the inner
pressure barrier layer.
The composite tubular member, according to a further aspect of the invention,
can
include an interface disposed at an end of the composite tubular member. The
interface is
also connected with the energy conductor for coupling signals flowing along
the energy
conductor with external equipment. The external equipment can be a signal
processor.
In another aspect of the present invention, there is provided interfacing
apparatus for
a composite spoolable tubular member that has a at least one fluid passage and
that has a set
of one or more energy conductors, a substantially fluid impervious pressure
barrier layer,
and a composite layer formed of fibers and a matrix, the interfacing apparatus
comprising a
combination of pressure sealing means engagable with the spoolable tubular
member for
fluid communication with the fluid passage therein and for maintaining a
pressure
differential between the passage and ambient conditions, load bearing means
engagable
with the spoolable tubular member for the transfer of a mechanical load
between the
spoolable tubular member and the interfacing apparatus, and an energy coupler
for signal
communication with at least one energy conductor of the spoolable tubular
member. The
interfacing apparatus is further arranged for removable and replaceable
engagement with
further equipment.
An additional embodiment of the invention provides for an interfacing
apparatus for
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6
the composite spoolable tubular member. The interfacing apparatus includes a
pressure
sealing element, a load bearing element, and an energy coupler. The pressure
sealing
element is engagable with the spoolable tubular member for fluid communication
with a
fluid passage in the composite tubular member. The pressure sealing element
maintains a
pressure differential between the passage and ambient conditions. The load
bearing element
engages the spoolable tubular member
and transfers a mechanical load between the spoolable tubular member and the
interfacing
apparatus. The energy coupler connects with at least one energy conductor of
the spoolable
tubular member for signal communication.
A further embodiment of the invention provides for a composite tubular member
for
spooling onto a reel and for unspooling for deployment, the composite tubular
member
comprising an inner protective layer, a substantially fluid impervious
pressure barrier layer,
and a composite layer formed of fibers and a matrix. The composite layer and
the pressure
barrier layer and the inner protective layer together constituting a wall of
the tubular
member.
In another aspect, the present invention resides in a composite tubular member
for
spooling in an open bore configuration onto a reel and for unspooling for
deployment, said
composite tubular member comprising (a) a substantially fluid impervious
pressure barrier
layer, (b) a composite layer comprising fibers and a matrix, said composite
layer and said
pressure barrier layer together constituting a wall of said tubular member,
(c) an optical
fiber extending lengthwise along said tubular member; and (d) an optical
sensor integrally
formed with said optical fiber and connected for signal communication by way
of said
optical fiber, so that said optical sensor responds to an ambient condition of
said tubular
member and communicates on said optical fiber a signal responsive thereto
wherein said
sensor is mounted with the wall of said tubular member.
Brief Description of the Drawings
A more complete understanding of the invention may be obtained by reference to
the
drawings in which:
FIGURE 1 is a cross-sectional view of a composite tubular member constructed
according to the invention that includes a liner, a composite layer, an energy
conductor, and
a sensor;
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-7-
FIGURE 2 is a side view of a flattened out composite layer, constructed
according to the invention, that has triaxially braided fiber components and
which is
suitable for constructing the composite layer of the composite tube shown in
FIG. 1;
FIGURE 3 is a cross-sectional view of the composite tubular member of FIG. 1
having an inner liner surrounded by multiple composite layers;
FIGURE 4 is a side view, partially broken away, of a composite tubular member
constructed according to the invention having a liner, an interface layer, and
a composite
layer;
FIGURE 5 is a cross-sectional view of the composite tubular member according
to the invention having a pressure barrier layer, an internal composite layer,
an energy
conductor, and a sensor;
FIGURE 6 is a cross-sectional view of the composite tubular member of FIG. 1
having an inner protective layer;
FIGURE 7 is a cross-sectional view of the composite tubular member of FIG. 1
having an outer pressure barrier layer;
FIGURE 8 is a cross-sectional view of the composite tubular member of FIG. I
having an outer protective layer;
FIGURE 9 is a cross-sectional view of the composite tubular member of FIG. I
having an outer pressure barrier layer and an outer protective layer;
FIGURE 10 is a cross-sectional view of the composite tubular member of FIG. I
having an inner protective layer, an outer pressure barrier layer. and an
outer protective
layer;
FIGURE 11 is a cross-sectional view of the composite tubular member of FIG.
10 having multiple energy conductors and multiple sensors;
FIGURE 12 is a cross-sectional view of the composite tubular member of FIG. 1
having the energy conductor and sensor embedded in the pressure barrier layer;
FIGURE 13 is a cross-sectional view of the composite tubular member of FIG. 1
having the energy conductor and sensor embedded in the composite layer;
FIGURE 14 is a cross-sectional view of the composite tubular member of FIG. 1
having the energy conductor and sensor positioned between the pressure barrier
layer
and the composite layer;
FIGURE 15 is a cross-sectional view of the composite tubular member of FIG. 1
having a second energy conductor helically oriented and connected to a second
sensor;
FIGURE 16 is a cross-sectional view of the composite tubular member of FIG. 1
having a second energy conductor axially oriented and connected to a second
sensor;
FIGURE 17 is a cross-sectional view of the composite tubular member of FIG. I
having the sensor mounted to the composite tubular member;
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FIGURE 18 is a cross-sectional view of the composite tubular member of FIG. I
having a
distributed sensor;
FIGURE 19 is a cross-sectional view of the composite tubular member of FIG. I
having a
plurality of sensors connected in parallel between two energy conductors;
FIGURE 20 illustrates the bending events that occur when running coiled tubing
in and out
of a well bore;
FIGURE 21 illustrates the composite tubular member of FIG. 1 connected to a
signal
processor;
FIGURE 22 illustrates the composite tubular member of FIG. 18 connected to an
optical
signal processor;
FIGURE 23 schematically shows a signal processor connected to multiple energy
conductors embedded within the composite tubular member of FIG. 1; and FIGURE
24 shows an
interface mounted to the composite tubular member of FIG. 1.
Detailed Descrintion of Illustrated Embodiments
Composite fibers (graphite, Kev1arTM, fiberglass, boron, etc.) have numerous
assets
including high strength, high stiffness, light-weight, etc., however, the
stress strain response of
composite fibers is linear to failure and therefore non ductile. Composite
coiled tubing must
therefore address the strain limitations in another manner, i.e., by providing
a construction to meet
the requirements with a near elastic response or with large deformations of
the matrix. Such a
composite arrangement must have high resistance to bending stresses and
internal pressure and
external pressure. It must also have high axial stiffness, high tensile and
compressive strength and
be resistant to shear stress. All of these properties are combined in the
composite tubular member
of the invention to provide a coiled tubing which can be bent to a radius
compatible with winding
onto a reasonable size spool.
P.K. Mallick in the text book entitled Fiber-Reinforced Composites. Materials,
manufacturine and Desi ng. defines a composite in the following manner: "Fiber-
reinforced
composite materials consist of fibers of high strength and modulus embedded in
or bonded to a
matrix with distinct interfaces (boundary) between them. In general, fibers
are the principal load-
carrying member, while the surrounding matrix keeps them in the desired
location and orientation,
acts as a load transfer medium between them, and protects them from
environmental damages due
to elevated temperatures and humidity, for example". This definition defines
composites as used in
this invention with the fibers selected from a variety of available materials
including carbon,
aramid, and glass and the matrix or resin selected from a variety of available
materials including
thermoset
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-9-
resin such as epoxy and vinyl ester or thermoplastic resins such as
polyetheretherketone
(PEEKTm), polyetherketoneketone (PEKK), nylon, etc. Composite structures are
capable of
carrying a variety of loads in combination or independently, including
tension, compression,
pressure, bending, and torsion.
