CA2604819C

CA2604819C - Method of applying a strain sensor to a cylindrical structure

Info

Publication number: CA2604819C
Application number: CA2604819A
Authority: CA
Inventors: Frederick Henry Kreisler Rambow
Original assignee: Shell Canada Ltd
Current assignee: Shell Canada Ltd
Priority date: 2005-04-15
Filing date: 2006-04-13
Publication date: 2014-05-20
Anticipated expiration: 2026-04-13
Also published as: EP1869402B1; CN101175970A; AU2006236751B2; US20060233482A1; CA2604819A1; BRPI0609787A2; AU2006236751A1; MY139772A; NO20075851L; BRPI0609787B1; DE602006003197D1; NO338703B1; EA200702240A1; EP1869402B8; ATE411508T1; EA015016B1; US7245791B2; EP1869402A1; JP2008537117A; WO2006113327A1

Abstract

Method for determining a preferred application of a plurality of strain sensors or sensors to a structure are disclosed for monitoring and imaging deformation of the structure as it is subjected to various forces.

Description

METHOD OF APPLYING A STRAIN SENSOR TO A CYLINDRICAL STRUCTURE
Field of the Invention The present invention relates to a method of applying a strain sensor to a cylindrical structure, for monitoring deformation of the structure.
Background of the Invention Wells in compactable sediments (or tectonically active areas) are subject to deformation over the productive life of the field. The result is the catastrophic loss of producing zones up to and including the loss of a whole well. The problem is exacerbated by the increasingly rapid off-take rates and the completion of multiple zones in a single well.
An observable phenomenon is that at first a well casing will bend or begin to buckle, frequently at casing joints, or interfaces in the formation. As the compaction continues, the movement results in a significant misalignment of the well axis. The result can be the complete loss of the well investment resulting in deferred and/or lost production, if not the replacement cost of a well, which is extremely expensive. The ability to detect early bending would warn of a later buckle or collapse and allow for changes in production practices and/or remedial action. Detection of deformation forces, in-situ, can become a complex problem, particularly when such forces include axial, hoop and shear stresses.
Optical fiber that is treated with Fiber Bragg Gratings may be suitable for use in monitoring compaction-induced strain on the tubular structure. Fiber Bragg Gratings may be made by laterally exposing the core of a single-mode fiber to a periodic pattern of intense UV light. This creates areas of increased refractive index within the fiber. The fixed index modulation is referred to as a Fiber Bragg Grating ak 02604819 2013-04-02 (hereinafter "FBG"). All reflected light signals combine coherently to one large reflection at one wavelength when the grating period is equal to half the input wavelength. For all intents and purposes, the grating is transparent for other wavelengths of light. Light therefore, moves through the grating with negligible attenuation or signal variation with only the Bragg wavelength being affected, i.e., strongly backreflected at each FBG sensor. In other words, the center frequency of the grating is directly related to the grating period, which is affected by thermal or mechanical changes in the environment.
Thus, temperature, strain and other engineering parameters may be calculated by measuring the normalized change in reflected wavelength. Being able to preset and maintain the grating wavelength is, thus, what makes FBG sensors so useful. See "Fiber Bragg Grating" 3M US
Online, 27 November 2000.
U.S. patent No. 6,854,327 describes the use of bent, instead of stretched, FBG sensors that alter amplitude reflection and broaden frequency. The FBG sensors react to displacement forces with a predictable, altered, wavelength response that may be compared with a calibration curve to estimate shape and the magnitude of displacement One embodiment is described as a helical-shaped optical fiber, wherein the FBG sensors are positioned in the bends of the optical fiber.
A need therefore, exists for determining a preferred application of strain sensors to a tubular structure for detecting and measuring large deformations of the structure.

ak 02604819 2013-04-02 ' 63293-4118 Summary of the Invention In one embodiment, there is provided a method of applying a strain sensor to a cylindrical structure, for monitoring deformation of the cylindrical structure, the method comprising:
selecting a desired sensitivity to axial strain in the cylindrical structure;
determining at least one strain factor corresponding to the desired sensitivity, which at least one strain factor represents a ratio between strain transmitted to the strain sensor as caused by axial strain in the cylindrical structure and the axial strain in the cylindrical structure;
determining a preferred wrap angle relative to an imaginary reference line extending along a surface of the cylindrical structure, in dependence of the at least one determined strain factor; and applying the strain sensor to the cylindrical structure aligned with the preferred wrap angle to measure strain in = the direction of the preferred wrap angle.
The invention is based on the insight that by selecting a preferred wrap angle, the amount of strain the strain sensor will be exposed to, and even the sign of the strain (tension versus compression) may be regulated. This opens a path to various applications, as will be set forth below in the following description.
A preferred application of a strain sensor system, based on a preferred wrap angle, has to the applicant's not been proposed. Based on selection of the wrap angle, the application of strain sensors - particularly an FBG system -to a tubular structure may be uniquely tailored to detect and = measure various types and levels of strain the tubular structure is likely to encounter in a particular environment.
Thus, strain on the tubular structure may be more accurately detected, in-situ, and measured in real time. As a result, deformation of the tubular structure may be anticipated, if not avoided.
These and other aspects, features and advantages of the present invention will be described in the following description of the various embodiments and related drawings.
Brief Description of the Drawings The present invention is illustrated in more detail below with reference to the attached drawing figures, wherein:
FIG. 1 is an elevational view of a cylindrical structure illustrating a plurality of sensors or transducers applied to the structure along three different sections (A, B, C) of the structure;
FIG. lA is a linear perspective of section A in FIG. 1;
FIG. 2 is a graph of illustrating the determination of preferred number of strain sensors (N) and preferred number of wraps needed to cover a predetermined length;
FIG. 3 is a graph illustrating the relationship between the strain factor (m) and various wrap angles (0);
FIG. 3A is a graph illustrating the relationship between strain factor (m) and wrap angle (0) according to a predetermined Poisson ratio (v);
FIG. 4 is a graph illustrating the relationship between strain (s) applied to steel and corresponding Poission's ratio (v);
FIG. 5 is a graph illustrating the relationship between the length of sensing fiber and the length of the tubular structure versus the wrap angle (0);
FIG. 6 is a graphical illustration of the resulting wavelength response, relative to DN numbered strain sensor, from a cylindrical structure undergoing offset shear in a controlled test;
FIG. 7 is an elevational view of a cylindrical structure illustrating shear forces on the structure;
FIG. 7A is an image of a wavelength response illustrating the corresponding strain measured by the strain sensors in FIG. 7;
FIG. 8 is a graph illustrating the wavelength response resulting from the lateral force applied by the weight of a pipe, plotted as wavelength shift (Ak) versus grating number FIG. 9 is a graph showing the wavelength response resulting from the forces from a weight suspended from the center of the pipe horizontally suspended at each end, plotted as wavelength shift (Ak) versus grating number (DN);
FIG. 10 is an elevational view of a cylindrical structure illustrating bending forces on the structure;
FIG. 10A is an image of a wavelength response illustrating the corresponding strain measured by the strain sensors in FIG. 10;
FIG. 11 is a graph illustrating the wavelength response resulting from the application of a crushing force applied near the center of the pipe of Fig. 8, plotted as wavelength shift(A7) versus grating number (DN);
FIG. 12 is a graph illustrating the wavelength response for the pipe of FIG. 11, plotted as wavelength shift (Ak) versus grating number (DN), wherein the clamps near the center of the pipe have been rotated 90 degrees;
FIG. 13 is an elevational view of a cylindrical structure illustrating crushing or ovalization forces on the structure;

FIG. 13A is an image of a wavelength response illustrating the corresponding strain measured by the strain sensors in FIG. 13;
FIG. 13B is a top view of FIG. 13;
FIG. 14 is a plot illustrating the relative strain amplitude (WA) as a function of the azimuth angle (4)) in degrees around a tubular structure;
FIG. 15 is a graph illustrating-the strain factor (m), and nm shift, versus wrap angle (0) for a structural material undergoing plastic deformation.
FIG. 16 is a graph illustrating the wavelength shift (AX) plotted versus grating number (DO for various levels of applied axial strain;
FIG. 17 is a graph comparing the average, peak and root-mean-square (rms) wavelength response with calculated or expected wavelength response, plotted as wavelength shift Ak (nm) versus the axial strain applied Ea (%);
FIG. 18 is a graph illustrating the average wavelength shift Ak (actual) over the applied strain sensors at each level of applied axial strain Ea (%}, compared to the calculated wavelength shift;
FIG. 19 is a graph of wavelength shift Ak (nm) versus grating number (DN), illustrating an axial strength of about zero;
FIG. 20 is a graph of wavelength shift Ak (nm) versus grating number (DN), illustrating an applied axial strain of 0.25 percent;
FIG. 21 is a graph of wavelength shift Ak (nm) versus grating number (DN), illustrating an applied axial strain of 0.75 percent;

