Armored cable containing a hermetically sealed tube incorporating an optical fiber

Claim 2

An armored optical cable suitable for use in an environment which subjects said cable to repeated longitudinal elongation and relaxation forces, said cable comprising: a central hermetically sealed tube core, said core comprising at least two metal sections fitting together around one or a plurality of buffered optical fibers and forming a cylindrical tube, said metal sections hermetically joined into said tube, wherein said metal sections were preshaped by rolling from an anealed wire, and wherein said metal sections and the tube formed therefrom are fabricated from metals which exhibit a yield strain greater than about 0.85; at least six substantially solid elements wound helically around said core in a given handedness; at least twice the number of said at least six elements of inner armor wires wound around and contacting said at least six elements of the same handedness in a unilay helical configuration, said at least six elements and said inner armor wires being fabricated around said core at the same time wherein the elements and the wires of the same handedness and the core form a central bundle; and a plurality of outer armor wires contacting said inner armor wires, said out armor wires wound in an opposite helical handedness to the handedness of said inner armor wires such that the torques exerted by said inner armor wires and said outer armor wires substantially balanced.

Claim 3

The cable according to claim 1 wherein said core comprises three helically wound optical fibers embedded in a cushioning material within said core.

Claim 4

The cable according to claim 2 wherein said sections of said core undergo precipitation hardening after being rolled into cylindrical sections and prior to being joined by laser welding.

Claim 5

The cable according to claim 3 wherein said sections are fabricated from stainless steel wires or nonferrous alloy wires.

Claim 6

The cable according to claims 1 or 4 wherein said at least six elements are insulated solid conductor strands of a copper-plated steel wire conductors.

Claim 7

The cable according to claim 5 wherein the inner armor wire is galvanized steel wire.

Claim 8

The cable according to claim 6 wherein the conductor strands and the inner armor wires from substantially uniform in size interstical spaces there between, said intersticial spaces are occupied by jacketed optical fibers, insulated conductors, a corrosion inhibitor lubricant, or galvanized steel wire fillers.

Claim 9

The cable according to claim 7 wherein the central core element conductor strands inner armor wires are coated with a nitrile rubber-based filling compound.

Claim 10

The fiber according to claim 7 wherein the outer armor wires are galvanized, preformed, plough steel wires and the central core element, the conductors, the inner and outer armor wires are substantially round.

Claim 11

the cable according to claim 9 wherein the central core conductor strands inner armor wires are coated with a nitrile rubber-based filling compound.

Claim 12

The cable according to claim 9 wherein the sections are joined along longitudinal seams and said at least six elements are eight elements.

Claim 13

The cable according to claim 11 wherein the central core element, the conductor strands and inner armor wires are coated with a nitrile rubber-based filling compound and said conductor strands are insulated.

Claim 14

The cable according to claim 12 wherein said tube has a yield stress greater than about 100,000 psi.

Claim 15

The cable according to claim 1 wherein the central core, conductor strands and inner armor wires are coated with a nitrile rubber based filling compound.

Claim 16

An armored optical well logging cable comprising: a central substantially round hermetically sealed tube core having an outer diameter of between about 0.110 to about 0.120 inches, and an inner diameter of about 0.06 inches, said core including therein a plurality of optical fibers embedded in an elastomer, said core formed from two metal sections joined longitudinally together around said fibers and forming a cylindrical tube, said tube exhibiting a yield strain greater than about 0.85; eight substantially round and insulated solid conductor strands wound around said central core with a right hand lay and about a 3.5 inch lay length and a diameter of 0.071 inches such that the outer diameter of the central core and the conductor strands is about 0.262 inches; sixteen substantially round inner armor strands of galvanized steel wire having an outer diameter of about 0.058 inches wound around and contacting said conductor strands in the same handedness and lay length as said conductor strands, said conductor strands and said inner armor being fabricating in the same operation, wherein said central core, said conductor strands and said inner armor wires from a central bundle having an outer diameter of about 0.368 inches; and twenty-four substantially round outer strands of galvanized steel wire wound around and contacting said sixteen inner strands in a let hand lay with a 3.5 inch lay length, said twenty-four strands having a diameter of about 0.049 inches such that the total cable diameter has an outside diameter of about 0.469 inches.

