Optoelectronic composite intelligent sensing submersible pump flat cable

Abstract

This utility model relates to the field of cable technology and discloses a flat cable for a submersible pump for photoelectric composite intelligent sensing. It includes several cable conductors, with an optical fiber cable fixed parallel to one side of each conductor. The optical fiber cable has a tensile core and a conductor core at its center. A heat-resistant sheath is extruded over the conductor core, and a polytetrafluoroethylene (PTFE) film insulating layer is wrapped around the heat-resistant sheath. A modified ethylene propylene rubber protective layer is extruded over the PTFE film insulating layer. Multiple layers of PTFE emulsion are coated on the conductor core. The cable conductor includes a multi-stranded copper conductor, with an insulation layer extruded on the outside of the copper conductor. An insulating insulating layer is wrapped around the outside of the insulation layer. In this utility model, the optical fiber is laterally fixed and integrated with the power transmission section, meeting the requirements of pipelines for controlling the cable's outer diameter in special operating environments. This effectively prevents damage caused by the power transmission cable and optical fiber communication line becoming entangled and pulled together during lowering and lifting.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to a flat cable for a submersible pump used in optoelectronic composite intelligent sensing. Background Technology

[0002] Submersible pump cables are critical equipment for powering ESP (Electric Submersible Pump) units in oil and gas extraction. They are primarily used in downhole lifting operations for resources such as oil, natural gas, and shale oil / gas, undertaking power transmission and requiring resistance to high temperatures, high pressures, and corrosive environments. Globally, approximately one-third of crude oil production relies on ESP technology, with the application rate reaching as high as 90% in offshore oil fields. Due to the harsh operating environments, cables are required to be safe and reliable, long-lasting, compact, water-resistant, resistant to mold and salt spray, lightweight, and inexpensive. They must also possess excellent resistance to high and low temperatures, flame retardancy, oil resistance, moisture resistance, seawater corrosion resistance, seawater impact resistance, and excellent electrical and mechanical properties. Submersible pumps must be placed in a small-diameter vertical shaft or pipeline when in operation, and a water level gauge is needed to obtain downhole liquid level data. However, due to the limited space in the well or pipeline, conventional storage-type water level gauges cannot read the liquid level value in real time, but can only read it each time the pump is raised, resulting in a very limited number of production parameters and poor timeliness. Real-time water level gauges can monitor the downhole liquid level in real time, but lowering the real-time water level gauge and the corresponding fiber optic communication line at the same time will take up more space in the well, and hundreds of meters of leachate riser pipe, cables, and fiber optic communication lines are prone to entanglement and damage during the lowering and raising process.

[0003] Fiber optic water level gauges have gradually become the main monitoring equipment for downhole liquid levels in oil wells due to their advantages such as high sensitivity, immunity to power cable interference, and low cost. Utility Model Content

[0004] The purpose of this utility model is to provide a flat cable for submersible pumps for photoelectric composite intelligent sensing, which solves the following technical problems: conventional storage-type water level gauges cannot read the liquid level value in real time, but can only read it each time the pump is raised, resulting in a very limited number of production parameters and poor timeliness; real-time water level gauges can monitor the downhole liquid level in real time, but the simultaneous lowering of the real-time water level gauge and the corresponding fiber optic communication line will further occupy the space inside the well, and hundreds of meters of leachate riser pipe, cable, and fiber optic communication line are prone to entanglement and damage during the lowering and raising process.

[0005] The objective of this utility model can be achieved through the following technical solution: a flat cable for a submersible pump for photoelectric composite intelligent sensing, comprising several cable conductors, with an optical fiber cable fixedly attached to one side of each cable conductor in parallel, the optical fiber cable comprising a central tensile core, a conductor core disposed on the outer side of the tensile core, the conductor core being extruded with a heat-resistant sheath, the heat-resistant sheath being wrapped with a multi-layer polytetrafluoroethylene film isolation layer, the polytetrafluoroethylene film isolation layer being extruded with a modified ethylene propylene rubber protective layer, and the optical fiber cable being extruded with an outer sheath. The copper conductor is made of multi-strand ultra-fine tin-plated oxygen-free copper wire processed by high-precision stranding, ensuring excellent conductivity and mechanical stability.