FIG. 22 is an elevational view of a cylindrical structure illustrating compressional forces on the structure;
FIG. 22A is an image of a wavelength response illustrating the corresponding strain measured by the strain sensors in FIG. 22;
FIG. 23 is a theoretical plot of delta strain As versus distance (d) along a line above a reservoir.
Detailed Description of the Preferred Embodiments The subject matter of the present invention is described with specificity however, the description itself is not intended to limit the scope of the invention. The claimed subject matter thus, might also be embodied in other ways to include different steps or combinations of steps similar to the ones described herein, in conjunction with other present or future technologies. Moreover, although the term "step"
may be used herein to connote different methods employed, the term should not be interpreted as implying any particular order among or between various steps herein disclosed except when the order of individual steps is explicitly described.
The following description refers to the use of strain sensors in the form of a plurality of transducers that may comprise one or more conventional FBG sensors such as, for example, the transducers described in U.S. Patent Nos.
5,798,521, 6,426,496, or 6,854,327. Optionally, FBG sensors may be i) specially treated (short-term blazed) as described in "Characteristics of short-period blazed FBG sensors for use as macro-bending sensors", 'APPLIED OPTICS, 41, 631-636 (2002), Baek, S., et al.; and/or ii) bent as described in "Long-Period Fiber Grating Bending Sensors in Laminated Composite Structures", SPIE
Conference on Sensory Phenomena and Measurement Instrumentation for Smart Structures and Materials, March ak 02604819 2007-10-04 1998, San Diego, Calif., SPIE Vol. 3330, 284-292, Du, W., et al.; and/or iii) coated as described in "Ultrastrong Fiber Gratings and Their Applications", SPIE Conference Phototonics East "Optical Fiber Reliability and Testing", 3848-26, Sep. 20-, 1999, Starodubov, D. S., et al.
The present invention, however, is not limited to the use of FBG-type sensors and may be implemented with conventional sensors or transducers capable of detecting axial and/or radial strain such as, for example, strain gauges as described in "Strain Gauge Technology," A. L.
Window (Editor), Elsevier Science Pub. Co., 2nd edition, November 1992.
Thus, the novel techniques and methods described herein may be implemented and applied through the use of any type of strain sensor or transducer capable of detecting signals and transmitting signals, regardless of whether it is a FBG sensor, strain gauge or other conventional type sensor or transducer. Furthermore, the use of an optical fiber as a transmission means to illustrate various applications of the invention described herein is not exclusive of other well-known transmission means that may be used to connect the transducers such as, for example, electrical wires, which are capable of transmitting power and a signal. Furthermore, conventional wireless transducers may be used provided that they include a power source.
Referring now to FIG. 1, an elevational view of a cylindrical structure 10 such as, for example, a tubular structure (e.g., drill pipe) or casing, is illustrated with a plurality of FBG type sensors 20 applied to the structure 10 on a fiber 30 at different preferred wrap angles in sections A, B and C. FIG. 1A is a linear perspective of section A in Figure 1, illustrating the fiber 30 wrapped around the tubular 10 at a preferred wrap angle represented by 01 or 02.

The preferred wrap angle may be measured relative to a first imaginary reference line 40 extending longitudinally along a surface of the structure 10. Alternatively, the preferred wrap angle may be measured relative to a second imaginary reference line 50 circumferencing the structure 10, which also represents the circumference (C) in FIG. 1A.
For purposes of the following description, however, wrap angle 0 and preferred wrap angle 01 are defined relative to the second imaginary reference line 50 and is represented by 01.
Nevertheless, 02 could be used, instead, by simply substituting 7c/2-02 for Olor calculating Olbased on 02as = 90 - 02.
In FIG. 1A, the length of one wrap of fiber 30 around the structure 10 is represented as S. The distance along the first imaginary line 40, which may be the vertical distance between each wrap of fiber 30, is represented as L.
Relationships between 01, L, X, S, and C are illustrated by:
L=S*sin(03.) and C=S*cos(01). In this transformed geometry, S
represents the hypotenuse of a right triangle formed by L, C, and S.
Axial strain along the axis of the structure 10 caused by compaction can be represented as E=L/L. Axial strain along the axis of the structure 10 caused by compaction can be translated to strain in the strain sensor 20 and represented as sf =AS/S, which may manifest itself in the strain sensor 20 as axial, hoop and/or sheer stress.
The relationship between strain (sf) in the strain sensor 20 and its wavelength response is therefore, represented by:
Ail=2(1¨Pe)K6f where AX represents a strain sensor wavelength shift due to strain (sf) imposed on the strain sensor 20 and X represents the average wavelength of the strain sensor 20. The bonding coefficient of the strain sensor 20 to a substrate or system on which the strain is to be measured is represented by K.
A "combined" response for bending (also buckling, shearing) and axial strain may be represented by:
1" COS
= A,(1 - Pe) = K =(¨ 1 + = (1 (s ))2+cos2 64 + v(s r cos 0))2 wherein AA, is the wavelength shift measured on a given grating and 2µ, is the original wavelength of the grating which may nominally be 1560 nanometers. The term (1-Pe) is a fiber response which is nominally 0.8. Bonding coefficient K
typically may be 0.9 or greater. The wrap angle (or orientation angle of the sensor) with respect to first imaginary axis of the tubular is represented by 0. The axial strain E on the tubular that may be from compaction or other external source. The radius of the tubular or cylindrical structure is represented by r, and 0 is an arbitrary azimuth angle with respect to some reference along the axis of the tubular that allows one to orient the direction of the buckle or bend with respect to this. Capital R represents the bend radius of the buckle or bend in the pipe. As the bend radius gets very large (straight unbent pipe), this portion of the signal vanishes. The Poisson ratio v of the structure may change with strain. An independent measurement may be employed to extract the value of v. One can, by using two wrap angles simultaneously, solve for this.
For simplicity in the examples that follow, the bonding coefficient (K) is assumed to be constant. Pe represents the strain and temperature effect on the index of refraction of the strain sensor 20.
P, may be a function of strain and temperature, including torque on the strain sensor 20, but is neglected in the following examples. Since it is well known that temperature variations may impart additional strain to the fiber 30, the strain sensors 20 and structure 10, which affect the index of refraction in the fiber 30, temperature variations may be considered independently for calibrating the strain measurements. This can easily be done either by a separate temperature measurement that could be performed by mechanically decoupling short lengths of the fiber 30 from the structure 10, using a separate but similar fiber that is entirely decoupled mechanically from the structure 10 or by any other means of measuring the temperature in the vicinity of the structure 10 undergoing the strain measurement.
The foregoing properties may be used to relate the strain (se) in the strain sensor 20 to the axial compaction strain (6) in the structure 10.
The strain (se) in the strain sensor 20 can be related to the preferred wrap angle (00 and the strain (6) along the axis of the structure 10 by:
AS
¨ = ¨1+ Vsin(6) )2 * (1¨ s)2 + cos(0 )2 * (1 +v)2 The Poisson ratio (v) is an important property of the structure 10, which is relevant to the strain (E) the structure 10 may encounter as illustrated in the examples to follow.
The strain factor relating axial strain (6) in the structure 10 to strain (se) transmitted to the strain sensor 20 is represented by:
¨1+ Vsin(002 * (1 ¨ s)2 + cos(002 * (1 + vs)2 = _________________________________________________________ which may also be translated to:
ASIS=m*ALIL=m*e.
Comparison of the strain factor (m) to other variables reveals that it is highly sensitive to the preferred wrap angle (00, somewhat sensitive to the Poisson ratio (v), and quite insensitive to applied axial strain (0.
Application of the Sensors The primary requirements for sensitivity and resolution are a sufficient number of sensors 20 positioned around the circumference (C) of the structure 10 and adequate vertical spacing between the sensors 20 so that a sinusoidal pattern associated with a bend, buckle, shear or crushing (ovalization) force can be clearly detected and imaged. As demonstrated by the relationships below, sensitivity to axial strain and radial strain, and hence bending strain, is also a function of the preferred wrap angle (00.
Preferably, at least ten strain sensors 20 per wrap of the fiber 30 may be used to adequately capture one cycle of the sinusoidal signal produced by a deformation of the structure 10. It is also desirable to have at least eight to ten turns or wraps of the fiber 30 covering the vertical distance of the structure 10 over which the deformation is expected to occur. Fewer strain sensors 20 will reduce the resolution and ability to unambiguously distinguish between a bend, buckle, shear or crushing type deformation. In terms of the preferred wrap angle (00 and the diameter (D) (in inches) of the structure 10 the length of structure 10 (in feet) covered by each wrap is represented as:

g*D*tan(01) To obtain the length in feet, the length in meters must be divided by 0.30. To obtain the diameter in inches, the diameter in centimeters must be divided by 2.54.
In terms of the preferred wrap angle (00 and the diameter (D) (in inches} of the structure 10, the length of one wrap around the structure 10 (in feet) is represented as:
S7r*D*cos(01) ¨ ______________________________________________ I ¨

The total length of the fiber 30 (in feet) based on a preferred number of wraps (Nn,) around the structure 10 and the length of one wrap (S1) around the structure 10 (in feet) is represented as:
S=S1*Nn, The axial length of the fiber 30 (in feet) along the structure 10 is based on a preferred number of wraps (N,,,) around the structure 10 and the length of structure 10 (in feet) covered between each wrap is represented as:
Z = Li*Nõ
Thus, the preferred number of wraps (Nw) around the structure 10 may be determined by the axial length (Z) of the structure 10 wrapped in the fiber 30 divided by the length (LO of structure 10 covered between each wrap of the fiber 30. In addition to the preferred wrap angle (00, the preferred number of wraps (Nw) may be used to determine a preferred application of the fiber 30 and strain sensors 20 to the structure 10.

The strain sensor spacing may be as short as 1 centimeter or as long as necessary to accommodate a judicious number of strain sensors 20 per wrap of the fiber 30 on a structure 10 having a large diameter. The total number of strain sensors 20 per wrap of the fiber 30 as a function of strain sensor spacing (Sg) (in centimeters) and wrap length (S1) is represented as:
n=2.54*Si*12 = 2.54*g*/)*cos(91) Sg Sig Assuming that all of the strain sensors 20 on the fiber 30 are within the wrapped portion of the fiber 30, then the total number of strain sensors 20 on the fiber 30 is represented as:
=2.54*S*12 2.54*k*g*/)*cos(01) Sg Sg Similarly, the preferred strain sensor spacing (Sg) may be easily determined with a known preferred number of strain sensors (N) and a predetermined total length (S) of fiber 30.
Roughly, the maximum number of strain sensors 20 that can be used on one fiber 30 with this technique may be about 1000. Thus, the preferred wrap angle (00, the preferred number of wraps (Nw) and the preferred number of strain sensors (N) may be used to determine a preferred application of the fiber 30 and strain sensors 20 to the structure 10.
Using the previous equations, plots such as the one in FIG. 2 may be compiled and used to determine the preferred number of strain sensors (N) and the preferred number of wraps (Nw) needed to cover a predetermined length and diameter for the structure 10 and the preferred strain sensor spacing (Sg). Plotted on the left axis are the length of the fiber (S, in units of 0.30 meter - corresponding to feet), the axial length (Z, in units of 0.30 meter - corresponding to feet) of the structure 10 wrapped in the fiber 30 and the total number (N) of strain sensors in the form of gratings that may be compared to a wrap angle range for a predetermined number of wraps (Nw) and a predetermined strain sensor spacing (Sg). Plotted on the right axis are the total number of gratings per wrap (n) and the axial length (Li in units of 0.30 meter - corresponding to feet) of the structure 10 covered between each wrap that may be compared to a wrap angle (0) range for a predetermined strain sensor spacing (Sg) and a preferred number of wraps (Nw). In FIG. 2, line 1 plots the length of the structure Z against wrap angle (0) for a case whereby D = 15 cm (6.0 inches); line 2 plots the length of the fiber (S) for a case where the number of wraps (NW) = 100; line 3 plots the number of gratings having a spacing (S) of 5.0 mm; line 4 plots the number of gratings per wrap; and, line 5 plots the length of the structure Z
against wrap angle (01) per wrap.
In FIG. 2, D= 152 mm (6 inches), Nw=100 and Sg=5 mm.
This figure shows that wrap angles between 20 and 40 degrees tend to optimize resolution considering the length of fiber (S) and the length of the structure (Z) being monitored. This information may be used with the strain factor (m) to design a preferred application of the fiber 30 to the structure 10.
FIG. 3, illustrates the relationship between the strain factor (m) and wrap angle 0. A predetermined Poisson ratio (v) of 0.5 was chosen based on the observation of steel tubular performance after yielding at high compaction strains. A predetermined strain (c) of 5.0 percent was selected based upon the maximum anticipated strain the structure may encounter.