Webster's Ninth New Collegiate Dictionary defines hose as "a flexible tube for
conveying fluids". By comparison, a hose is distinctly different from a
composite tube. Hose
products such as umbilical lines used in subsea application are constructed of
high strength
fibers such as aramid, dacron, or nylon laid down in a geodesic pattern onto a
substrate plastic
liner tubular structure. Alternatively, a hose may be constructed of high
strength fibers with a
low modulus binder such as rubber. In either case, a hose is designed to carry
pressure loads
and to exhibit good bending flexibility, but a hose has very limited ability
to carry
compressive, tension and torsion loads or external pressure. The composite
tube described in
this invention can carry high intemal pressure and it can also carry high
compressive, tension,
extemal pressure, and torsion loads, independently or in combination. Such
capability is
essential if the tubing is to be used for applications such as coiled tubing
in which the tubing is
pushed into a high pressure reservoir and to overcome the friction to movement
within the well
bore, especially for highly deviated or horizontal wells. In addition, the
tube is required to
carry its own weight as it is suspended for 20,000-feet or more in a well bore
and to be able to
have high pulling capability to extract tools or to overcome being stuck from
sand and
circulating solids which have collapsed around the tube. Such loads in the
case of coiled tubing
in deep wells can be in excess of 20,000 pounds. In other applications the
tubing must also be
capable of carrying high torsion loads.
In forming composite structures, several well known techniques may be used
such as
pultrusion, fiber winding, braiding and molding. In pultrusion, fibers are
drawn through a resin
impregnating apparatus, then through dies to provide the desired shape.
Alternatively, the resin
may be injected directly within the die. Heat forming and curing structures
are provided in
conjunction with the dies. In fiber winding, the various layers forming the
composite structure
are each formed by winding or wrapping fibers and a polymer matrix around a
mandrel or some
other underlying structure that provide a desired shape. Successive composite
layers can then be
applied to underlying composite layers. A triaxial braiding structure can be
manufactured using
the fiber winding techniques disclosed in Quigley, U.S. Patent No. 5,188,872
and in Quigley,
U.S. Patent No. RE 35,081.
FIGURE 1 illustrates a composite tube 10 constructed of a substantially fluid
impervious pressure barrier 12 and a composite layer 14. The composite coiled
tube is
generally formed as a member elongated along axis 17. The coiled tube can have
a
CA 02561402 2008-06-27
variety of tubular cross-sectional shapes, including circular, oval,
rectangular, square, polygonal
and the like. The illustrated tube has a substantially circular cross-section.
The composite tube
also includes an energy conductor 70 extending lengthwise along the tubular
member, and a
sensor 72 mounted with the tubular member.
5 The sensor 72 is a structure that senses either the absolute value or a
change in value of
a physical quantity. Exemplary sensors for identifying physical
characteristics include acoustic
sensors, optical sensors, mechanical sensors, electrical sensors, fluidic
sensors, pressure sensors,
temperature sensors, strain sensors, and chemical sensors.
Optical sensors are discussed in the 12 February 1996 edition of the Japanese
10 Technology Evaluation Center Panel on Optoelectronics in Japan and the
United States. Donald
B. Keck authored the chapter on Optical Sensors and Specialty Fibers. The
document is
published by the hlternational Technology Research Institute, JTEC/WTEC
Program, Loyola
College, Baltimore, MD, International Standard Book Number (ISBN) 1883712394.
Optical sensors include intensity sensors that measure changes in the
intensity of one or
more light beams and interferometric sensors that measure phase changes in
light beams caused
by interference between beams of light. Optical intensity sensors can rely on
light scattering,
spectral transmission changes, microbending or radiative losses, reflectance
changes, and
changes in the modal properties of optical fiber to detect measurable changes.
Optical chemical sensors utilize fiber optics to perform remote spectroscopy
(either
absorption or fluorescence) of a substance.
Optical temperature sensors include those sensors that: remotely monitor
blackbody
radiation; identify optical path-length changes, via an interferometer, in a
material having a
known thermal expansion coefficient and refractive index as a function of
temperature; monitor
absorption characteristics to determine temperature; and monitor fluorescence
emission decay
times from doped compositions to determine temperature. For instance, optical
fibers having a
Bragg Grating etched therein can be used to sense temperature with an
interferometer
technique.
Bragg Gratings can also be used to measure strain. Particularly, a refractive
index
grating can be created on a single-mode optical fiber and the reflected and
transmitted
wavelength of light from the grating can be monitored. The reflected
wavelength of light varies
as a function of strain induced elongation of the Bragg Grating. Other optical
sensors measure
strain by stimulated Brillouin scattering and through polarimetry in
birefringent materials.
Hybrid sensors including optical fibers can also be fashioned to detect
electrical and magnetic
fields. Typically, the optical fiber monitors changes in some other material,
such as a piezo
crystal, that changes as a function of electrical or magnetic
CA 02561402 2006-10-16
. õ., ...,.,.,...~...
-11-
fields. For example, the optical fiber can determine dimensional changes of a
piezoelectric or
piezomagnetic material subjected to electric or magnetic fields, respectively.
Bragg Gratings
in an optical fiber can also be used to measure high magnetic fields. In
particular, the Naval
Research Laboratory has identified that the reflectance of a Bragg Grating as
a function of
wavelength differed for right and left circularly polarized light. The Naval
Research
Laboratory observed that magnetic fields can be detected by
interferometrically reading the
phase difference due to the Bragg Grating wavelength shifts.
Fiber optic sensors for measuring current also exist. Hoya Glass and Tokyo
Electric
Power Co. identified that a single-mode optical fiber made of flint glass
(high in lead) can be
used to sense current. Current is measured by observing the rotation of
polarized light in the
optical fiber.
Optical pressure sensors exist that rely on movable diaphragms, Fabry-Perot
interferometers, or microbending. The movable diaphragm typically senses
changes in
pressure applied across the diaphragm using piezoresistors mounted on the
diaphragm. The
resistance of the piezoresistors varies as the diaphragm flexes in response to
various pressure
levels. The Fabry-Perot interferometers can include one two parallel
reflecting surfaces
wherein one of the surfaces moves in response to pressure changes. The
interferometers then
detects the movement of the surface by comparing the interference patterns
formed by light
reflecting of the moving surface. Microbending sensors can be formed of two
opposing
serrated plates that bend the fiber in response to the pressure level. The
signal loss in the fiber
resulting from the movement of the opposing serrated plates can be measured,
thereby
sensing displacement and pressure change.
Various optical sensors exist for measuring displacement and position. Simple
optical
sensors measure the change in retroreflectance of light passing through an
optical fiber. The
change in retroreflectance occur as a result of movement of a proximal mirror
surface.
Additionally, optical sensors can be employed to measure acoustics and
vibration.
For example, an optical fiber can be wrapped around a compliant cylinder.
Changes in
acoustic waves or vibrations flex the cylinder and in turn stress the coil of
optical fiber. The
stress on the optical fiber can be measured interferometrically and is
representative of the
acoustic waves or vibrations impacting the cylinder.
Mechanical sensors suitable for deployment in the composite tubular member 10
include piezoelectric sensors, vibration sensors, position sensors, velocity
sensors, strain
gauges, and acceleration sensors. The sensor 72 can also be selected from
those electrical
sensors, such as current sensors, voltage sensors, resistivity sensors,
electric field sensors,
and magnetic field sensors. Fluidic sensors appropriate for selection as the
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sensor 72 include flow rate sensors, fluidic intensity sensors, and fluidic
density sensors.
Additionally, the sensor 72 can be selected to be a pressure sensor, such as
an absolute
pressure sensor or a differential pressure sensor. For example, the sensor 72
can be a =
semiconductor pressure sensor having a moveable diaphragm with piezoresistors
mounted thereon.
The sensor 72 can be also selected to be a temperature sensor. Temperature
sensors include thermocouples, resistance thermometers, and optical
pyrometers. A
thermocouple makes use of the fact that junctions between dissimilar metals or
alloys in
an electrical circuit give rise to a voltage if they are at different
temperatures. The
resistance thermometer consists of a coil of fine wire. Copper wires lead from
the fine
wire to a resistance measuring device. As the temperature varies the
resistance in the
coil of fine wire changes.
FIGURE 1 also illustrates an energy conductor connected to the sensor 72 and
embedded in the composite tubular member. The energy conductor 70 can be
either a
hydraulic medium, a pneumatic medium, an electrical medium, an optical medium,
or
any material or substance capable of being modulated with data signals or
power. For
example, the energy conductor can be a fluid impermeable tube for conducting
hydraulic
or pneumatic energy along the length of the composite tube. The hydraulic or
pneumatic
energy can be used to control or power the operation of a machine, such as
activating a
valve, operably coupled to the composite tube. Alternatively, the energy
conductor can
be an electrically conductive medium, such as copper wire, for transmitting
control,
data, or power signals to an apparatus operably coupled to the composite tube.
