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WO1996041066A1 - Systeme de diagraphie combinant une camera video et des detecteurs des conditions environnementales de fond de trou - Google Patents

Systeme de diagraphie combinant une camera video et des detecteurs des conditions environnementales de fond de trou Download PDF

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Publication number
WO1996041066A1
WO1996041066A1 PCT/US1996/006928 US9606928W WO9641066A1 WO 1996041066 A1 WO1996041066 A1 WO 1996041066A1 US 9606928 W US9606928 W US 9606928W WO 9641066 A1 WO9641066 A1 WO 9641066A1
Authority
WO
WIPO (PCT)
Prior art keywords
camera
cable
instrument
optical fiber
inspection system
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1996/006928
Other languages
English (en)
Inventor
Philip K. Schultz
Mathew B. Riordan
Gregory Linville
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Expro Americas LLC
Original Assignee
DHV International Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by DHV International Inc filed Critical DHV International Inc
Publication of WO1996041066A1 publication Critical patent/WO1996041066A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401—Optical cables
    • G02B6/4415—Cables for special applications
    • G02B6/4416—Heterogeneous cables
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/023—Arrangements for connecting cables or wirelines to downhole devices
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/028—Electrical or electro-magnetic connections
    • E21B17/0285—Electrical or electro-magnetic connections characterised by electrically insulating elements
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/002—Survey of boreholes or wells by visual inspection
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/006—Detection of corrosion or deposition of substances
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH OR ROCK DRILLING; MINING
    • E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B47/00—Survey of boreholes or wells
    • E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
    • E21B47/13—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency
    • E21B47/135—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency using light waves, e.g. infrared or ultraviolet waves
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
    • G02B6/4401—Optical cables
    • G02B6/4415—Cables for special applications
    • G02B6/4427—Pressure resistant cables, e.g. undersea cables

Definitions

  • the invention is related generally to the remote viewing of passageways and other limited access areas and, more particularly, to remotely viewing such limited access areas with a down-hole instrument having multiple sensors.
  • the camera system may detect turbulence created by a leak and may identify different fluids leaking into the well bore.
  • the well bore may contain water, oil, or gas or combinations of them, there is sometimes a need to determine if these substances actually exist by viewing the contents of the well bore.
  • Down-hole video is also useful in identifying down-hole fish and can shorten the fishing job. Plugged perforations can be detected as well as the flow through those perforations while the well is flowing or while liquids or gases are injected through the perforations. Corrosion surveys can be performed with down-hole video and real-time viewing with video images can identify causes for loss of production, such as sand bridges, fluid invasion, or malfunctioning down-hole flow controls. In addition, in some cases a need exists to measure non-visual bore hole environmental parameters at the inspection site. Such measurements can provide valuable information to ascertain fluid volumetric leakage and infiltration rates, fluid constituents, casing wall thickness, internal and external corrosion, cement casing corrosion, and the severity of faulty bore hole conditions and the cause thereof.
  • Such parameters sensed may include fluid temperature, pressure, capacitance, the magnetic permeability of casings, ultrasonic resonance of cement and other materials, current density through casings, magnetic phase shift, isotope detection and flow velocity, among others. For example, by measuring flow velocity, including flow direction, those at the surface can determine volumetric leakage and severity of faulty bore hole conditions.
  • the probe may comprise a rugged instrument containing a plurality of sensors, such as a temperature sensor, a pressure sensor, a flow meter, and others.
  • instrument probes of this sort have not incorporated visual inspection capabilities. Therefore, if both visual and non-visual environmental parameter sensing were required, two instruments would be dispatched to an inspection site. As these bore holes are typically of a small diameter, simultaneous dispatch of two instruments in the hole is many times impossible. In addition, since bore hole inspections are commonly performed at extreme depths, on the order of several kilometers or more, successive dispatch and retrieval of the two instruments increases inspection time dramatically. Where the bore hole is under pressure, these procedures are made even more difficult. Thus, it has been found desirable to have both visual and non-visual sensing capabilities in an instrument probe.
  • a support cable is used to lower the instrument probe into the bore hole and subsequently retrieve the instrument therefrom.
  • the support cable of a well logging instrument is repeatably pulled around at least one sheave and wound on and off a winch drum as it is lowered into and lifted out of bore holes.
  • the support cable must withstand repeated bending and tensions of thousands of pounds.
  • the support cable may contain strength members that preserve the integrity of the cable as it and the instrument probe are being moved through and from the bore hole.
  • a communication link is incorporated into the support cable and is attached between the instrument probe and a surface station to communicate the sensor signals to the surface from the instrument probe.
  • Optical communication fibers offer certain advantages in communication systems used in this environment.
  • optical fibers are sensitive to point stresses and bending.
  • the fiber may impart significant attenuation to its conducted signal when bent.
  • the support cable is repeatably pulled around at least one sheave and wound on and off a winch drum as it is lowered into and lifted out of bore holes. Stretching the support cable can stretch the optical fibers thereby increasing their stress and aggravating their attenuation.
  • high pressures and high temperatures in the well holes may assist moisture in invading the cable and the optical fiber. Moisture invading the optical fiber through micro-cracks can increase its attenuation and reduce its strength.
  • the support cable connecting the instrument probe with the remote controller must protect the optical fibers as well as be strong enough to withstand repeated bending about sheaves and a winch drum, withstand stretching forces and the high temperatures and pressures in the bore hole.
  • Down-hole instrument probes can be made extremely small due to the existence of charge-coupled device imaging systems and other technologies that can function as a camera in the down-hole instrument. Electrical circuitry inside such an instrument can also be made small with the use of semi-conductor devices.
  • the instrument probe containing the remote video camera system and other electrical equipment is connected to the surface equipment by the umbilical instrument cable thereby permitting transmission of electrical power to the video camera and communication of data from the video camera to the surface equipment.