Based on these structural parameters (P(v), (6)), the strain factor (m) may be determined for each wrap angle illustrated in Fig. 3. The results in Fig. 3 reveal that the strain each strain sensor experiences can be decreased or even reversed (compression to tension) by carefully choosing the preferred wrap angle (0 = 01).
The ability to easily regulate the amount of strain the fiber and each strain sensor will be exposed to, and even the sign of the strain (tension vs compression) is very important. Most conventional fiber sensors manufactured from glass can be exposed to no more than one or two percent strain (in tension) before damage or failure occurs.
Compressional strain in fiber sensors manufactured from glass is even more problematic. Thus, high axial compressional strain exerted on tubular structures in compacting environments can be converted to mild extensional strain in the fiber sensor by simply adjusting the wrap angle.
The same principle may be applied to recalculate the amount of strain on other conventional sensor systems that may be used.
In FIG. 3A, the strain factor (m) is illustrated for each wrap angle 0 according to a predetermined Poisson ratio (v) of 0.3 and a predetermined strain (6) of 0.10 percent for the structure analyzed. These conditions could correspond to applications where mild compaction may be anticipated. For good sensitivity to mild compaction strains (compressional) and excellent sensitivity to lateral deformations, it may be advantageous based on FIG. 3A to select a preferred wrap angle of on the order of 20 degrees.
FIGS. 3 and 3A illustrate that, at a zero-degree wrap angle, the strain factor (m) is equal to the Poisson ratio (v).
In other words, the compressional strain (6) on the structure is translated to an axial expansion defined by Poisson's ratio (v).
Likewise, in the limit of no wrap (vertical application along casing or a 90-degree wrap angle) the extension or compression of the structure can be measured directly. The latter has the disadvantage that, in high compressional strains, the fiber and/or strain sensors are likely to be damaged and/or undergo buckling and mechanically disconnect from the structure. But for mild extensional strains as often seen in an overburden layer, it may be best to choose 90 degrees or near 90 degrees, such as between 80 and 90 degrees) (corresponding to axial application or near-axial application).
FIG. 4 illustrates Poisson's ratio (v) for steel versus strain applied. For steel behaving elastically, the nominal Poisson ratio is near 0.3.
It has been observed that the Poisson ratio (v) of tubular structures undergoing high compaction strains (beyond the elastic limit) is better approximated at 0.5. This is a theoretical limit for the conservation of volume. The Poisson ratio (v) may therefore, be predetermined according to the anticipated or maximum strain the structure may encounter, however, may be between about 0.3 and about 0.5 for tubular steel structures. As a general rule, the Poisson ratio (v) may be approximated at 0.5 if the predetermined strain is at least 0.3 percent or greater in a tubular steel structure.
The principles illustrated in FIG. 3 and FIG. 3A may be used to determine a preferred application of the strain sensors 20 to the substantially cylindrical structure 10 in FIG. 1A for monitoring deformation of the structure in various formation environments. According to one method, a preferred wrap angle range (e.g., between 0 and 90 degrees) may be selected for determining the relative strain factor (m) associated with each wrap angle in the preferred wrap angle range. A broad wrap angle range between 0 degrees and 90 degrees may be preferred, however, different, narrower, ranges may be selected.
The strain factor (m) should be determined for at least one wrap angle within the preferred wrap angle range. The preferred wrap angle (Or) within the preferred wrap angle range may be determined based on at least one determined strain factor (m), and used to determine the preferred application of the strain sensors 20 to the structure 10 in FIG. 1A. As illustrated in Fig. 2, a number of other variables, including the preferred number of strain sensors (N) and the preferred number of wraps (Nw), may also be considered in determining the preferred application of the strain sensors 20 to the structure 10 based on sensitivity and resolution requirements.
Determining the preferred wrap angle (00 within the preferred wrap angle range may, alternatively, be based on a preferred strain factor range comprising a plurality of the strain factors determined in the manner described above. The determined strain factor or determined strain factor range may be selected to determine the preferred wrap angle (00 within the preferred wrap angle range based on a maximum strain the strain sensor 20 and/or fiber 30 can withstand.
If a transmission means other than the fiber 30 is used, or wireless transducers are used, then the determined strain factor or determined strain factor range used to determine the preferred wrap angle (00 within the preferred wrap angle range may be based on a maximum strain the alternative transmission means and/or transducers, or wireless transducers, can withstand.
In FIG. 3, for example, the predetermined Poisson ratio (v) and anticipated axial strain (s) reveal a need for sensitivity to high compaction strains. Assuming the strain sensors and/or fiber are limited to about 2 percent strain before failure occurs, then the wrap angle at which the strain sensors and/or fiber may fail at 5 percent anticipated strain on the structure is determined by dividing the maximum strain the strain sensor and/or fiber may withstand (0.02) by the anticipated strain (0.05), which reveals a strain factor (0.4) that corresponds with a wrap angle of about 15 degrees.
Consequently, a wrap angle of greater than about 15 degrees is required to prevent damage to the strain sensors and/or fiber and preferably may be about 30 degrees. A wrap angle greater than about 35 degrees, where the strain factor is zero, may produce undesirable compression and buckling in the fiber and/or strain sensors.
Once a preferred application of the strain sensors has been determined, the strain sensors may be applied to the structure 10 along a preferred application line represented by the fiber 30 in FIG. 1A. The preferred wrap angle may be formed between the preferred application line and the first imaginary reference line 40 or the second imaginary reference line 50.
The strain sensors 20 and the fiber 30 may be applied to an exterior surface of the structure 10 (as illustrated in FIG. 1), an interior surface of the structure 10, a channel within the structure 10 or be made an integral component of the structure 10 when forming or manufacturing the structure 10. In the event that the tubular structure 10 comprises a screen assembly having multiple screen components, including a sand screen, the strain sensors 20 and the fiber 30 may be applied to an interior surface and/or an exterior surface of one of the multiple screen components or in a channel within any one of the multiple screen components or between any two of the component layers. Additionally, the strain sensors 20 and the fiber 30 may be applied to an exterior surface of one of the multiple screen components and the interior surface of another one of the multiple screen components.
Furthermore, the strain sensors 20 and the fiber 30 may be applied to the structure 10 in a protective sheath and/or a protective sheet coating the strain sensors 20 and the fiber 30, provided that the protective coating is capable of transferring strain from the structure 10 to the strain sensors 20. Acceptable protective coatings may comprise, for example, a metal, a polymer, an elastomer, a composite material or a thin tube comprising one or more of these materials that is flexible yet capable of being applied to the structure 10 in a way that couples the strain experienced by the structure 10 with the strain sensors 20. In the event the structure 10 must be run in a well bore, the strain sensors 20 and fiber 30 may be applied before the structure 10 is run in the well bore.
Alternatively, the strain sensors 20 and the fiber 30 may be applied to the structure 10 after it is run in the well bore using a conduit, or may be applied to the interior or exterior surface of the structure 10 after the structure 10 is run in the well bore. Any conventional conduit capable of being coupled to the structure 10 is acceptable.
Acceptable materials for the conduit may comprise, for example, a metal, a polymer, an elastomer, a composite material or a thin tube comprising one or more of these materials that is flexible yet capable of being applied to the structure 10 in a way that couples the strain experienced by the structure 10 with the strain sensors 20.
The strain sensors 20 and the fiber 30 may be introduced into an opening in the conduit and positioned therein with a fluid capable of securing the strain sensors 20 and the fiber 30 within the conduit and transferring strain on the structure 10 to each strain sensor 20. The fluid may, for example, comprise any conventional polymer, polymer solution, polymer precursor, or epoxy. The fluid may also be used to convey the strain sensors 20 and the fiber 30 through the conduit. Additionally, the strain sensors 20 and the fiber 30 may be positioned in the conduit with the fluid by applying force on either, or both, ends of the fiber 30 to push and/or pull the same through the conduit. For example, a weighted object may be attached to the leading end of the fiber 30 to propel (pull) the fiber 30 and strain sensors 20 through the conduit. The conduit may be positioned within the structure 10 along the preferred application line or on the structure 10 along the preferred application line. In either case, the preferred wrap angle may be formed between the preferred application line (represented by the fiber 30 in FIG. IA) and the first imaginary reference line 40 or the second imaginary reference line 50.
If the structure 10 comprises a screen assembly having multiple screen components, the conduit may be positioned within one of the multiple screen components along the preferred application line or on one of the multiple screen components along the preferred application line.
Application of the strain sensors 20 and fiber 30 to a structure 10 after it has been positioned in a well bore may be preferred in that this technique does not require the tubular structure to be rotated or a fiber spool to be rotated about the structure during application of the strain sensors 20 and the fiber 30.
Similar advantages may be preferred by application of the strain sensors 20 and the fiber 30 to the structure 10 in a protective sheet, which may be positioned on the structure 10 and fastened along one side as described further in U.S. Patent No. 6,854,327.
Multiple and Variable Wrap Angles As reservoir depletion progresses, the sensitivity/resolution requirements and strain factors are likely to change. By combining multiple wrap angles over a single zone of the formation, the sensitivity and dynamic range of the measurements may be extended. For example, a fiber wrapped at 20 degrees may fail at one level of strain while the same fiber wrapped at 30 degrees or more may not fail at the same level of strain or at a slightly higher level of strain.
Another advantage multiple wrap angles provide is better characterization of the change in the Poisson ratio (v) as the structural material yields under higher strains. Common steel used in tubulars may have a Poisson ratio of near 0.3 while it is elastic but trends toward 0.5 after the material yields. Applying the fiber 30 and strain sensors 20 at two or more wrap angles, as illustrated in FIG. 1, will allow the characterization of this change.
This is particularly important for fibers that are wrapped near the angle that would null the fiber strain.
This null point changes primarily as a function of the Poisson ratio (v) for the structure 10. With multiple wrap angles, this behavior can be measured directly on the structure 10 in the well while it is undergoing compaction strain.
Thus, if different wrap angles may be preferred due to different forces acting on the tubular structure, the methods described above in reference to Figs. 3 and 3A may be used to determine another preferred wrap angle within the preferred wrap angle range.
The preferred application of the strain sensors 20 may be based on the preferred wrap angle and another preferred wrap angle and applied to the structure 10 over the same section or over different sections as illustrated by section B and sections A, C in FIG. 1, respectively. In either case, the preferred ak 02604819 2007-10-04 wrap angle and another preferred wrap angle may each be determined according to a respective determined strain factor (m) = Each respective determined strain factor (m) may be selected according to a predetermined force and another predetermined force to be applied to the structure 10, over the same section or over different sections, which impacts the same by variations in the Poisson ratio (v) and axial strain (s).
Restrictions on the number of strain sensors, the wrap length and the strain sensor spacing may also be overcome using multiple wrap angles. Therefore, multiple wrap angles may be used to extend the measuring length of a single region along the structure or span multiple zones along the structure as illustrated in sections A, B and C of FIG. 1.
The addition of multiple wrap angles may also be used to branch into multiple structures such as multi-lateral wells.
Although the wavelength response is more complicated, the application of the fiber 30 and the strain sensors 20 at variable wrap angles may also be desirable. Configurations utilizing multiple and variable wrap angles over a single section of the structure 10, like section B in FIG. 1, may be preferred. Other configurations, such as those suggested in U.S. Patent No. 6,854,327, may be used, however.
The present invention will now be described further with reference to its application in different formation environments such as, for example, formation shear and formation compaction. In each of the examples to follow, a cylindrical structure was tested using a Distributed Sensing System (DSS) manufactured by Luna Innovations Incorporated under license from NASA. The LUNA INNOVATIONS Distributed Sensing System (DSS) utilizes technology covering an optical fiber containing multiple FBG sensors, and a projection device or monitor capable of imaging a wavelength response produced by the FBG sensors as a result of structural strain detected by the FBG sensors. The present invention, however, is not limited to such technology by the following examples, and other transmission means and transducers and/or strain sensors may be used as described hereinabove.
Formation Shear Wells crossing a slip zone or a fault may be in danger of shearing. A shearing zone could be encountered when placing a well across a fault, through salt and/or across weak shale in a tectonically active area or an area undergoing compaction, such as the overburden area.
Shear movement may entirely shear off the well bore or at least restrict passage of tubing, workover equipment, and the like. It is, therefore, desirable to detect and measure the rate of shearing so that hydrocarbon or fluid off-take, well location, well design and similar considerations can be modified to mitigate or prevent damage to the tubular structure and/or casing in the future.
Conventional techniques used to detect and measure shear movement often require tools such as gyroscopes or other devices to take measurements. For various reasons it may be impractical or impossible to run such conventional logging tools into the well. For example, the well may already have sustained considerable damage so that it cannot be entered.
Strain sensors, however, may be pre-positioned on the tubular structure and/or casing without having to run conventional logging tools into the well. Accordingly, in-situ measurements can be taken of shear forces at any time without disturbing the well and with essentially no additional cost. The onset of damage can be observed substantially in real time so that remedial action can be taken as soon as possible.

