Method for manufacturing a reinforced load-carrying logging cable with a hydraulic conduit

Abstract

The invention relates to the manufacture of a reinforced load-carrying logging cable with a hydraulic conduit for use in the oil and gas industry. The present method includes forming, in a multilayer extruder, a hydraulic conduit-liner having an additional layer made of polybutylene terephthalate. The hydraulic conduit-liner is passed through three cooling baths, the first having a maximum temperature of 25°С, the second having a maximum temperature of 40°С and the third having a maximum temperature 23°С. After cooling, the hydraulic conduit-liner is passed through a drawing device at a set speed and pulling force. The resulting workpiece is placed on a reel and a transverse reinforcing ply in the form of a tape is applied with a pitch of 5-15 mm by stranding. Next, a longitudinal reinforcing ply is applied successively in two opposite directions in accordance with set parameters. An outer sheath of high-density polyethylene is applied and bonded layers of the polymer base of the hydraulic conduit-liner are formed by virtue of the high-density polyethylene material penetrating through the layers of the mesh of reinforcing elements right down to the polymer base. The technical result is that of increasing the mechanical properties of the article for use with hydraulic fluids having a high temperature factor, and providing for sufficient length of the article to carry out downhole operations.

Description

[0001] Method of manufacturing a load-bearing geophysical reinforced cable with a hydraulic channel

[0002] The invention relates to industrial small-scale or serial production and can be used in the cable industry for the manufacture of a product and its subsequent use in the oil and gas industry.

[0003] A method for manufacturing a flexible load-bearing polymer pipe is known (patent for utility model No. 2315223 dated 13.04.2006). The disadvantage of this method is the low operating temperature limit of the resulting product, which does not allow its use in conditions involving working fluids with a high temperature factor.

[0004] The closest to the proposed method is the method of manufacturing a flexible draw-through pipe (patent for utility model No. 44782 dated 18.06.2004), which includes the formation of concentric layers of materials and the production of a polymer shell reinforced with steel wire. The disadvantage of this utility model is the absence of the stage of introducing transverse reinforcing elements that determine the radial strength of the product and the multilayer structure of the pipe walls, which leads to their delamination.

[0005] The technical task of the present invention is to eliminate the said disadvantages.

[0006] The technical result of the work performed is the development of a method for manufacturing a load-bearing geophysical reinforced cable with a hydraulic channel with connected layers using an additional layer of polymer material with high mechanical properties and an increased operating temperature, having a sufficient length for performing downhole operations.

[0007] The technical result is achieved by creating a structure with connected layers of polymeric materials with different characteristics, inside which transverse and longitudinal reinforcing conductive elements in the form of a spiral are located at a certain angle to the pipe axis.

[0008] The method for manufacturing a load-bearing geophysical reinforced cable with a hydraulic channel is carried out as follows.

[0009] Upon receipt of materials required in the process of GPT production, an incoming inspection operation is carried out in accordance with the regulatory documentation developed by the GPT manufacturer. Or according to the regulatory documentation according to which the material was manufactured (TU, GOST, OST). After the conclusion of the enterprise's control body on compliance, the required materials are transferred to production for the manufacture of a load-bearing geophysical reinforced cable with a hydraulic channel.

[0010] The extrusion method is used in the production of the base of the hydrochannel liner. An extrusion line is used in the production, consisting of the main units: the main extruder, two coextruders, an extrusion head, a vacuum bath, two cooling baths, a pulling device, and a receiving device. For production, an extrusion line is required, which includes at least three extruders and a special multi-layer extrusion head for forming a five-layer (multi-layer) monolithic hydrochannel liner.

[0011] The main extruder is the core part of the line.

[0012] The main elements of the line are extruders, which are used to melt and transform raw materials into pipes, and an extrusion head in which the working tool, mandrel and matrix are installed, determining the geometric parameters and shape of the pipe. Other elements include cooling systems, various devices for monitoring the production process, as well as winding and laying systems for pipes. Polyethylene pipe production lines are used in various industries. Depending on the application, pipes can have different diameters, wall thicknesses and structures, as well as other characteristics.

[0013] There are various types of pipe production lines, including single-layer pipe lines and multi-layer pipe lines. Single-layer pipes are used to transport liquids and gases in domestic conditions. Multi-layer pipes, on the other hand, have a more complex structure and are used in more demanding conditions, such as transporting hot water or other media. By using a line with a multi-layer extrusion head, it is possible to use materials with different characteristics and parameters.The arrangement of layers in the body of the hydraulic channel-liner is arranged in the following proportional dependence: the first layer of IND is not less than 30+ / - 5% of the wall thickness of the hydraulic channel-liner, the second layer of adhesive (adhesive base) is not more than 5+ / - 2% of the wall thickness of the hydraulic channel-liner, the third layer of PBT is not less than 15+ / - 7% of the wall thickness of the hydraulic channel-liner, the fourth layer of adhesive (adhesive base) is not more than 5+ / - 2% of the wall thickness of the hydraulic channel-liner, the fifth layer of HDPE is not less than 45+ / - 5% of the wall thickness of the hydraulic channel-liner.