  • sinker bars having the standard outside diameter of 3.5 cm (1.375 in) would be used. Even if using the high density tungsten weights, each bar would be 1.8 meters (6 ft) long and has a weight of only 20.4 kg (45 lbs). This would result in the need for 15 sinker bars placed end to end on the cable and at 1.8 m (6 ft) each, a total length of 27.4 m (90 ft) of sinker bars results. Adding this length to the length of the instrument itself, which may be 4.5 m (15 ft), a total length of 31.9 m (105 ft) exists for the complete assembly. As shown in FIG.
  • a down-hole instrument cable it is also important for a down-hole instrument cable to include electrical conductors for the conduction of electrical energy such as power. Electrical conductors also take up space in a cable and therefore it has been recognized that the electrical conductors should also be kept to as small a size as possible. However, certain electrical performance requirements must still be met. Additionally, the conditions within a well to which the instrument cable is exposed can be quite harsh, with hydrostatic well pressures in excess of 421 kg/cm 2 (6,000 psi) and ambient wall temperatures reaching 110° C (230° F) and higher. Wells may contain certain caustic fluids such as hydrogen sulfide which can cause optical fiber deterioration and poor performance. The fiber must be protected from leakage of such fluids.
  • the well can also be quite deep, and the length of the down- hole instrument cable can exceed 4,572 to 4,877 meters (15,000 to 16,000 ft). Longitudinal stresses placed on an optical fiber in such a long cable can sever or fracture the optical fiber, causing significant signal attenuation.
  • the cable must be designed not only to resist physical damage to its outer surface from use in the well, and provide a robust fluid seal to protect the optical fiber and electrical conductors, but also to support the weight of the down-hole instrument and the cable itself.
  • the fluids in the well bore affect visibility as do any dissolved particulate matter from mineral deposits or the like contained in those fluids.
  • the dissolved compounds are particularly troublesome for visual inspection systems having self- contained light sources as the compounds tend to reduce visibility by reflecting back the light into the camera without adequately illuminating the subject matter to be viewed thus resulting in glare.
  • the instrument probes for well bores must be rugged to withstand the sometimes harsh conditions encountered in typical operation. High heat levels can apply enormous stress to a camera system. Any additional heat applied to the camera brings it that much closer to its operational limits and may cause it to fail. Thus heat is a major concern.
  • lamps are arranged around the exterior of the camera in a ring or a "doughnut" to provide lighting on the subject matter viewed by the camera.
  • these lamps are mounted so close to the camera, the heat developed by these lamps reaches the camera and may affect its performance as discussed above. Reducing the light output of the lamps to reduce the heat created may also reduce the viewing effectiveness of the camera, especially in environments containing dark oil or other dark substances.
  • this approach provides direct lighting of the subject matter viewed by the camera and may result in glare from well bore contents.
  • mounting such lamps around the camera results in an increase in the diameter of the camera thereby making it unusable in very small well bores.
  • some well bore inspection instruments carry a self-contained power supply, typically battery packs.
  • these battery packs In addition to adding weight and bulk to the instrument probe, these battery packs have a limited life which is directly dependent upon the intensity of the lights.
  • many battery packs of the size which can fit in a bore hole logging instrument probe can provide power for only 3 to 3 ⁇ hours when used with halogen lamps.
  • the battery packs Upon dissipation of the stored energy, the battery packs must be removed and replaced with charged batteries or a charging process must occur which may take many hours. This usually requires that the instrument probe be removed from the well hole, disassembled and re-assembled.
  • the present invention provides an inspection system with an instrument probe having a plurality of environmental sensing devices one of which is a video sensor for providing images of well characteristics.
  • at least one of the plurality of sensors includes a television camera and an optical fiber or fibers are used to conduct the plurality of sensor signals to the surface for remote real-time viewing and analysis.
  • a light source is mounted behind the camera for providing back-light illumination of the walls of the bore hole, casing and fittings.
  • a suspension member is used to firmly extend the camera forward of the light source. The length of the suspension member is selected in dependence upon the inner diameter of the bore hole or casing.
  • the power source for the light source and the plurality of real-time sensors including the camera is located at the surface. Power is conducted to the components in the instrument probe through a multi-conductor support cable having the optical fiber, the electrical conductors and the strength members.
  • a multi-conductor support cable having the optical fiber, the electrical conductors and the strength members.
  • all cable components are enclosed in a smooth outer sheath which in another aspect may be made of stainless steel.
  • the outside sheath is thin enough so that it may be routinely pulled around sheaves and rolled on the winch drum for transport yet is strong enough to protect the inner conductors and strength members.
  • the support cable has the optical fiber located in the center and a buffer material surrounding the optical fiber.
  • a protective sheath surrounding the optical fiber and the buffer material a first insulator surrounds the protective sheath with the first insulator being formed of a heat resistant material, a layer of electrical conductors surrounds the insulator, a second insulator surrounds the layer of electrical conductors with the second insulator also being formed of a heat resistant material, and strength member strands surround the second insulator to form the outer surface of the cable.
  • a support cable provides not only the optical fiber, support and strength members but also the power transmission means necessary to operate the plurality of real-time sensors including the camera, lights and other equipment in the instrument probe.
  • the instrument includes a multiplexer for multiplexing the sensor signals onto the optical fiber or fibers in the cable.
  • the instrument further includes an instrument carrier having at least one memory gauge having a self-contained battery.
  • FIG. 1 is a view of a down-hole instrument system used in a well bore also showing related surface equipment;
  • FIG. 2 is an enlarged view of a portion of FIG. 1 showing the down-hole instrument in more detail in which a light source is mounted to the distal end of the instrument and a camera is suspended from that same distal end by means of suspension members;
  • FIG. 3 is an enlarged detail of the lighting system and camera mounting system shown in FIG. 2 in accordance with one aspect of the invention
  • FIG. 4 is a side view of the lighting and camera system in accordance with certain aspects of the invention.