Field experience reveals that shearing and buckling may result in a loss of clearance, or a complete shear-off, typically over a 0.9- to 1.8-meter (3- to 6-foot) interval of the tubular structure or casing. Thus, a preferred application of the strain sensors to such a structure in a shearing zone should be designed for at least this sensitivity.
In FIG. 5, line 1 plots the length of the structure Z
(in units of 0.30 meter) against wrap angle (0) for a case whereby D = 7.6 cm (3.0 inches); line 2 plots the length of the fiber (S) for a case where the number of wraps (NW) = 80;
line 3 plots the number of gratings having a spacing (S) of 2.0 mm; line 4 plots the number of gratings per wrap; and, line 5 plots the length of the structure Z against wrap angle (0) per wrap.
Assuming a 76-millimeter (3-inch) diameter tubular structure to be monitored across a slip or shear zone, the location of which is known to be within ten feet, requires at least 6.1 meters (20 feet) of coverage along the tubular.
Applying the principles taught by the present invention to the known variables illustrated in FIG. 5 reveals that about 20.4 meters (67 feet) of sensing fiber is needed to cover about 7.3 meters (24 feet) of the tubular structure assuming a preferred wrap angle of about 21 degrees.
Given a preferred strain sensor spacing of about 2 centimeters, about 12 strain sensors per wrap are recommended, which is greater than the minimum recommendation of 10 strain sensors per wrap. The total number of strain sensors is about 1000.
A need also exists for imaging deformation of an object, in order to image the shape and magnitude of the deformation.
The same wrap technique may be used to image, detect and measure bending and buckling of the cylindrical structure as will be explained in the forthcoming examples.
Example 1 FIG. 6, illustrates the resulting wavelength response, relative to each numbered strain sensor, from a cylindrical structure undergoing offset shear in a controlled test. The cylindrical structure is seventy-six (76) millimeters (three (3) inches) in diameter and six hundred ten (610) millimeters (twenty-four (24) inches) long. Although the strain sensor spacing along the optical fiber in this test is about 1 centimeter, a spacing of 2 centimeters may be adequate to measure the same shear response in a cylindrical structure with the same diameter. A preferred wrap angle of about 2G
degrees was used.
The detectable variation in wavelength response, representing lateral offset, was between 0.025 mm (0.001 inches) up to about 15.24 mm (0.600 inches).
In this example, a 0.025 mm (0.001-inch) lateral offset translates into a dogleg in the structure of about less than one-half degree for each one hundred-foot section of the structure, which is inconsequential.
However, a lateral offset of about 2.54 mm (0.1 inch) over the same length of structure translates into a dogleg of approximately 48 degrees for each 30.5 meter (one hundred-foot) section of the structure, which could prevent entry with production logging tools. Knowing the magnitude of the lateral offset (dogleg) before attempting entry could therefore, prevent lost and stuck logging tools and lost wells.
The wavelength response illustrated in FIG. 6 may be imaged, in real time, on a projection device such as the monitors manufactured by Luna Innovations. The detection of variations in the wavelength response at each strain sensor as the structure is being monitored will reveal changes in the deformation of the structure and what type of force is causing the structure to deform.
Variations in the wavelength response are therefore, revealed by variations in the amplitude of the wavelength response at each strain sensor. The ability to detect strain on the structure and image the same in the form of a wavelength response on a projection device, however, is not limited to a cylindrical structure and may be applied to most any object capable of transferring strain from the object to the strain sensor.
FIG. 7 represents a simple illustration of a shear force applied to the structure 10.
Here, the structure 10 is subjected to a shearing force 210 on one side of the structure 10 and another shearing force 220 on another side of the structure 10. The wavelength response, representing strain on the structure 10 measured by the strain sensors 20, associated with the shearing forces 210, 220 is periodic and approximately sinusoidal as illustrated in FIG. 7A.
The period of wavelength response or signal is equal to about one cycle per wrap of the fiber 30 around the structure 10. The amplitude of the periodic signal is determined by the magnitude of shear forces 210, 220. The wavelength response in FIG. 7A is positioned adjacent the structure 10 in FIG. 7 to illustrate points of strain on the structure 10 and the corresponding wavelength response produced as a result of such strain.
For example, the strain on the structure 10 between the shear forces 210, 220 is minimal compared to the strain on the structure 10 near each shear force 210, 220 as illustrated by the maximum wavelength response 230 and minimal wavelength responses 240A, 240B.
The minimal wavelength responses 240A, 240B also illustrate how the shear forces 210, 220 cause the structure 10 to compress and stretch (in tension), respectively. The application of pre-positioned strain sensors 20 on the structure 10 thus, enables in-situ detection of strain on the structure 10, which can be translated through well-known conventional means and imaged in real time.
Formation Compaction Axial compaction is commonly measured with radioactive tags and special logging tools, which typically requires shutting in the well. Measurement of strain on the tubular structure or casing below one percent is difficult to achieve, however, with these conventional techniques. At higher strains, a bend or a buckle in the casing or tubular structure is also difficult to detect without pulling the production tubing and running acoustic or mechanical multi-finger calipers or gyroscopes into the well.
The disadvantages associated with conventional means of detecting and measuring strain induced by axial compaction may be avoided with pre-positioned strain sensors. In other words, the application of pre-positioned strain sensors on the structure may be used for in-situ detection and measurement of axial compaction forces in the manner described above.
Example 2 In this example, accurate measurements of low strain and high sensitivity to bending or buckling induced by axial compaction are important objectives. A thin-walled PVC pipe was tested using the weight of the pipe, horizontally suspended by its ends, as the applied force. A preferred wrap angle of about 20 degrees was used to apply the strain sensors and optical fiber to a 3-meter (10-foot) long section of the pipe with a 16.5-centimeter(6.5-inch) diameter. A 5-centimeter strain sensor spacing was used to resolve the wavelength response from a buckle or a bend.
In FIG. 8, the wavelength response resulting from the lateral force applied by the weight of the pipe is illustrated. A maximum lateral offset of about 1.78 mm (0.07 inches) was detected.
The wavelength response in FIG. 8 clearly reveals a bend or a buckle because one period or cycle of the wavelength response corresponds to one wrap of the fiber. A 1.78 mm (0.07-inch) lateral offset represents less than a 7-degree bend or buckle for each one hundred-foot section of the pipe, which is significant and can be detected by conventional caliper and acoustic imaging tools. In order to run such tools into the well, the well must be shut in and the production tubing must be pulled.
Example 3 In this example, the same pipe was tested using a weight hung from the center of the pipe, which was horizontally suspended at each end. The lateral offset due to a bend is about 5.791 millimeters (0.228 inches). As illustrated in FIG. 9, a relatively clean periodic signal is apparent everywhere except at the ends and at the center of the wavelength response where the weight is hanging and distorting the signal. The distorted signals are a special case related to pipe crushing caused by local loading on the pipe.
FIG. 10 represents a simple illustration of a lateral force on the structure 10 induced by axial compaction. Here the structure 10 is subjected to a lateral force 310 on one side of the structure 10.
The wavelength response, representing strain on the structure 10 measured by strain sensors 20, associated with the lateral force 310 is periodic and approximately sinusoidal as illustrated in FIG. 10A. The period of the wavelength response or signal is equal to about one cycle per wrap of the fiber 30 around the structure 10.
The amplitude of the periodic signal is determined by the magnitude of the lateral force 310. The wavelength response in FIG. 10A is positioned adjacent the structure 10 in FIG.
10 to illustrate points of strain on the structure 10 and the corresponding wavelength response produced as a result of such strain.
For example, the strain on the structure 10 near the lateral force 310 is greater compared to the strain on the structure 10 at each end as illustrated by the maximum wavelength responses 330A, 330B and the minimal wavelength response 320. The maximum wavelength responses 330A, 330B
also illustrate how the lateral force 310 causes the structure 10 to compress and stretch (in tension), respectively.
Example 4 In addition to detecting a bend or a buckle, the onset of ovalization or crushing forces may also be detected and distinguished from a bend or a buckle. A pure ovalization or crushing force should produce a pure ovalization wavelength response. In this example, the same pipe was tested with clamps that were applied as a crushing force near the center of the pipe and slightly tightened with the orientation of the applied force aligned across the diameter of the pipe so as to slightly decrease its cross-sectional diameter. The resulting wavelength response is illustrated in FIG. 11, and reveals a period of about two cycles per wrap as opposed to one cycle.
In this example, the minimum diameter is decreased by 1.27 millimeters(0.05 inches) due to the applied crushing force.
Example 5 In this example, the same pipe was tested by rotating the clamps near the center of the pipe 90 degrees.
The resulting wavelength response is illustrated in FIG. 12, and also reveals a period of about two cycles per wrap. In this example, the minimum diameter is decreased by 1.78 millimeters (0.07 inches).
The increased strain (and therefore deformation) is obvious when comparing FIG. 11 and FIG. 12. It is a simple matter to scale the resulting shift in wavelength to a strain and the resulting strain to a relative crushing.
FIG. 13 represents a simple illustration of a crushing force on the structure 10 induced by axial compaction. Here, the structure 10 is subjected to a crushing force 410 on all sides of the structure 10.
The wavelength response, representing strain on the structure 10 measured by strain sensors 20, associated with the crushing force 410 is a substantially constant periodic signal as illustrated in FIG.
13A. The period of the wavelength response or signal is equal to about two cycles per wrap of the fiber 30 around the structure 10, which is easily distinguished from the wavelength response exhibited by a bend or a buckle discussed in the examples above. The amplitude of the periodic signal is determined by the magnitude of the crushing force 410.
The wavelength response in FIG. 13A is positioned adjacent the structure 10 in FIG. 13 to illustrate points of strain on the structure 10 and the corresponding wavelength response produced as a result of such strain. For example, the strain on the structure 10 is substantially constant around the structure 10 as illustrated by the substantially constant wavelength responses 420A, 420B.
In FIG. 133, an end view of FIG. 13 illustrates the crushing force 410 and the resulting deformation of the structure 10 illustrated by the dashed line 430.
FIG. 14 further illustrates the relative strain amplitude (WA), as measured by a wavelength response in the FBG sensor or other stain sensor or transducer, as a function of azimuth around a tubular structure subjected to a crushing force. The maximum compressive strain (negative signal) occurs at 0 (or 360) and 180 degrees. The maximum tensile strain (positive signal) occurs at 90 and 270 degrees. The neutral stain occurs at 45, 135, 225, and 315 degrees.

