Armored Submersible Power Cable Lead Barrier XLPE Cushion

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Solution Overview

Problem

Power cables used in the oil and gas industry face challenges in high-temperature and high-pressure environments, where corrosive gases and fluids can damage the insulation and conductor, leading to gas permeation and rupture of the gas barrier layer, causing mechanical and electrical failures.

Innovation Solution

A power cable design featuring a conductor with a lead (Pb) barrier layer, a cushion layer of crosslinked polyethylene (XLPE), and metallic armor, which helps protect against corrosive gases and fluids, and reduces the risk of deformation during armoring processes by using an extruded cushion layer instead of braided fibers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a lead barrier layer is used to protect against corrosive gases, then gas permeation resistance is improved, but the cable becomes more susceptible to mechanical damage and deformation during armoring processes

Engineering Contradiction:

Improvegas permeation resistanceVSAvoidmechanical strength during armoring

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent applies a cushion layer of crosslinked polyethylene (XLPE) over the lead barrier layer before the armoring process. This cushion layer acts as a protective barrier that absorbs mechanical stresses and prevents deformation of the lead layer during armoring, while the lead layer continues to provide gas permeation resistance. This resolves the contradiction by providing beforehand protection to the vulnerable lead barrier layer.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If traditional braided fiber cushioning is used during armoring, then mechanical protection is provided, but material costs and manufacturing time increase

Engineering Contradiction:

Improvemechanical protection during armoringVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent replaces the traditional mechanical braided fiber cushioning system with an extruded crosslinked polyethylene (XLPE) cushion layer. This substitution eliminates the complex braiding process and associated materials, while providing equivalent or superior mechanical protection during armoring. The extrusion process is simpler and more efficient than braiding, thereby reducing manufacturing time and material costs while maintaining mechanical protection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the cable is designed with multiple protective layers for harsh environments, then reliability in high-temperature and high-pressure environments is improved, but device complexity increases

Engineering Contradiction:

Improvereliability in harsh environmentsVSAvoidcable structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a composite structure with distinct layers serving specific functions: lead barrier layer for gas permeation resistance, crosslinked polyethylene (XLPE) cushion layer for mechanical protection and environmental resistance, and metallic armor for external mechanical protection. Each layer is optimized for its specific function using appropriate materials, achieving high reliability in harsh environments while keeping the overall design systematic and manageable through clear functional segmentation.

Inventive Principle:

Principle #40Composite materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The cable design enhances the integrity and longevity of power cables in harsh environments by preventing gas permeation and mechanical damage, while also reducing material costs and manufacturing time through improved armoring processes.

Implementation Method 1

a lead (Pb) barrier layer disposed about the conductor

Methodology Applied

Scientific EffectPermeation barrier: Diffusion Barrier

Implementation Method 2

a cushion layer disposed about the lead (Pb) barrier layer where the cushion layer includes crosslinked polyethylene (XLPE)

Methodology Applied

Scientific EffectCrosslinking: Chemical Bonding

Implementation Method 3

metallic armor wrapped about the cushion layer

Methodology Applied

Scientific EffectMetallic reinforcement:

Data Source

PatentUS11646134B2Armored submersible power cable

Publication Date: 2023.05.09 SCHLUMBERGER TECH CORP

AI summary

A method can include extruding polyethylene about a lead (Pb) barrier layer disposed about a conductor to form an assembly; and armoring at least one of the assemblies with metallic armor to form a cable. A power cable can include a conductor; a lead (Pb) barrier layer disposed about the conductor; a cushion layer disposed about the lead (Pb) barrier layer where the cushion layer includes crosslinked polyethylene (XLPE); and metallic armor wrapped about the cushion layer.