CN111430079A - 一种电潜泵复合管缆及其制备方法 - Google Patents
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Abstract
本发明公开了一种电潜泵复合管缆,包括钢管外壳和隔离层,所述隔离层包裹在所述乙丙护套的外周面上,所述钢管外壳包裹在所述隔离层的外周面上,所述隔离层的内部设置有多根信号缆总成和多根注剂管,各所述信号缆总成和各所述注剂管设置于所述乙丙护套的内部中心且交错布置;钢管外壳的设计能够提供电潜泵所需要的拉力,同时能够有效的隔离侵入液体,有效的解决腐蚀等问题。该电潜泵复合管缆的制备方法,主要包括隔离层的制作和钢管外壳的加工成型两步,隔离层的设置有效的保证了钢管外壳的加工过程中的安全性,尤其是在焊接工位,能够隔离焊接的预热,防止焊接时对信号缆产生烫伤问题。
Description
技术领域
本发明涉及潜油泵电缆技术领域,尤其涉及一种电潜泵复合管缆及其制备方法。
背景技术
潜油泵电缆是潜油泵机组配套使用的专用电缆,一般应用于油井中,电缆的下端与潜油泵相连,电缆的上端与地面上的机组控制柜相连。而且在油井作业过程中,会通过电缆向井内加注化学注剂,现有的潜油泵电缆通常为扁形结构,而油井中工作条件恶劣,常处于高温、高压且腐蚀性较强的环境中,同时电潜泵只能配套在连续油管上使用,本身由于承重等方面的问题,长度不能太长,同时外表皮为铠装,对外浸入液体的保护能力较差,容易产生脱铠等问题。
发明内容
本发明的目的是提供一种电潜泵复合管缆,解决现有技术潜油泵电缆的外表皮为铠装,对外浸入液体的保护能力较差,容易产生脱铠的问题。
为解决上述技术问题,本发明采用如下技术方案:
本发明一种电潜泵复合管缆,包括钢管外壳和隔离层,所述隔离层包裹在所述乙丙护套的外周面上,所述钢管外壳包裹在所述隔离层的外周面上,所述隔离层的内部设置有多根信号缆总成和多根注剂管,各所述信号缆总成和各所述注剂管设置于所述乙丙护套的内部中心且交错布置。
进一步的,所述信号缆总成和所述注剂管的数目具体设置为三根且交错布置;各所述信号缆总成均包括最内层的导体,所述导体的外侧设置有烧结膜,所述烧结膜的外侧设置有乙丙绝缘层,所述乙丙绝缘层的外侧设置有F4膜,所述F4膜的外侧设置有尼龙布层;所述注剂管包括一根第一注剂管和两根第二注剂管,所述第一注剂管的直径大于所述第二注剂管的直径。
进一步的,所述隔离层具体设置为尼龙带层、钢板或保护钢管。
一种电潜泵复合管缆的制备方法,制作如上所述的电潜泵复合管缆的方法,具体包括以下步骤:
步骤一,隔离层的制作:电潜泵线缆的初始状态的最外层为乙丙护套,所述钢带铠装层的内部设置有多根信号缆总成和多根注剂管,将所述隔离层通过相应的加工设备设置在所述乙丙护套的外周面上;
步骤二,钢管外壳的加工成型:将用于生产所述钢管外壳的钢卷原料放置于第一钢带放置架上,将步骤一中包裹有所述隔离层备用线缆放置于放线架上,钢卷原料的起始端依次经过钢管初步成型设备、放线架、激光焊接设备、无损探伤设备、拉拔设备、牵引机后加工成套设在所述备用线缆上的钢管外壳,最后,复合有钢管外壳的成品电潜泵复合管缆通过第二收线架缠绕收卷,以备下个工序使用。
进一步的,所述步骤一中,当隔离层设置为尼龙带层时,初始状态的电潜泵线缆卷轴放置在所述放线架上,初始状态的电潜泵线缆起始端通过绕包机形成包裹有尼龙带层的备用线缆,所述备用线缆通过第一收线架缠绕收卷,以备下个工序使用。
进一步的,所述步骤一中,当隔离层设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架上,初始状态的电潜泵线缆起始端依次通过铠装机、牵引机形成包裹有保护钢管的备用线缆,所述备用线缆通过第一收线架缠绕收卷,以备下个工序使用。