[0006] As a further embodiment of this utility model: the conductor core is coated with a multilayer polytetrafluoroethylene emulsion, and the polytetrafluoroethylene emulsion is used for curing and protecting the emulsion before the optical fiber is connected to the disulfide pipe. A second coating is applied to the outer layer of the first coating. This two-coating process ensures that the surface of the optical fiber is not damaged under high temperature and pressure through the coating method.

[0007] As a further embodiment of this utility model: the heat-resistant protective layer is made of coated externally extruded ETFE high-performance engineering plastic material.

[0008] ETFE high-performance engineering plastic material is a copolymer of ethylene and tetrafluoroethylene, possessing exceptional comprehensive properties, such as excellent heat resistance, low-temperature resistance, flame retardancy, electrical insulation, and corrosion resistance. It also exhibits unique non-adhesiveness and low friction. As a further embodiment of this utility model: the cable conductor comprises a copper conductor formed by multiple strands twisted together, an insulating layer is extruded on the outside of the copper conductor, and an insulating isolation layer is wrapped around the outside of the insulating layer.

[0009] As a further embodiment of this utility model, the insulating layer is made of special ethylene propylene rubber.

[0010] As a further embodiment of this utility model: an outer sheath is extruded onto the outer side of the insulating isolation layer.

[0011] As a further embodiment of this utility model: both the outer sheath one and the outer sheath two are made of special modified chlorinated polyethylene material; Outer sheath one and outer sheath two are made of special modified chlorinated polyethylene, which has the advantages of being waterproof, oil-resistant, moisture-proof, seawater corrosion-resistant, wear-resistant, and having good mechanical properties with high and low temperature resistance. Compared with ordinary rubber, it has better tensile and tear strength, mildew resistance, salt spray resistance, and waterproof performance, while maintaining flexibility.

[0012] As a further aspect of this invention, all optical fibers have passed a rigorous 100kpsi strength test.

[0013] Optical fibers meet the requirements for properties such as bending resistance, tensile strength, torsion resistance, high temperature resistance, corrosion resistance, and oil resistance.

[0014] The beneficial effects of this utility model are: (1) This utility model adopts the combination of optical fiber side-mounted fixing and power transmission part, which can meet the pipeline's need for cable outer diameter control in special use environments. It effectively prevents the power transmission cable and optical fiber communication line from being tangled and pulled together during the lowering and lifting process. The middle connection between the power transmission and optical fiber communication cables uses a peelable structure, which can be used separately at different lengths. (2) The optical fiber of this utility model adopts a high tensile strength, torsion resistance, and bending resistance process and is resistant to high temperature. The optical fiber can be undamaged in a high-temperature pipe at 200℃. In the bending test, the optical fiber can be bent multiple times with a bending radius ≤50mm without breaking. Its oil resistance can meet the requirements for long-term use in submersible pumps. It effectively solves the problems of traditional optical fibers being easy to melt in sulfurized pipes, having poor tensile strength, being easy to bend and break, and being very easy to be damaged in the special environment of submersible pumps. (3) The outer sheath of this utility model adopts a tightly extruded structure, which has the characteristics of being waterproof, oil-resistant, moisture-proof, seawater corrosion-resistant, wear-resistant, high and low temperature resistant, and having high mechanical properties. This allows the cable to be used more frequently and effectively, greatly improving the service life of the cable. The oil resistance allows the cable to be used for a long time in oily environments, and the seawater corrosion resistance allows the cable to be used for a long time in seawater.

[0015] Additional aspects and advantages of this invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings.

