Patent Application
20130280420
The invention relates to methods for manufacturing a composite cable, cables resulting from the manufacturing process and the use of a composite cable.
Work is performed in an oil or gas well to stimulate or treat the well, whereby the production is increased, to replace various equipment such as valves, sleeves etc., to make measurements, to monitor the state of the well, or other intervention tasks requiring equipment being accessed inside, operated inside, installed into, or retrieved through the production conduits of a well.
Intervention into a well to access well hardware, measure performance, or increase the production rate or volume is made after a cost/benefit evaluation. Even if the intervention is deemed advantageous, the intervention costs may be too high or the work considered too difficult and time consuming. For remote subsea wells, simply gaining access to the Christmas tree just to insert the wireline is a challenge without the extraordinary efforts of using a large vessel and deploying a pressure containing conduit (completion/workover riser) to shield the wireline from environmental forces from ocean, that is, a “heavy” intervention. Onshore or offshore platform wells have easy access into the Christmas tree; relying on the surrounding infrastructure (access roads, cranes, platform structures, etc) allows smaller, quickly deployable, low cost wireline units to be dispatched to the well, that is, a “light” intervention. Because of this, the oil recovery from an onshore or offshore platform or onshore well is up to twice the recovery of a subsea well with similar reservoir conditions. As mentioned above, this is caused by the more easy access making a better program for well maintenance and reservoir management practically possible and profitable. To bridge this economic gap between onshore/platform and subsea well interventions, Riserless Light Well Intervention (RL WI) techniques have been introduced. These techniques utilize much smaller vessels and far less equipment. As the name implies, RL WI does away with the completion/workover riser by deploying the wireline drum and unit from the surface and allowing the wireline to traverse “open water” down to the subsea well, or deploying the wireline drum unit subsea on top of or adjacent to the subsea well. However, these techniques may be limited to accessing only those wells located in relatively shallow water, depending on the material strength of the wireline.
Recently, some subsea wells along with some onshore or platform wells are being constructed very deep or with unusual access routes to access petroleum reservoirs (some wells are drilled to near horizontal angles, side lateral angles, up dip, or combinations thereof), making traditional wireline access physically challenging. Usually, the weight of the intervention tool suspended by the wireline is sufficient to lower the tool to its desired location in the well, by unwinding wireline off of its take-up reel and feeding it into the well. As the well length increases or the well path moves from vertical to horizontal, the tool weight may not be enough to deploy the wireline tool properly. Even with the use of a “tractor” to electro-mechanically pull the tool further into the well, there are limitations on how far it can reach due to the drag forces acting on the cable, thereby increasing the load necessary to pull the tool (and tractor) out of the well, not to mention taxing the axial strength of the wireline to maintain structural integrity to lower or retrieve the wireline tool.
A well intervention may be difficult, as existing barriers have to be removed before entering the well. There are strict rules regarding the measures required to prevent an uncontrolled blowout during such works. Thus, when well intervention is to be performed, a provisional pressure barrier, such as a blowout preventer, has to be provided along with a pressure control head (PCH) which allows the wire line to enter or egress the well while the well is in a pressurized state. The wireline that enters the well often is provided in one of two configurations: slick line and braided wire cable. But they have their limitations in use, The slick line has a smooth outer diameter which is relatively small, lightweight and simpler to seal around for pressure control (traditionally called a stuffing box). However, it is limited in tensile strength and cannot pass electrical current unless it is sheathed with an insulating jacket. A braided cable is stronger and can convey electrical power and signals through its internal core, but this comes at a price in that it has a rough braided exterior requiring a different PCH design incorporating a grease injection unit to fill the crevices in the cable's exterior geometry to create a temporary smooth bore that the PCH's seals can pressure seal against. The grease injection unit becomes problematic in subsea RL WI applications as it becomes increasingly difficult to remotely pump grease to the PCH. In addition, the grease can trap well hydrocarbons as the cable exits the well, which could lead to minor hydrocarbon release to the environment, or worse, form hydrates with the surrounding sea water. The braided exterior also creates a rougher exterior, which can increase the relative frictional drag between the cable and the side wall of the well conduit, making it unsuitable for some horizontal and long reach wells.
Both braided wires and slick lines have relatively limited strength and a moderately high weight to strength ratio as metallic alloys such as improved plow steels and stainless steels are traditionally used. These materials are becoming less efficient in providing the needed strength for the deeper wells and longer lateral offsets. In addition, the material's weight is heavier than the density of the surrounding sea water or well bore fluids, compounding the load requirements on the wireline itself as more wireline is paid out into the well.
