CC-0146B), entitled"Pressure Isolated Bragg Grating Temperature Sensor", Serial No. (CiDRA Docket No. CC-0014A), entitled"Fiber Optic Bragg Grating Pressure Sensor", and Serial No. (CiDRA Docket No. CC-0230), entitled"Large Diameter Optical Waveguide, Grating, and Laser", all filed contemporaneously herewith, and Serial No. (CiDRA Docket No. CC-0130), entitled"Method and Apparatus For Forming A Tube-Encased Bragg Grating", filed December 4,1998. All of the aforementioned applications contain subject matter related to that disclosed herein.

Technical Field This invention relates to tube encased fiber optic pressure sensors, and more particularly to fluid ingression protection mechanisms for a tube-encased fiber grating pressure sensor.

Background Art Sensors for the measurement of various physical parameters such as pressure and temperature often rely on the transmission of strain from an elastic structure (e. g., a diaphragm, bellows, etc.) to a sensing element. In a fiber optic pressure sensor, the sensing element may encased within a glass tube or housing comprised substantially of glass. One example of a fiber optic based sensor is that described in U. S. Patent application Serial No. CC-0036 entitled"Tube Encased Fiber Grating Pressure Sensor"to Robert J. Maron, which is incorporated herein by reference in its entirety.

The use of fiber optic based devices is widespread in the telecommunications industry wherein the impervious nature of the glass provides adequate protection given the relatively mild working environments. A relatively recent known use of fiber optic pressure sensors is in an oil well to measure temperature and pressure at various locations along the length of the well bore. The sensors are typically deployed in metal housings in the wellbore and are attached on the outside of the casing. The sensors many times may be subjected to extremely harsh environments such as temperatures up to 200 degrees C and pressures up to 20 kpsi. These sensors are exceptionally sensitive and are capable of measuring various parameters, such as temperature and pressure, with extreme accuracy. Along with the sensitivity and accuracy of fiber optic sensors comes the realization of many problems when such sensors are used in a harsh environment. Known problems include such as poor signal to noise ratios, wavelength drift, wavelength shifts, optical losses, hysteresis and mechanical reliability. It is the realization of the these problems and the discovery of the causes that will advance the state of the art in fiber optic based well bore monitoring systems.

One such known problem is"creep"of the sensor over time. It has been discovered that the attachment of the sensing element to the elastic structure can be a large source of error if the attachment is not highly stable. In the case of sensors that measure static or very slowly changing parameters, the long-term stability of the attachment to the structure is extremely important. A major source of such long-term sensor instability is this creep phenomenon, i. e., change in strain on the sensing element with no change in applied load on the elastic structure, which results in a DC shift or drift error in the sensor signal. Various techniques now exist for attaching the fiber to the structure to minimize creep, such as adhesives, bonds, epoxy, cements and/or solders.

In addition, the sensors are subject to fluids containing hydrocarbons, water and gases that can have deleterious effects on the accuracy of the sensors. For instance, it has been discovered that the performance of wellbore deployed fiber optic sensors is adversely affected by exposure to hydrogen wherein a fiber will experience irreversible loss along its length. Further, when the fiber optic sensors include Bragg

gratings, exposure to hydrogen causes a shift in the index of the grating that severely lessens the accuracy of the sensor. Increased pressure and temperature of the hydrogen increases the rate at which the fiber optic cables and sensors are degraded.

It has also been discovered that certain side-hole fiber optic pressure sensors and eccentric core optical fiber sensors experience deleterious effects, such as those described above, when exposed to water at high temperatures and pressures. The adverse effects are presumed to be caused by thin swollen surface layers that lay in close proximity to the sensitive fiber optic core. The observed shifts and changes are presumed to be due to the ingress of water molecules and the subsequent direct expansion of the silica that makes up the fiber itself. In one particular instance the fibers had a core center to surface separation distance of only 10 um.