  • FIG. 5 is a partially cutaway view of the light and camera mounting arrangement shown in FIG. 4 and showing mounting seals;
  • FIG. 6 presents a view of a mounting means for mounting the camera to the camera frame;
  • FIG. 7 presents an alternate embodiment where a light cylinder is mounted about the camera
  • FIG. 8 presents a further embodiment wherein multiple light sources are mounted to the distal end of the instrument body
  • FIG. 9 presents an additional embodiment wherein the light source is mounted at the proximal end of the camera
  • FIG. 10 is a side view of an instrument probe that is in place in a well bore showing a part of the support cable, cable head, camera section, light section, sensor section, and a fluid velocity sensing device
  • FIG. 11 is a partial cross-sectional side view of part of the instrument probe showing the cabling, power distribution section, fiber optic transmitter section, sensor section, camera section, lens and mounting points of the support legs used to hold the light section and the velocity sensing device in front of the lens of the camera;
  • FIG. 12 is a partial cross-sectional view of the light section and velocity sensing device of the instrument probe showing a halogen lamp and the legs and mountings;
  • FIG. 13 is a side view of an instrument probe which is in place in a well bore showing a part of the support cable, cable head, sensor section, camera section, light section, and the velocity sensing device and a back-lighting arrangement in accordance with an alternative embodiment of the invention
  • FIG. 14 is a view of the instrument probe of FIG. 10 having an instrument carrier with memory sensors;
  • FIG. 15 is a cross-sectional view of a support cable in accordance with the principles of the invention.
  • FIG. 16 is a graph showing sinker bar weight versus well pressure
  • FIG. 17 is an overall diagram of a well logging system with which the instrument cable of the invention can be used;
  • FIG. 18 is a cross-sectional view of an embodiment of an instrument cable in accordance with the invention.
  • FIG. 19 is a partial cross-sectional view of an embodiment of a cable termination assembly of the instrument cable in accordance with the invention.
  • FIG.20 is a partial cross-sectional view of the contact subassembly of FIG. 19, showing one preferred sealing arrangement
  • FIG. 21 is a partial cross-sectional view of the contact subassembly similar to that of FIG. 20, showing an alternate sealing arrangement.
  • DETATLED DESCRIPTION OF THF. PREFERRED EMBODIMENTS in the following description, like reference numerals will be used to refer to like or corresponding elements in the different figures of the drawings.
  • FIG. 1 shows a well logging instrument probe 10 connected to a surface station 12 by a cable 14 that is wrapped around a sheave 11.
  • the surface station 12 includes a surface controller 13, a controller enclosure 17 and a transportable platform 15 which in this case is a skid unit.
  • the surface controller 13 controls the operation of the winch and the probe 10 and receives and processes information provided by the probe 10.
  • the control enclosure 17 may include a recorder, such as a video tape recorder, for recording the information provided by the probe 10.
  • the cable 14 comprises transmission lines to transmit communication and power signals between the instrument probe 10 and the surface station 12.
  • the instrument probe 10 of this embodiment comprises essentially four main components: an instrument body 16, a high intensity light source 18, a plurality of suspension members 20 and a camera 22.
  • the instrument body 16 also includes transmission lines that interconnect other components of the probe 10 to the cable 14.
  • the cable 14 is connected to the proximal end 24 of the instrument body 16 by any conventional manner known in the art which adequately secures the probe 10 to the cable 14 and provides for the electrical connections between the instrument body and the cable transmission lines.
  • the cable 14 is used to lower and raise the instrument probe 10 within the well bore 28 by means of the rotation of the sheave 11 and a spool 26 about which the cable 14 is wound.
  • the spool 26 is located at the surface station 12.
  • the high intensity light source 18 is mounted onto the distal end 30 of the instrument body 16.
  • the light source 18 comprises a high intensity lamp, preferably a halogen or quartz bulb, contained within a lamp housing 32.
  • the bulb is mounted in a lamp socket which may be any commercially available socket that supports the selected lamp.
  • the lamp and socket are surrounded by the lamp housing 32 that is clear and water tight and which may be threadably connected to the distal end 30 of the instrument body 16.
  • the lamp socket is wired to the power transmission lines within the instrument body 16.
  • Disposed at the base of the light source 18 is a concave parabolic reflector 34.
  • the concave reflector 34 has a polished metal surface such as stainless steel and is shaped to direct the light generated by the light source 18 distally from the instrument body 16 towards the well bore walls 36 and the camera 22.
  • the camera 22 is located distally to the light source 18 which puts it within the field of illumination 38 (FIG.2) created by the light source 18 and the concave reflector 34.
  • the plurality of suspension members 20 are used to rigidly mount the camera 22 to the distal end 30 of the instrument body 16. In the case shown in FIGS. 1-4, four suspension members 20 are used; however, more or fewer may be used as required. These are mounted to the distal end 30 of the instrument body 16 and the proximal end of the camera 22 and by so mounting, do not increase the overall diameter of the probe 10. Additionally, suspending the camera 22 at a distance from the light source 18 provides some insulation for the camera 22 from the heat produced by the light source 18.
  • the camera 22 comprises a camera housing 40 within which is mounted a video camera 42, a lens 44, seals 46, and a mounting frame 48.
  • the suspension members 20 rigidly connect the camera mounting frame 48 to the distal end 30 of the instrument body 16. The connection may be achieved by welding the members 20 to the distal end 30 and camera 22 or by threading the ends of the suspension members 20 and securing them with nuts.
  • a least one of the suspension members 20 comprises a hollow cavity 50 which contains the power and signal lines 52 to convey power and data signals between the camera 22 and the instrument body 16.
  • the suspension members 20 have a predetermined length to separate the camera 22 from the light source 18. This length in one embodiment was selected such that an object positioned in front of the camera lens at a distance of approximately thirty-six inches (91 mm) could be clearly seen by the camera with the light source used. This was tested for different diameter pipes including pipes having a diameter of approximately 2 inches (5 mm) and pipes having an outer diameter of 13 inches (33 mm).