The
energy conductor can also be selected from optical medium, such as fiber
optics, for
transmitting an optical signal along the composite tube. Different types of
fiber optics,
such as single-mode fibers, multimode fibers, or plastic fibers, may be more
suited
depending upon the type of sensor 72 that is connected to the conductor 70.
The
composite tube can include one or more of the described energy conductors.
The hydraulic control line embodiment of the energy conductor 70 used in the
composite tube 10 can be either formed of metal or of a polymeric material. In
the case
of a metal control line, the metals forming the hydraulic line can include,
individually or
in combination, steel, copper, titanium, lead, or stainless steel. Hydraulic
control lines
typically have a diameter less than 1/2 an inch. In the case of a polymeric
hydraulic line,
the polymeric materials making up the hydraulic line can be thermoplastic or
thermoset
materials, or metal/polymer composites. For instance, the hydraulic line can
be formed
of homo-polymers, co-polymers, composite polymers, or co-extruded composite
polymers. The polymeric materials forming the hydraulic line are preferably
selected
from a group of various polymers, including but not limited to: polyvinylidene
fluoride,
CA 02561402 2006-10-16
-13-
etylene tetrafluoroethylene, cross-linked polyethylene ("PEX"), polyethylene,
and polyester.
Further exemplary thermoplastic polymers include materials such as
polyphenylene sulfide,
polyethersulfone, polyethylene terephthalate, polyamide, polypropylene, and
acetyl.
The hydraulic line can also include fibers to increase the load carrying
strength of the
hydraulic line and the overall load carrying strength of the spoolable
composite tube 10.
Exemplary composite fibers include graphite, KevlarTM, fiberglass, boron, and
polyester fibers,
and aramid.
The hydraulic line embodiment of the energy conductor 70 can be formed to be
resistive to corrosive chemicals such as heterocyclic amines, inorganic sulfur
compound, and
nitrogenous and acetylenic organic compounds. Three types of material,
polyvinylidene
fluoride ("PVDF"), etylene tetrafluoroethylene ("ETFE"), and polyethylene
("PE"), have been
found to meet the severe chemical exposure characteristics demanded in
particular applications
involving composite coiled tubing. Two particularly attractive materials for
the hydraulic line
are the RC 10-089 grade of PVDF, manufactured by Atochem, and Tefzel
manufactured by
DuPont.
In other aspects, the hydraulic line embodiment of the energy conductor 70
comprises
co-polymers formed to achieve enhanced characteristics, such as corrosion
resistance, wear
resistance and electrical resistance. For instance, a hydraulic line can be
formed of a polymer
and an additive such that the hydraulic line has a high electrical resistance
or such that the
hydraulic line dissipates static charge buildup within the composite tube 10.
In particular,
carbon black can be added to a polymeric material to form a hydraulic line
having a resistivity
on the order of 10 ohms/centimeter.
As further illustrated in FIGURE 1, the composite layer 14 and the pressure
barrier 12
constitute a wall 74 of the tubular member 10. The energy conductor 70 is
embedded within the
wal 174, and the sensor 72 is mounted with the wall 74 of the tubular member.
The sensor is
connected with the energy conductor such that a signal generated by the sensor
can be
communicated by way of the energy conductor 70. For instance, the sensor 72
can generate a
signal responsive to an ambient condition of the tubular member 10 and the
sensor can
communicate this signal on the energy conductor 70.
A sensor 72 mounted with the wall is interpreted within the scope of this
document to
include a sensor attached to the exterior of the wall or a sensor disposed
within the wall. For
instance, a sensor 72 mounted with the wall 74 can be a sensor disposed within
the pressure barrier
layer 12 as illustrated in FIG. 12, or it can be a sensor disposed within the
composite layer 14 as
illustrated in FIG. 13; or it can be a sensor positioned between the pressure
barrier layer 12 and the
composite layer 14 as
CA 02561402 2006-10-16
-14-
illustrated in FIG. 14. Moreover, a sensor 72 mounted with the wall 74 can be
a sensor
mounted to the exterior of the wall, as shown in FIG. 17.
Pressure barrier layer 12 serves as a pressure containment member to resist
leakage of
intemal fluids from within the composite tube 10. In one embodiment the
pressure barrier layer
12 is metallic, in a second embodiment the pressure barrier layer 12 is formed
of polymeric
materials, and in a third embodiment the pressure barrier layer is formed of a
metal/polymer
composite such as a metal and polymer foil. The polymeric materials forming
the layer 12 can
have an axial modulus of elasticity exceeding 100,000 psi. A pressure barrier
layer 12 having a
modulus exceeding 100,000 psi is preferable as it is indicative of a tube
capable of carrying
high internal pressure. In addition, a pressure barrier layer with an axial
modulus of elasticity
less than 500,000 psi advantageously allows the pressure barrier layer to
bend, rather than pull
away from the composite layer, as the composite tube is spooled or bent around
a reel.
In the case of a metal pressure barrier layer, the metals forming the pressure
barrier
layer can include, individually or in combination, steel, titanium, lead,
copper, or stainless
steel. In the case of a polymeric pressure barrier layer, the polymeric
materials making up the
pressure barrier layer 12 can be thermoplastic or thermoset materials. For
instance, the pressure
barrier layer can be formed of homo-polymers, co-polymers, composite polymers,
or co-
extruded composite polymers. Homo-polymers refer to materials formed from a
single
polymer, co-polymers refers to materials formed by blending two or more
polymers, and
composite polymers refer to materials formed of two or more discrete polymer
layers that have
been permanently bonded or fused. The polymeric materials forming the inner
pressure barrier
layer are preferably selected from a group of various polymers, including but
not limited to:
polyvinylidene fluoride, etylene tetrafluoroethylene, cross-linked
polyethylene ("PEX"),
polyethylene, and polyester. Further exemplary thermoplastic polymers include
materials such
as polyphenylene sulfide, polyethersulfone, polyethylene terephthalate,
polyamide,
polypropylene, and acetyl.
Pressure barrier layer 12 can also include fibers to increase the load
carrying strength of
the pressure barrier layer and the overall load carrying strength of the
spoolable composite tube
10. Exemplary composite fibers include graphite, KevlarTM, fiberglass, boron,
and polyester
fibers, and aramid.
The pressure barrier layer 12 can be formed to be resistive to corrosive
chemicals such
as heterocyclic amines, inorganic sulfur compound, and nitrogenous and
acetylenic organic
compounds. Three types of pressure barrier layer material, polyvinylidene
fluoride ("PVDF"),
etylene tetrafluoroethylene ("ETFE"), and polyethylene ("PE"), have been found
to meet the
severe chemical exposure
CA 02561402 2006-10-16
-15-
characteristics demanded in particular applications involving composite coiled
tubing.
Two particularly attractive materials for the pressure barrier layer are the
RC 10-089
grade of PVDF, manufactured by Atochem, and Tefzel manufactured DuPont.
In other embodiments of pressure barrier layer 12, the pressure barrier layer
comprises co-polymers formed to achieve enhanced pressure barrier layer
characteristics, such as corrosion resistance, wear resistance and electrical
resistance.
For instance, a pressure barrier layer 12 can be formed of a polymer and an
additive such
that the pressure barrier layer has a high electrical resistance or such that
the pressure
barrier layer dissipates static charge buildup within the composite tube 10.
In particular,
carbon black can be added to a polymeric material to form a pressure barrier
layer 12
having a resistivity on the order of 108 ohms/centimeter. Accordingly, the
carbon black
additive forms a pressure barrier layer 12 having an increased electrical
conductivity that
provides a static discharge capability. The static discharge capability
advantageously
prevents the ignition of flammable fluids being circulated within the
composite coiled
tube 10.
In a further aspect of the invention, the pressure barrier layer 12 has a
mechanical
elongation of at least 25%. A pressure barrier layer with a mechanical
elongation of at
least 25% can withstand the increased bending and stretching strains placed
upon the
pressure barrier layer as it is coiled onto a reel and inserted into and
removed from
various well bores. Accordingly, the mechanical elongation characteristics of
the
pressure barrier layer prolong the overall life of the composite coiled tube
10. In
addition, the pressure barrier layer 12 preferably has a melt temperature of
at least 2500
Fahrenheit so that the pressure barrier layer is not altered or changed during
the
manufacturing process for forming the composite coiled tubing. A pressure
barrier layer
having these characteristics typically has a radial thickness in the range of
0.02 - 0.25
inches.
