Mechanical properties play a critical role in defining fiber optic cable reliability and life expectation. One of the key measurands which dictate mechanical reliability is the residual strain in the final cable after it is manufactured. Wires&Bytes measures distributed strain at the in-house Test Centre to study residual strain in their cables before shipping to the end customer. This is an extremely valuable measurement tool that can help to understand the cable mechanics in depth, for example, predicting the lifetime of optical fiber and fiber optic cables in applications.

At Wires&Bytes cables are tested with a Brillouin analyzer which enables measuring the distribution of mechanical stress and fiber elongation along the entire length by the following techniques:

• BOFDA (Brillouin Optical Frequency Domain Analysis)
• BOFDR (Brillouin Optical Frequency Domain Reflectometry)

  What we measure:

• Central Brillouin Frequency
• Strain sensitivity of Brillouin Frequency
• Temperature sensitivity of Brillouin Frequency

  How you benefit:

• Precise and complete characteristics of specialty cables for distributed monitoring
• Fast and efficient system deployment and predictable and accurate response to events
• Reliability and long cable lifetime
• No slippage of strain measuring fibers

The experience and data gained from the Brillouin analyzer help us in advising customers how to deploy cables in the most efficient way and with the best installation methods.

Need more details on that? Send us an inquiry and our sales team will be glad to answer all your questions!

A breakthrough in monitoring of overhead power lines

The most part of the world electric transmission grid was built between the 1940s and 1980s in the times when fossil fuels dominated in energy demand and consumption, electric power system was developing simultaneously with it and at the same time the concepts such as renewable energy, high-speed internet and digitalization were in the infancy or even non-existent and seemed quite futuristic. In the last decade, the investments in renewable energy sources from distant windmill parks as well as massive digitalization have grown significantly. As a result, some parts of the transmission grid have become overloaded causing instabilities in the system.

To ensure the reliability of the power supply when the demand is growing, the current carrying capacity (ampacity) of some lines must be planned and gradually increased. One way of increasing the ampacity is to “reconductor” the overhead lines. Replacing the traditionally used ACSR (Aluminum Conductor Steel Reinforcement) conductors with High Temperature Low Sag (HTLS) conductors can increase the ampacity with no need to modify the existing towers and insulators. In this respect a new generation of conductor technology is introduced to the market.

Composite core technology

A composite core technology like ACCS (Aluminum Conductor Composite Single core) with composite core manufactured by De Angeli Prodotti (Italy) is one of those brand-new conductors. In the composite core conductor, the steel core is replaced by carbon-fiber strength member formed in the pultrusion process. Thus, there is no need for hard aluminum wires traditionally used in ACSR types of conductor anymore, because softer fully annealed aluminum with higher conductivity providing higher ampacity can be used instead. Compared to ACSR conductors, composite core conductor types have less weight, higher tensile strength and lower thermal expansion coefficient but can carry approximately double current. As a result, unnecessary investments in power towers can be avoided, as existing can be used for the grid upgrade.

The deployment of composite core conductor technology is not straightforward as it requires satisfying certain technical standards and procedures in both production and installation, respectively. In collaboration with De Angeli Prodotti, a renowned manufacturer of carbon-fiber based powerline phase conductors, Wires&Bytes successfully introduced and deployed DFOS technology into a different application and industry – the power transmission, for the purposes of novel generation of HTLS conductors and their installation check and documentation. A special version of De Angeli’s ACCS conductor, now named and promoted as ACCS-Sens, integrating 3 specialty optical fibers is prototyped and manufactured at the production facility in Italy.

The installation of such conductor involves following the precise procedures that require real-time multi-fiber DFOS measurements. The concept exploits the idea of converting central carbon-fiber carrier into DFOS-ready mechanical beam making it suitable for strain, temperature, bending, vibration, and acoustic fully distributed measurements from the single end of the ACCS-Sens. After almost 2 years of R&D activities for the successful “fiber-sensitization” of conductor and adaptation of existing DFOS interrogation equipment, the technology is finally premiered on the installation site in Belgium in April 2021. The measurements revealed mechanical conditions which the conductor went through during its manufacturing and reeling processes continuing with the site delivery, installation, and stringing processes on the powerline. Moreover, presuming further innovation in the HV fitting technology, the application of these principles is feasible in the future during the operation as well. The acquisition of data from the conductor that is now provided can be beneficial to all in the supply and deployment chain: manufacturers, installers, operators, and grid owners. As the technology matures it might offer reaching longer distances thus introducing a novel type of powerline monitoring with competitive “per-km” costs. Along with further improvements and innovations it has potential to become a significant part of the data-driven smart grid plans across the globe.

