Composite Cable for Well Intervention
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Solution Overview
Problem
Existing wireline technologies for well intervention, such as braided and slick lines, face limitations in tensile strength, weight, and frictional drag, especially in deep or horizontally deviated wells, and are inefficient in transmitting power and signals, with issues like microcracks and differential elastic modulus leading to reduced cable lifespan and conductivity.
Innovation Solution
A composite cable made with carbon or glass fibers in a polymer matrix, featuring a smooth outer surface and low friction coating, with embedded electrical and optical conductors, and a manufacturing process that includes preheating, chemical treatment, and controlled curing to prevent microcracks and enhance bonding, providing high axial strength and neutral buoyancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If braided wire cable is used to increase tensile strength and electrical conductivity, then the cable can convey electrical power and signals, but the rough braided exterior increases frictional drag and requires complex grease injection units
Solution Approach 1:
The patent uses a composite cable construction with a smooth outer jacket material (such as polyethylene or polypropylene) combined with internal steel wire strands for strength. This composite structure provides both the required tensile strength and a smooth exterior surface that reduces frictional drag in horizontal and deviated wells, eliminating the need for grease injection units.
2Object-affected harmful factors
If slick line is used to reduce frictional drag and simplify sealing, then the cable has smooth outer diameter and is easier to seal, but the tensile strength is limited and electrical conductivity cannot be achieved
Solution Approach 1:
The patent combines a smooth outer jacket (providing low friction) with internal steel wire reinforcement strands (providing high tensile strength). This composite structure overcomes the limitations of pure slick line by incorporating steel elements that provide both strength and electrical conductivity while maintaining a smooth exterior surface for reduced drag.
3Length of moving object
If wireline length is increased to reach deeper or horizontally deviated wells, then the operational reach is extended, but the drag forces increase and axial strength requirements are exceeded
Solution Approach 1:
The patent employs a composite cable design with high-strength steel wire strands embedded in a smooth outer jacket. This construction provides superior axial strength that can withstand the increased drag forces and tensile loads associated with longer wirelines in deep or horizontally deviated wells, enabling extended operational reach without exceeding strength limits.
4Reliability
If grease injection unit is added to seal around braided cable, then pressure sealing is achieved, but the system complexity increases and hydrocarbon trapping risks arise
Solution Approach 1:
The patent uses a composite cable with a smooth outer jacket material that can be directly sealed against using simple rubber packers or stuffing boxes, eliminating the need for complex grease injection units. The smooth surface of the outer jacket provides an ideal sealing surface, achieving reliable pressure sealing while significantly reducing system complexity and eliminating hydrocarbon trapping risks.
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 composite cable achieves significantly higher tensile strength and reduced frictional drag, enabling effective well intervention in challenging well geometries while maintaining structural integrity and signal transmission, with a longer operational reach and reduced environmental impact.
Implementation Method 1
a coating of a material having low friction coefficient
Data Source
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AI summary
The present invention relates to methods for manufacturing a composite cable, cables resulting from the manufacturing process and use of a composite cable in a well. According to the invention there are several elements to enhance a composite cable, where among a preheating process of conductors before joining them with a matrix, aligning the fibers in the matrix in parallel with each other and the conductors, adding exothermic starting agent to the liquid resin, forming the matrix.