However, as discussed hereinbefore, many other problems and errors associated with fiber optic sensors for use in harsh environments still exist. There is a need to discover the sources of these problems and errors and further there is a need to discover solutions thereto to advance the state of the art in fiber optic sensor use.

Summary of the Invention Objects of the present invention include a fiber optic pressure sensor with fluid blocking provisions for use in a harsh environment.

According to the present invention a fluid blocking fiber optic pressure sensor comprises an optical fiber, having at least one pressure reflective element embedded therein, wherein the pressure reflective element has a pressure reflection wavelength, a sensing element, having the optical fiber and the reflective element encased therein, the sensing element being fused to at least a portion of the fiber and the sensing element being strained due to a change in external pressure, the strain causing a change in the pressure reflection wavelength, and the change in the pressure reflection wavelength being indicative of the change in pressure and a fluid blocking coating disposed on the external surface of the sensing element.

According further to the present invention the sensing element comprises a tube and the fluid blocking coating comprises at least one layer. According still further, the fluid blocking coating comprises a fluid blocking material of gold,

chrome, silver, carbon or silicon nitride or other similar material capable of preventing the diffusion of water molecules into to the sensing element. According still further to the present invention, the coating comprises a first layer comprised of chrome disposed on the outside surface of the sensing element and a second layer comprised of gold disposed on the first layer. In one embodiment the first layer has a thickness of about 250 A and the second layer has a thickness of about 20,000 A.

The present invention provides a fluid blocking fiber optic pressure sensor having a fiber grating encased in and fused to at least a portion of a sensing element, such as a capillary tube, which is elastically deformable based on applied pressure.

The invention substantially eliminates drift, and other problems, associated with water, and other fluid, absorption into the tube. The tube may be made of a glass material for encasing a glass fiber. Also, the invention provides low hysteresis. Also, one or more gratings, fiber lasers, or a plurality of fibers may be encased in the coated tube. The grating (s) or reflective elements are"encased"in the tube by having the tube fused to the fiber on the grating area and/or on opposite axial sides of the grating area adjacent to or a predetermined distance from the grating. The grating (s) or laser (s) may be fused within the tube or partially within or to the outer surface of the tube. Further, the invention may be used as an individual (single point) sensor or as a plurality of distributed multiplexed (multi-point) sensors. Also, the invention may be a feed-through design or a non-feed-through design. The tube may have alternative geometries, e. g., a dogbone shape, that provides enhanced force to wavelength shift sensitivity and is easily scalable for the desired sensitivity.

The invention may be used in harsh environments (high temperature and/or pressure), such as in oil and/or gas wells, engines, combustion chambers, etc. In one embodiment, the invention may be an all glass sensor capable of operating at high pressures (>15 kpsi) and high temperatures (>150 °C). The invention will also work equally well in other applications independent of the type of environment.

The foregoing and other objects, features and advantages of the present invention will become more apparent in light of the following detailed description of exemplary embodiments thereof.

Brief Description of the Drawings Fig. 1 is a side view of a fluid blocking tube-encased fiber optic sensor, in accordance with the present invention; Fig. 2 is a graphical representation of the performance of a prior art tube- encased fiber grating sensor; Fig. 3 is a graphical representation of the performance of a tube-encased fiber grating sensor, in accordance with the present invention; and Fig. 4 is a graphical representation of the performance of an alternative embodiment of a tube-encased fiber grating sensor, in accordance with the present invention.