The pressure barrier layer can act as a vehicle for transmitting chemicals
that act
upon the interior of the well bore, and the pressure barrier layer can also
provide a
conduit for transmitting fluids that power or control machines operably
coupled with the
composite tube.
The composite layer 14 can be formed of a number of plies, each ply having
fibers disposed with a matrix, such as a polymer, resin, or thermoplastic.
Preferably, the
matrix has a tensile modulus of at least 250,000 psi and has a maximum tensile
eIongation of at least 5% and lias a glass transition temperature of at least
180 Degrees
Fahrenheit. The fibers typically comprise structural fibers and flexible yarn
components. The structural fibers are formed of either carbon, nylon,
polyester, aramid,
thennoplastic, or glass. The flexible yarn components, or braiding fibers, are
formed of
CA 02561402 2006-10-16
-16-
either nylon, polyester, aramid, thermoplastic, or glass. The fibers included
in layer 14
can be woven, braided, knitted, stitched, circumferentially wound, or
helically wound.
In particular, the fibers can be biaxially or triaxially braided. The
composite layer 14
can be formed through pultrusion processes, braiding processes, or continuous
filament
winding processes. A tube formed of the pressure barrier layer 12 and the
composite
layer 14 form a composite tube has a tensile strain of at least 0.25 percent
and being
capable of maintaining an open bore configuration while being spooled on a
reel.
The pressure barrier layer 12, illustrated in FIG. 1, can also include grooves
or
channels on the exterior surface of the pressure barrier layer. The grooves
increase the
bonding strength between the pressure barrier layer 12 and the composite layer
14 by
supplying a roughened surface for the fibers in the composite layer 14 to
latch onto. The
grooves can further increase the bonding strength between the pressure barrier
layer 12
and the composite layer 14 if the grooves are filled with a matrix. The matrix
acts as a
glue, causing the composite layer to be securely adhered to the underlying
pressure
barrier layer 12. Preferably, the grooves are helically oriented on the
pressure barrier
layer relative to the longitudinal axis 17.
FIGURE 2 shows a "flattened out" view of a preferred composite layer 14 having
a fiber component 20 interwoven with a plurality of like or different fiber
components,
here shown as a clockwise helically oriented fiber component 16 and a
counterclockwise
helically oriented fiber component 18. The configuration of layer 14 shown in
FIGURE
2, is appropriately denoted as a "triaxially braided" ply. The fiber
components 16, 18,
20 are suspended in a matrix 22.
HeIically oriented fibers are fibers that follow a spiral path. Typically,
helical
fibers spiral around a mandrel underlying the composite tube or they spiral
around
underlying layers of the composite tube. For example, a helically oriented
fiber follows
a path comparable to the grooves around the shaft of a common screw. A helical
fiber
can be described as having an axial vector, an angle of orientation, and a
wrapping
direction. The axial vector indicates that the helical fiber can follow a path
along the
length of the tube 10 as it spirals around the tube, as opposed to a fiber
that continually
wraps around a particular section of the tube 10 without extending along the
length of
the tube. The angle of orientation of the helical fiber indicates the helical
fiber's angle
relative to a defined axis, such as the longitudinal axis 17. For example, a
helical fiber
having an angle of 0 degrees is a fiber that extends parallel to the
longitudinal axis and
that does not wrap around the tube 10, while a fiber having an angle of 90
degrees
circumferentially wraps around the tube 10 without extending along the length
of the
tube. The wrapping direction of the helical fiber is described as either
clockwise or
counter-clockwise wrapping around the tube 10.
CA 02561402 2006-10-16
-17-
The fiber components can be formed of carbon, glass, aramid (such as kevlar
or twaron ), thermoplastic, nylon, or polyester. Preferably, fibers 16 and 18
act as
braiding fibers and are formed of either nylon, polyester, aramid,
thermoplastic, or glass.
Fiber 20 acts as a structural fiber and is formed of either carbon, glass, or
aramid. Fiber
20 increases the axial strength of the composite layer 14 and the spoolable
tube 10.
The matrix material 22 is generally a high elongation, high strength, impact
resistant polymeric material such as epoxy. Other altemative matrixes include
nylon-6,
vinyl ester, polyester, polyetherketone, polyphenylen sulfide, polyethylene,
polypropylene, and thermoplastic urethanes.
Fiber 20 extends helically or substantially axially relative to the
longitudinal axis
17. The helically oriented fiber component 16 and 18 tend to tightly bind the
longitudinal fiber component 20 with the matrix material 22 in addition to
providing
increased bending stiffness along axis 17 and increased tortional strength
around axis 17.
The helically oriented fiber components 16 and 18 can be interwoven amongst
themselves. To this end, successive crossings of two fiber components 16 and
18 have
successive "over" and "under" geometries.
In one aspect of the invention, the composite layer includes a triaxial braid
that
comprises an axially extending fiber component 20, a clockwise extending
second fiber
component 16 and a counter-clockwise extending third fiber component 18,
wherein the
fiber 20 is interwoven with either fiber 16 or fiber 18. Each helicallv
oriented fiber 16.
18 can therefor be considered a braiding fiber. In certain aspects of the
invention, a
single braiding fiber, such as fiber 16 binds the fiber component of a given
ply together
by interweaving the braiding fiber 16 with itself and with the axially
extending fiber 20.
A fiber is interwoven with itself, for example, by successively wrapping the
fiber about
the member and looping the fiber with itself at each wrap.
In another aspect of the invention, axially extending structural fiber 20 is
oriented relative to the longitudinal axis 17 at a first angle 28. Typically,
fiber 20 is
helically oriented at the first angle 28 relative to the longitudinal axis 17.
The first angle
28 can vary between 5 - 20 , relative to the axis. The first angle 28 can
also vary
between 30 - 70 , relative to the axis 17. Although it is preferred to have
fiber 20
oriented at an angle of 45 relative to axis 17.
The braiding fiber 16 is oriented relative to structural fiber 20 at a second
angle
24, and braiding fiber 18 is oriented relative to structural fiber 20 at a
third angle 26.
The angle of braiding fibers 16 and 18, relative to structural fiber 20, may
be varied
between +\- 10 and +\- 60 . In one aspect of the invention, fibers 16 and 18
are
oriented at an angle of +\- 20 relative to fiber 20.
CA 02561402 2006-10-16
-18-
One failure mechanism of the composite tube during loading, especially under
bending/pressure and tension and compression loading, is believed to be the
development of micro-cracks in the resin and the introduction of microscopic
defects =
between fibers. The development of some micro-cracks is also believed to be
inevitable
due to the severe loads placed on the tube during the manufacturing and
bending of the
tube. However, the effects of these micro-cracks and microscopic defects can
be
retarded by restraining the growth and accumulation of the micro-cracks and
microscopic defects during the manufacturing and use of the composite coiled
tube. The
applicants have discovered that the selection of fibers 16 and 18 from the
group of fibers
consisting of nylon, polyester, glass and aramid mitigates and stops the
growth of the
microscopic defects. Thus, the selection of fibers 16 and 18 from the
particularly noted
materials improves the damage tolerance and fatigue life of the composite
coiled tubing
10.
Applicant has further detenmined that the total volume of any particular
fibrous
material in any selected layer of the composite coiled tube affects the
overall mechanical
characteristics of the composite coiled tube 10, including a reduction in
crack
propagation. It additionally follows that the total volume of any particular
fibrous
material in the whole composite coiled tube also affects the mechanical
characteristics of
the composite coiled tube 10. A composite coiled tube having improved strength
and
durability characteristics is obtained by forming a composite layer 14 wherein
the
combined fiber volume of the clockwise extending and counter-clockwise
extending
braiding fibers 16 and 18 constitute less than 20% of the total fiber volume
in the
composite layer 14. Further in accordance with this embodiment, the fiber
volume of
the axially extending fiber 20 should constitute at least 80% of the fiber
volume of the
composite layer 14. Preferably, the first composite layer 14 includes at least
80% by
fiber volume of substantially continuous fibers oriented relative to the
longitudinal axis
17 of the tube at an angle between 30-70 degrees.
When the matrix 20 is added to composite layer 14, the volume of matrix in the
layer 14 typically accounts for 35% or more of the volume in the composite
layer 14.