进一步的,所述保护钢管形成的隔离层与所述乙丙护套之间为空腔结构。
进一步的,所述当隔离层设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架上,将用于生产所述隔离层的钢卷原料放置于第一钢带放置架上,钢卷原料的起始端依次经过钢管初步成型设备、放线架、激光焊接设备、无损探伤设备、拉拔设备、牵引机后加工成套设在初始状态线缆上的钢管结构隔离层,最后,复合有钢管结构隔离层的备用线缆通过第二收线架缠绕收卷,以备下个工序;其中,经过所述激光焊接设备时采用小功率激光焊接,焊接深度控制在80%~100%,保护钢管的厚度为0.2~0.5mm。
进一步的,当所述隔离层设置为钢板时,所述钢板粘结在所述乙丙护套上,且位于所述钢管外壳焊接成型时的激光焊接处的下方;复合时,将用于生产所述钢管外壳的钢卷原料放置于第一钢带放置架上,将初始状态的电潜泵线缆卷轴放置于放线架上,将用于隔离层的钢板带放置在第二钢带放置架上;将用于生产所述钢管外壳的钢卷原料的起始端依次经过钢管初步成型设备、放线架、第二钢带放置架、激光焊接设备、无损探伤设备、拉拔设备、牵引机后加工成套设在所述备用线缆上的钢管外壳,最后,复合有钢管外壳的成品电潜泵复合管缆通过第二收线架缠绕收卷,以备下个工序使用。
与现有技术相比,本发明的有益技术效果:
本发明电潜泵复合管缆,整体采用圆形结构,包括钢管外壳、钢带铠装层和隔离层,使线缆具有较高的强度,管缆内部设置有三根注剂管,其中电缆内直径较大的第一注剂管可加注冷却剂、清洗剂、防腐剂等注剂,有利于保证电缆的使用性能和使用寿命,直径较小的第二注剂管可加注液压油,提高了井内空间利用效率,有利于保证液压油稳定供给,并且减少了安全隐患;增加了钢管外壳,本身能够提供电潜泵所需要的拉力,同时外管能够有效的隔离侵入液体,同时钢管材料多种,可以有效的解决腐蚀等问题。该电潜泵复合管缆的制备方法,主要包括隔离层的制作和钢管外壳的加工成型两步,其中电潜泵线缆的初始状态的最外层为钢带铠装层,隔离层的设置,有效的保证了钢管外壳的加工过程中的安全性,尤其是在焊接工位,隔离层的设计避免能够隔离焊接的预热,防止焊接时产生烫伤问题。
附图说明
下面结合附图说明对本发明作进一步说明。
图1为本发明电潜泵复合管缆剖视图;
图2为本发明隔离层制备过程示意图一;
图3为本发明隔离层制备过程示意图二;
图4为本发明电潜泵复合管缆制备过程示意图一;
图5为本发明电潜泵复合管缆制备过程示意图二;
图6为本发明松紧调节装置结构示意图;
图7为本发明隔离层为钢板时轴侧示意图;
附图标记说明:1、钢管外壳;2、隔离层;3、乙丙护套;4、导体;5、烧结膜;6、乙丙绝缘层;7、F4膜;8、尼龙布层;9、第一注剂管;10、第二注剂管;11、松紧调节装置;12、放线架;13、绕包机;14、第一收线架;15、铠装机;16、牵引机;17、第一钢带放置架;18、钢管初步成型设备;19、激光焊接设备;20、无损探伤设备;21、拉拔设备;22、第二收线架;23、第二钢带放置架;24、第一定滑辊;25、调节辊;26、第二定滑辊;27、导向片。
具体实施方式
如图1所示,一种电潜泵复合管缆,包括钢管外壳1和隔离层2,所述隔离层2包裹在所述乙丙护套3的外周面上,所述钢管外壳1包裹在所述隔离层2的外周面上,所述隔离层2的内部设置有多根信号缆总成和多根注剂管,各所述信号缆总成和各所述注剂管设置于所述乙丙护套3的内部中心且交错布置。具体的,所述钢管外壳1的材质具体为2205不锈钢,所述钢管外壳具体为外径44.5mm,壁厚4mm的2205不锈钢连续长管。