Claim 17

An armored optical well logging cable comprising: a central substantially round hermetically sealed tube core having an outer diameter of between about 0.110 to about 0.120 inches, and an inner diameter of about 0.06 inches, said core including therein a plurality of optical fibers embedded in an elastomer, said core formed from two metal sections joined longitudinally together around said fibers and forming a cylindrical tube, said tube exhibiting a yield strain greater than about 0.85; eight substantially round and insulated solid conductor strands wound around said central core with a right hand lay and about a 3.5 inch lay length and a diameter of 0.071 inches such that the outer diameter of the central core and the conductor strands is about 0.262 inches; sixteen substantially round inner armor strands of galvanized steel wire having an outer diameter of about 0.058 inches wound around and contacting said conductor strands in the same handedness and lay length as said conductor strands, said conductor strands and said inner armor being fabricating in the same operation, wherein said central core, said conductor strands and said inner armor wires from a central bundle having an outer diameter of about 0.368 inches; and twenty-four substantially round outer strands of galvanized steel wire wound around and contacting said sixteen inner strands in a let hand lay with a 3.5 inch lay length, said twenty-four strands having a diameter of about 0.049 inches such that the total cable diameter has an outside diameter of about 0.469 inches.

Claim 18

The cable according to claim 15 wherein the central bundle is filled with an elastomeric filling compound.

Claim 19

The cable according to claim 16 wherein the interstics formed between said inner armor strands and outer armor strands are filled with a corrosion inhibitor and lubricant.

Claim 20

The cable according to claim 17 wherein the eight interstices formed between said inner armor strands and said conductor strands are occupied by eight substantially round wire filler elements, said wire filler elements having a maximum diameter of about 0.028 inches.

Claim 21

The cable according to claim 18 wherein said tube has a yield stress greater than about 100,000 psi.

Claim 22

The cable according to claim 17 wherein said core is further coated with a corrosion resistant metal layer or high temperature plastic to an outer diameter of about 0.120±0.002 inches.

Claim 23

The cable according to claim 20 wherein said core containing the fibers is heated to between about 300° F. to about 500° F. during the joining of the sections by laser welding.

Claim 24

A process of forming an armored optical fiber cable comprising: rolling at least two annealed metal wires into sections, said sections capable of fitting together to form a cylindrical tube central core having an inner diameter sufficient to accept at least one or a plurality of buffered optical fibers; forming said central core around said buffered optical fibers from the rolled sections; joining hermetically said sections into said tube central core; winding conductor elements helically around said tube central core, said winding is of a given handedness and lay length; winding a layer of inner armor wires of the same handedness as said conductor elements and with the same lay length and applied at the same time as said conductor elements helically around said conductor elements; and fabricating a layer of outer armor wires of opposite handedness to said layer of inner armor wires and with such a lay length that the torques extended by said inner and outer armor are substantially balanced when the cable is under tension.

Claim 25

A process of forming an armored optical fiber cable comprising: rolling at least two annealed metal wires into sections, said sections capable of fitting together to form a cylindrical tube central core having an inner diameter sufficient to accept at least one or a plurality of buffered optical fibers; forming said central core around said buffered optical fibers from the rolled sections; joining hermetically said sections into said tube central core; winding conductor elements helically around said tube central core, said winding is of a given handedness and lay length; winding a layer of inner armor wires of the same handedness as said conductor elements and with the same lay length and applied at the same time as said conductor elements helically around said conductor elements; and fabricating a layer of outer armor wires of opposite handedness to said layer of inner armor wires and with such a lay length that the torques extended by said inner and outer armor are substantially balanced when the cable is under tension.

Claim 26

The process according to claim 22 wherein the fabrication further comprises laying down cable elements in the intersticial space formed between said conductor elements and said layer of inner armor wires at the same time as said conductor elements and said layer of inner armor wires are being formed.

Claim 27

A process according to claim 22 wherein the joining is performed by laser welding.

Claim 28

A process acording to claim 24 wherein said sections undergo precipitation hardening prior to welding to increase the yield strength of the finished sections.

Claim 29

A process according to claim 25 further comprising injecting an elastomer into a section and onto said buffered fibers prior to forming the said tube.

Claim 30

A process according to claim 26 further comprising forming a high temperature resistant plastic coating around said tube central core prior to winding said conductor elements around said tube central core.