Accordingly, the combined volume of all the fibers in composite layer 14
account for
less than 65% of the volume of the composite layer 14. It is thus evident,
that the
volume of fibers 16 and 18 account for less than 13% of the total volume of
the
composite layer 14 and that the volume of fiber 20 accounts for at least 52%
of the total
volume of the composite layer 14.
Matrix 20 in composite layer 14 is selected such that transverse shear strains
in
the laminar can be accommodated without breaching the integrity of the coil
composite
tube 10. The strains generally is the result of bending the spoolable
composite tube over
CA 02561402 2008-06-27
19
the reel. These strains do not impose significant axial stresses on the fiber,
but they do impose
significant stresses on the matrix 20. Accordingly, matrix 20 should be chosen
such that the
maximal tensile elongation is greater than or equal to 5%. The Applicant has
further shown that
choosing a matrix having a tensile modulus of at least 100,000 psi adds to the
ability of the coil
composite tube to withstand excessive strain due to bending. In accordance
with the further
aspect of the invention, the matrix 20 also has a glass transition temperature
of at least 180
Fahrenheit so that the characteristics of the resin are not altered during
high temperature uses
involving the coiled composite tube 10. The tensile modulus rating and the
tensile elongation
ratings are generally measured as the coil composite tube is being
manufactured at 70
Fahrenheit. Matrix materials having these characteristics include epoxy, vinyl
ester, polyester,
urethanes, phenolics, thermoplastics such as nylon, polyropelene, and PEEKTM.
FIGURE 3 illustrates a coiled composite tube 10 having an inner pressure
barrier layer
12, a first composite layer 14A, a second composite layer 14B, a third
composite layer 14C. and
the sensor 72 embedded within the composite layers. Each of the composite
layers is formed of
fibers embedded in a matrix, and each of the composite layers successively
encompasses and
surrounds the underlying composite layer or pressure barrier layer 12. At
least one of the
composite layers, 14A. 14B, 14C, includes a helically oriented fiber in a
matrix. Preferably, at
least one of the composite layers 14A, 14B, 14C. contains a ply as described
in FIG. 2. In
particular, one of the composite layers 14A, 14B, 14C, has a first helically
extending fiber, a
second clockwise extending fiber, and a third counterclockwise extending fiber
wherein the first
fiber is interwoven with at least one of the second and third fibers. The
other two composite
layers contain fiber suspended in a matrix. The fibers can be axially
extending,
circumferentially wrapped, or helically wrapped, biaxially braided or
triaxially braided.
According to one aspect of the invention, the fibers in each of the composite
layers are
all selected from the same material. In other aspects of the invention, the
fibers in each of the
composite layers are all selected from the different materials. For example,
composite layer 14A
can comprise a triaxially braided ply having clockwise and counter-clockwise
helically oriented
fibers formed of polyester and having a helically extending fiber formed of
glass; composite
layer 14B can coinprise a ply having a circumferentially wound kevlar fiber;
and composite
layer 14C can comprise a triaxially braided ply having a clockwise and counter-
clockwise
helically oriented fibers formed of glass and having a helically extending
fiber formed of
carbon.
CA 02561402 2006-10-16
-20-
The Applicant's have discovered that additional composite layers beyond the
initial
composite layer 14 of FIG. 1, enhance the capabilities of the coiled composite
tube. In
particular, the interaction between the additional composite layers creates a
synergistic effect
not found in a single composite layer. The Applicant discovered that composite
layers having
carbon fibers carry proportionately more of the load as the strain in the
coiled composite tube
increases, as compared to an equivalent design using glass fibers or aramid
fibers. While a
composite layer using KevlarTM (i.e. aramid) fibers provide excellent
pressure/cyclical
bending capabilities to the coiled composite tube 10. The KevlarTM fibers have
a weakness
10 when compared to the carbon fibers in compressive strength. Accordingly, a
coiled
composite tube 10 incorporating both KevlarTM and carbon fibers provides a
composite
structure having improved characteristics not found in composite structures
having composite
layers formed of only carbon fibers or only KevlarTM fibers.
Accordingly, one aspect of the invention incorporates a composite layer 14A
formed
of carbon fibers and polyester fibers in a triaxially braided structure and a
second composite
layer 14B formed of KevlarTM fibers. The KevlarTM fibers can be incorporated
into either a
conventional bi-axial braid, triaxial braid. or helical braid. For instance,
the second composite
layer can include two sets of aramid fibers bi-axially braided together. The
coiled composite
tube 10 having an inner composite layer 14A formed with carbon fibers and an
exterior
composite layer 14B formed with KevlarTM fibers provides a coiled composite
tube having
balanced strength in two directions and provides a coiled composite tube
having a
constricting force which helps restrain the local buckling of delaminated
sublamina and
subsequent delamination growth, thereby improving the fatigue resistance of
the coiled
composite tube 10. Certainly, this aspect of the invention can include a third
composite layer
14C external to the second composite layer 14B. The third composite layer 14C
can, for
instance, include a matrix and a fiber helically oriented relative to the
longitudinal axis 17.
In another aspect of the invention, as illustrated in FIGURE 3, the composite
layer 14A
comprises a triaxially braided ply having an axially extending fiber formed of
carbon and having a
clockwise extending fiber and a counter-clockwise extending fiber both formed
of polyester. In
addition, the helically extending fiber 20 is oriented at an 45 angle to the
axis of the coiled
composite tube 10. Further in accordance with this embodiment, composite layer
14B is triaxially
braided and comprises a helically extending fiber formed of carbon and
oriented at an angle of 45
relative to the axis 17 of coiled composite tube 10. Composite layer 14B
further includes a
clockwise extending second fiber and a counter-clockwise extending third fiber
formed of
polyester. The third composite layer 14C, is biaxially braided, and comprises
a KevlarTM
CA 02561402 2006-10-16
= -21-
fiber extending helically and oriented at a 54 angle to the axis 17 of the
composite
coiled tube 10.
= FIGURE 4 illustrates a composite coiled tube elongated along an axis 17 and
having an inner pressure barrier layer 12, an interface layer 56, and a
composite layer 14.
The sensor 72 and the energy conductor 70 are shown embedded in the composite
layer
14 of the composite member 10. The interface layer 56 surrounds the pressure
barrier
layer 12 and is sandwiched between the pressure barrier layer 12 and the
composite layer
14. The interface layer 56 improves the bonding between the inner pressure
barrier layer
12 and the composite layer 14.
Preferably, the pressure barrier layer 12 is integrally attached to the
composite
layer 14. However, in alternative embodiments the pressure barrier layer 12
can be non-
bonded or partially bonded to the composite'layer 14. During certain operating
conditions experienced in down hole service, the external surface of the tube
will be
subjected to higher pressure than the interior of the tube. If the pressure
barrier layer is
not bonded to the composite layer 14, the external pressure could force the
pressure
barrier layer to buckle and separate from the composite layer such that the
pressure
barrier layer collapses. In addition, loading and bending of the tube may
introduce
microscopic cracks in the composite layer 14 which could serve as microscopic
conduits
for the introduction of extemal pressure to be applied directly to the outer
surface of the
pressure barrier layer 12. Once again, these extemal pressures could cause the
pressure
barrier layer 12 to collapse. The interface layer 56 provides a mechanism for
bonding
the pressure barrier layer 12 to the composite layer 14 such that the pressure
barrier layer
does not collapse under high external pressures. The interface layer 56 can
also reduce
cracking and the propagation of cracking along the composite layer 14 and
pressure
barrier layer 12.
In accordance with one aspect of the invention, the interface layer 56
comprises a
fiber reinforced matrix where the fiber volume is less than 40% of the total
volume of
the interface layer 56. The matrix and the fiber forming interface layer 56
predominately act as an adhesive layer that bonds the pressure barrier layer
12 to the
composite layer 14. The fibers within the interface layer 56 can be oriented
in various
ways, including a woven or non-woven structure. Preferably, the fibers within
the
interface layer 56 are polyester fibers. An interface layer having this
structure is able to
prevent the pressure barrier layer from separating from the composite layer
even when
the differential pressure between the exterior and interior of the tube 10
exceeds 1,000
psi.
