Coiled Tubing Cable With Waveguide and Metallic Tubulars
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Solution Overview
Problem
Existing coiled tubing systems face challenges in withstanding abrasive and corrosive fluids, as well as high pressures, while efficiently transmitting power and communications signals downhole.
Innovation Solution
A power and communications cable with electromagnetic waveguides, surrounded by protective layers including an inner metallic tubular, electrically conductive material, electrically insulating material, and an outer metallic tubular resistant to corrosion and abrasion, which also serves as a conductive return path for power and communication signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable is used to transmit power and communications signals inside coiled tubing, then real-time monitoring and control of downhole operations is enabled, but the cable must withstand abrasive and corrosive fluids as well as high pressures which complicates the cable design and material selection
Solution Approach 1:
The cable is divided into multiple concentric layers, each performing a specific function: the inner metallic tubular provides structural support and electrical conductivity, the electrically insulating material layer isolates electrical signals, and the outer metallic tubular resistant to corrosion and abrasion protects against harsh fluids. This segmentation allows each layer to be optimized independently for its specific function while collectively solving the contradiction between signal transmission reliability and resistance to harsh conditions.
2Reliability
If multiple protective layers are added to protect against high pressures and abrasive fluids, then the cable's resistance to harsh conditions is improved, but the cable diameter increases which may limit its ability to be deployed through coiled tubing
Solution Approach 1:
The cable structure employs a nested concentric layer configuration where the electromagnetic waveguide and inner metallic tubular are positioned inside the electrically insulating material, which in turn is surrounded by the outer metallic tubular. This nested arrangement maximizes the protective functionality of multiple layers while minimizing the overall cable diameter, enabling deployment through coiled tubing despite the need for robust protection against high pressures and abrasive fluids.
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 effectively transmits power and communications signals under harsh conditions, resisting abrasion, corrosion, and high pressures, ensuring reliable operation of downhole tools and data transmission.
Implementation Method 1
an electromagnetic waveguide, an inner metallic tubular surrounding the electromagnetic waveguide
Implementation Method 2
an electrically conductive material surrounding the inner metallic tubular, an electrically insulating material surrounding the electrically conductive material, and an outer metallic tubular resistant to corrosion and abrasion surrounding the electrically insulating layer
Data Source
AI summary
A power and communications cable may include an electromagnetic waveguide, an inner metallic tubular surrounding the electromagnetic waveguide, an electrically conductive material surrounding the inner metallic tubular, an electrically insulating material surrounding the electrically conductive material, and an outer metallic tubular resistant to corrosion and abrasion surrounding the electrically insulating layer. The example system may include an electrical device locatable in the wellbore and coupleable to the cable and a control unit coupleable to the cable and operable to supply power to and communicate with the electrical device via the power and communications cable.