CN108712794A - 一种加热管缆 - Google Patents
一种加热管缆 Download PDFInfo
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Abstract
本申请涉及一种加热管缆及其制备方法。加热管缆包括外管和铠装电缆，铠装电缆设置在外管内，铠装电缆包括由内向外依次设置的至少三根加热电缆、第二绕包层和铠装层，铠装层挤包第二绕包层，第二绕包层绕包加热电缆；每根加热电缆包括由内向外依次设置的发热导体、复合膜层和第一绕包层，复合膜层烧结设置在发热导体的外壁上，第一绕包层绕包发热导体。采用本申请的加热管缆，外管屈服强度≥620MPa，不仅强度高，而且加热效果较现有技术可提高30％，极大地提高了加热管缆的加热效果，在采油工程中具有广阔的适用前景。
Description
技术领域
本申请涉及一种加热管缆，适用于石油工程的技术领域。
背景技术
最近二十年，工业发展速度越来越快，对石油的需求量逐渐递增，油田对采油效率的要求也越来越高，但是，石油开采却面临着很多问题。目前的管缆基本可以满足陆地及浅海采油需要，但是随着油井深度的不断加深，采油环境的日趋恶劣，急需向深海采油方向发展。
油井结蜡是油田开发过程中存在已久的问题，当原油从地下抽到地面时，由于溶解气体的逸出和膨胀而使原油温度逐渐降低，蜡就从原油中按分子量的大小顺序结晶析出，并继而沉积在油管内壁上，致使井筒变窄，油井产量降低，严重时还会堵塞油管造成油井停产。原油对蜡的溶解度随温度的降低而减小，当温度降低到原油对蜡的溶解度小于原油的含蜡量的某一值时，原油中溶解的蜡便开始析出。为了防止蜡析出从而堵住油管，一般采用超声波技术，其主要利用超声波的声能击碎原油和石蜡的高分子链，使之变为低分子链，提高了流动性，使其利用的电能一部分转为声能而另一部分转为热能，而转为热能的部分则白白的浪费了。超声波电热清蜡装置即利用了电能转换成的声能，又利用电能在传输过程中释放的热能，对能源进行了综合利用。
申请人曾提出了一种中频感应加热管缆及其制备方法，其中利用电感应加热原理将连续油管变成热载体形成加热管缆，加热流经油管和管缆环空的天然气或原油，实现消除结蜡等作用。但由于其中的加热导体位于中心位置并且只有一根，因此加热效果有限。为此，现有技术中需要一种加热效果更好的加热管缆。
发明内容
为克服现有技术中的上述缺陷，本申请提供了一种加热管缆，其能够更好地对原油进行加热，从而提高了采油效率。
根据本申请的一种加热管缆，包括外管和铠装电缆，铠装电缆设置在外管内，铠装电缆包括由内向外依次设置的至少三根加热电缆、第二绕包层和铠装层，铠装层挤包第二绕包层，第二绕包层挤包加热电缆；每根加热电缆包括由内向外依次设置的发热导体、复合膜层和第一绕包层，复合膜层烧结设置在发热导体的外壁上，第一绕包层绕包发热导体。
优选地，外管为2205不锈钢管，发热导体为铜导体；复合膜层为聚酰亚胺-F46复合膜。
优选地，聚酰亚胺-F46复合膜包括内层双胶膜、中层双胶膜和外层单胶膜；内层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为右向，搭盖率为66-67％；中层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为左向，搭盖率为66-67％；外层单胶膜的厚度为0.035-0.04mm、宽度为16-20mm，层数为1层，绕向为右向，搭盖率为49-51％。