  • the window 44 Mounted to the distal end 54 of the camera 22 is the window 44.
  • the video camera 42 is mounted inside the camera housing 40 adjacent the window 44 and coupled thereto for viewing purposes.
  • the field of view 56 (shown in FIG. 2) of the camera with the lens is distal to the camera 22 and therefore also to the light source 18 and instrument body 16.
  • the seals 46 inside the camera housing 40 protect the video camera 42 from damage that may be otherwise caused by leaking liquids or gases.
  • the mounting frame 48 receives the housing 40 to mount the housing to the suspension members 20 and so to the instrument body 16. A threaded connection is shown in this embodiment.
  • the lens 44 may have a wide angle or other optical characteristic to direct the field of view 56 of the video camera 42 for a particular purpose.
  • the camera 22 also comprises a convex parabolic reflector 58 that faces the light source 18 and is shaped to direct light away from the camera 22 towards the walls 36 of the well bore.
  • the illumination angle of this convex reflector 58 is indicated by the numeral 59 in FIG. 2. In this way, further light is directed at the well bore walls 36 that will reflect to a position in the field of view 56 of the camera to result in indirect lighting.
  • This reflector may also be formed of stainless steel or other suitable reflective substance.
  • the angle 59 of reflection is selected in one embodiment to be equal to the angle of the light source reflector 34.
  • the camera housing 40 has at least two J- shaped notches 60, one of which is shown in FIG. 6, at its opening. These notches engage corresponding pins 62 mounted to the camera frame 48.
  • the housing 40 is first slid onto the pins 62 and then rotated to move the horizontal portion of the notch 60 to engage the pins 62. After the rotation, the housing is then slid again to engage the termination portion 64 of each notch of the housing with the pins 62.
  • the pin/notch combination locks the housing 40 to the camera frame 48.
  • a cap 66 threadably connected to the camera frame 48 is then rotated until the cap 66 contacts the camera housing 40.
  • the wires to be connected between the video camera 42 and the suspension members 20 may be coupled together by means of a connector located on a bulkhead. Alternately, there may be a terminal block at a bulkhead at the video camera to which the wires are secured such as by soldering. Other wiring techniques, such as hard ⁇ wiring directly between the camera and the instrument body equipment, may be used.
  • the camera housing 40 may be mounted to the frame 48.
  • Set screws rather than J-shaped notches may be employed.
  • the housing may be threaded for connection to the frame.
  • the light source/camera assembly of another embodiment includes an adaptor 68 configured to connect the present light and camera assembly to the instrument body 16.
  • the adapter 68 includes fluid seals 70 mounted in channels. O-ring type seals are shown.
  • the instrument body 16 includes an opening for receiving the adapter 68 and a connector for coupling the wires from the light/camera assembly to corresponding wires in the instrument body 16.
  • the field of illumination 38 of the light source 18 and the field of illumination provided by the camera 22 reflector 58 both strike the bore hole walls 36 and do not directly illuminate the field of view 56 of the camera 22. It has been found that this arrangement results in improved lighting of the contents of the bore hole 28 for the camera 22. It is believed that this arrangement provides indirect lighting of the bore hole contents thereby reducing glare and increasing visibility.
  • a high intensity light source 18 may be used because of its physical separation from the camera 22. Thus, more light is provided than if low intensity/low heat producing light sources were used.
  • the mounting of the suspension members 20 to the distal end of the instrument body rather than to the periphery and the use of a reduced diameter camera frame 48 to which to mount the other ends of the suspension members 20 to the camera 22 result in maintaining the diameter of the probe 10 at the dimension required by the instrument body. In other words, the camera/light source assembly does not increase the diameter of the probe. This also increases the versatility of the probe. Adding the light source shown herein does not limit the probe to only larger bore holes.
  • the camera housing 40 is covered by a light transmission sleeve 72.
  • the sleeve 72 comprises a light transmission medium such as glass or plastic or other substance capable of conducting light without substantial attenuation.
  • the sleeve 72 receives light from the light source 18, conducts that light to the distal end 54 of the camera, and radiates that light into the closer part of the field of view of the camera 22.
  • the upper 74 and lower 76 edges of the sleeve 72 are beveled to collect light from the light source and transmit the light to the field of view of the camera.
  • the upper bevel is facing the light source 18 and the lower bevel is facing the window 44.
  • the light source 18 continues to provide indirect lighting for the field of view of the camera 22 while the sleeve 72 provides a greater amount of light for the field of view closer to the camera window 44.
  • the light source 18 may comprise a ring of high intensity lights 78 mounted in the reflector 34 on the distal end 30 of the instrument body 16. Each of the lights in this ring of lights is mounted on the reflector and is thus at the angle of that portion of the reflector in which they are located. Their light output is thus directed to the bore hole walls so that they also provide indirect light to the field of view of the camera 22.
  • the embodiment shown in FIG. 9 illustrates the mounting of the light source 18 to the proximal end 80 of the camera 22 rather than to the distal end 30 of the instrument body 16. However, the light source 18 remains in line with the longitudinal axis of the instrument body 16 and provides indirect lighting.
  • Light from the light source 18 will be reflected by the reflector 34 mounted on the distal end 30 of the instrument body 16 for provision to objects in front of the lens 44.
  • the lamp used in the light source 18 is surrounded by a lamp cover 34 as in previous embodiments and this lamp cover 34 is placed in the environment so that the heat developed by the lamp will be dispersed in the bore hole rather than provided to the camera 22.
  • the light source 18 is thus insulated from the camera 22.
  • the support cable 14 is connected to the probe 100.
  • the probe 100 has six main sections, a cable head 102, an electronics section 104, a non-visual sensor section 106, a camera head 108, a light head 110, and a velocity sensing head 112.
