Composite Slickline Cable Optimized Residual Strain
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Solution Overview
Problem
Slickline cables used in subterranean well operations experience premature failure due to uneven and excessive stress, making it difficult to track and manage residual strain, leading to potential fatigue and failure during repeated use for various operations.
Innovation Solution
A composite slickline cable is developed with an optical fiber that has optimized residual strain, achieved through a pultrusion process where independent tensions are applied to carbon fiber elements and the optical fiber, allowing for a predetermined strain level between -1000 and 500 microstrain, which is maintained when the cable is unstressed and at ambient temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional slickline cables are used without optimized residual strain control, then manufacturing is simpler, but the useful life and reliability are reduced due to premature failure from stress-related damage
Solution Approach 1:
The patent applies preliminary action by establishing optimized residual strain in the optical fiber during the pultrusion manufacturing process. Tensions are applied to the optical fiber and carbon fiber elements before the polymer resin is applied and cured, creating a predetermined strain state that will compensate for future operational stresses. This preliminary strain optimization prevents premature failure and extends useful life.
Solution Approach 2:
The patent implements parameter changes by controlling the tension forces applied to the optical fiber and carbon fiber elements during manufacturing. By adjusting these tension parameters, the patent establishes specific residual strain levels in the optical fiber that optimize its performance and durability under operational conditions, transforming the strain parameter from uncontrolled to precisely managed.
2Duration of action of stationary object
If independent tensions are applied to carbon fiber elements and optical fiber during pultrusion to optimize residual strain, then the useful life is extended, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by establishing optimized residual strain in the optical fiber during the pultrusion manufacturing process. Tensions are applied to the optical fiber and carbon fiber elements before the polymer resin is applied and cured, creating a predetermined strain state that will compensate for future operational stresses. This preliminary strain optimization prevents premature failure and extends useful life.
Solution Approach 2:
The patent utilizes composite materials by combining optical fiber, carbon fiber elements, and polymer resin in a pultrusion process. The composite structure allows independent tensioning of different components during manufacturing, enabling precise control of residual strain in the optical fiber while maintaining the structural integrity provided by the carbon fiber reinforcement.
3Reliability
If residual strain is optimized to between -1000 and 500 microstrain, then stress-related damage is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent implements parameter changes by controlling the tension forces applied to the optical fiber and carbon fiber elements during manufacturing. By adjusting these tension parameters, the patent establishes specific residual strain levels in the optical fiber that optimize its performance and durability under operational conditions, transforming the strain parameter from uncontrolled to precisely managed.
Solution Approach 2:
The patent applies feedback principles by monitoring and controlling the tension forces applied during pultrusion to achieve the target residual strain range. The manufacturing process incorporates control mechanisms that adjust tensions based on measured parameters, ensuring the final product falls within the optimized strain range of -1000 to 500 microstrain, thereby reducing stress-related damage.
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 optimized residual strain in the optical fiber extends the useful life of the composite slickline cable by reducing the risk of premature failure from stress-related damage, enabling more reliable and durable performance across multiple operations.
Implementation Method 1
A method of optimizing residual strain in at least one optical fiber in a composite slickline cable includes establishing a first strain in a plurality of reinforcing fibers responsive to the application of a first tension on the reinforcing fibers; establishing a second strain in the at least one optical fiber responsive the application of to a second tension on the at least one optical fiber
Implementation Method 2
applying a polymer material to the plurality of reinforcing fibers and the at least one optical fiber; solidifying the polymer material around the reinforcing fibers and the at least one optical fiber to form the composite slickline cable
Data Source
AI summary
A disclosed example embodiment includes a composite slickline cable having an optical fiber with optimized residual strain. The composite slickline cable includes a fiber reinforced polymer and at least one optical fiber disposed within the fiber reinforced polymer such that axial stress applied to the composite slickline cable is shared by the at least one optical fiber and the fiber reinforced polymer. In the axially unstressed state of the composite slickline cable, the at least one optical fiber has a residual strain between about −1,000 microstrain and about 500 microstrain.