具体的,所述信号缆总成和所述注剂管的数目具体设置为三根且交错布置;各所述信号缆总成均包括最内层的导体4,所述导体4的外侧设置有烧结膜5,所述烧结膜5的外侧设置有乙丙绝缘层6,所述乙丙绝缘层6的外侧设置有F4膜7,所述F4膜7的外侧设置有尼龙布层8;所述注剂管包括一根第一注剂管9和两根第二注剂管10,所述第一注剂管9的直径大于所述第二注剂管10的直径。具体的,导体4具体设置为裸铜导体,所述烧结膜具体设置为聚酰亚胺~F46膜。所述第一注剂管和第二注剂管的材质具体为825合金,其中,第一注剂管9为外径9.525mm,壁厚1.245mm的毛细管,用于加注冷却剂、清洗剂、防腐剂等注剂,第二注剂管10为外径6.35mm,壁厚1.245mm的毛细管,用于加注液压油便于潜油泵的液压控制。
具体的,所述隔离层2具体设置为尼龙带层、钢板或保护钢管。钢板或保护钢管具体可采用2205不锈钢。隔离层的设置进一步增强了复合管缆的强度,延长其使用寿命。尼龙带层制作的隔离层2的厚度为0.15~0.20mm,优先选用0.18mm,钢板作为隔离层的尺寸和厚度为1~2mm,保护钢管作为隔离层的厚度为1~2mm。
如图2~5所示,一种电潜泵复合管缆的制备方法,制作如上所述的电潜泵复合管缆的方法,具体包括以下步骤:
步骤一,隔离层2的制作:电潜泵线缆的初始状态的最外层为乙丙护套3,所述钢带铠装层2的内部设置有多根信号缆总成和多根注剂管,将所述隔离层2通过相应的加工设备设置在所述乙丙护套3的外周面上;
步骤二,钢管外壳1的加工成型:将用于生产所述钢管外壳1的钢卷原料放置于第一钢带放置架17上,将步骤一中包裹有所述隔离层2备用线缆放置于放线架12上,钢卷原料的起始端依次经过钢管初步成型设备18、放线架12、激光焊接设备19、无损探伤设备20、拉拔设备21、牵引机16后加工成套设在所述备用线缆上的钢管外壳1,最后,复合有钢管外壳1的成品电潜泵复合管缆通过第二收线架22缠绕收卷,以备下个工序使用。具体的,备用线缆的放线速度2m/min,钢卷原料的放料速度是2m/min,激光焊接的功率是5000w,焊接厚度为3~5mm,优先选用3.95mm。
如图2所示,所述步骤一中,当隔离层2设置为尼龙带层时,初始状态的电潜泵线缆卷轴放置在所述放线架12上,初始状态的电潜泵线缆起始端通过绕包机13形成包裹有尼龙带层的备用线缆,所述备用线缆通过第一收线架14缠绕收卷,以备下个工序使用。具体的,初始线缆的放线速度是5m/min,尼龙带层的厚度具体设置有0.15~2mm,优先选用0.18mm。
如图3所示,所述步骤一中,当隔离层2设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架12上,初始状态的电潜泵线缆起始端依次通过铠装机15、牵引机16形成包裹有保护钢管的备用线缆,所述备用线缆通过第一收线架14缠绕收卷,以备下个工序使用。所述保护钢管形成的隔离层2与所述所述乙丙护套3之间为空腔结构,具体的所述空腔结构的间隙值为0.3~0.5mm,防止焊接烫伤。初始线缆的放线速度是2m/min,保护钢管的厚度是1.17~1.2mm。
如图4所示,所述当隔离层2设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架12上,将用于生产所述隔离层2的钢卷原料放置于第一钢带放置架17上,钢卷原料的起始端依次经过钢管初步成型设备18、放线架12、激光焊接设备19、无损探伤设备20、拉拔设备21、牵引机16后加工成套设在初始状态线缆上的钢管结构隔离层,最后,复合有钢管结构隔离层的备用线缆通过第二收线架22缠绕收卷,以备下个工序;其中,经过所述激光焊接设备19时采用小功率激光焊接,焊接深度控制在80%~100%,保护钢管的厚度为0.2~0.5mm。小功率激光焊接功率为1000w,具体的初始线缆的放线速度是1~1.5m/min,保护钢管的厚度是1.17~1.20mm。