  • the velocity sensing head includes a spinner type flow meter 114 positioned at the distal end of the probe 100.
  • the light head 110 and velocity sensing head 112 are attached to the camera head 108 through three legs 116, two of which are shown. Legs of different lengths may be used depending upon the inner diameter of the well bore 28 or casing. The larger the inner diameter of the well bore 28, the longer the legs should be so as to not interfere with the camera viewing angle and so as to properly illuminate the well bore walls for inspection.
  • Section 118 of the cable is coupled to an optical transmitter section 120.
  • electrical signals from the camera and other sensors representing respective visual images and non-visual sensing data are converted into optical signals and coupled to an optical fiber disposed within the cable.
  • the optical fiber is used for the transmission of the visual images and other sensing data to the surface.
  • the optical transmitter section 120 also includes a multiplexing system for multiplexing the multiple sensor signals received from the plurality of sensors, including visual signals, for transmission along the single optical fiber to the surface station.
  • Electrical-optical converters and multiplexers are well known in the art as well as couplers for coupling the converter 120 to the optical fiber, and thus no further details are given herein.
  • the electrical power brought into the instrument probe 100 by the cable 14 is converted 122 into the voltages needed by the camera, the sensors, the light source and the electrical-optical converter.
  • the voltage supplied by the cable 14 may be 100 Ndc while the camera operates on 12 Ndc and the light on 50 Ndc.
  • the electrical/optical converter may require 12 Vdc.
  • Such converter boards are well known in the art, for example, Model SWA175-4300 by Power- One, Inc., Camarillo, California.
  • the next section of the instrument probe is the non-visual sensor section 106.
  • This section includes in this embodiment a plurality of environmental parameter sensors shown in block form in FIG. 11.
  • a temperature sensor 124 a pressure sensor 126, and a capacitance sensor 128 are provided. Ports 130 leading to each sensor are formed in the instrument 100 wall.
  • the non- visual sensor section 106 is not restricted to the foregoing combination and may include a lesser combination or a greater combination or may include other types of parameter sensors.
  • the temperature sensor 124 may be in many forms such as a thermocouple, thermistor, platinum RAD, quartz crystal temperature transducer, or a combination thereof.
  • the pressure sensor 126 may be in many forms such as a quartz crystal pressure transducer or others known to those skilled in the art.
  • the next section in the instrument probe 100 is the camera 108 head.
  • the camera 128 was a charge coupled device (CCD) type television camera that is capable of providing high speed, high resolution images in relatively dim light.
  • CCD charge coupled device
  • One camera found to be usable in an embodiment is the CCD Video Camera Module having a model number of XC 37 made by Sony Corporation.
  • Coupled to the camera is a lens 130 which in one embodiment was a fisheye lens, and a quartz window 44.
  • the window 44 seals the camera head 108 at its bottom end and protects the lens 130 against high pressure/high temperature fluids that may exist in the well bore. Its angle is selected so as to not obstruct the viewing angle of the lens 130. Also shown in FIG.
  • the electrical light conductors 132 and velocity sensor conductors 134 are separately routed through the legs to the light head. In the embodiment shown, three legs were used although only two legs are shown in this figure.
  • the next section of the instrument probe 106 is the light head 110 and velocity sensing head 112.
  • the light head is shown having a halogen lamp 136 and is facing the camera lens 130 (FIG. 11) in confronting relationship.
  • the light head 110 and velocity sensing head 112 are attached to the camera section by the legs 116 that are welded into the light head 110 in this embodiment.
  • the length of the legs 116 is selected based on the inner diameter of the bore or casing. Where the camera must see further because of a larger inner diameter of the casing, the legs 116 are made longer so that the light head will not obstruct the view of the lens. Where the inner diameter is small, the legs may be shorter so that more light is placed within the camera viewing angle.
  • Electrical power conductors 132 that provide electrical power to the light traverse one or more of the legs 116.
  • Other light sources may be used such as incandescent lamps. Additionally, light other than visible light may be used, for example, infrared and ultraviolet.
  • the velocity sensing head 112 is positioned at the distal end of the probe and is attached to the forward end of the light head 110 to project distally therefrom. In this configuration, the velocity sensing head may be used to pinpoint flow contributions from perforations, well bore leaks and disrupted flow.
  • the velocity sensor head includes a distal velocity sensing device 114.
  • the velocity sensing device in this embodiment is a spinner type flow meter 114, although other devices are usable.
  • the spinner 114 is mounted to the distal end of a shaft 140 rotatably mounted to a spinner head 142 of the velocity sensor head 112.
  • the spinner is formed of a plurality of triangularly shaped fins 144 extending radially outwardly from a longitudinal central axis aligned with the shaft. Fluid flow impinges on the fins 144 causing rotation of the shaft 140 attached thereto. Electrical contacts surrounding the shaft are detected by the spinner head 142 as it rotates. The speed of the rotation of the shaft is proportional to the velocity of the fluid flowing past the spinner. The direction of flow is determined using a plurality of reed switches (not shown) or by other means.
  • the spinner 114 is spaced apart from the instrument probe. In this position, the spinner is distanced from the probe which limits turbidity and other fluid flow influences caused as fluid passes by the instrument probe. As such, the spinner provides unobstructed fluid flow measurement for increased accuracy.
  • an alternative configuration of an instrument probe 150 is illustrated.
  • the light head 152 and light 154 are mounted at the distal end of the probe body 156, the light 154 projecting distally outwardly therefrom, and the velocity sensing head 158 including the velocity sensing device in the form of a spinner 160 is disposed in-line in the instrument body, medially along the probe length, generally behind the light head 152 and spaced therefrom by a shroud 162 that allows fluid flow across the spinner 160.
  • a shroud 162 that allows fluid flow across the spinner 160.
  • FIG. 13 a back-lighted camera arrangement similar to that shown in FIG.2 is presented. The camera is mounted in front of the light 154.