A deformation applied to an optical cable results in positive or negative longitudinal strain exerted along the circumference of the cable and this can be exploited for bend measurements using fiber optic cables. It is well-known in the industry that optical fibers are sensitive to longitudinal strain. A one-dimensional displacement — either expansion, or compression of the fiber — represents scalar strain, whereas three-dimensional displacement represents vectorial strain. The latter provides information on “bending” at that position. This is where a special class of fiber optic bend measurement cables can be deployed. The intelligent cable design using off-the-axis integration of multiple fibers inside the cable will provide full information on bending at that location.

Vector displacement information is extremely useful in various applications such as crack growth monitoring, umbilical, pipeline, tunnels, powerlines, and robotic arms. When a cable is embedded into the structure, it will take the shape of the structure allowing to explore the configuration. One of the demanding needs of the industry is to understand the dynamic movement of the structure using fiber optic sensing. Hence a cable that provides information on the cable bending along the entire length brings several benefits to the owners and operators, e.g., providing dynamic inclination information for the long structures and infrastructural objects helps the owners to predict the lifetime of their assets.

For fiber optic cables the cable bend measurement capability can be categorized in measurement ranges:

• short range: of a few meters
• middle range: of a few tens and a few hundreds of meters
• long range: of a few kilometers or tens of kilometers.

Measurement ranges determine possible interrogation techniques to be used. Long-range bend measurements capability has always been the focus for Wires&Bytes. The integration of these interesting features into new generation of fiber optic cables has resulted into a family of cables called MulitSense. Various MultiSense designs have been implemented in the field and their technical capabilities have been exceeding the customers’ requirements and expectations so far.

Taking into account the demanding applications, Wires&Bytes has developed a BendSense cable. Our new cable design is a further evolution of our MultiSense design to provide information on vectorial deformation from the cable. The new cable has multiple fibers, configured either twisted or non-coplanar inside the cable. This allows optical fibers to be sensitive to the bending regardless the bend plane and offering the end user to deduce bend direction and amplitude of the deformation.

All the cables have been thoroughly tested in our lab using BOTDR technology making sure Wires&Bytes delivers fit-to-purpose products. Wires&Bytes aims at helping you to develop and manufacture cables for specific bend measurements. You can be rest assured you are provided with the best technique to interrogate your cable, data acquisition, processing, and visualization, so you can get detailed insights of your assets’ integrity with our bend measurement cables.

Safe and reliable operation of any pipeline system requires applying new technologies to improve its inspection, operation, maintenance, and integrity management.

Wires&Bytes offers pipeline companies a holistic view toward preventing and detecting leaks and other damages using fiber optic technology. Pipeline integrity monitoring is one of those modern tools which ensures that pipelines do not cause harm to people or the environment, at the same time being reliable and secure source of information to pipeline operators.

Advantages:

• Combination of optical and electronic sensors in one system
 
• A wide range of measured parameters (point sensors of pressure, humidity, fluid composition)
 
• Downholes and formations health assessment in continuous mode
 
• Remote control allowing to optimize operating modes
 
• Control over the implementation of procedures for oil and gas production intensification
 
• Monitoring of remote objects and objects in harsh environment

👉   Visit the page to take a look at the video, where the process of pipeline integrity monitoring is shown and learn more

Fatigue failure by flexing is a common failure mode for cables in a high flex environment. In order to predict it, there are various analysis tools and test procedures.

Keeping up with the latest developments, Wires&Bytes is presenting its newest addition to the Test Center — a reversing cable cycling machine, with programmable tension loads, suitable for precise bending tests. It fully complies with EN/IEC norms, but its technical possibilities exceed them!

This machine enables sophisticated lifecycle testing to customers’ exact specifications to ensure smoother and safer operations. It is now possible to cycle test and characterize for repeatable bending diverse cable types including electrical, fiber optic and mechanical slicklines and also wirelines of small sizes.