Best Mode for Carrying Out the Invention Referring to Fig. 1, a tube-encased fiber Bragg grating transducer comprises a known optical waveguide 10, e. g., a standard telecommunication single mode optical fiber, having a pressure Bragg grating 12 and a temperature Bragg grating 13 impressed (or embedded or imprinted) in the fiber 10 wherein the fiber is encased within shell 20 such as is described in copending US Patent Application CC-0036B, titled Bragg Grating Pressure Sensor, filed December 6,1999, and CC-0078B, titled Tube-Encased Fiber grating, filed December 6,1999 which are hereby incorporated by reference in its entirety. In One embodiment the transducer element 1 is constructed by fusing a bare photosensitive fiber 10 in a fused silica capillary tube 15, which functions as a piston as will be described herein below. In the embodiment shown in Fig. 1, Bragg grating 12 is approximately 5mm in length (although other lengths are possible) and is disposed in the"dogbone"region 16, and Bragg Grating 13 is comprised of a different reflective wavelength and is disposed as shown in an area adjacent region of the piston. Grating 12 is used for interrogation of pressure (pressure grating), while grating 13 is used to differentially remove temperature effects that are common to all gratings (temperature grating). A cylindrical, pressure- tight shell 20 is fused at its ends to the capillary 15, such that the gratings 12,13 and dogbone region 16 are sealed inside thereby. For single-ended transducers (not

shown), an angle is polished on the end of the glass package opposite the fiber exit to minimize back reflections and their detrimental effects to Bragg grating interrogation.

The mechanical principles of operation of transducer 1 are based on the elastic response of the shell 20 to an external pressure field represented by P. The sealed shell behaves like a thick walled pressure vessel with capped ends under an externally applied pressure loading. In an embodiment the outside diameter of shell 20 is approximately 6mm although other lengths are possible and other embodiment include shells that are integral with the sensor as described hereinbelow. The shell 20 isolates the grating portion of the fiber and protects it from the harsh environment thereby. The axial dimensional change, represented by a change in LI, of the shell is the net effect of shortening due to an end wall pressure 26 increase and a smaller magnitude lengthening due to radial Poisson's effects of pressure 28. The piston/dogbone region 16 acts like a relatively flexible tie-rod within the pressure vessel of transducer 1, essentially sensing the end wall axial displacement in response to the pressure P. This type of loading results in axial compressive strain in the piston/dogbone component, and axial, radial and tangential compression in the shell.

The reduced diameter (and hence stiffness) of the dogbone region 16 of shell 15 causes the majority of the axial displacement of the shell to be concentrated across this short region, enhancing the strain response to pressure of the Bragg grating 12 written within the fiber 10. The temperature grating 13 in the piston portion of shell 15 exhibits an undesired response to pressure, though to a smaller degree based on the relative cross-sectional area of the piston region in relation to the dogbone region 16.

This creates a lower net response to pressure for the device, but is necessary to differentially cancel the significant effects of temperature on Bragg wavelength.

Still referring to Fig. 1, the shell 20 is provided with a layer 30 in accordance with the present invention to provide a barrier to ingression of water, among other fluids, to the shell 20, the capillary tube 15 and gratings 12,13 as will be described more fully herein after. The fiber 10 has an outer diameter of about 125 microns and comprises silica glass (SiOz) having the appropriate dopants, as is known, to allow light 14 to propagate along the fiber 10. The gratings 12,13 are similar to that described in US Patent No. 4,725,110 and 4,807,950, entitled"Method for Impressing

Gratings Within Fiber Optics", to Glenn et al; and US Patent No. 5,388,173, entitled "Method and Apparatus for Forming Aperiodic Gratings in Optical Fibers", to Glenn, which are hereby incorporated by reference to the extent necessary to understand the present invention. However, any wavelength-tunable grating or reflective element embedded, etched, imprinted, or otherwise formed in the fiber 10 may be used if desired, or may comprise a Fabry-Perot type device. As used herein, the term "grating"means any of such reflective elements. Further, the reflective element (or grating) 12,13 may be used in reflection and/or transmission of light. Still further, the present invention encompasses embodiments wherein any number of gratings are disposed within a glass, or substantially all glass, shell 20. In addition the present invention includes any device wherein optical fibers are used to measure the strain on a glass housing or shell and where the fiber is connected to the shell by an adhesive such as epoxy or other methods of attachment.

