Downhole Cable Armor Segregation for Gas Sealing
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Solution Overview
Problem
The sealing capabilities of armor wire cables used in well operations are compromised if the armor wire cables are not properly segregated, allowing pressurized gas to escape through contact pathways.
Innovation Solution
A cable design featuring a cable core with a first and second armor wire layer separated by insulating layers and an outer jacket, where the second armor wire layer is segregated from the first, preventing gas leakage by embedding the armor wires into insulating layers and using a barrier to control embedment depth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If armor wire cables are allowed to be in contact, then the cable structure is simpler, but sealing capability deteriorates allowing pressurized gas to travel up the cable
Solution Approach 1:
The cable is divided into multiple armor wire layers (first, second, and third layers) that are segregated from one another by insulating layers. This segmentation prevents direct contact between armor wire layers, eliminating pathways for pressurized gas to travel up the cable while maintaining structural integrity.
Solution Approach 2:
Insulating layers are introduced as intermediary elements between the armor wire layers. These insulating layers act as barriers that prevent direct contact between metal armor wires, thereby blocking gas pathways while allowing the cable to maintain its mechanical strength and flexibility.
2Reliability
If armor wire layers are segregated from one another, then sealing capability is improved, but cable structure becomes more complex
Solution Approach 1:
The cable employs a nested structure where insulating layers are positioned within the overall cable construction, embedding the segregation function into the existing multi-layer armor wire structure. The first, second, and third armor wire layers are nested with insulating layers between them, creating a compact integrated design.
Solution Approach 2:
The insulating layers function as thin film barriers between armor wire layers. These thin insulating films provide effective gas sealing while adding minimal structural complexity, allowing the cable to maintain flexibility and compactness despite the added segregation layers.
3Object-affected harmful factors
If armor wires are embedded into insulating layers, then gas leakage is prevented, but manufacturing precision requirements increase
Solution Approach 1:
The insulating layers are pre-positioned and configured with specific embedment depth characteristics before the armor wire layers are applied. This preliminary preparation of the insulating layers ensures that when armor wires are embedded, the gas sealing function is automatically achieved without requiring precise real-time control during the embedding process.
Solution Approach 2:
The insulating layers are designed with specific physical parameters (such as hardness, viscosity, or embedment resistance) that control the depth to which armor wires will naturally embed. By adjusting these material parameters, the embedment depth is controlled passively through material properties rather than active manufacturing control, reducing precision requirements.
Data Source
AI summary
A cable that has a cable core with a first armor wire layer and a second armor wire layer. The second armor wire layer is segregated from the first armor wire layer, and an outer jacket is disposed about the second armor wire layer.