Fibre Composite Rod Cable Radial Strength via Braided Layer
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Solution Overview
Problem
Existing petroleum well intervention cables with unidirectional carbon fibre mantles are prone to disintegration under high pressure and sudden pressure drops, leading to mechanical failure and the need for complete rod replacement, as they lack sufficient radial strength and fluid-proofness.
Innovation Solution
A fibre composite rod intervention power cable design featuring a central electrical cable portion, a bonding layer, a unidirectional carbon fibre composite mantle layer, and a braided fibre composite layer, which provides enhanced tensile strength, radial strength, and fluid-proofness through a braided fibre composite layer that prevents radial disruption and fluid intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a unidirectional carbon fibre mantle layer is used to provide tensile strength, then the rod can be made resiliently flexible and spoolable, but the rod becomes prone to radial disruption and disintegration under high pressure
Solution Approach 1:
The patent applies composite materials by combining a unidirectional carbon fibre mantle layer (for tensile strength) with a braided fibre composite layer (for radial strength and fluid-proofness). This multi-layer composite structure resolves the contradiction by assigning different functional requirements to different material layers, allowing the rod to simultaneously achieve both tensile strength and radial strength.
Solution Approach 2:
The patent segments the protective structure into distinct functional layers: an inner unidirectional carbon fibre mantle layer for tensile strength and an outer braided fibre composite layer for radial strength and fluid containment. This segmentation allows each layer to specialize in its specific function without compromising the other, resolving the contradiction between tensile and radial strength requirements.
2Ease of operation
If the carbon fibre mantle is made thin to allow bending and spooling, then the rod becomes flexible, but it becomes vulnerable to fluid intrusion and pressure disruption
Solution Approach 1:
The patent segments the protective structure into an inner unidirectional carbon fibre mantle layer (enabling flexibility) and an outer braided fibre composite layer (preventing fluid intrusion). This segmentation allows the thin inner layer to provide flexibility while the thicker outer layer provides fluid-proofness, resolving the contradiction between flexibility and fluid containment.
Solution Approach 2:
The patent uses composite materials with different structural characteristics: the unidirectional carbon fibre mantle provides flexibility and tensile strength, while the braided fibre composite layer provides fluid-proofness and radial strength. This composite approach allows the rod to be both flexible and resistant to fluid intrusion simultaneously.
3Shape
If closely arranged insulated conductors are used to minimize cable core diameter, then the rod diameter is reduced for easier injection, but the insulation thickness must be minimized risking electrical short-circuit
Solution Approach 1:
The patent applies composite materials by using fibre composite layers (unidirectional carbon fibre mantle and braided fibre composite) as both structural and electrical insulation components. The fibre composite material provides high dielectric strength, enabling adequate electrical insulation between closely arranged conductors while maintaining a small overall rod diameter for easy injection.
Solution Approach 2:
The fibre composite layers serve multiple functions simultaneously: they provide tensile strength, radial strength, fluid-proofness, and electrical insulation. This multi-functionality allows the rod to maintain small diameter with closely arranged conductors while ensuring adequate electrical insulation through the inherent insulating properties of the fibre composite material.
Data Source
AI summary
A fiber composite rod intervention cable includes a central electrical cable portion; a bonding layer; a generally unidirectional carbon fiber composite mantle layer; a protective, balanced braided fiber composite layer. The central electrical cable portion includes a generally central electrical conductor with a first cross-section conductive area; an inner insulation layer on the central electrical conductor; and a coaxial electrical conductor layer having a second cross section conductive area equal to the first cross-section conductive area. The fiber composite rod intervention cable is arranged for being injected into a well from a drum unit via an injection unit at the wellhead and may carry an intervention tool, a logging tool, a well tractor with or without an energy source.