[0014] The process of making the base is carried out as follows.

[0015] During this operation, bulk materials (e.g. low-density polyethylene HDPE, polypropylene PP or polybutylene terephthalate PBT) are loaded into the receiving devices (hopper) of the extruder. Under the influence of temperature (from 135C to 260C) and pressure generated by the barrel-screw pair in the extruder, the bulk material passes into a plastic state (melt). In the extrusion head, the melt, when passing through the working tool (mandrel and matrix), is formed into a hydrochannel-liner with the required design parameters of the outer and inner diameter, as well as the wall thickness. Then, the resulting hydrochannel-liner enters the calibrator of the vacuum bath, where, under the influence of vacuum and a temperature of no more than 25 C of the cooling liquid, the outer diameter, inner diameter and wall thickness of the hydrochannel-liner are completely formed.Next, the base blank in the form of a liner hydrochannel passes through three cooling baths: the first with a temperature of no more than 25 C, the second bath of no more than 40 C, the third bath of no more than 23 C, in which the product is cooled to the ambient temperature. After the cooling baths, the blank passes through a pulling device, which produces a constant linear movement of the liner hydrochannel from the extrusion group to the receiving device at a given speed, which varies from 1 to 10 m / min and pulling force. After the pulling device, the blank gets to the receiving device, in which the receiving drum is located. The receiving device winds the liner hydrochannel onto the receiving drum for uniform layer-by-layer placement on the process drum.

[0016] Next, a transverse reinforcing layer is applied using the twisting method.

[0017] Twisting is a process of combining individual elements (wires, cores, tapes, groups of bundles), in which each of them is located along a helical line around the central (one or more) elements. Each peripheral element of the twist forms a spiral in space. The main purpose of twisting is to give the product a stable structure and flexibility, as well as to ensure the ability to transmit a signal. Twisting is carried out as a result of a combination of two movements: rectilinear (translational) and rotational. In this case, rotation can be done both clockwise and counterclockwise. The direction of twisting is judged by the location of the turns of the elements in the twisted product. Twisting is called left-handed when each element of the twist, if you look at it along the axis, goes from right to top to left, and right-handed when the element trajectory is from left to top to right. Twisting is carried out on twisting machines.

[0018] Tangential and central tape-wrapping machines are used to apply the transverse reinforcing layer. During this operation, tape (steel or polymer) is applied with a small pitch of 5-15 mm.

[0019] During this technological operation, the reinforcing element is laid on the hydrochannel-liner with the specified step parameters. During this operation, the translational movement of the hydrochannel-liner and the rotational movement of the equipment into which the reinforcing element is loaded are combined.

[0020] From the delivery device of the line for applying a transverse reinforcing layer, the workpiece passes through the twisting unit. In the twisting unit, the reinforcing element (for example, a metal tape) is applied with a given pitch. The linear movement is set by the pulling device, which ensures constant movement of the workpiece, and the winding (laying) of the reinforcing element is performed by the rotational movement of the tape winder around the axis of the hydrochannel-liner. After passing through the pulling device, the hydrochannel-liner gets to the receiving device, where it is wound onto the receiving technological drum with a given force and laying pitch for uniform, layer-by-layer placement on the technological drum.

[0021] The next stage involves applying a longitudinal reinforcing layer with conductive elements in the form of conductive cores, wire, tapes or optical fiber.

[0022] According to the description, this operation fully corresponds to the transverse reinforcement operation. The difference is that in this case, a different type of twisting equipment is used. Twisting is performed on lantern and rigid frame type twisting machines. The need to use rotational motion determines the limited speed of the twisting process compared to modern processes based only on the rectilinear translational movement of the workpiece-product (for example, extrusion) and, therefore, does not provide the possibility of a sharp increase in the productivity of twisting machines, desirable for the intensification of the entire cable production. Rigid frame machines are a version of cage twisting machines that do not have a pay-off device, since the workpiece on reels is installed directly in the twisting cages, which significantly simplifies the technology.In the twisting section, the pay-off coils with wire are arranged in three or more rows, as close as possible to the rotation axis, which allows increasing the rotation speed to 180-350 rpm. Unlike the transverse reinforcing layer, the longitudinal reinforcing layer is laid in two layers with a pitch of 110-200 ±40 mm for the first layer-layer with the number of reinforcing elements from 10 to 36 pieces and with a pitch of 150-250 ±40 mm for the second layer-layer with the number of reinforcing elements from 15 to 36 pieces. Twisting is performed sequentially in two opposite directions and opposite to the ratio of the transverse layer.