Claim 31

In a method of well logging to obtain data about earth formations surrounding a wellbore wherein one end of an optical fiber cable is connected to a surface transmitter/receiver and the end opposite thereto is connected to an instrument for measuring and transmitting data about the earth formations through said optical fiber cable to the transmitter/receiver during the lowering and raising of the instrument in the wellbore, the improvement comprising: transmitting said data through an armored optical fiber cable which comprises; a central hermetically sealed tube core including one or a plurality of buffered optical fibers, said core formed from at least two metal sections joined hermetically together around said inner core and forming a cylindrical tube, sections hermetically wherein said metal sections were preshaped by rolling from an annealed wire, and wherein said tube exhibits a yield strain of greater than 0.85; at least six substantially solid elements wound helically around said tube in a given handedness; at least twice the number of said at least six solid elements of inner armor wires wound around and contacting said at least six solid elements with the same handedness in a unilay helical configuration, said at least six solid elements and said inner armor wires being fabricated around said tube at the same time wherein the elements and the wires of the same handedness and the tube form a central bundle; and a plurality of outer armor wires contacting said inner armor wires, said outer armor wires wound in an opposite helical handedness to the handedness of said inner armor wires such that the torques exerted by said inner armor wires and said outer armor wires substantially balanced; and transmitting electrical power or signals through said at least six elements.

Claim 32

In a method of well logging to obtain data about earth formations surrounding a wellbore wherein one end of an optical fiber cable is connected to a surface transmitter/receiver and the end opposite thereto is connected to an instrument for measuring and transmitting data about the earth formations through said optical fiber cable to the transmitter/receiver during the lowering and raising of the instrument in the wellbore, the improvement comprising: transmitting said data through an armored optical fiber cable which comprises; a central hermetically sealed tube core including one or a plurality of buffered optical fibers, said core formed from at least two metal sections joined hermetically together around said inner core and forming a cylindrical tube, sections hermetically wherein said metal sections were preshaped by rolling from an annealed wire, and wherein said tube exhibits a yield strain of greater than 0.85; at least six substantially solid elements wound helically around said tube in a given handedness; at least twice the number of said at least six solid elements of inner armor wires wound around and contacting said at least six solid elements with the same handedness in a unilay helical configuration, said at least six solid elements and said inner armor wires being fabricated around said tube at the same time wherein the elements and the wires of the same handedness and the tube form a central bundle; and a plurality of outer armor wires contacting said inner armor wires, said outer armor wires wound in an opposite helical handedness to the handedness of said inner armor wires such that the torques exerted by said inner armor wires and said outer armor wires substantially balanced; and transmitting electrical power or signals through said at least six elements.

Claim 33

The process according to claim 28 wherein the data is transmitted through a plurality of helically wound optical fibers embedded in a cushioning material within said tube and said electrical power or signals are transmitted through insulated copper-plated steel wires conductors forming said at least six elements.

Claim 34

The process according to claim 29 wherein the data is transmitted through the optical fibers of said armored optical fiber cable which further incorporates wire control elements located in the interstices between said inner armor wires and said at least six elements.

Claim 35

An armored optical fiber cable suitable for use in an environment which subjects said cable to repeated longitudinal elongation and relaxation forces, said cable comprising: a central hermetically sealed tube core, said core comprising at least two metal sections fitting together around one or a plurality of buffered optical fibers and forming said core, wherein said metal sections were preshaped by rolling from an anealed wire, and wherein said metal sections and the tube formed therefrom are fabricated from metals which exhibit a yield strain greater than about 0.85; a plurality of insulated conductor elements wound helically around said central core in a given handedness and lay length; a plurality of inner armor wires wound around and substantially continuously contacting adjacent insulated conductor elements, said inner armor wires having the same handedness and lay length as said insulated conductor elements; and a plurality of torque balancing outer armor wires wound around said outer armor wires in an opposite helical handedness to the handedness of said inner armor wires.

Claim 36

An armored optical fiber cable suitable for use in an environment which subjects said cable to repeated longitudinal elongation and relaxation forces, said cable comprising: a central hermetically sealed tube core, said core comprising at least two metal sections fitting together around one or a plurality of buffered optical fibers and forming said core, wherein said metal sections were preshaped by rolling from an anealed wire, and wherein said metal sections and the tube formed therefrom are fabricated from metals which exhibit a yield strain greater than about 0.85; a plurality of insulated conductor elements wound helically around said central core in a given handedness and lay length; a plurality of inner armor wires wound around and substantially continuously contacting adjacent insulated conductor elements, said inner armor wires having the same handedness and lay length as said insulated conductor elements; and a plurality of torque balancing outer armor wires wound around said outer armor wires in an opposite helical handedness to the handedness of said inner armor wires.

Claim 37

The armored optical fiber cable of claim 31 further characterized in that said insulated conductor elements are substantially solid and include a layer of electrically conductive material attached to a body of different material having a yield strength under tension substantially higher than that of said electrically conductive material.

Claim 38

The armored optical fiber cable of claim 32 further characterized that the inner armor wires are smooth so as to provide a smooth interface for transferring compressive loads to said insulated conductor elements.