如图5所示,当所述隔离层2设置为钢板时,所述钢板粘结在所述乙丙护套3上,且位于所述钢管外壳1焊接成型时的激光焊接处的下方;复合时,将用于生产所述钢管外壳1的钢卷原料放置于第一钢带放置架17上,将初始状态的电潜泵线缆卷轴放置于放线架12上,将用于隔离层2的钢板带放置在第二钢带放置架23上;将用于生产所述钢管外壳1的钢卷原料的起始端依次经过钢管初步成型设备18、放线架12、第二钢带放置架23、激光焊接设备19、无损探伤设备20、拉拔设备21、牵引机16后加工成套设在所述备用线缆上的钢管外壳1,最后,复合有钢管外壳1的成品电潜泵复合管缆通过第二收线架22缠绕收卷,以备下个工序使用。具体的,如图7所示,初始线缆的放线速度是2m/min,钢板的尺寸宽15mm,厚度是1.17~1.2mm,通过导向片27将钢板压制在乙丙护套3上,形成沟槽,然后直接焊入,钢管外壳1牵拉后将钢板直接定位在了所述乙丙护套3的沟槽内。具体的,导向片27位于钢管初步成型设备18控制成型后的钢带的运行位置,防止焊接时偏移;同时具备一个新的功能,在作为隔离用钢板的表面压槽,使焊接时激光的余高能够在凹槽里面成型。
此外,隔离层也做成钢带铠装层,钢带铠装层的材质为316L不锈钢的S形铠装,且表面均匀密布有弧状凸起,其外径在35.70mm至36.50mm之间。加工方法采用如图4所述的生产线即可。
此外,如图6所示,所述放线架12、第一钢带放置架17、第二钢带放置架23的后侧设置有松紧调节装置11,所述松紧调节装置通过三个高度不等的滚轮组成,包括第一定滑辊24、调节辊25和第二定滑辊26,所述调节辊25通过定位销可转动的连接在安装架上,所述安装架上从上向下等间距布置有多个定位孔,所述定位销插入到不同高度的定位孔内,以调整中间、调节辊25的高度,从而快速的调整初始线缆、钢卷原料、备用线缆的松紧度。调节辊25的高度调整还可以通过气缸、油缸或电缸等竖直移动的动力工具驱动实现调节,气缸、油缸或电缸与整体设备的控制器电连接,实现自动化操作,操作方便快捷,省时省力,同时减轻工人的劳动强度。
以上所述的实施例仅是对本发明的优选方式进行描述,并非对本发明的范围进行限定,在不脱离本发明设计精神的前提下,本领域普通技术人员对本发明的技术方案做出的各种变形和改进,均应落入本发明权利要求书确定的保护范围内。
Claims (9)
1.一种电潜泵复合管缆,其特征在于:包括钢管外壳(1)和隔离层(2),所述隔离层(2)包裹在所述乙丙护套(3)的外周面上,所述钢管外壳(1)包裹在所述隔离层(2)的外周面上,所述隔离层(2)的内部设置有多根信号缆总成和多根注剂管,各所述信号缆总成和各所述注剂管设置于所述乙丙护套(3)的内部中心且交错布置。
2.根据权利要求1所述的电潜泵复合管缆,其特征在于:所述信号缆总成和所述注剂管的数目具体设置为三根且交错布置;各所述信号缆总成均包括最内层的导体(4),所述导体(4)的外侧设置有烧结膜(5),所述烧结膜(5)的外侧设置有乙丙绝缘层(6),所述乙丙绝缘层(6)的外侧设置有F4膜(7),所述F4膜(7)的外侧设置有尼龙布层(8);所述注剂管包括一根第一注剂管(9)和两根第二注剂管(10),所述第一注剂管(9)的直径大于所述第二注剂管(10)的直径。