  • FIG. 14 presents another embodiment in which an instrument carrier 163 is connected to the support cable 14 at a position proximal to the down-hole instrument.
  • a device may be used to contain memory sensors; i.e., sensors that store sensed data along with a time reference that are to be downloaded later at the surface for evaluation.
  • the sensors in the carrier 163 sense and store data internally until the instrument 100 and carrier 163 are withdrawn from the well. The data is then downloaded from the memory in the carrier 163 and analyzed.
  • the carrier typically would include a battery or batteries for powering the sensors and memory.
  • the carrier 163 may have a longitudinal slot so that it can be mounted to and removed from the cable 14 fairly rapidly.
  • the cable is mounted longitudinally through the carrier so that the carrier cannot be removed from the cable unless the cable is pulled through the mounting hole.
  • power for the instrument probe 100 resides at the surface at the controller 13.
  • the power source at the controller 13 is transmitted to the support cable 14 via slip rings at the drum 26 in accordance with techniques known to those skilled in the art.
  • the real-time or surface readout instruments are powered from the surface power unit through the cable. Any memory instrument or memory gauges are battery powered.
  • the in-line instruments mounted in the instrument body including a temperature sensor, pressure sensor (indicated by pans 130), velocity sensor 158, and camera 152 and light 154, are all powered through the support cable 14 from surface power.
  • the camera and light are powered by surface power while the instrument carrier 163 includes a battery or batteries as its power source.
  • a multi-layer cable is provided.
  • a cross-sectional view of a cable 64 in accordance with the invention is presented. Disposed at the center is the optical fiber 166 and immediately around it is a buffer layer 168. Although only a single optical fiber is shown in this embodiment, multiple fibers may be used to comprise a fiber optic cable.
  • the buffer layer 168 provides mechanical isolation. Surrounding the buffer layer 168 and coaxial therewith is an inner layer of electrically conductive strands 170 which in one embodiment are formed of copper. These strands form a power conductor that conducts power from the controller 13 to the instrument probe components.
  • conductive strands 170 Surrounding the inner layer conductive strands 170 is a layer of insulation 172 and surrounding the insulation is a layer comprising strength member strands 174 alternating with outer, electrically conductive strands 176. In this embodiment, one outer conductive strand 176 is interspaced with two strength member strands 174.
  • ten outer electrically conductive strands which in one embodiment are formed of copper, are alternately interspaced in the total of thirty strands in the layer.
  • the power conductor resistance when formed of copper strands is 6.1 ohms per 305 meters (1000 feet).
  • the twenty steel and the ten copper resistive loop strands have a resistance of 18.1 ohms per 305 m (1000 ft).
  • the loop resistance is 24.2 ohms per 305 m (1000 ft). Because of this arrangement of alternately interspaced copper and steel strands, the loop resistance is lowered.
  • the diameter of the strength members then may be selected to satisfy only strength concerns rather than both strength and electrical conductivity concerns. It has been found that in a cable in accordance with the invention, the strength members are significantly smaller thus resulting in a much smaller and lighter support cable yet one with loop resistance low enough so that a manageable voltage may be used at the surface.
  • the optical fiber 166 used was a 50/125/245 multi- mode fiber with a buffer formed of Hytrel which is available from Dupont in Wilmington, Delaware.
  • the optical fiber had a 0.050 mm core with 0.125 mm cladding.
  • the Hytrel buffer was 0.18 mm (0.007 in.) in average thickness.
  • the power conductors were 0.38 mm (0.015 in.) in diameter and were formed of copper HDBC, the insulator was 0.48 mm (0.019 in.) in thickness, and each strength member and resistive loop conductor was 0.25 mm (0.010 in.) in diameter.
  • the insulation was compounded Hytrel and the strength strands were formed of improved plow steel.
  • an outer sheath 178 Surrounding all of the above members is an outer sheath 178 which in one embodiment, is made of stainless steel sheet having a thickness of 0.20 mm (0.008 in.). In one embodiment, the stainless steel sheet was formed into a tube shape and welded lengthwise to form the outer sheath. The stainless steel is strong and fluid resistive thus protecting the internal components. It was found that forming the outer sheath of stainless steel provides a smooth outer surface thus facilitating its movement in pressure sealing glands and around sheaves and drums. Because it is relatively thin, it can be rolled on the sheaves and drums as necessary. Because of the commonly-experienced high pressures of fluids found in bores, the cable entry point into the instrument probe 100 must be sufficiently sealed to protect against the entry of extraneous fluids.
  • a second down-hole instrument cable 189 in accordance with an aspect of the invention includes an optical fiber 190 that is centrally located in the cable 189 for carrying optical signals over long distances, and which is capable of operating at elevated temperatures.
  • an optical fiber 190 that is centrally located in the cable 189 for carrying optical signals over long distances, and which is capable of operating at elevated temperatures.
  • the optical fiber is preferably hermetically sealed in a layer of inorganic material 192, such as carbon, to protect the optical fiber from the deleterious effects of hydrogen and other gases, that can cause attenuation of the optical signal, particularly at elevated temperatures and pressures.
  • the coating of inorganic material is typically a very thin layer less than 500 A applied to the optical fiber over the outer cladding layer of the optical fiber, and is preferably covered with a polymer coating 194, that can be a thermosetting acrylate coating resin such as 2-hydroxyethyl acrylate or hydroxypropyl acrylate.
  • the optical fiber is a 50/125 CPC3 multi-mode optical fiber available from Corning.
  • the diameter of the core of the optical fiber is about 0.050 mm (0.002 in); the outer diameter of the cladding is about 0.125 mm (0.005 in), and the outer diameter of the polymer coating is about 0.250 mm (0.10 in).
  • the hermetically coated optical fiber is also preferably coated with a layer of silicone 196, which is in turn covered in a layer of tetrafluoroethylene (TFE) fluorocarbon polymer 198, to provide a surface coating with a low coefficient of friction.