Example 6 In this example, the sensitivity is decreased to allow for measurements of higher axial strains (s...2 percent} on a tubular structure. As the structural material begins to undergo plastic deformation, the Poisson ratio (v) will tend towards 0.5 in the limit of plastic deformation. In FIG. 15, the solid line plots the strain factor m as a function of wrap angle 0, assuming v = 0.50 and s 2.0 percent.
Therefore, according to FIG. 15, a wrap angle of approximately 01 = 30 degrees or greater is preferred. For example, a wrap angle of 30 degrees will yield a strain factor (m) of 0.15, which translates to a strain of 1.5 percent in the fiber for a 10 percent strain on the structure. A wrap angle of 20 degrees would yield a strain factor of 0.33, which would translate to a strain of 3.3 percent and would break or damage the fiber.
The preferred wrap angle could be slightly higher (about 35 degrees) to more nearly null out the applied strain on the fiber (m=0) when very high axial strains on the tubular structure (on the order of 10 percent) are expected and when the intent is to measure buckling rather than axial strain. The dashed line in FIG. 15 shows the rim shift on the right hand axis.
FIG. 16, illustrates the wavelength shift (L\a, in nm) for various levels of pure applied axial strain (compression) on the same tubular structure, plotted versus the grating number (DN). In FIG. 16, the lines and their associated axial strains are identified as follows: 16a = 0.1% axial strain;
16b = 0.2% axial strain; 16c = 0.3% axial strain; 16d = 0.4%
axial strain; 16e = 0.5% axial strain; 16f = 0.75% axial strain; 16g = 1.0% axial strain; 16h = 1.25 % axial strain;
and 16i = 1.5 % axial strain. The signal at a 30-degree wrap angle is reduced from that of a 20-degree wrap angle, as described in reference to Fig. 15. The reduction in signal as a function of wrap angle thus, follows the form shown in FIG. 15 and the strain factor (m) equation described above.
A 30-degree wrap angle should easily accommodate and measure up to five percent axial strain while imparting only a fraction of that strain to the fiber. As the axial strain increases, the onset of buckling and other higher modes of deformation are revealed by the periodic nature of the wavelength response.
Even though FIG. 16 reveals the onset of tubular buckling, the overall wavelength response remains substantially linear as axial strain increases. This concept is further illustrated in FIG. 17, which compares the average (0), the peak (4,) and the root-mean-square (rms) (X) wavelength response AX with the calculated (---) or expected wavelength response at various levels of applied axial strain Ea-At about 1.5 percent axial strain, the peak reading begins to diverge slightly from a linear response as the structural material begins to slightly buckle.
One of the most sensitive areas in a well to compaction and deformation is the completion zone. This is particularly true in highly compacting unconsolidated formations in which sand control is required.
In order to control formation areas comprising sand, the base pipe is usually fitted with a filter, commonly referred to as a sand screen. A gravel pack (carefully sized sand) may also be used between the sand screen and the outer casing or formation. The sand screen may comprise a conventional sand screen wire wrap and multiple other conventional screen components (hereinafter referred to as a screen assembly}.
The wire wrap in the screen assembly is designed to allow fluid to flow through openings that are small enough to exclude large particles.
High axial strain imposed on the base pipe can close the wire wrap openings and impair fluid flow. Bends or buckles in the base pipe may also compromise the structural integrity of the screen assembly, thereby causing a loss of sand control.
In this event, the well must be shut in until repairs can be made. Such failures require, at a minimum, a work over of the well and in extreme cases, a complete redrill. Consequently, monitoring the structure for bends, buckles and axial strain in the completion zone is preferred¨
particularly where sand control is required. Accordingly, the strain sensors may be applied to the base pipe and/or screen assembly at about a 20-degree wrap angle.
Example 7 In this example, a 914-millimeter (36-inch) tubular structure having about a 76-millimeter (3-inch) diameter and a Poisson ratio (v) of about .5, was tested in a controlled environment using a 21-degree wrap angle for the application of the strain sensors and fiber. Various amounts of axial strain Ea were applied at each end of the structure, which was otherwise unsupported. The average wavelength response (actual, 41) over the applied strain sensors at each level of applied axial strain is compared to the calculated wavelength (0) response in FIG. 18. At about 0.05 percent strain, there is a departure from the linear calculated wavelength response suggesting a bend or a buckle is beginning to form in the structure tested.
The following Figures (FIGS. 19, 20 and 21) progressively illustrate why a departure from the calculated wavelength response occurs and how it can be used with a periodic signal to detect and determine the magnitude of the bend or buckle in the same structure tested.
For convenience, a vertical representation of the tubular structure, as it reacts to the applied axial strain, is illustrated (in black) in the middle of FIGS. 19, 20 and 21.
In FIGS. 19, 20 and 21, wavelength shift Ak (nm) is plotted against grating number (DN). In FIG. 19, the applied axial strain is nominal or about zero.
In FIG. 20, applied axial strain is 0.25 percent.
In FIG. 21, the applied axial strain is increased to 0.75 percent. In FIG. 20, the wavelength response illustrates the applied strain, however, there is no apparent deformation in the structure.
In FIG. 21, the wavelength response is noticeably greater than the wavelength response in FIG. 20, and there appears to be a bend or a buckle in the structure. As the axial strain applied to each end of the structure increases, the structure is compressed, which causes deformation in the form of a bend or a buckle.
FIG. 22 represents a simple illustration of pure axial strain (force) applied to the structure 10.
Here, the structure 10 is subjected to an axial force 520.
The wavelength response 530, representing strain on the structure 10 measured by the strain sensors 20, associated with the axial force 520 is substantially constant as illustrated in FIG. 22A. Thus, the axial force 520 causes the structure 10 to shorten or compress and expand in the direction indicated by the arrows 510. As a result, the wavelength response 530 is substantially constant until the structure 10 begins to deform in the shape of a bend or a buckle as demonstrated by the progressive illustration in FIGS. 19, 20 and 21, above.
One of the areas in the well where the least amount of strain is likely to occur in compacting reservoirs is in the overburden. The highest tensile strains are usually observed very near the compacting zone and the magnitude of the strain reduces as the distance from the compacting zone increases.
This is reflected in the theoretical plot in FIG. 23, plotting delta strain (As) versus the distance (d) along the line (in feet) as Delta Sext ZZ (*), wherein the reservoir is undergoing 8.0 percent compaction strain and the maximum extensional strain in the overburden is 1.0 percent.
The actual magnitude of the extensional strain in the overburden just above the reservoir is highly dependent upon the reservoir geometry and the material properties of the reservoir and overburden.
The ratio of the extensional strain just above the reservoir to the compressional strain in the reservoir can be used as one diagnostic for reservoir performance. Likewise, the amount of a tensional strain in the overburden affects such things as seismic signals used for 4D seismic measurements.
Thus, the fiber and strain sensors are preferably applied at about 90 degrees longitudinally along the structure to increase sensitivity to tensile strains.
When the fiber and strain sensors are positioned on a tubular structure specifically designed for monitoring such strain, a very accurate measurement can be made.
Furthermore, three or more fibers containing strain sensors may be longitudinally and equidistantly positioned around the tubular structure in order to detect not only axial strain on the structure but also bending strain. The strain on the outside of the radius of curvature of the bend or buckle will be higher (in tension) than the strain on the inside radius. Thus, when 3 or more fibers containing strain sensors are positioned in this manner, the detection and measurement of a long radius bend is possible through the uneven wavelength response.