3.根据权利要求1所述的电潜泵复合管缆,其特征在于:所述隔离层(2)具体设置为尼龙带层、钢板或保护钢管。
4.一种电潜泵复合管缆的制备方法,其特征在于:制作如权利要求1~3所述的电潜泵复合管缆的方法,具体包括以下步骤:
步骤一,隔离层(2)的制作:电潜泵线缆的初始状态的最外层为乙丙护套(3),所述隔离层(2)的内部设置有多根信号缆总成和多根注剂管,将所述隔离层(2)通过相应的加工设备设置在所述乙丙护套(3)的外周面上;
步骤二,钢管外壳(1)的加工成型:将用于生产所述钢管外壳(1)的钢卷原料放置于第一钢带放置架(17)上,将步骤一中包裹有所述隔离层(2)备用线缆放置于放线架(12)上,钢卷原料的起始端依次经过钢管初步成型设备(18)、放线架(12)、激光焊接设备(19)、无损探伤设备(20)、拉拔设备(21)、牵引机(16)后加工成套设在所述备用线缆上的钢管外壳(1),最后,复合有钢管外壳(1)的成品电潜泵复合管缆通过第二收线架(22)缠绕收卷,以备下个工序使用。
5.根据权利要求3所述的电潜泵复合管缆的制备方法,其特征在于:所述步骤一中,当隔离层(2)设置为尼龙带层时,初始状态的电潜泵线缆卷轴放置在所述放线架(12)上,初始状态的电潜泵线缆起始端通过绕包机(13)形成包裹有尼龙带层的备用线缆,所述备用线缆通过第一收线架(14)缠绕收卷,以备下个工序使用。
6.根据权利要求3所述的电潜泵复合管缆的制备方法,其特征在于:所述步骤一中,当隔离层(2)设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架(12)上,初始状态的电潜泵线缆起始端依次通过铠装机(15)、牵引机(16)形成包裹有保护钢管的备用线缆,所述备用线缆通过第一收线架(14)缠绕收卷,以备下个工序使用。
7.根据权利要求6所述的电潜泵复合管缆的制备方法,其特征在于:所述保护钢管形成的隔离层(2)与所述乙丙护套(3)之间设置为空腔结构。
8.根据权利要求3所述的电潜泵复合管缆的制备方法,其特征在于:所述当隔离层(2)设置为保护钢管时,初始状态的电潜泵线缆卷轴放置在所述放线架(12)上,将用于生产所述隔离层(2)的钢卷原料放置于第一钢带放置架(17)上,钢卷原料的起始端依次经过钢管初步成型设备(18)、放线架(12)、激光焊接设备(19)、无损探伤设备(20)、拉拔设备(21)、牵引机(16)后加工成套设在初始状态线缆上的钢管结构隔离层,最后,复合有钢管结构隔离层的备用线缆通过第二收线架(22)缠绕收卷,以备下个工序;其中,经过所述激光焊接设备(19)时采用小功率激光焊接,焊接深度控制在80%~100%,保护钢管的厚度为0.2~0.5mm。
9.根据权利要求3所述的电潜泵复合管缆的制备方法,其特征在于:当所述隔离层(2)设置为钢板时,所述钢板粘结在所述乙丙护套(3)上,且位于所述钢管外壳(1)焊接成型时的激光焊接处的下方;
复合时,将用于生产所述钢管外壳(1)的钢卷原料放置于第一钢带放置架(17)上,将初始状态的电潜泵线缆卷轴放置于放线架(12)上,将用于隔离层(2)的钢板带放置在第二钢带放置架(23)上;将用于生产所述钢管外壳(1)的钢卷原料的起始端依次经过钢管初步成型设备(18)、放线架(12)、第二钢带放置架(23)、激光焊接设备(19)、无损探伤设备(20)、拉拔设备(21)、牵引机(16)后加工成套设在所述备用线缆上的钢管外壳(1),最后,复合有钢管外壳(1)的成品电潜泵复合管缆通过第二收线架(22)缠绕收卷,以备下个工序使用。
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