CA 02561402 2006-10-16
-22-
The matrix within the interface layer 56 can comprise a filled polymeric layer
or
an unfilled polymeric layer. A filled polymeric layer uses a polymeric matrix
having
additives that modify the properties of the polymeric layer. The additives
used in the
filled polymeric layer include particulates and fibers. For instance, carbon
black powder
can be added to the polymeric layer to increase the conductivity of the
interface layer 56,
or chopped glass fibers can be added to the polymeric layer to increase the
stiffness of
the interface layer 56.
According to a further embodiment of the invention, the interface layer has an
axial modulus of elasticity that lies between the modulus of the elasticity of
the pressure
banier layer 12 and the modulus of elasticity of the composite layer 14. The
interface
layer 56 thus has a modulus of elasticity that transitions between the modulus
of
elasticity of the pressure barrier layer 12 and the composite layer 14. By
providing a
transitional modulus of elasticity, the interface layer aids in preventing the
pressure
barrier layer 12 from pulling away from the composite layer 14 during the
bending
action of the composite coiled tube 10.
The interface layer 56 furthermore increases the fatigue life of the coiled
composite tube 10. The structure of the interface layer 56 achieves this by
dissipating
shear stress applied along the length of the coiled composite tube 10. By
dissipating the
shear, the interface layer reduces cracking and the propagation of cracks
along the
composite layer 14.
FIGURE 5 illustrates a composite tube 10 elongated along axis 17 and
constructed of a substantially fluid impervious pressure barrier 12 and a
composite layer
14. The composite tubular member includes an energy conductor 70 extending
lengthwise along the tubular member, and a sensor 72 mounted with the tubular
member. The energy conductor 70 and the sensor 72 are embedded in the
composite
layer 14.
The embodiment of the composite tube 10 shown in FIG. 5 has a pressure barrier
layer positioned outside of the composite layer 14. In accordance with this
embodiment
of the invention, the composite layer 14 acts to reduce wear or damage to the
pressure
barrier layer 14 caused by the environmental factors within the tube or caused
by
substances within the interior of the tube 10.
In accordance with a further embodiment of the invention, the composite tube
of
FIG. 5 can be formed without the energy conductor 70 and without the sensor
72. This
tubular member is formed having an inner composite layer enclosed by a
pressure
barrier. Additional layers can then be added to this tubular member. The
additional
layers added include the layer illustrated in FIGURE 10.
CA 02561402 2006-10-16
-23-
FIGURE 6 illustrates a composite tubular member 10 having an inner pressure
barrier
layer 12, a composite layer 14, and an inner protective layer 80. The energy
conductor 70 and
the sensor 72 are embedded in the composite tube 10. Particularly, the
conductor and sensor
are embedded in a wall of the composite tube 10, wherein the composite layer
14 and the
pressure barrier layer 12 constitute the wall. The conductor and sensor are
not typically
embedded in the protective layer 80.
The inner protective layer 80 provides resistance to substances passing within
the
composite tubular member 10, such as corrosive fluids or wire line. The inner
protective layer
can be formed of a filled or unfilled polymeric layer, or the inner protective
layer can be
formed of a metal. Alternatively, the inner protective layer 80 can be formed
of a fiber, such
as KevlarT'" or glass, and a matrix. The fibers of the inner protective layer
80 can be woven in
a mesh or weave pattern, or the fibers can be braided or helically braided.
It has further been discovered by the Applicant that particles can be added to
the inner
protective layer to increase the wear resistance of the inner protective layer
80. The particles
used can include any of the following, individually or in combination with one
another:
ceramics, metallics, polymerics, silicas, or fluorinated polymers. Adding
Teflon (MP 1300)
particles and an aramid powder (PD-1' polymer) to the matrix of the inner
protective layer 80
has been found to be one effective way to reduce friction and enhance wear
resistance.
In the case where the inner protective layer includes fibers, the particles
added to the
inner protective layer 80 are such that they consist of less than 20% by
volume of the matrix.
In the case where the inner protective layer does not contain fiber, a
particulate such as
Teflon MP 1300 can also be added to the polymeric protective layer. When the
inner layer
80 does not include fiber, the particles typically comprise less than 60% by
coating volume of
the inner protective layer 80.
FIGURE 7 illustrates a composite coiled tube elongated along an axis 17 and
having
an inner pressure barrier layer 12, a composite layer 14, and an outer
pressure barrier layer
58. The pressure barrier layer 58 prevents gases or liquids (i.e. fluids)
located externally of
the tube 10 from penetrating into the composite coiled tube.
It is important for two reasons that fluids not penetrate into the composite
layer 14.
First, a fluid that penetrates through the tube 10 to pressure barrier layer
12 can build up to a
sufficient level of pressure capable of collapsing the pressure barrier layer
12. Second, a fluid
that penetrates the coiled composite tube 10 during exposure in the well bore
36 may outgas
when the coil composite tube 10 is returned to atmospheric pressure.
CA 02561402 2006-10-16
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Accordingly, a coiled composite tube 10 can function effectively without a
pressure barrier layer 58 under certain conditions. For example, when micro-
fractures
and defects in the composite layer 14 do not develop to a size that allows
fluids to
penetrate the composite layer 14, a pressure barrier layer is not necessary.
However,
when micro-fractures and passages through the composite layer 14 do allows for
the migration of fluids the use of a pressure barrier layer 58 is preferred.
As illustrated in
FIG. 7, the pressure barrier layer 58 generally is positioned outside of the
composite
layer 14.
The pressure barrier layer 58 can be formed of a metal, thermoplastic,
thermoset
films, an elastomer such as a rubber sheet, or metal/polymer composites such
as a metal
polymer foil. All these various materials can function as a pressure barrier
because they
substantially prevent the diffusion of fluids. Preferable properties of the
pressure barrier
layer include low permeability to fluids (i.e., gases or liquids), high
elongation, and
bondability to composite layer 14. lt is also preferred that the pressure
barrier layer 58
have a minimum tensile elongation of 10% and an axial modulus of elasticity of
less
than 750,000 psi. These values of tensile elongation and modulus of elasticity
are
measured at 70 Fahrenheit during the manufacturing of the coiled composite
tube 10.
The permeability of the pressure barrier layer should be less than 0.4 x 10 to
the -10 ccs
per sec-cm2-cm-cmhg.
The impermeable pressure barrier layer 58 can be formed of an impermeable
films formed of metals or polymers. For instance, acceptable polymeric films
include
films formed of polyester, polyimide, polyamide, polyvinyl fluoride,
polyvinylidene
fluoride, polyethylene, and polypropylene, or other thermoplastics.
The impermeable film of layer 58 can be a seamless polymer layer which is
coextruded or formed via a powder deposition process. Alternatively, the
impermeable
film can be helically wrapped or circumferentially wrapped around the
composite layer
to form an overlapping and complete barrier. That is, the fiber or material
forming the
pressure barrier layer must be wrapped in such a fashion that no gaps exist
and the
pressure barrier layer 58 is sealed.
Another aspect of the invention provides for a pressure barrier layer 58
having a
fused particle coating. A fused particle coating is formed by grinding a
polymeric
material into a very fine powder. The fine powder is then heat-fused onto the
other
materials forming the pressure barrier layer 58 or onto the underlying
composite layer
14.
FIGURE 8 illustrates an embodiment of the composite tubular member 10
having an inner pressure barrier layer 12, a composite layer 14, and an outer
protective
CA 02561402 2006-10-16
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layer 60. The composite tube 10 also includes the energy conductor 70 and the
sensor 72
embedded within the composite layer 14.
Outer protective layer 60 provides abrasion resistance and wear resistance by
forming an
outer surface to the coil composite tube that has a low co-efficient of
friction thereby causing
objects to slip off the coiled composite tube. In addition, the outer
protective layer 60 provides a
seamless layer for holding the inner layers of the coiled composite tube
together. The outer
protective layer can be formed of a filled or unfilled polymeric layer,
spirally wrapped films, or
metal/polymer composites. Alternatively, the outer protective layer 60 can be
formed of a fiber,
such as KevlarTi" or glass, and a matrix. The fibers of the outer protective
layer 60 can be woven
in a mesh or weave pattern around the inner layers of the coiled composite
tube 10, or the fibers
can be braided or helically braided around the inner layers of tube 10. In
either case, the fibers in
the outer protective layer are wrapped helically around the inner layers of
the coiled composite
tube 10 in order to provide a seamless structure.