To mitigate the disadvantages experienced with the above wireline configurations, it is proposed to instead use a wireline made from a carbon-fibre filled composite cable. A composite cable has a high strength to size ratio and strength to weight ratio and can be made axially stiff or rod-like to enable it to be pushed or pulled into highly deviated wells. Its construction can be made with a very smooth impervious outer surface to reduce the frictional drag forces in the well and simplify the sealing design of the PCH (like the slick line). Another advantage is that it can be constructed to include electrical and/or optical conductors in its cross-sectional matrix for power and signal transmission into the well. This further increases the operational reach of the composite cable by enabling power for tractor assist. The composite cable's construction has substantially more axial strength than its steel counterparts by almost an order of magnitude. The tensile strength of a cable with carbon fibres in a vinyl ester matrix may be in the region of 130,000 MPa. Finishing the surface of the cable with a low friction compound and smooth surface finish may further reduce frictional drag and make it less susceptible to chemical attack from well bore fluids.
A number of publications exist suggesting various kinds of cables that can be used for well intervention. U.S. Pat. No. 6,600,108 describes a cable consisting of a number of electrical conductors grouped together within a jacket; the void between the conductors being filled with a filler, for example an elastomer. To increase its strength, the cable has a steel armor winding around the jacket.
Another example is disclosed in US Patent Application No. 2006/0045442. This application discloses a conductor bundle with an optical fibre centrally positioned on the centre axis of the conductor bundle and a plurality of metallic conductors helically positioned around the optical fibre. This conductor bundle may be used as one of the conductor bundles described above.
None of the above devices can correctly be described as a cable, as they are intended to be surrounded by a helically wound steel armor around the jacket, similar in construction to the exterior of a braided cable. They therefore have all the same disadvantages of the braided cable as explained above.
WO 2006/054092 describes a slickline cable for well intervention consisting of an electrical conductor covered by an insulating material. This insulated conductor is surrounded by a polyetheretherketone (PEEK) with carbon fibres which are braided around a central conductor. When manufacturing this cable, the conductor and braids are brought together and heated such that the matrix melts and the cable is formed by a pultrusion process.
None of these publications mentions an acceptably diminutive diameter to be ideally suited for wireline well intervention, nor do they address the problems associated with the manufacture of a composite cable identified in this disclosure. One such problem is the presence of cracks (especially micro-cracks) that enable hydrocarbons to enter the matrix. As the cable is withdrawn from the well hydrocarbon gas that has entered into the cracks expands. This shortens the life of the cable. Another problem is the difference in elastic modulus of copper and fibres. This has on occasions resulted in the copper conductors being stretched to the point that they no longer conduct.
An object of the invention is to manufacture a cable that is especially good for use in well intervention.
Still another object is to provide a method for manufacturing a cable which has high strength and at the same time can withstand large temperature and pressure differences. There is also an aim to provide such a cable with an outer smooth surface.
These objects are achieved with the methods, cables and uses defined in the attached independent claims, with preferred embodiments given in the dependent claims.
According to a further aspect, the invention relates to a cable for together with the present device and/or method, which comprises a plastic material reinforced by carbon or glass fibre, whereby the cable achieves the desired degree of rigidity and a coating of a material having low friction coefficient.
The invention will now be described with reference to the accompanying drawings, wherein:
In
As shown on
The present invention provides a cable comprising at least one electrical conductor 1, 2, 3 encased in one or several separate isolators 4, 5, 6, 12 arranged within a matrix 9. The cable may also comprise at least one optical fibre within the cable. In addition, the cable may comprise one electrical conductor arranged in one separate isolator and possibly two other electrical conductors arranged in a common but separate isolator from the first. The matrix 9 comprises a polymer matrix with reinforcement fibres embedded in the matrix.
Carbon fibres arranged to be embedded in the matrix and form reinforcements of the polymer matrix 9 are each wound on a number of bobbins 29 in a fibre rack 30. These reinforcement fibres may be carbon or glass or other suitable fibre material. The fibres are thereafter combined with a polymer that makes up the matrix 9 of the finished composite. In an embodiment of the invention the polymer is a thermoset polymer such as a vinyl ester in the form of a liquid resin that is poured into a resin bath 32. As the fibres pass through the resin bath 32 they will be soaked/coated with the liquid resin. On exiting the resin bath, the carbon tows are positioned within the cross section of the finished cable in a pre-shaping section 33. This section compromises an array of tooling which squeezes away excess resin as the product is moving forward and gently shapes the rod prior to entering the main die nozzle 34. The pre shapers also ensure that the conductors are located in their correct position in the cable, the correct fibre distribution and that a homogenous cross section is achieved. The main die 34 gives the cable its final shape. Thereafter the cable passes through the post-curing station 36. Optionally the cable can pass through a station 37 to be covered by an isolation layer. The cable is drawn through the machine by pullers 38, 39, and there may be provided a meter 40 for measuring the length of the cable before it is wound onto the final drum 44. Optionally, an ultrasound quality check 42 may be included in the set-up. There are also means (not shown) to provide a constant tension on the conductors.