优选地，第一绕包层为玻璃布绕包，厚度为0.16-0.2mm，宽度为25mm，层数为3层，绕包方向为右向，搭盖率为40-50％；第二绕包层为玻璃布绕包，厚度为0.16-0.2mm，宽度为45mm，层数为1层，绕包方向为右向，搭盖率为40-50％；铠装层为双层不锈钢钢带铠装层，钢带的厚度为0.2mm，宽度为20mm，绕包方向为左向，最大间隙率为50％。
本申请的另一方面涉及一种用于制备如上所述加热管缆的方法，包括以下步骤：
(1)制备发热导体
采用拉伸机对铜坯进行拉伸，线速控制在82米/分钟以下，拉伸机转速控制在15转/分钟，退火速度为30-35米/分，退火系数为1.0-1.5；
(2)烧结复合膜
在聚酰亚胺薄膜的单面或双面涂以聚全氟乙丙烯乳液并高温烘干，烧结采用380-400℃的高温工频烧结方式，线速控制在1.0-1.5米/分钟；
(3)浸水试电
将烧结后的电缆线芯浸入水中12小时后，采用35kV直流电进行5min的耐压测试；
(4)干燥
将电缆线芯放于干燥间进行干燥，干燥温度80～100℃，时间36小时以上，确保线芯表面干燥；
(5)线芯绕包
在干燥完毕的线芯外部采用玻璃布进行三层绕包，形成加热电缆；
(6)成缆绕包
将三根加热电缆绞合成一股，成缆后绕包，对电缆缝隙进行填充，并包紧电缆，使电缆不松散；
(7)内管铠装
采用双层不锈钢钢带铠装层对成缆后的线包进行Z形连锁铠装，铠装过程中的搭盖率为至少40％，线速为3-4米/分钟；
(8)制作外管
外管采用2205不锈钢管，采用激光连续焊接技术，铠装电缆预置在外管内；激光功率为3200±300w，焊接速度为2.0±0.2m/min，焦距232mm，离焦量-2.8-0mm，熔合区外保护气流量0.3-1.5m3/h，熔池后保护气流量0.4-1.2m3/h，保护气类型为氩气。
采用本申请的加热管缆，外管屈服强度≥620MPa，不仅强度高，而且加热效果较现有技术可提高30％，极大地提高了加热管缆的加热效果，在采油工程中具有广阔的适用前景。
附图说明
图1是根据本申请的加热管缆的截面示意图。
具体实施方式
为使本发明的目的、技术方案和优点更加清楚明白，下文中将结合附图对本发明的实施例进行详细说明。需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互任意组合。本申请中的方向术语，例如“前后左右”、“上下外内”等均是为了描述的方便，并不构成对保护范围的限定。本领域技术人员知道上述方向之间的简单替换并不脱离本申请的保护范围。
如图1所示，其中显示了根据本申请的加热管缆的截面示意图。加热管缆包括外管6和铠装电缆，铠装电缆挤包设置在外管6内，铠装电缆包括由内向外依次设置的至少三根加热电缆、第二绕包层4和铠装层5，铠装层5挤包第二绕包层4，第二绕包层4挤包加热电缆；每根加热电缆包括由内向外依次设置的发热导体1、复合膜层2和第一绕包层3，复合膜层2烧结设置在发热导体1的外壁上，第一绕包层3挤包发热导体1。外管6可以采用2205合金的双相不锈钢管。优选地，外管的直径与发热导体的直径之比为3-10。
在优选实施方式中，发热导体1为铜导体，直径为5.0-5.5mm。复合膜层2优选为聚酰亚胺-F46复合膜，由聚酰亚胺薄膜单面或双面涂以F46(聚全氟乙丙烯乳液)高温烘干而成，具有优良的耐高低温性、电气绝缘性、耐辐射性、化学稳定性、阻燃性、以及高温自粘密封的特点。