Other materials and dimensions for the optical fiber or waveguide 10 may be used if desired. For example, the fiber 10 may be made of any glass, silica, phosphate glass or other glasses, or made of glass and plastic or plastic, or other materials used for making optical fibers. For high temperature applications, optical fiber made of a glass material is desirable. Also, the fiber 10 may have an outer diameter of 80 microns or other diameters. Further, instead of an optical fiber, any optical waveguide may be used, such as, a multi-mode, birefringent, polarization maintaining, polarizing, multi-core or multi-cladding optical waveguide, or a flat or planar waveguide (where the waveguide is rectangular shaped), or other waveguides.

As used herein the term"fiber"includes the above described waveguides.

The shell 20 and capillary tube 15 are made of a glass material, such as natural or synthetic quartz, fused silica, silica (Si02), Pyrex by Coming (boro silicate), or Vycor by Coming (about 95% silica and 5% other constituents such as Boron Oxide), or other glasses. The capillary tube 15 should be made of a material such that the shell (or the inner diameter surface of a bore hole in the shell 20) can be fused to (i. e., create a molecular bond with, or melt together with) the outer surface (or cladding) of the optical fiber 10 such that the interface surface between the inner diameter of the capillary tube 15 and the outer diameter of the fiber 10 become

substantially eliminated (i. e., the inner diameter of the capillary tube 15 cannot be distinguished from and becomes part of the cladding of the fiber 10).

It has been discovered by the Applicant that the tube-encased fiber Bragg gratings of the prior art exhibited significant drift when disposed in harsh environments in the presence of fluids. It was discovered upon further investigation that the relatively impervious nature of glass is severely degraded by elevated temperatures and pressures. During testing of fiber optic based sensors (as described in the above referenced copending applications) this drift was discovered. The otherwise stable sensors were immersed in a bath of silicone based oil at constant elevated pressures and temperatures. Silicone oil was used because it was thought to be a stable fluid for transferring pressure to the transducer without contamination.

After a relatively short period of about one week at 170° C degrees and atmospheric pressure sensor, both temperature and pressure, exhibited a significant and rapid shift in wavelength as best shown in Fig. 2. Figure 2 represents a fairly standard plot for stability testing of fiber optic sensors wherein trace 31 represents the relative reflected wavelength of pressure grating 12 and trace 32 represents the relative reflected wavelength of temperature grating 13 over a 55-day testing period. That is to say that the traces 31,32 are plotted relative to the actual wavelength and represent an offset measurement therefrom. The relative offset of the reflected wavelength of pressure grating 12 is represented by trace 31 and shows a fairly stable average reflected relative wavelength of about 1.0013 nanometers for the first five days of the test.

Between day five and day 28 there was observed a significant shift of about 7.8 pico meters to a relative level of 1.0091 where it seemed to stabilize for a period of about 27 days (conclusion of the test). Similarly, but to a lesser extent, the relative offset of the reflected wavelength of temperature grating 13 represented by trace 32 shows a fairly stable average reflected relative wavelength of about 1.0035 nanometers for the first five days of the test and then shows a significant shift of about 1.5 pico meters to a relative level of 1.005 nanometers where it to seemed to stabilize. Had the transducer been installed in an environment for monitoring the temperature and pressure of an oil well having fluctuating conditions, the drift would have made accurate determination of the actual conditions impossible. For instance, for a 0 to

15,000 psi operational range sensor, having a sensitivity of 0.3846 pm/psi (or 2.6 psi/pm), this drift would translate into a 20.28 psi error.