The amount of fibres in the finished cable should preferably be above 60% and more preferably 67%-71%. This is important both for the process when manufacturing the cable but it will also give the finished cable a higher tensile strength. The fibres used are also in a whole length for the length of the cable.
The congealing of the resin is chemically initiated by the heat from the main die 34 and a rigid, cured cable is formed that corresponds to the cavity of the die. The pull speed, temperature of the die, surrounding temperature and surrounding moisture are registered and stored regularly, possibly every fourth second by a system for registering and storing the data.
To form the matrix 9 there is used a polymer matrix with embedded fibres. The polymer matrix may be formed by a thermoset polymer which may be added through a resin bath as explained. It also possible to envisage a thermoset polymer added through strips of material added in a similar manner as the fibre.
A thermoset 40 polymer is a polymer which becomes harder after a curing process during which energy is added to the polymer. During this curing process there are formed crosslinks in the material. Alternative the matrix may be formed by thermoplastic resin.
In the case with a polymer matrix added to the fibres in a bath, chemical agents are added to the liquid resin to improve the properties of the finished cable. The amount of and type of agents used are dependent upon several factors, such as the size (nominal diameter) of the cable, the kind of resin/polymer matrix used and the desired curing process, which will be described in more detail below.
There are several problems associated with manufacturing a cable that will be used in a hydrocarbon well environment. The first is the bonding between the insulator and the copper conductors and between the insulator and the matrix. It is important to ensure that the composite cable can support the weight of the copper during well intervention operations. The cable will be subject to high tensile loads due to the long vertical sections. If bonding is not achieved then the copper conductors can break due to tensile and/or gravity loads.
According to the invention, this condition is mitigated by possibly different steps. First, the conductor (which has arrived finished encased in an isolator) may be heated to around 150° C. This is done he pre-heater 26. This has the effect of “baking” the thermoplastic isolator to create a better bonding between the isolator and the copper and to remove absorbed water in the isolator material, for instance PEEK, around the conductors, possibly copper conductors.
Any water in the plastic isolator can lead to the formulation of steam bubbles during the later curing process of the cable. Such bubbles will reduce the strength and bonding within the cable. Second, the conductor's surface may be treated to improve the chemical bonding between the molecules in the plastic and the resin. There are many kinds of treatments that can be used, such as a chemical treatment, for example washing with an acid. However, in an embodiment of the invention the plastic is subjected to an electrical discharge. This treatment is of a kind manufactured by Vetaphone under the trade name “Corona-Plus” and is a treatment generally used on plastic films to improve the surface for writing or printing. However, this treatment has to the knowledge of the inventors never before been used to improve the bonding between a hard thermoplastic such as PEEK and a resin liquid for use in a composite cable.
Another problem relates to the formation of cracks in the composite when it cures, During curing the matrix will shrink. During shrinkage cracks may form in the matrix of the composite due to temperature gradients during curing. Often such cracks are micro-cracks, which may escape an ordinary visual examination. Cracks can weaken the finished cable and even cause the cable to break under a load far lower than the design load. One reason for this is that hydrocarbon gas molecules can migrate into the cracks due to the high pressure in the well. When the cable is withdrawn from the well the pressure decreases. This causes any gas bubbles to expand in size. Any gas molecules trapped inside the cable matrix will also expand and try to exit the cracks, but the expansion rate at normal pulling speeds is such that the gas cannot escape from the cracks and the result can be very damaging to the cable. Another reason is that cracks may cause serious stress concentrations that may cause fibres to break.
According to the invention this problem may be addressed in two ways. The cable is heated as it passes through the curing station 36 of the manufacturing process. This heating is controlled partly by applying heat to the cable and partly by adding chemicals to the resin/polymer matrix to cause an exothermal reaction that heats the 10 cable from within and ensures a uniform heating over the cable cross section.
In an embodiment of the invention three different chemicals are used as initiators, each of them will be activated within a designed temperature range during the curing. These are carefully controlled by the chemical formulations and the temperature profiles. This will reduce internal, or residual, stresses from the curing process.