  • TFE tetrafluoroethylene
  • the hermetically coated optical fiber, together with the coatings of silicone and TFE, are disposed in a protective sheath 200, which in one preferred embodiment is a stainless steel tube laser welded longitudinally, having a wall thickness of about 0.200 mm (0.008 in), so that it is thin enough to be relatively flexible.
  • the protective sheath additionally provides a fluid seal.
  • the stainless steel is preferably formed from a strip of stainless steel, which is folded in the shape of a tube. As the tube is folded, the coated optical fiber is inserted in the tube.
  • the stainless steel protective sheath is advantageous because it can be laser welded, which results in less heat being applied to its contents during assembly. Olen tubes formed from copper or brass and soldered have been used in conventional techniques, but it has been found over the years that when a soldered copper or brass tube has an extended length, the solder joint tends to split open.
  • An inert gel layer 202 is also preferably injected into the protective sheath around the coated optical fiber as the sheath is folded into the shape of a tube and laser welded.
  • the inert gel layer functions to reduce shock, friction and abrasion that the optical fiber would otherwise experience due to the rolling and unrolling of the cable on the winch drum, and other twisting and bending motions which the cable undergoes during use.
  • the inert gel also helps to support the weight of the optical fiber within the protective sheath, to prevent the optical fiber from rupturing itself due to its own weight when the support cable is suspended in a well bore.
  • One inert gel typically used is a thixotropic buffer tube compound having a viscosity of about 280 ⁇ 15, (Penetrometer, ASTM D-217) and smooth, buttery consistency, and is available under the trade name "SYNCOFOX” from Synco Chemical Corporation.
  • an inner insulator jacket 204 Surrounding the protective sheath is an inner insulator jacket 204, preferably made of a high temperature resistant material which is an electrical insulator, having a relatively high melting point exceeding 148 °C (298 °F), such as polypropylene which has a melting point at about 168-171 °C (333-340 °F).
  • a high temperature resistant material which is an electrical insulator, having a relatively high melting point exceeding 148 °C (298 °F), such as polypropylene which has a melting point at about 168-171 °C (333-340 °F).
  • Other materials which also may be suitable for use as an insulator jacket are high temperature resistant fluorocarbon polymers such as TFE, and ethylene- tetrafluoroethylene copolymer (ETFE), sold under the trade name "TEFZEL" by E. I. du Pont.
  • the inner insulator jacket typically has a thickness of about 0.254 mm (0.010 in), and an
  • an inner layer of electrically conductive strands 206 is a single layer of a braid of bare copper wire strands, which is braided onto the polypropylene inner insulator jacket 204 as the jacket is extruded over the stainless steel protective sheath 200.
  • braided copper as the electrical conductor layer results in an increase in the density of copper in that layer over prior techniques which use a helical "serve" of copper.
  • an increase in electrical conductive capacity results with this relatively thin copper layer.
  • the layer size would be larger to obtain the same conductive capacity provided by the braided approach shown here.
  • the inner insulator jacket 204 may not be included and the braid of copper 206 may be formed directly on the protective sheath 200.
  • An outer insulator jacket 208 also preferably formed of a material having a relatively high melting point, and in this embodiment is also polypropylene, but which may also be formed of the other materials mentioned above in relation to the inner jacket 204, surrounds the inner layer of electrically conductive strands, and typically has a wall thickness of about 0.56 mm (0.022 in) and an outer diameter of about 3.30 mm (0.13 in).
  • This layer is preferably formed in two extrusions. In the first extrusion, the polypropylene flows into the copper braid resulting in a stabilizing jacket. The second extrusion provides the thickness of the layer 208 required for fluid seal purposes.
  • the outer jacket 208 also forms an electrical insulator between the strength members 210 which are used for conducting electricity and the copper braid layer 206.
  • a plurality of strength member strands 210 preferably surround the outer insulator jacket 208, and in one preferred embodiment comprise an inner layer 210 of strength member strands wound helically around the outer insulator jacket in one direction, and an outer layer 212 of stainless steel armor strength member strands wound helically around the inner layer of strength member strands in an opposite serve or winding.
  • the opposite serves of strength member strands help prevent the cable from becoming twisted.
  • the strength member strands were formed of galvanized improved plow steel. Other embodiments may use stainless steel as the strands or an alloy known as MP 35 for particularly corrosive environments, such as where hydrogen sulfide is present.
  • an exemplary total diameter of the cable 189 is approximately 5.72 mm (0.225 in), and with minor variations in the thickness of the various layers of the cable, the total diameter can typically range from about 4.76 mm (3/16 in) to about 7.94 mm (5/16 in).
  • the plurality of strength member strands are electrically conductive, and can provide a leg of an electrical power supply loop.
  • the support cable 189 includes a cable termination assembly 220, as is illustrated in FIGS. 19, 20 and 21.
  • the cable termination assembly generally includes an electrical conductive cable head body 222 coaxially disposed about the distal end of the support cable 189, an electrically conductive rope socket body 224 disposed within and secured to the cable head body 222 and coaxially disposed about the support cable, an electrically conductive clamp ring 226 disposed within the cable head body and secured over the rope socket body, and an electrically conductive contact sub-assembly 228 secured to a distal end of the cable head body.
  • Down-hole well fluids typically can enter the cable head body through the proximal end of the lumen 230 extending axially through the cable head body over the outer armor strength member strands of the cable, particularly at high pressures, permitting well fluids to enter the interior chamber 232 of the cable head body.
  • the rope socket body is typically secured to the cable head body by set screws 234 in cable head body.
  • the plurality of strength member strands are terminated a short distance distally of the rope socket body, are folded back over the conical flange 236 of the rope socket body, and are matingly locked in place over the conical flange by the clamp ring 226, completing an electrical connection of the strength member strands to the cable head body.