[0023] At the final stage, the main outer shell is applied using an extrusion line. The extrusion line is a set of equipment designed to process polymer raw materials (granules) into a homogeneous melt and give it a shape by pressing through an extrusion head and a special extrusion tool (mandrel and matrix), the cross-section of which corresponds to the configuration of the finished product with the formation of bonded layers of the polymer base of the hydrochannel liner, layers of reinforcing elements and a layer of HDPE due to the penetration of the HDPE material through the layers of the mesh of reinforcing elements up to the polymer base of the hydrochannel liner.

[0024] The technological operation is carried out on an extrusion line, which includes: an extruder (or a group of extruders), cooling baths (at least 3x), a pulling device, a receiving device, a giving device, and a device for heating the workpiece.

[0025] In this technological operation, the HDPE material in the form of granules is loaded into the receiving hopper of the extruder, in which, under the influence of temperature (from 175 C to 250 C) and pressure, pumped by the barrel-screw pair in the extruder, the bulk material passes into a plastic state (melt). In the extrusion head, the melt, when passing through the working tool (mandrel and matrix), is formed on the body of the workpiece of the required outer diameter, as well as the required adhesion of the inner and outer layers. After that, the product gets into cooling baths in which the required temperature of the cooling liquid is maintained (the first bath no more than 65 C, the second bath no more than 45 C and the third bath no more than 23 C), due to which a smooth, step-by-step cooling of the applied material occurs.

[0026] The product then enters the pulling device, which sets the constant rectilinear movement of the product through the extrusion head. Afterwards, the product is sent to the receiving device, where it is wound onto the receiving drum for uniform, layer-by-layer placement on the drum.

[0027] When applying the outer polymer layer to the workpiece, it is necessary to maintain the following basic, initially specified parameters: the diameter of the product, the integrity of the shell, the adhesion of the outer layer with the internal hydraulic channel liner.

[0028] In addition, during production, interoperational control of the product is carried out in accordance with the internal regulations of the manufacturing enterprise.

[0029] An example of practical implementation.

[0030] A sample cable, KGGG 25 / 44OM4, was manufactured using this method, using the following materials: PE 100 polymers as the base material of the liner and outer layer and PBT as the material of the additional layer with improved mechanical properties, steel tape for the transverse reinforcing layer, high-carbon steel wire as the longitudinal layer of reinforcing elements, an optical module with four fibers as a signal conductor for connecting downhole equipment.

[0031] The finished cable had the following parameters: internal diameter 25+ / -1 mm, external diameter 44+2 / - 1 mm. Tests of the finished sample showed that the breaking force was 140 kN, the maximum permissible temperature was 90°C, the maximum working pressure at a temperature of 90°C was 20 MPa, which corresponds to the declared technical result.

Claims

Method of manufacturing a load-bearing geophysical reinforced cable with a hydraulic channel Invention formula A method for manufacturing a load-bearing geophysical reinforced cable with a hydraulic channel, including the process of manufacturing a hydraulic channel-liner, for the implementation of which bulk polymeric materials are loaded into the receiving devices of a multilayer extruder, where the bulk material passes into a plastic state and when passing through the working tool, a hydraulic channel-liner with an additional layer of polybutylene phthalate (PBT) and the required parameters of the outer diameter, inner diameter and wall thickness is formed, then the hydraulic channel-liner passes through three cooling baths, the first with a temperature of no more than 25 °C, the second bath no more than 40 °C, the third bath no more than 23 °C, in which the product is cooled to the ambient temperature, after the cooling baths the workpiece passes through a pulling device, which produces a constant linear movement of the hydraulic channel-liner from the extrusion group to the receiving device at a given speed,which varies from 1 to 10 m / min and a pulling force of up to 500 kg, after the pulling device, the workpiece 5 enters the receiving device, in which a receiving technological drum is placed for uniform layer-by-layer placement of the workpiece on the drum; then a transverse reinforcing layer is applied in the form of a tape with a small pitch of 5-15 mm using the twisting method; then a longitudinal reinforcing signal-conducting layer is applied sequentially in two opposite directions in two layers with a pitch of 110-200 ±40 mm for the first layer of the wrap with the number of reinforcing elements from 10 to 36 pieces and with a pitch of 150-250 ±40 mm for the second layer of the wrap with the number of reinforcing elements from 15 to 36 pieces; the main outer shell of low-density polyethylene (LDPE) is applied using an extrusion line with the formation of connected layers of the polymer base of the hydrochannel-liner,layers of reinforcing elements and a layer of HDPE due to the penetration of HDPE material through the layers of the mesh of reinforcing elements, right down to the polymer base.