[0017] Figure 1 This is a schematic diagram of the cable conductor structure of this utility model; Figure 2 This is a schematic diagram of the structure of the optical fiber cable of this utility model.

[0018] In the diagram: 1. Cable conductor; 11. Copper conductor; 12. Insulation layer; 13. Insulation isolation layer; 14. Outer sheath II; 2. Fiber optic cable; 21. Cable tensile core; 22. Conductor core; 23. Polytetrafluoroethylene emulsion; 24. Temperature-resistant protective layer; 25. Polytetrafluoroethylene film isolation layer; 26. Modified EPDM rubber protective layer; 3. Outer sheath I. Detailed Implementation

[0019] The embodiments of this utility model are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain this utility model, and should not be construed as limiting this utility model.

[0020] In this utility model, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "on top of," and "over" the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0021] In the field of cable technology, conventional storage-type water level gauges cannot read liquid level values ​​in real time, and simultaneously lowering a real-time water level gauge and its corresponding fiber optic communication line would further encroach on the well space, easily causing entanglement and damage. This has a significant impact on the accuracy and cost of monitoring the liquid level in oil wells. This utility model proposes a photoelectric composite intelligent sensing flat cable for submersible pumps to address the problems of conventional storage-type gauges not being able to read liquid level values ​​in real time and the space-consuming and entanglement issues associated with using water level gauges and fiber optic communication lines. Through a series of innovative designs, it achieves an integrated design of communication fiber optic and power cable. The specific implementation method is as follows: like Figure 1 A photoelectric composite intelligent sensing submersible pump flat cable includes a power transmission section and a signal sensing section. The power transmission section includes several cable conductors 1, each of which includes a multi-strand copper conductor 11. The copper conductor 11 is made of multi-strand ultra-fine tin-plated oxygen-free copper wire processed by high-precision stranding to ensure excellent conductivity and mechanical stability. An insulation layer 12 is extruded on the outside of the copper conductor 11. The insulation layer 12 is insulated with special ethylene propylene rubber. An insulating isolation layer 13 is wrapped around the outside of the insulation layer 12. An outer sheath 14 is extruded on the outside of the insulating isolation layer 13. The outer sheath 14 is made of chlorinated polyethylene. The outer sheath 14 is made of specially modified chlorinated polyethylene and has advantages such as waterproof, oil-resistant, moisture-proof, seawater corrosion-resistant, wear-resistant, high and low temperature resistant, and good mechanical properties. It has better tensile strength and tear resistance than ordinary rubber, is resistant to mildew and salt spray, has good waterproof performance, and maintains flexibility.

[0022] like Figure 2The signal sensing part includes an optical fiber cable 2 that is parallel and fixed to one side of the cable conductor 1. The optical fiber cable 2 is covered with an outer sheath 3. The center of the optical fiber cable 2 includes a cable tensile core 21. A conductor core 22 is provided on the outside of the cable tensile core 21. The center of the optical fiber cable 2 is a tensile filling core formed by stranding 7 Kevlar fibers with high tensile strength. The conductor cores 22 of 6 single-mode optical fibers are arranged around the central conductor core 22 in sequence to form a cable. The optical fiber is integrated with the power transmission section using a lateral external mounting method, while simultaneously extruding modified chlorinated polyethylene. A dedicated fiber mounting device secures the optical fiber parallel to the side of the flat cable. The spacing between the mounting points and the angle of the fiber arrangement should be uniform to prevent the fiber from being stretched, squeezed, or slipped during extrusion and cabling. The intermediate external mounting points are easily detachable, allowing the optical fiber and power transmission components to be used together or separately depending on operational requirements.