  • the number of the strength member strands folded back determine the break-away force required for the cable to be separated from the instrument probe. By judiciously selecting the number of the folded back strength member strands, the force may be set so that if the instrument probe becomes stuck in a well, the cable can be pulled free of the instrument probe, and the probe can be recovered separately. Strength members not folded back are cut off.
  • the outer insulator jacket 238 is not terminated at this point, and the rest of the cable, including the outer insulator jacket, electrical conductors, inner insulator jacket, protective sheath and buffer layers, and the optical fiber of the cable continue on through the inner chamber 232 of the cable head body to extend through an axial lumen 240 of the contact subassembly 228.
  • the sealing nipple 242 of the contact subassembly includes an exterior annular recessed portion 246, for snap-fit mating with a generally conical, flexible sealing boot 248, having an internal rib 250 corresponding to the recess 246 of the sealing nipple.
  • the boot includes a narrow aperture 252, which fits tightly over the outer insulator jacket of the cable, and is further compressed over the cable and sealing nipple to form a seal between the contact subassembly and the well fluids by the high pressure of the well fluids.
  • the cable exits through an aperture 254 of the contact sub-assembly at the distal end 256 of the contact subassembly.
  • the contact subassembly is connected to the distal end of the cable head body by external proximal threads 258 which are matingly secured to corresponding internal threads 260 of the distal portion of the cable head body.
  • the distal portion of the contact subassembly includes a shoulder 262 for receiving the chassis of the converter assembly 34, and includes sockets 264 for set screws for securing the chassis of the converter assembly to the contact subassembly.
  • O- ring seals 266 are provided in sockets 268 for further sealing of the distal end of the contact subassembly and the chassis of the converter assembly from well fluid pressure.
  • an electrical connector 268 is electrically connected to the contact subassembly, completing the electrical connection through the contact subassembly and strength member strands, to provide a first electrical terminal for the camera head, light head, and electro/ optical converter.
  • the outer insulator jacket 238 typically terminates a short distance distally of the contact subassembly, exposing the inner layer of electrically conductive strands, to which an electrical connector 270 is electrically connected, such as by welding, soldering, bolts or screws, or the like, to provide a second electrical terminal.
  • the distal end 272 of the optical fiber is located distally of the contact subassembly for connection to the electro/optical converter, for communicating signal data from the camera to the surface equipment.
  • the sealing nipple can be sealed by an appropriate sealing material, which can for example comprise a first layer of adhesive backed TFE tape 274, typically about 12.7 mm (0.5 in) wide, a second layer of splicing tape 276, such as 23# rubber splicing tape available from 3M, and a third layer of all-weather tape 278 such as Super 88 all-weather vinyl tape available from 3M.
  • the well fluid pressure has been found to compress the multiple tape layers to also effectively seal the contact assembly from the well fluids.
  • the electrical and optical connections of the support cable to the instrument probe are made fluid tight for use in high pressure well fluid environments.
  • the seal is made of standard components, the seal is economical to provide and manufacturing on a repeatable basis is facilitated.
  • the layers of mechanical, thermal and electrical insulation in the cable surrounding the optical fiber minimize attenuation of signal data carried by the optical fiber which can occur due to damage by hydrogen and other gases at elevated temperatures and pressures, and severing or fractures of the optical fiber due to mechanical stresses.
  • attenuation of the signal data communicated from the instrument probe is further minimized.
  • the electrical conductors in the down-hole instrument cable of the invention which can be used for carrying electrical power from the surface for operation of the instrument probe or other devices can also be used to conduct electrical signals, especially when the instrument probe can be operated from battery power carried by the instrument probe itself.
  • the size of the cable is minimized by the dual function of the strength member strands to protect the cable from physical damage and as part of an electrical path.
  • a well bore inspection system including an instrument probe having a plurality of environmental sensors, at least one of such sensors being a visual sensing device such as a camera for sensing the well walls, well contents, and other well characteristics and the other sensors being non-visual environmental sensing devices.
  • the instrument probe is attached to a reduced-diameter support cable for lowering the probe into the well bore and moving it to selected inspection sites therein.
  • the plurality of sensor signals generated from the sensing devices are transmitted through an optical fiber to the surface through the reduced-diameter cable.
  • the power source for the instrument probe is located at the surface, power being provided therefrom to the probe through the reduced-diameter cable.
  • the support cable includes the optical fiber cable and the electrical power cable therein, the design thereof resulting in a smaller diameter cable having a smooth outer surface to facilitate handling, yet one having the required strength.
  • an instrument probe is provided having an improved lighting arrangement for illumination of the field of view of the camera. Also provided is a quick connect and disconnect feature to allow for swapping the camera/light source assembly with the instrument body.
  • the instrument probe is not limited to the temperature, pressure, capacitance, and flow sensors described above but may include other sensors.
  • ultrasonic, magnetic, and nuclear sensors may be mounted in the instrument.
  • Gamma ray, neutron porosity and other sensors may be installed in the instrument as needed.
  • flow sensors other than spinners may be used; for example, strain gauges or piezo-resistive elements may be usable.

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Abstract

Une sonde porte-instruments servant à explorer un passage comporte plusieurs détecteurs de paramètres relatifs à l'environnement dont l'un est une caméra fournissant des images visuelles du passage. Une source de lumière est placée derrière la caméra pour assurer un rétro-éclairage du passage. La source d'énergie pour la sonde porte-instrument se situe en surface. Un câble porte-sonde de faible diamètre comporte en son centre des fibres optiques destinées à transmettre à la surface les signaux des détecteurs. Une couche tampon et une gaine de protection entourent les fibres optiques pour les protéger des conditions adverses de l'environnement.
PCT/US1996/006928 1995-06-07 1996-05-17 Systeme de diagraphie combinant une camera video et des detecteurs des conditions environnementales de fond de trou Ceased WO1996041066A1 (fr)

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