Having illustrated embodiments with particularity, the invention may be summarized in broader terms as follows.
In addition to a method of applying a strain sensor to a cylindrical body, more specifically the invention relates to methods for determining a preferred application of a plurality of transducers or sensors to a cylindrical structure for monitoring deformation of the structure as the structure is subjected to various forces.
The present invention is in other aspects also directed to methods for imaging deformation of an object as the object is subjected to various forces.
In various embodiments, there is provided a method for imaging deformation of an object comprising the steps of:
applying a plurality of strain sensors to the object at a preferred wrap angle;
detecting deformation of the object at each strain sensor; and imaging the deformation detected at each strain sensor on a projection device.
The object may be cylindrical and each strain sensor may detect axial and radial strain on the object.
The method may further comprise the steps of:
selecting a preferred wrap angle range;
determining a strain factor for at least one wrap within the preferred wrap angle range; and determining the preferred wrap angle within the preferred wrap angle range based on at least one determined strain factor.
The deformation detected at each strain sensor may be transmitted through at least one of a fiber optic, wired and wireless medium to the projection device. The deformation image may be displayed as a wavelength response at each strain sensor and a corresponding strain sensor number.

The plurality of strain sensors may be applied to one of an interior surface and an exterior surface of the structure.
They may be applied in at least one of a protective sheath and a protective sheet. They may be applied to one of a channel within the structure and integrally within the structure when it is formed.
Each of the plurality of strain sensors may be wirelessly coupled to another one of the plurality of strain sensors.
The plurality of strain sensors may be independently powered.
Each of the plurality of strain sensors may be coupled to another one of the plurality of strain sensors through a transmission medium capable of transmitting a signal. The plurality of strain sensors may be connected by an optical fiber.
The method may further comprise the steps of:
monitoring the wavelength response; and detecting variations in the wavelength response at each strain sensor. The variations in the wavelength response may be detected by variations in an amplitude for the wavelength response at each strain sensor. Various types of deformation may be detected based upon the wavelength response.
There is also provided a method of determining a preferred application of a plurality of strain sensors to a cylindrical structure for monitoring deformation of the structure comprising:
selecting a preferred wrap angle range;
determining a strain factor for at least one wrap angle within the preferred wrap angle range;
determining a preferred wrap angle within the preferred wrap angle range based on at least one determined strain factor; and determining the preferred application of the plurality of strain sensors to the structure base on the preferred wrap angle.
The step of determining the strain factor is preferably based on a predetermined Poisson ratio for the structure, which may be based upon the predetermined strain for the structure. The predetermined strain for the structure may be based upon a maximum strain the structure may encounter.
This method may further comprise the step of applying the plurality of strain sensors to the structure along a preferred application line. The preferred wrap angle may be formed between the preferred application line and one of a first imaginary reference line extending longitudinally along a surface of the structure and a second imaginary reference line circumscribing the structure.
It may also further comprise the steps of:
determining the strain factor for each wrap angle within the preferred wrap angle range; and determining the preferred wrap angle within the preferred wrap angle range based on at least one of the determined strain factors. The step of determining the preferred wrap angle within the preferred wrap angle range may be based on a preferred strain factor range comprising a plurality of the determined strain factors. The step of determining the preferred wrap angle within the preferred wrap angle range may be based on at least one of the plurality of determined strain factors within the strain factor range.
The method may also comprise the step of selecting at least one of the determined strain factors, and/or the strain factor range, based on a maximum strain sensor strain.
The method may further comprise the steps of:
determining the strain factor for a plurality of wrap angles within the preferred wrap angle range;

determining another preferred wrap angle within the preferred wrap angle range based on at least one of the determined strain factors; and determining the preferred application of the plurality of strain sensors to the structure based on the preferred wrap angle and another preferred wrap angle, and optionally the steps of:
selecting the at least one determined strain factor based on a predetermined force to be applied to an area of the structure; and selecting at least another one of the determined strain factors based on another predetermined force to be applied to least one of the area of the structure and another area of the structure.
Optionally the step of applying the plurality of strain sensors to at least one of the area of the structure and another area of the structure based on at least one of the preferred wrap angle and another preferred wrap angle is provided.
The method may further comprise the steps of:
introducing at least one of the plurality of strain sensors into an opening in a conduit;
positioning at least one of the plurality of strain sensors within the conduit; and introducing a fluid into the opening in the conduit to at least partially solidify and secure at least one of the plurality of strain sensors within the conduit.
This conduit may be positioned within the structure along a preferred application line and the preferred wrap angle is formed between the preferred application line and one of a first imaginary reference line extending longitudinally along a surface of the structure and a second imaginary reference line circumferencing the structure.