The amount of and types of chemical additives added to the polymer matrix, depends as said on several factors. The type of polymer matrix chosen will influence the choice of additives added. To achieve the desired temperature gradient through the cable during the curing process there are added additives which give an exothermic reaction in the matrix, which exothermic reactions start at a given temperature or temperature interval to the polymer matrix or resin. One example of such an additive is a curing agent in the form of an organic peroxide, whereof one is a peroxycarbonate. These agents may also be initiators for (co)polymerization and thereby provide more cross links in the matrix after curing. When adding several different agents giving an exothermic reaction, the temperature intervals for these agents may be overlapping. These agents may also be vulcanization agents.
In addition to these agents giving an exothermic reaction within the matrix and thereby working as curing agents, there may be added agents as accelerators for accelerating the process and slip agents to improve the slip of the matrix in relation to the different equipment use in the manufacturing process. There may also be added agents to limit or prevent shrinkage of the matrix during the curing process. In some instances there may also be added additional styrene into the matrix mix or there may be enough styrene in the polymer matrix originally to ensure good cross-binding in the polymer matrix or resin. During the process the fibres (tows) 50, after exiting from the resin bath 32, are pulled into the pre-shapers 33. During this phase the resin is in a liquid phase in one embodiment. Then the resin enters a gel phase and eventually forms a solid. Through these steps the cable is heated in a controlled manner. This will create crosslinks in the resin and result in a stronger bond between the resin molecules and between the resin and the fibres. Some of the heating comes from the dies as the cable is drawn through. However, the heating must be in a controlled manner and this is ensured by adding heat to the cable. The added heat around the cable triggers the start of the initiators for the exothermal process, which initiators are agents added to the polymer matrix. The various initiators will be functional at various temperatures and the controlled heating ensures that each component reacts at a preset stage in the process. By both externally and internally heating the cable one can achieve a desired temperature gradient through the cable during the curing process. The temperature gradient is substantially even across the cable during this process. By substantially even one should herein understand that the temperature may form a graph with a shallow arc when looking at it in a cross section of the cable giving a low temperature gradient across the cable. The temperature in a cable without the exotherm agents will form a more arced graph across the cable. The heat transport out of the cable (during curing) must be tightly controlled, There are exothermic reactions in the matrix during the curing phase and that is managed through the combined use of heaters and chemical additives, as discussed above.
The temperature rises from about 140° C. during this phase until it reaches about 180° C. in the constant diameter section of the cable. When leaving this section the cable is allowed to cool down. However, this cooling must also be managed to avoid temperature gradients across the cable. The temperature reduction should be done such that it ensures minimum residual stress in the cable. The temperature gradient across the cable is in this phase very important, and to manage this there are installed after heaters 36 (
To achieve the high axial strength of the cable, the carbon fibres in the matrix are given an orientation parallel with a longitudinal axis of the cable, i.e. the fibres are not wound or braded around the cable but kept in an orientation parallel to the centrally located conductors in the cable. The fibres are also arranged substantially in parallel with each other. The fibres are therefore not wound or braded. This is achieved with the mentioned pre-shaper stage, one possible embodiment of which is schematically shown in
It should be noted that the above description discloses just one example of how a cable can be manufactured and it should be apparent that different matrix and different cable size require other additive agents and/or different kind of agents. Also a larger size cable may require other proportions of agents than a smaller diameter cable.
The manufacturing process is now explained with several specific steps introduced into the making of a final cable. One will understand that a cable may be made with only introducing one or several but not all of the steps as described above. One may envisage a manufacturing method as previous known with the addition of the preheating of the conductors before they are joint with the outer matrix layer but with the further method as prior known. Alternatively the outer layer of the isolator may be treated by an electric charge. Alternatively the cable may be formed as prior known but with reinforcement fibres only parallel with the conductors. In another embodiment a prior known method may be improved by the addition of adding curing agents giving an exothermic reaction in the matrix. One may also envisage a method using some of these elements in addition to prior solutions but not all, or a method using all of these novel steps in the method for manufacturing a cable. It is also possible to envisage a composite cable comprising at least one fibre in a polymer resin matrix arranged within the polymer resin matrix wherein that the at least one fibre in the polymer resin matrix is arranged in parallel with the axis of the composite cable.
The invention is now explained with a non-limiting embodiment, and a skilled person will understand that there may be made alterations and modifications to the embodiment within the scope of the invention as defined in the attached claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 073832 | Jul 2007 | NO | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12452770 | Jun 2010 | US |
| Child | 13921187 | US |