It has further been discovered by the Applicant that particles can be added to
the outer
protective layer to increase the wear resistance of the outer protective layer
60. The particles
used can include any of the following, individually or in combination with one
another:
ceramics, metallics, polymerics, silicas, or fluorinated polymers. Adding
Teflon (MP 1300)
particles and an aramid powder (PD-T polymer) to the matrix of the outer
protective layer 60 has
been found to be one effective way to reduce friction and enhance wear
resistance.
In the case where the outer protective layer includes fibers, the particles
added to the
outer protective layer 60 are such that they consist of less than 20% by
volume of the matrix. In
the case where the outer protective layer does not contain fiber, a
particulate such as TeflonC
MP 1300 can also be added to the polymeric protective layer. When the outer
layer 60 does not
include fiber, the particles typically comprise less than 60% by coating
volume of the outer wear
resistant layer 60,
FIGURE 9 illustrates an embodiment of the composite tubular member 10 having
an
inner pressure barrier layer 12, a composite layer 14, an outer pressure
barrier 58, and an outer
protective layer 60. An energy conductor 70 is connected with a sensor 72, and
both the
connector and the sensor are embedded in the composite layer 14.
FIGURE 10 illustrates an embodiment of the composite tubular member 10 having
an
inner protective layer 80, an inner pressure barrier layer 12, a composite
layer 14, an outer
pressure barrier 58, and an outer protective layer 60. An energy conductor 70
is connected with a
sensor 72, and both the connector and the sensor are embedded in the composite
layer 14.
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FIGURE 11 illustrates an embodiment of the composite tubular member 10
having an inner protective layer 80, an inner pressure barrier layer 12, a
composite layer
14, an outer pressure barrier 58, and an outer protective layer 60. An energy
conductor
70 extends lengthwise along the tubular member and connects with a sensor 72.
A
second energy conductor 70A extends lengthwise along the tubular member and
connects with a second sensor 72A. A third energy conductor 70B extends
lengthwise
along the tubular member and connects with a third sensor 72B.
As shown in FIG. 11, the tubular member can include multiple sensors connected
with multiple energy conductors. Each of the sensors can be located at
different
positions along the composite member 10. For instance, the sensors can be
axially
displaced, circumferentially displaced, or helically displaced from each other
along the
composite tubular member 10. The multiple sensors can each be separately
connected to
energy conductors as shown in FIG. 11. or the multiple sensors can be
connected to a
single conductor as shown in FIG. 18.
Multiple sensor form a matrix of sensors that span the composite tubular
member. The matrix of sensors provides for increased accuracy in locating the
position,
relative to the tubular member, of the ambient condition being measured by the
sensors.
FIGURE 12 illustrates a composite coiled tube elongated along an axis 17
wherein the composite tube includes a pressure barrier layer 12, a composite
layer 14, an
energy conductor 70, and a sensor 72. The energy conductor provides a path for
passing
power, communication, data, or control signals from the surface down through
the tube
to a machine attached to the end of the tube, and the energy conductor can
provide a
signal communication path with a sensor 72 connected to the energy conductor
70.
As illustrated in FIGUREs 12-14, the energy conductor 70 and the sensor 72 can
be located anywhere within a wa1174 of the tubular member 10 formed of the
pressure
barrier layer 12 and the composite layer 14. For example, FIG. 12 shows the
energy
conductor 70 and the sensor 72 embedded in the pressure barrier layer 12; FIG.
13
shows the energy conductor 70 and the sensor 72 embedded in the composite
layer 14;
and FIG. 14 shows the energy conductor 70 and the sensor 72 positioned between
the
composite layer 14 and the pressure barrier layer 12.
In general, the conductor and the sensor can be embedded within or adjacent to
any composite layers or pressure barrier layers located within the tubular
member 10.
But is preferable to locate the energy conductors in those layers nearest the
interior
surface of the tube and not in those layers located near the exterior surface
of the tube.
If an energy conductor is located near the exterior surface of the tube it is
more likely to
be subjected to corrosive surfaces or materials located outside the tube 10.
In addition,
an energy conductor located near the interior of the tube 10 will be subjected
to smaller
CA 02561402 2006-10-16
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bending strains when compared to an energy conductor located near the exterior
of the
tube.
An energy conductor can be embedded in any of the layers forming the tube 10
using the same methods known in the art for adding a fiber to the composite
layer.
Typically, an energy conductor 70, with at least one sensor 72 attached
thereto, is wound
onto a mandrel or any underlying structure while applying a matrix. Energy
conductors
can also be added to a fiber composite layer with a pultrusion process. For
example, the
energy conductor can be drawn through a resin impregnating apparatus, then
through
dies to provide the desired shape.
A primary concern in placing the conductor 70 in the inner areas of the
composite tube 10 is to ensure that the bending strains on the conductor 70
are
minimized. This is particularly critical if the conductor 70 is a fiber optic
cable.
However. fiber optic cables formed of plastic may eliminate some of these
problems
because the plastic optical cables are less likely to be damaged by bending
strains.
As shown in FIGURE 15, the energy conductors can be helically oriented
relative to the longitudinal axis 17 of the composite tube to minimize the
bending strain
on the energy conductors. The composite tubular member 10 includes an inner
pressure
barrier layer 12, a composite layer 14, a first energy conductor 70A attached
to a first
sensor 72A, and a second energy conductor 70B attached to a second sensor 72B.
The
first energy conductor 70A and the second energy conductor 70B are wrapped
around
the tubular member 10 in opposite clockwise rotations.
The helical orientation of the energy conductors 70A, 70B allows the
compression strain experienced by the section of the energy conductor located
on the
interior bend of the tube to be offset by the expansion strain experienced by
the section
of the conductor located on the exterior bend of the tube. That is, the
conductor 70A,
70B is able to substantially distribute the opposing strains resulting from
the bending
action of the composite tube across the length of the conductor 70A, 70B,
thereby
reducing the damage to the energy conductor.
FIGURE 16 illustrates a composite tubular member having energy conductors
70A, 70B that extend substantially parallel to the axis 17 of the tubular
member 10. The
axially extending conductors 70A and 70B are connected to the sensors 72A and
72B,
respectively. Orienting the conductors axially along the length of the tube 10
increases
the composite tube's axial stiffness and tensile strength. As further shown in
FIG 16, the
conductors 70A and 70B can be oriented so that they are diametrically opposed.
FIGURE 17 illustrates a composite tubular member 10 formed of a pressure
barrier layer 12 and a composite layer 14. Energy conductor 70 is connected
with sensor
72 and conductor 70 is embedded within the tubular member 10. The sensor 70 is
CA 02561402 2006-10-16
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mounted to the tubular member 10. In particular, the sensor 72 is mounted to
the
interior surface of the tube 10, such that at least a portion of the sensor
extends into the
interior of the tube or such that a channel extends from the sensor to the
interior of the
tube.
The sensor 72 shown in FIG. 17 is a "point sensor". Point sensors operate only
at a single point. For example, a point sensor may be at the end of an energy
conductor
that brings energy to and from the sensor along the path of the energy
conductor. Point
sensors are also illustrated in FIGs. I and 5-14. Both FIGs. 16 and 17
illustrate
composite tubular members each having two point sensors.
FIGURE 18 illustrates a composite tubular member having a "distributed
sensor". Distributed sensors exist when the sensing is performed in multiple
points
along the length of the energy conductor. In particular, the composite tube 10
illustrated
in FIG. 18 includes an energy conductor 70 having sensors 76A. 76B. and 76C
distributed along the length of the energy conductor. Examples of distributed
sensors
include optical fibers having Bragg Gratings distributed along the length of
the optical
fiber for measuring strain or temperature. The sensors 76A, 76B, and 76C are
also
connected in series along the energy conductor 70.
FIGURE 19 illustrates a composite tubular member having sensors-connected in
parallel. The composite tubular member includes a first sensor 78A. a second
sensor
78B, a third sensor 78C, a first energy conductor 82, and a second energy
conductor 84.
Each of the sensors 78A, 78B, and 78C includes an input side connected with
the first
energy conductor 82; and each of the sensors 78A, 78B, and 78C includes an
output side
connected with the second energy conductor 84. In this arrangement, input
signals can
be received by the sensors from the first energy connected 82 and output
signals can be
sent by the sensors along the second energy conductor 84.