Claim 39

The armored optical fiber cable of claim 33 where said inner armor wires are electro-galvanized steel wires.

Claim 40

The armored optical fiber cable of claim 34 where said conductor elements and said inner armor wires form substantially uniform in size interstitial spaces therebetween, said interstitial spaces are occupied by jacketed optical fibers, insulated conductors, a corrosion inhibitor lubricant, or galvanized steel wire fillers.

Claim 41

An armored optical fiber cable suitable for use in well logging which subjects said cable to repeated longitudinal elongation and relaxation forces, said cable comprising: a central hermetically sealed tube core, said core comprising at least two metal sections fitting together around one buffered optical fiber of a plurality of helically wound buffered optical fibers and forming said core, wherein said metal sections were preshaped by rolling from an anealed wire, and wherein said metal sections and the tube formed therefrom are fabricated from metals which exhibits a yield strain greater than about 0.85; plurality of substantially solid insulated conductor elements wound helically around said central core in a given handedness and lay length, said solid insulated conductor elements being disposed in and substantially filling a first annular ring at any given cross-section along the length of said cable; a plurality of inner armor wires wound around said insulated conductor elements, said inner armor wires having the same handedness and lay length as said insulated conductor elements, said inner armor wires being disposed in and substantially filling a second annular ring concentric with said first annular ring at any cross-section along the length of said cable, each of said inner armor wires resting on an adjacent insulated conductor element and not in the grooves formed between adjacent insulated conductor elements to provide said cable with flexibility and to reduce friction between said insulated conductor elements and said inner armor wires, said central core, said insulated conductor elements and said inner armor wires forming a central bundle; and a plurality of torque balancing outer armor wires wound around said inner armor wires in an opposite helical handedness to the handedness of said inner armor wires, said outer armor wires being disposed in and substantially filling a third annular ring generally concentric with said second annular ring at any given cross-section along the length of said cable.

Claim 42

An armored optical fiber cable suitable for use in well logging which subjects said cable to repeated longitudinal elongation and relaxation forces, said cable comprising: a central hermetically sealed tube core, said core comprising at least two metal sections fitting together around one buffered optical fiber of a plurality of helically wound buffered optical fibers and forming said core, wherein said metal sections were preshaped by rolling from an anealed wire, and wherein said metal sections and the tube formed therefrom are fabricated from metals which exhibits a yield strain greater than about 0.85; plurality of substantially solid insulated conductor elements wound helically around said central core in a given handedness and lay length, said solid insulated conductor elements being disposed in and substantially filling a first annular ring at any given cross-section along the length of said cable; a plurality of inner armor wires wound around said insulated conductor elements, said inner armor wires having the same handedness and lay length as said insulated conductor elements, said inner armor wires being disposed in and substantially filling a second annular ring concentric with said first annular ring at any cross-section along the length of said cable, each of said inner armor wires resting on an adjacent insulated conductor element and not in the grooves formed between adjacent insulated conductor elements to provide said cable with flexibility and to reduce friction between said insulated conductor elements and said inner armor wires, said central core, said insulated conductor elements and said inner armor wires forming a central bundle; and a plurality of torque balancing outer armor wires wound around said inner armor wires in an opposite helical handedness to the handedness of said inner armor wires, said outer armor wires being disposed in and substantially filling a third annular ring generally concentric with said second annular ring at any given cross-section along the length of said cable.

Claim 43

The armored optical fiber cable of claim 36 further characterized by the presence of at least six of said insulated conductor elements.

Claim 44

The armored optical fiber cable of claim 36 characterized by the presence of at least twelve of said inner armor wires.

Claim 45

The armored optical fiber cable of claim 38 characterized in that the said optical fiber is contained in said core.

Claim 46

The armored optical fiber cable of claim 36 further characterized by the presence of interstitial elements located in said grooves formed between adjacent ones of said insulated conductor elements to control the placement of the inner armor wires.

Claim 47

The armored optical fiber of claim 40 characterized in that said interstitial elements are occupied by jacketed optical fibers, insulated conductors, galvanized steel wire fillers or combinations thereof.

Claim 48

The armored optical fiber cable of claim 40 characterized in that said interstitial elements are smooth bright galvanized wires.

Claim 49

The armored optical fiber cable of claim 42 further characterized in that the inner armor wires are electro-galvanized steel wires.

Claim 50

The armored optical fiber cable of claim 40 further characterized in that said insulated conductor elements include a layer of electrically conductive material attached to a body of different material having a yield strength under tension substantially higher than that of said electrically conductive material.