Torque-balanced wireline cable with polymer sealing
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Solution Overview
Problem
Wireline cable designs face issues with torque imbalance, cable stretch, and pressurized gas infiltration due to the larger diameter of outer armor wires, leading to potential explosions and fire hazards in oilfield operations.
Innovation Solution
Incorporating soft polymer layers between the inner and outer armor wire layers and reversing the size configuration by using larger armor wires in the inner layer to achieve torque balance, while utilizing stranded wires and higher melting point polymers for enhanced sealing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If larger diameter armor wires are placed in the outer layer to provide protection against impact, cut-through, and abrasion damage, then protection capability is improved, but torque imbalance increases causing cable stretch and core deformation
Solution Approach 1:
The patent inverts the conventional armor wire size arrangement by placing larger diameter armor wires in the inner layer instead of the outer layer. This reversal achieves torque balance between layers while the outer layer still provides protection through its positioning and counterhelical configuration, resolving the contradiction between protection capability and torque balance.
Solution Approach 2:
The patent applies different armor wire diameters to different radial positions (layers) of the cable. The inner layer receives larger diameter wires for torque balance, while the outer layer uses smaller diameter wires optimized for its protective function, allowing each layer to have locally optimized properties that resolve the overall contradiction.
2Strength
If outer armor wires carry the bulk of the load (60% of load), then outer layer protection is enhanced, but cable core stretches and inner armor wires tighten causing point-to-point contact and zinc layer wear
Solution Approach 1:
The patent inverts the load distribution arrangement by having the inner layer carry the majority of the load (60%) through larger diameter wires, while the outer layer carries less load. This inversion prevents core stretching and zinc layer wear by balancing the mechanical stresses, thereby improving reliability and corrosion resistance while maintaining overall load carrying capacity.
3Strength
If larger outer armor wires are used to prevent abrasion damage, then abrasion resistance is improved, but torque imbalance causes inner armor wires to tighten and outer armor wires to open
Solution Approach 1:
The patent inverts the armor wire size configuration by placing larger wires in the inner layer and smaller wires in the outer layer. This inversion achieves torque balance that prevents the inner wires from tightening and outer wires from opening under load, while the outer layer maintains abrasion resistance through its positioning and structural configuration.
4Stability of the object's composition
If armor wire layers are applied counterhelically to minimize torque imbalance, then torque balance is improved, but gaps between armor wires allow pressurized gas infiltration leading to explosion hazards
Solution Approach 1:
The patent introduces a polymer coating as an intermediary substance that fills the gaps between armor wires in the counterhelical layers. This coating maintains the torque-balanced counterhelical configuration while simultaneously preventing pressurized gas infiltration through the armor wire gaps, thereby eliminating the explosion hazard while preserving torque balance.
Data Source
Figure 1~3
Figure 4A~5D
Figure 6A~7D
AI summary
A torque-balanced, gas-blocking wireline cable and a method of making the cable includes an electrically conductive cable core for transmitting electrical power and surrounding inner and outer layers of a plurality of armor wires. Gas blocking is achieved by placing a soft polymer layer over the core before the inner wires are cabled thereon. The inner wires imbed partially into the soft polymer layer such that no gaps are left between the inner wires and the core. A second soft polymer layer is optionally extruded over the inner wires before the outer wires are applied. The second soft polymer layer fills any spaces between the inner and outer wire layers and prevents pressurized gas from infiltrating between the wires. The inner wires have larger diameters than the outer wires such that the inner wires carry approximately 60 % of the load and torque imbalance is prevented.