优选地，聚酰亚胺-F46复合膜包括内层双胶膜、中层双胶膜和外层单胶膜；内层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为右向，搭盖率为66-67％；中层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为左向，搭盖率为66-67％；外层单胶膜的厚度为0.035-0.04mm、宽度为16-20mm，层数为1层，绕向为右向，搭盖率为49-51％。第一绕包层3可以为玻璃布绕包，厚度为0.16-0.2mm，宽度为25mm，层数为3层，绕包方向为右向，搭盖率为40-50％。加热电缆绞合成缆，绞合节距为490-560mm。第二绕包层4也可以为玻璃布绕包，厚度为0.16-0.2mm，宽度为45mm，层数为1层，绕包方向为右向，搭盖率为40-50％。铠装层5可以为双层不锈钢钢带铠装层，钢带的宽度为20mm，厚度为0.2mm，绕包方向为左向，最大间隙率为50％。
下面介绍根据本申请的加热管缆的制备方法，包括以下步骤：
一、加热电缆制造
工艺流程：制备发热导体→烧结复合膜→浸水试电→干燥→线芯绕包→成缆绕包→内管装铠。
(1)制备发热导体
采用拉伸机对铜坯进行拉伸，线速控制在82米/分钟以下，拉伸机转速控制在15转/分钟，退火速度为30-35米/分，退火系数为1.0-1.5。由于拉伸会导致材料发生加工硬化，使材料内部在冷加工后保留相当大的内应力，退火的过程就是去除内应力的过程。
(2)烧结复合膜
在聚酰亚胺薄膜的单面或双面涂以F46并高温烘干，烧结采用380-400℃的高温工频烧结方式，线速控制在1.0-1.5米/分钟。
(3)浸水试电
将烧结后的电缆线芯浸入水中12小时后，采用35kV直流电进行5min的耐压测试，如果无击穿或失压情况，则转下一道工序，目的是检测电缆线芯是否有破损及薄弱点。
(4)干燥
由于浸水试电以后电缆的表面粘有水分，因此将电缆线芯放于干燥间进行干燥，干燥间温度80～100℃，时间36小时以上，确保线芯表面干燥。
(5)线芯绕包
在干燥完毕的线芯外部采用玻璃布进行三层绕包，形成加热电缆。
(6)成缆绕包
将三根加热电缆绞合成一股，成缆后绕包，对电缆缝隙进行填充，并包紧电缆，使电缆不松散，且具有保护线芯的作用。
(7)电缆铠装
采用双层不锈钢钢带铠装层对成缆后的线包进行Z形连锁铠装，铠装过程中的搭盖率为至少40％，线速为3-4米/分钟。
二、管-缆复合
工艺流程：放带→钢带清洗→U成型(同时放入铠装电缆)→O成型→激光焊接→清除焊缝外毛刺→定径→去应力回火→精整→收卷。类似工艺可参考申请人的在先申请201610008224.6和201710122020.X，不再赘述。
(1)放带
将钢带置于储带盘内，为生产线提供钢带材料。
(2)钢带清洗
清洗钢带表面，确保焊接表面干净无油污。
(3)U成型(并放入铠装电缆)
将钢带加工成U型，同时在上端开口处将铠装电缆置于内部。
(4)O成型
将铠装电缆完全包裹在成型的钢带内，令电缆贴于内下表面。
(5)激光焊接
通过激光焊接技术，铠装电缆预置在外管内。焊接参数为：连续焊接模式，激光功率3200±300w，焊接速度2.0±0.2m/min，焦距232mm，离焦量-2.8-0mm，熔合区外保护气流量0.3-1.5m3/h,熔池后保护气流量0.4-1.2m3/h，保护气类型为氩气。
(6)清除焊缝外毛刺
通过外置三组打磨头，对外管外毛刺进行修整，达到与外表面平滑过渡的效果。
(7)定径
通过对外管的定径，使外管和铠装电缆贴合。
(8)去应力回火
对整管进行去应力回火，提高管缆低周疲劳性能。
(9)精整
通过对外管的精整，使外管尺寸达到规定范围，确保圆整度符合要求。
(10)收卷
将管缆收到一个滚筒上。
采用本申请的上述制备方法制备的加热管缆，外管屈服强度≥620MPa，不仅强度高，而且加热效果较现有技术可提高30％，极大地提高了加热管缆的加热效果，在采油工程中具有广阔的适用前景。
虽然本发明所揭露的实施方式如上，但所述的内容只是为了便于理解本发明而采用的实施方式，并非用以限定本发明。任何本发明所属技术领域内的技术人员，在不脱离本发明所揭露的精神和范围的前提下，可以在实施的形式上及细节上作任何的修改与变化，但本发明的专利保护范围，仍须以所附的权利要求书所界定的范围为准。
Claims (8)
1.一种加热管缆，包括外管和铠装电缆，铠装电缆设置在外管内，其特征在于，铠装电缆包括由内向外依次设置的至少三根加热电缆、第二绕包层和铠装层，铠装层绕包第二绕包层，第二绕包层绕包加热电缆；每根加热电缆包括由内向外依次设置的发热导体、复合膜层和第一绕包层，复合膜层烧结设置在发热导体的外壁上，第一绕包层绕包发热导体。
2.根据权利要求1所述的加热管缆，其特征在于，外管为2205不锈钢管，发热导体为铜导体。
3.根据权利要求1或2所述的加热管缆，其特征在于，复合膜层为聚酰亚胺-F46复合膜。
4.根据权利要求3所述的加热管缆，其特征在于，聚酰亚胺-F46复合膜包括内层双胶膜、中层双胶膜和外层单胶膜；内层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为右向，搭盖率为66-67％；中层双胶膜的厚度为0.035-0.04mm、宽度为14-18mm，层数为1层，绕向为左向，搭盖率为66-67％；外层单胶膜的厚度为0.035-0.04mm、宽度为16-20mm，层数为1层，绕向为右向，搭盖率为49-51％。
5.根据权利要求1或2或4所述的加热管缆，其特征在于，第一绕包层为玻璃布绕包，厚度为0.16-0.2mm，宽度为25mm，层数为3层，绕包方向为右向，搭盖率为40-50％。
6.根据权利要求5所述的加热管缆，其特征在于，第二绕包层为玻璃布绕包，厚度为0.16-0.2mm，宽度为45mm，层数为1层，绕包方向为右向，搭盖率为40-50％。
7.根据权利要求6所述的加热管缆，其特征在于，铠装层为双层不锈钢钢带铠装层，钢带的厚度为0.2mm，宽度为20mm，绕包方向为左向，最大间隙率为50％。
8.用于制备根据权利要求1-7中任一项所述加热管缆的方法，包括以下步骤：
(1)制备发热导体
采用拉伸机对铜坯进行拉伸，线速控制在82米/分钟以下，拉伸机转速控制在15转/分钟，退火速度为30-35米/分，退火系数为1.0-1.5；
(2)烧结复合膜
在聚酰亚胺薄膜的单面或双面涂以聚全氟乙丙烯乳液并高温烘干，烧结采用380-400℃的高温工频烧结方式，线速控制在1.0-1.5米/分钟；
(3)浸水试电
将烧结后的电缆线芯浸入水中12小时后，采用35kV直流电进行5min的耐压测试；
(4)干燥
将电缆线芯放于干燥间进行干燥，干燥温度80～100℃，时间36小时以上，确保线芯表面干燥；
(5)线芯绕包
在干燥完毕的线芯外部采用玻璃布进行三层绕包，形成加热电缆；
(6)成缆绕包
将三根加热电缆绞合成一股，成缆后绕包，对电缆缝隙进行填充，并包紧电缆，使电缆不松散；
(7)电缆铠装
采用双层不锈钢钢带铠装层对成缆后的线包进行Z形连锁铠装，铠装过程中的搭盖率为至少40％，线速为3-4米/分钟；
(8)制作外管
外管采用2205不锈钢管，铠装电缆预置在外管内，采用激光连续焊接技术焊接外管；激光功率为3200±300w，焊接速度为2.0±0.2m/min，焦距232mm，离焦量-2.8-0mm，熔合区外保护气流量0.3-1.5m3/h，熔池后保护气流量0.4-1.2m3/h，保护气类型为氩气。
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