In accordance with the present invention, it was discovered that trace amounts of water in the silicone oil were accountable for the drift shown in Fig. 2. As discussed herein above, the prior art uses of fiber optic based sensors exhibited drift due to the expansion of layers of the glass close to the fiber. In the case of the prior art uses of glass tube encased sensors, the glass shell was considered to be an adequate barrier, both in materials and proximity to the gratings, to environmental influences on the accuracy of the sensors. Through testing it was validated that at elevated temperatures and pressures the glass shell 20 (Fig. 1) absorbed significant amounts of water and caused the shell to expand thereby causing a wavelength shift in the gratings 12,13 at constant pressure and temperature conditions. The expansion of the shell 20 as a result of water ingress has a greater influence on pressure grating 12 in the dogbone region because of the concentration of the axial displacement across the reduced cross section as described herein above and shown by trace 31 in Fig. 2 when compared to trace 32.

Once discovered, applying barrier layer 30 to shell 20 of transducer 1 as shown in Fig. 1 eliminates the cause of the error associated with drift. Barrier layer 30, when applied to the outside surfaces of transducer 1 eliminates the ingress of water, or other similar fluids, into shell 20 and thereby precludes expansion of the shell and the drift caused thereby. Although shown as coating optical fiber 10 and capillary tube 15, embodiments of the present invention encompass the coating of shell 20 with layer 30 to the extent necessary to preclude fluid ingress into the shell.

Layer 30 may comprise any material, or combination of materials, capable of preventing the diffusion of water molecules into shell 20. However, depending on the exact use of transducer 1 it may be critical to the operation of the transducer that layer 30 not cause significant levels of mechanical effects (including hysteresis) that could adversely affect the ability of the shell to react to pressure changes. For instance, if the characteristics of layer 30 were such that the stiffness of shell 20 was significantly increased, the sensitivity and or repeatability of the transducer may be unacceptably diminished. Other mechanical effects of the coating layer 30 which could have

deleterious effects on the operation of the transducer include coating creep, coating integrity, strain capability, etc. Both the material choice and thickness of layer 30 may contribute to these mechanical effects. Several materials have been considered based on their ability to block water molecules, adhere to the glass shell 20, and limit the amount of adverse mechanical effects. Among the materials considered are chrome, gold, silver, carbon and silicon nitride. Other similar materials and combinations of materials are contemplated by the present invention.

One embodiment of transducer 1 (Fig. 1) includes a coating 30 comprised of a combination of a first layer of chrome and a second layer of gold. The coatings may be applied to shell 20 using a standard sputtering process as will be more fully described herein below, however, the present invention encompasses any known method of coating the shell. In this particular embodiment, the chrome layer was applied in a uniform manner to achieve a thickness of about 250 A and then a second layer was applied in a uniform manner to achieve a gold layer of about 20,000 A.

Other satisfactory embodiments have been tested have gold layers as thin as 500 A.

Coating layer 30 of this embodiment is effective at reducing the drift exhibited by the prior art as best shown with reference to Fig. 3. Trace 31 represents the relative reflected wavelength of pressure grating 12 and trace 32 represents the relative reflected wavelength of temperature grating 13 over about a 46-day testing period in conditions substantially identical to those described herein above referring to Fig. 2.

The relative offset of the reflected wavelength of pressure grating 12 represented by trace 31 shows a fairly stable average reflected relative wavelength of about 1.008 nanometers for the first ten days of the test. Thereafter, between day ten and day 12, a small, but noticeable, shift of approximately 1.0 picometer is observed to a relative level of 1.009 where the sensor remained stable to the conclusion of the test. Coating 30 of this embodiment represents an improvement 6 times as effective at blocking water, and its deleterious effects, over the prior art. In addition, the reflected wavelength of temperature grating 13 represented by trace 32 shows an almost imperceptible change over the same time period. In addition, testing was performed on the embodiment described to quantify the mechanical effects of coating 30 on the

sensor and to validate that there was acceptable levels of creep or hysteresis caused by the coating.