The conduit may positioned on the structure along a preferred application line and the preferred wrap angle is formed between the preferred application line and one of a first imaginary reference line extending longitudinally along a surface of the structure and a second imaginary reference line circumferencing the structure.
At least one of the plurality of strain sensors may be positioned within the conduit by at least one of a compressional force and tensional force.
More specifically, there is provided a method of determining a preferred application of an optical fiber to a cylindrical structure, wherein the optical fiber includes at least one sensor, comprising:
selecting a preferred wrap angle range for the optical fiber;
determining a fiber strain factor for at least one wrap angle within the preferred wrap angle range;
determining a preferred wrap angle for the optical fiber within the preferred wrap angle range based on at least one determined fiber strain factor; and determining the preferred application of the optical fiber to the structure based on the preferred wrap angle.
At least one sensor may detect deformation of the structure.
The step of determining the fiber strain factor may be based on a predetermined Poisson ratio for the structure and a predetermined strain for the structure.
The method may further comprise the step of determining a preferred number of wraps based on a predetermined axial length of the structure, a diameter for the structure and the preferred wrap angle. Preferably, the preferred number of wraps is at least eight.
The method may further comprise the step of determining the preferred application of the optical fiber to the structure based on the preferred number of wraps. A preferred sensor spacing may be determined based on a preferred number of sensors and a predetermined length of fiber. the preferred number of sensors may be at least ten.
The step of determining the preferred application of the optical fiber to the structure may be based on the preferred number of sensors.
The preferred wrap angle range may be between about 00 and about 90 .
The method may further comprise the steps of:
determining the fiber strain for each wrap angle within the preferred wrap angle range; and determining the preferred wrap angle for the optical fiber within the preferred wrap angle range based on at least one of the determined fiber strain factors.
Herein, the step of determining the preferred wrap angle of the optical fiber within the preferred wrap angle range may be based on a preferred fiber strain factor range comprising a plurality of the determined fiber strain factors. The step of determining the preferred wrap angle for the optical fiber within the preferred wrap angle range may be based on at least one of the plurality of determined fiber strain factors within the fiber strain factor range.
The method may further comprise the step of selecting at least one of the determined fiber strain factors and or the fiber strain factor range, based on a maximum fiber strain.
The method may further comprise the steps of:
determining the fiber strain factor for a plurality of wrap angles within the preferred wrap angle range;
determining another preferred wrap angle for the optical fiber within the preferred wrap angle range based on at least another one of the determined fiber strain factors; and determining the preferred application of the optical fiber to the structure based on the preferred wrap angle and another preferred wrap angle, and optionally the steps of:
selecting at least one determined fiber strain factor based on a predetermined force to be applied to an area of the structure; and selecting at least another one of the determined fiber strain factors based on another predetermined force to be applied to at least one of the area of the structure and another area of the structure.
Optionally, the method further comprise the step of applying the optical fiber to at least one of the area of the structure and another area of the structure based on at least one of the preferred wrap angles and another preferred wrap angle.
The structure may comprise a screen assembly, which may comprise multiple screen components. The plurality of strain sensors may then be applied to at least one of an interior surface and an exterior surface of one of the multiple screen components. The plurality of strain sensors may be applied to the exterior surface of one of the multiple screen components and the interior surface of another one of the multiple screen components. The plurality of strain sensors are applied to one of the multiple screen components in at least one of a protective sheath and a protective sheet. The plurality of strain sensors may be applied to a channel within one of the multiple screen components.
A conduit may be positioned within one of the multiple screen components. For instance, it may be positioned along a preferred application line and the preferred wrap angle is formed between the preferred application line and one of a first imaginary reference line extending longitudinally along a surface of the structure and a second imaginary reference line circumscribing the structure.
At least one of the plurality of strain sensors may be introduced into an opening in the conduit and positioned within the conduit. A fluid may be introduced into the opening in the conduit to at least partially solidify and secure at least one of the plurality of strain sensors within the conduit, as described above.
The present invention may be utilized to detect and monitor deformation of any substantially cylindrical structure in a well bore caused by structural strain, regardless of the well bore or formation activity.
As described herein, the present invention may be uniquely tailored to detect and measure axial compaction, shear, bending, buckling, and crushing (ovalization) induced strain on the well bore structure due to fault movement and/or compaction in the formation. The present invention thus, may be applied to any substantially cylindrical structure in a well bore for purposes of detecting and monitoring deformation of the structure during production or other non-production operations such as, for example, completion (e.g., gravel packing/frac packing), production and stimulation operations.
Accordingly, the cylindrical structure may be provided in the form of a wellbore tubular, such as for instance a drill pipe, a production tube, a casing tube, a tubular screen, a sand screen, The present invention could also be used in any other situation where pipes expand and contract, or bend, such as, for example, refineries, gas plants, and pipelines. The present invention may also be useful for imaging deformation (shape/magnitude/movement) of other, non-cylindrical, objects and thus, could be used for displacement sensing using the same principles applied to different length scales.
The = present invention may also be used to obtain data for other = types of geomechanical modeling, including, for example dams or other structures.
It is therefore, contemplated that various situations, alterations and/or modifications may be made to the disclosed embodiments without departing from the scope of the invention as defined by the appended claims and equivalents thereof.

Claims

CLAIMS:

1. A method of applying a strain sensor to a cylindrical structure, for monitoring deformation of the cylindrical structure, the method comprising:
selecting a desired sensitivity to axial strain in the cylindrical structure;
determining at least one strain factor corresponding to the desired sensitivity, which at least one strain factor represents a ratio between strain transmitted to the strain sensor as caused by axial strain in the cylindrical structure and the axial strain in the cylindrical structure;
determining a preferred wrap angle relative to an imaginary reference line extending along a surface of the cylindrical structure, in dependence of the at least one determined strain factor; and applying the strain sensor to the cylindrical structure in alignment with the preferred wrap angle to measure strain in the direction of the preferred wrap angle.

2. The method of claim 1, wherein the step of determining the at least one strain factor is based on a predetermined Poisson ratio for the cylindrical structure.

3. The method of claim 1 or 2, wherein the step of determining the at least one strain factor is based on a predetermined strain for the cylindrical structure.

4. The method of claim 3, wherein the step of determining the at least one strain factor is based on a predetermined strain for the cylindrical structure and wherein the predetermined Poisson ratio for the structure is based upon the predetermined strain for the structure.

5. The method of claim 3 or 4, wherein the predetermined strain for the cylindrical structure is based upon a maximum strain the structure may encounter.

6. The method of any one of claims 1 to 5, wherein the desired sensitivity is based on a maximum strain sensor strain.

7. The method of any one of claims 1 to 6, wherein the strain sensor is one of a plurality of strain sensors that are applied along an application line along the preferred wrap angle.

8. The method of any one of claims 1 to 6, wherein the strain sensor is one of a plurality of strain sensors that are applied along an application line that extends along various wrap angles within a wrap angle range, which wrap angle range includes the preferred wrap angle.

9. The method of any one of claims 1 to 6, further comprising the steps of:
determining a plurality of preferred wrap angles in dependence of a plurality of strain factors; and applying a plurality of strain sensors to the cylindrical structure along a plurality of application lines along the plurality of preferred wrap angles, whereby said strain sensor is one of the plurality of strain sensors.

10. The method of any one of claims 7 to 9, wherein the plurality of strain sensors are connected by an optical fiber, and wherein applying at the plurality of strain sensors to the cylindrical structure includes applying the optical fiber along an application line which includes at least a section directed along the preferred wrap angle.

11. The method of claim 10, further comprising the step of determining a preferred number of wraps based on a predetermined axial length of the cylindrical structure, a diameter for the structure and the preferred wrap angle.

12. The method of claim 11, wherein the preferred number of wraps is at least eight.

13. The method of claim 10, 11, or 12, further comprising the step of determining a preferred strain sensor spacing based on a preferred number of strain sensors and a predetermined length of fiber.

14. The method of any one of claims 10 to 13, wherein each strain sensor comprises a Bragg grating written into the optical fiber.

15. The method of any one of claims 1 to 14, further comprising the steps of:
introducing the strain sensor into an opening in a conduit positioned relative to the structure along the preferred wrap angle;
positioning the strain sensor within the conduit; and introducing a fluid into the opening in the conduit to at least partially solidify and secure the strain sensor within the conduit.

16. The method of any one of claims 1 to 15, further comprising the step of:

providing the cylindrical structure in the form of a wellbore tubular, preferably a casing tube.