[0023] The conductor core 22 is coated with multiple layers of polytetrafluoroethylene emulsion 23. After the conductor core 22 is coated with polytetrafluoroethylene emulsion 23 for the first time, a second coating is applied to the outer layer of the first coating. The two coating processes ensure that the surface of the optical fiber is not damaged under high temperature and high pressure through the coating method. The fiber optic cable 2 undergoes an emulsion coating process. A dedicated coating device allows the fiber optic cable 2 to be cured and protected with an emulsion before being installed in the sulfur pipe. The coating process steps for fiber optic cable 2 are as follows: Step 1: Place the fiber optic cable 2 on a pay-off rack; Step 2: Lead the fiber optic cable 2 into a polytetrafluoroethylene (PTFE) hopper, allowing PTFE emulsion 23 to adhere to the surface of the fiber optic cable 2; Step 3: Pass the coated fiber optic cable 2 through a conductor wheel into a heat-curing device, allowing the surface emulsion to cure and become non-adhesive; Step 4: Guide the cured fiber optic cable 2 through an extrusion die into the die head for sheath extrusion.

[0024] The conductor core 22 is coated and then extruded with a high-temperature resistant sheath 24. The sheath 24 is made of coated and extruded ETFE high-performance engineering plastic material, a copolymer of ethylene and tetrafluoroethylene, possessing exceptional comprehensive properties such as excellent heat resistance, low-temperature resistance, flame retardancy, electrical insulation, and corrosion resistance. It also exhibits unique non-adhesiveness and low friction. Tight-buffered fiber optic cables 2 produced using ETFE as a buffer material inherit these excellent properties and can be used in applications requiring high temperature resistance, flame retardancy, and other special conditions.

[0025] The heat-resistant protective layer 24 is wrapped with multiple layers of polytetrafluoroethylene film isolation layer 25, and the polytetrafluoroethylene film isolation layer 25 is extruded with modified ethylene propylene rubber protective layer 26. The modified ethylene propylene rubber protective layer 26 has the advantages of high strength and high temperature resistance. In this implementation case, the heat-resistant protective layer 24 is wrapped with two layers of polytetrafluoroethylene film isolation layer 25, and the overlap rate is not less than 25%.

[0026] Fiber optic cable 2 meets the requirements for bending, tensile strength, torsion resistance, high temperature resistance, corrosion resistance, and oil resistance. All cores of fiber optic cable 2 have passed a rigorous 100kpsi strength test.

[0027] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A flat cable for a submersible pump used in optoelectronic composite intelligent sensing, characterized in that, The cable includes several cable conductors (1), and an optical fiber cable (2) is fixedly attached to one side of each cable conductor (1). The optical fiber cable (2) includes a central cable tensile core (21), and a conductor core (22) is provided on the outside of the cable tensile core (21). The conductor core (22) is covered with a heat-resistant sheath (24), and the heat-resistant sheath (24) is wrapped with a multi-layer polytetrafluoroethylene film isolation layer (25). The polytetrafluoroethylene film isolation layer (25) is covered with a modified ethylene propylene rubber protective layer (26), and the optical fiber cable (2) is covered with an outer sheath (3).

2. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 1, characterized in that, The conductor core (22) is coated with a multilayer polytetrafluoroethylene emulsion (23), which is used for curing and protecting the emulsion before the fiber optic cable (2) is subjected to disulfide pipe.

3. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 1, characterized in that, The heat-resistant protective layer (24) is made of coated externally extruded ETFE engineering plastic material.

4. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 1, characterized in that, The cable conductor (1) includes a copper conductor (11) formed by multiple strands twisted together. An insulation layer (12) is extruded on the outside of the copper conductor (11), and an insulating isolation layer (13) is wrapped around the outside of the insulation layer (12).

5. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 4, characterized in that, The insulation layer (12) is made of ethylene propylene rubber.

6. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 4, characterized in that, The outer side of the insulating layer (13) is extruded with an outer sheath (14).

7. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 6, characterized in that, Both the outer sheath one (3) and the outer sheath two (14) are made of special modified chlorinated polyethylene material.

8. The photoelectric composite intelligent sensing submersible pump flat cable according to claim 1, characterized in that, All optical fiber cables (2) passed the 100kpsi strength test.

Images