Cable Stopping Layer Prevents Core Deformation Under Tension
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Solution Overview
Problem
Standard wireline cables deform when bent under tension, leading to compression and insulation creep due to torque imbalances between armor wire layers, which can cause damage and premature failure, especially in high-temperature environments.
Innovation Solution
A method of manufacturing cables with a polymeric stopping layer made from materials like PEEK or ETFE, which provides mechanical and thermal protection, and a jacketing layer made from fluoropolymers, embedding armor wire layers within the jacketing layer to prevent deformation and damage, and using amended polymer materials with wear-resistant particles or fibers for enhanced strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard wireline cable structure is used, then manufacturing simplicity is maintained, but cable deformation and insulation creep occur under tension and torque
Solution Approach 1:
The cable is divided into distinct functional layers: a stopping layer (inner protective layer), a jacketing layer (outer protective layer), and armor wire layers. This segmentation allows each layer to perform its specific function in preventing deformation and insulation creep, with the stopping layer specifically designed to prevent armor wires from penetrating the cable core under tension.
Solution Approach 2:
The patent uses composite material structures combining different polymers (stopping layer material, jacketing layer material) and metal armor wires. The stopping layer and jacketing layer are made from specific polymer compositions that provide mechanical strength and resistance to deformation, while the armor wire layers provide tensile strength, creating a composite structure that resists both compression and tension forces.
2Force
If armor wire layers are placed at opposite lay angles to balance torque, then torque imbalance is reduced, but compressive forces cause constriction and insulation creep
Solution Approach 1:
The stopping layer acts as an intermediary barrier between the armor wire layers and the cable core. When armor wires exert compressive forces or attempt to penetrate the cable core under tension, the stopping layer intercepts these forces and prevents direct contact between the armor wires and the cable core insulation, thereby eliminating the insulation creep problem while maintaining the torque-balancing opposite lay angle configuration.
3Ease of operation
If cable is bent under tension over sheaves or drums, then cable routing is achieved, but compression deforms the cable into oval shape
Solution Approach 1:
The stopping layer is applied to the cable core before the armor wire layers are installed. This preliminary protective layer pre-prevents the cable core from deforming into an oval shape when the cable is bent under tension. The stopping layer maintains the circular cross-sectional shape of the cable core, which in turn prevents the armor wires from conforming to an oval shape and reduces the risk of insulation creep during routing operations over sheaves or drums.
4Adaptability or versatility
If high-temperature environments are encountered, then operational capability in subterranean formations is enabled, but thermal damage to cable core occurs
Solution Approach 1:
The patent selects polymer materials for the stopping layer and jacketing layer with specific thermal resistance parameters. These materials are chosen to maintain their mechanical properties and protective function at high temperatures encountered in subterranean formation operations. The material parameter selection ensures that the protective layers remain effective barriers against thermal damage to the cable core while enabling operation in high-temperature environments.
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 solution effectively prevents deformation and damage to the cable core, maintaining its shape and integrity under tension and high temperatures, reducing the risk of premature failure and enhancing operational reliability and safety.
Implementation Method 1
the stopping layer comprises a polymer layer configured to mechanically and thermally protect the cable core
Implementation Method 2
the stopping layer comprises a polymer layer configured to mechanically and thermally protect the cable core
Implementation Method 3
embedding armor wire layers within the jacketing layer to prevent deformation and damage
Data Source
AI summary
An embodiment of a method for manufacturing a cable, comprises providing a cable core comprising at least one conductor therein, extruding a stopping layer about at least the cable core, extruding a jacketing layer about the stopping layer, and cabling at least one armor wire layer about the jacketing layer to form the cable, wherein the stopping layer comprises a polymer layer configured to mechanically and thermally protect the cable core.