In an alternative embodiment, coating layer 30 of transducer 1 (Fig. 1) is comprised of a layer of carbon applied to glass shell 20. The coating was applied to shell 20 using a standard sputtering process. In this the carbon of coating layer 30 was applied in a uniform manner to achieve a thickness of about 500 A. Coating layer 30 of this particular embodiment of the invention is effective at reducing the drift exhibited by the prior art as best shown with reference to Fig. 4. Trace 31 represents the relative offset of the reflected wavelength of pressure grating 12 and trace 32 represents the relative offset of the reflected wavelength of temperature grating 13 over about a 5-day testing period in conditions substantially identical to those described herein above referring to Fig. 2. The plot in Fig. 4 was terminated earlier than that of Fig. 2 because of the close correlation of the results. Subsequent long term testing has validated the robustness of the coating. The reflected wavelength of pressure grating 12 represented by trace 31 shows a fairly stable average reflected relative wavelength of about 1.0072 nanometers for the entire duration of the test with no perceptible shift due to water ingression. Similarly, the reflected wavelength of temperature grating 13 represented by trace 32 shows an almost imperceptible change over the same time period. Carbon coating 30 of this embodiment represents an improvement at least 20 times as effective at blocking water, and its deleterious effects, over the prior art.

In an alternative embodiment of the present invention, the shell 20 and a portion of or all of the tube-encased fiber grating 1 may be replaced by a large diameter silica waveguide grating, such as that described in copending US Patent Application Serial No. (CiDRA Docket No. CC-0230), entitled"Large Diameter Optical Waveguide, Grating and Laser", which is incorporated herein by reference.

The waveguide includes coating 30 as described hereinabove to provide fluid blocking capability in accordance with the present invention.

As stated herein before any method of coating at least shell 20 of transducer 1 with a fluid blocking coating 30 is contemplated by the present invention. Coating 30 may be applied to shell 20 after the shell has been disposed about the fiber 10, and

capillary tube 15 (if applicable), but may be applied prior without departing from the scope of the present invention. One known method of providing coating 30 comprises the sputtering of the coating onto the glass shell 20. Prior to the sputtering process, shell 20 is prepared to ensure that coating 30 makes intimate contact with the surface of the shell. In one embodiment shell 20 is prepared for coating by wiping the outside surface of the shell, as well as other outside surfaces to be coated, such as capillary tube 15 and fiber 10 if applicable, with a degreasing solution, such as acetone. The surface may then be etched to enhance the adhesion of the coating to the shell. In one embodiment shell 20 is subjected first to an oxygen-ion etch followed by an argon-ion etch. Subsequent to the etching coating 30 is deposited onto the outside surface by sputtering, or other similar, coating process that ensures uniform coverage of the shell (and other components).

It should be understood that the dimensions, geometries, and materials described for any of the embodiments herein, are merely for illustrative purposes and as such, any other dimensions, geometries, or materials may be used if desired, depending on the application, size, performance, manufacturing or design requirements, or other factors, in view of the teachings herein.

For instance, the present invention further comprises a fluid blocking fiber optic pressure sensor, wherein the optical sensing element and the shell are comprised of a the same material and are essentially a relatively large diameter fiber section. As described hereinabove the sensor has at least one pressure reflective element disposed therein, the pressure reflective element having a pressure reflection wavelength the sensing element being axially strained due to a change in external pressure, the axial strain causing a change in the pressure reflection wavelength, and the change in the pressure reflection wavelength being indicative of the change in pressure. In this particular embodiment at least a portion of the sensing element has a transverse cross- section which is contiguous and made of substantially the same material and having an outer transverse dimension of at least 0.3 mm a fluid blocking coating disposed on the external surface of the sensing element.

Further, it should be understood that, unless otherwise stated herein, any of the features, characteristics, alternatives or modifications described regarding a particular

embodiment herein may also be applied, used, or incorporated with any other embodiment described herein. Also, the drawings shown herein are not drawn to scale.

Although the invention has been described and illustrated with respect to exemplary embodiments thereof, the foregoing and various other additions and omissions may be made therein and thereto without departing from the spirit and scope of the present invention.