As part of Wires&Bytes extensive R&D offerings, we consider it a matter of the utmost importance to possess modern measurement and testing equipment. Thus, all our customers can be sure of top-notch quality of all our finished products.

We welcome your questions and requests to learn more about how we conduct our tests.

Make sure to address even the smallest details!

There have been many serious bridge disasters throughout history.

  Why do bridges collapse?

• One: Natural disasters
• Two: Construction and demolition incidents
• Three: Design and manufacturing defects
• Four: Improper or neglected maintenance
• Five: Fire

The history of bridge construction and catastrophic failures has taught us a lot of things, but especially to think about safety first. Lessons learned: all the problems listed above can be tracked! Early detection of damage leads to prevention of critical issues and structural faults, reducing repair time and costs, and most importantly saving peoples’ lives!

Wires&Bytes offers a range of cables for structural health monitoring: Non-metallic MultiSense, UniTEF, SensoWire, and others. Discover more on our website.

Wires&Bytes welcomes a new team member — Thomas Utz who is joining us as a Director of Wireline Products.

Tom is based in Houston, Texas and is joining the rapidly growing US office of Wires&Bytes. He has been working in the Oil&Gas market for the last 40 years and has extensive experience in wireline industry. He previously worked at such companies as Rochester Corporation and Kerpen Kabel, Camesa and WireCo group and well-known in the industry.

With any sales and product inquiries, please contact Tom via tom.utz@wiresnbytes.com

Welcome onboard, Tom! Having you with us means a strong commitment from Wires&Bytes to grow our customers base.

Fiber optic cables are now routinely deployed for condition monitoring purposes, making them not only a reliable, sensitive, and smart source of information but also a medium to transfer data to the control room from the remote locations.

Introduction of multisensing cables allowed the customer to sense and transfer multiple sensing data, which was the key motivation behind the development. The new cable will decrease the installation and maintenance costs, optimize equipment operation, provide faster emergency response, reduce environmental damage, etc.

Advantages:

• combination of optical and electronic sensors in one system
 
• a wide range of measured parameters (e.g. temperature, acoustics, strain, pressure and humidity)
 
• assessment of well health in continuous and instantaneous mode
 
• remote control, allowing to optimize operating modes
 
• control over the implementation of process to enhance oil and gas production

👉  Visit the page to take a look at the video, where the process of Oil&Gas well downhole monitoring is shown and learn more

Last week we unveiled a Non-metallic MultiSense cable, today let’s take a closer look at its applications.

MultiSense is not just an eye-catching name, it provides a platform to monitor different physical changes with a single cable. Non-metallic version is fully dielectric (it cannot be revealed by metal detectors!), making it safe to use where electric current can be an issue. If you need a more robust cable with higher tensile strength, it can be encapsulated in stainless steel.

  This cable can be produced in two options:

• as a finished product ready for deployment
• as a semi-finished product for further integration into larger cable designs and other structures

  Where Non-metallic MultiSense can be applied:

• all types of Distributed Fiber Optic Sensing systems (DFOS): DTS (temperature), DAS (acoustic), DSS (strain)
• applications that require enhanced acoustic response using standard telecom fibers
• distributed monitoring: tunnels, roads, railways, conveyor lines, pipelines, dams and dykes, overhead and overground electric power lines, underground high-voltage electric lines
• intrusion detection
• simultaneous multiple measurements along with fibers for data communication

Send us a request via website and our sales team will provide you with the details!

Compact but multifunctional, Non-metallic MultiSense makes a change in the world of distributed sensing.

Despite its considerably small size and low weight, it is able to support all types of DFOS technologies and deliver multiple measurements. You might have already seen our Metallic MultiSense, but today let’s take a look at this design.

Non-metallic MultiSense is a combination of a gel-filled central PBT loose tube with optical fibers freely placed inside with 4 tight-buffered optical fibers, FRP rods, and outer jacket.

Please note that we design cables based on our customers’ specific technical requirements. In case of Non-metallic MultiSense besides any other requirements, the standard lay length may also be changed according to the project needs.

If you are interested in MultiSense and would like to learn more about it, please send an inquiry via website.