FIGURE 20 illustrates the bending cycles that a coiled composite tube 10 is
subjected to when performing a typical coiled tubing service. The tubing 10 is
inserted
and removed from a well bore 361ocated below the ground surface. A ree142 is
provided on the surface and the composite coiled tube 10 is stored on the reel
42. An
injector assembly 38 is located on the surface over the well bore 36. Injector
assembly
38 typically contains a roller belt 40 used to guide the coiled composite tube
10 through
the injector assembly 38 into the well bore 36. The coiled composite tube 10
typically is
subjected to six bending events as it is inserted and removed from the well
bore 36. The
first bending event 44 takes place when the coiled composite tube 10 is pulled
off the
service reel 42. When the coiled composite tube 10 reaches the assembly 38,
the coiled
tube passes through two bending events 46 and 48. The bending events 50, 52
and 54
are the reverse of bending events 44, 46, 48 and occur as the coiled composite
tube 10 is
CA 02561402 2006-10-16
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extracted from the well bore 36. The insertion and extraction of the tube 10
thus results
in a total of six bending events for every round trip of the coiled composite
tube 10. The
current steel tubing being used in the field can generally be cycled three
times through
the bending events described in FIGURE 20 in conjunction with high intenaal
pressures
before the steel tubing fails. In comparison, the coiled composite tube of the
Applicant's
invention can be cycled 10,000 times through the bending events described in
FIGURE
20.
FIGURE 21 illustrates a composite tubular member 10 having an energy
conductor 70 connected to a signal processor 86. The energy conductor 70 is
embedded
within the composite tubular member 10. The signal processor is shown, in
accordance
with one aspect of this embodiment, as including an optional coupler 88, a
source 90,
and a detector 92. The signal processor can be positioned external to the
composite
tubular member 10. or the signal processor can be embedded within the
composite
tubular member.
The signal processor 86 receives data from the sensor 72 in the form of energy
transmitted over the energy conductor 70. The signal processor then processes
the
received signal. The processing performed by the signal processing can include
transforming the signal, filtering the signal, sampling the signal, or
amplifying the
signal. The operations performed by the signal processor 86 generally enhance
the
understanding of the signal transmitted over the energy conductor 70. For
instance, the
signal processor 86 can amplify and retransmit the signal over the energy
conductor 70,
i.e. the signal processor can act as a repeater circuit.
In another aspect of the invention, the signal processor can include a source
90
for transmitting an energy signal over the energy conductor 70, and a detector
for
receiving an energy signal from the energy conductor 92. The signal processor
can also
include an optional coupler 88 for interfacing or multiplexing the source 90
and the
detector 92 with the energy conductor.
The energy signal transmitted by the source 90 is placed on the energy
conductor
70 by the coupler 88. The energy signal reaches the sensor 72 and is modified
by the
interaction between the sensor 72 and the ambient conditions of the composite
tubular
member 10. The sensor transmits the modified energy signal over the energy
conductor
70. The coupler 88 then interfaces the detector 90 with the energy conductor
70 so that
the detector can identify the patterns in the modified energy signal. The
detector
determines the ambient conditions sensed by the detector 72 by comparing the
properties
of the energy signal transmitted by the source 90 with the properties of the
modified
energy signal,
CA 02561402 2006-10-16
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FIGURE 22 illustrates a composite tubular member 10 having an energy
conductor 70 embedded therein and connected to a signal processor 86. The
energy
conductor 70 includes three sensors 94A, 94B, and 94C integrally formed with
the
energy conductor.
Where the sensors are integrally formed with the energy conductor, that is
where
the sensors are embedded in or are part of the energy conductor, the sensors
are termed
intrinsic sensors. Sensors 94A, 94B, and 94C are intrinsic sensors. When the
sensors
are external to the energy conductor and the energy conductor merely registers
and
transmits a signal generated by the energy conductor, the sensors are termed
extrinsic
sensors. An extrinsic sensor is illustrated, for example, in FIG. 17.
Examples of extrinsic sensors include moving gratings to sense strain, and
fiber-
to-fiber couplers to sense displacement. Examples of intrinsic sensors include
optical
fibers that sense strain using microbending losses of the optical fiber,
modified optical
fiber claddings used to make spectroscopic measurements, and Bragg Gratings
etched
into an optical fiber that modify interference patterns based upon changes in
strain of the
optical fiber.
FIG. 22 further illustrates an optical system coupled with an optical sensor
embedded within the composite tubular member 10 for sensing a selected ambient
condition of the tubular member 10. In particular, the energy conductor 70 can
be an
optical fiber embedded within the composite layer 14 of the tubular member.
The
sensors 94A, 94B. and 94C can represent Bragg Gratings integrally formed
within the
energy conductor 70. Signal processor 86 is an optical system for measuring a
selected
ambient condition. Signal processor 86 includes a light source 98, an optical
detector
100, and an optical coupler 96.
In operation, the light source 98 generates a broadband light source that
illuminates the optical coupler 96. The optical coupler, typically a beam
splitter, then
launches the beam of light onto the optical fiber 70. The first Bragg grating
94C reflects
a wavelength of the light and passes the remainder onto Bragg grating 94B.
Bragg
grating 94B then reflects a wavelength of the light and passes the remainder
onto Bragg
grating 94C. Bragg grating 94C then reflects a wavelength of the light. The
optical
coupler 96 also connects the optical detector 100 with the optical fiber.
Changes in the ambient conditions of the tube 10 can modify the reflection of
the light by the Bragg
gratings 94A, 94B. 94C. The optical detector measures the power of light in
the optical
fiber. The power of the output signal is indicative of the light beams
reflected by
sensors 94A, 94B, and 94C. The operation of Bragg Gratings is fully disclosed
in
Fernald et al., U.S. Patent No. 5,394,488, entitled "Optical Fiber Grating
Based Sensor";
CA 02561402 2008-06-27
31
and in Dunphy et al, U.S. Patent No. 5,426,297, entitled "Multiplexed Bragg
Grating Sensors".
FIGURE 23 illustrates a schematic representation of a signal processing unit
86 coupled
with an optical fiber 120 and coupled with an optical fiber 122. Each of the
optical fibers 120,
122 are embedded within the composite tubular member. The optical fiber 120,
however, is not
bonded to the composite tubular member, while the optical fiber 122 is bonded
to the composite
tubular member. Each of the optical fibers 120, 122 include a plurality of
sensors distributed
along the length of the optical fibers. Preferably, the sensors distributed
along the optical fibers
120, 122 are Bragg Gratings. As shown, the optical fiber 120 has temperature
measurement
devices 121A, 121B, 121C and 121N. The optical fiber 122 has strain
measurement devices
123A, 123B, 123C and 123N.
In operation, the optical fiber 120 distorts as the temperature in the
composite tubular
member changes. This distortion of the optical fibers as a function of
temperature also changes
the reflectivity of the Bragg Gratings distributed along fiber 120 as a
function of temperature.
Accordingly, the Bragg Gratings in fiber 120 detect temperature in the
composite tubular
member. The optical fiber 120, however, is bonded to the tubular member 10. As
a result, the
optical fiber 122 distorts primarily due to the strain in the composite tube
and not the
temperature in composite tube. This distortion of the optical fiber 122 as a
function of strain
also causes the Bragg gratings in optical fiber 122 to change as a function of
strain.
Accordingly, the Bragg Gratings in fiber 122 detect strain in the composite
tubular member.
FIGURE 24 illustrates a composite tubular member 10 having energy conductors
70 and
70A embedded therein. An interface 109 is removably and replaceably mounted to
the end of
the composite tubular member 10. The interface 109 includes a load bearing
connector 110, a
pressure seal 112, and energy couplers 114 and 114A.
In operation, the interface is mounted to the end of the tube 10 in order to
connect the
tube with another piece of equipment, such as a signal processor, a machine
for operating on the
inside of a well, or another tube. The interface can also act to simply seal
off the end of the tube.
The load bearing connector 110 of the interface 109 transfers axial, helical,
and radial load from
the coinposite tubular member to the interface 109. The pressure seal 112
maintains the pressure
differential between the fluid passage within the tubular member and the
ambient conditions
surrounding the tubular member 10. The energy conductors 114 and 114A provide
structure to
connect the energy conductors 70 and 70A, respectively, with another piece of
equipment.
It is also to be understood that the following claims are to cover all generic
and specific
features of the invention described herein, and all statements of the scope of
the invention
which, as a matter of language, might be said to fall there between. Having
described the
invention, what is claimed as new and secured by Letters Patent is:
