GB2560563A - Method and system for use in manufacturing an insulated slickline - Google Patents

Method and system for use in manufacturing an insulated slickline Download PDF

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Publication number
GB2560563A
GB2560563A GB1704175.7A GB201704175A GB2560563A GB 2560563 A GB2560563 A GB 2560563A GB 201704175 A GB201704175 A GB 201704175A GB 2560563 A GB2560563 A GB 2560563A
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Prior art keywords
slickline
metallic
core
insulating polymer
polymer layer
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GB1704175.7A
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GB2560563B (en
GB201704175D0 (en
Inventor
Martin Van Der Ende André
Van Bruchem Lourens
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Paradigm Technology Services BV
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Paradigm Technology Services BV
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Classifications

    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof
    • D07B7/145—Coating or filling-up interstices
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B7/00—Details of, or auxiliary devices incorporated in, rope- or cable-making machines; Auxiliary apparatus associated with such machines
    • D07B7/02—Machine details; Auxiliary devices
    • D07B7/14—Machine details; Auxiliary devices for coating or wrapping ropes, cables, or component strands thereof
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B19/00—Handling rods, casings, tubes or the like outside the borehole, e.g. in the derrick; Apparatus for feeding the rods or cables
    • E21B19/08—Apparatus for feeding the rods or cables; Apparatus for increasing or decreasing the pressure on the drilling tool; Apparatus for counterbalancing the weight of the rods
    • E21B19/084—Apparatus for feeding the rods or cables; Apparatus for increasing or decreasing the pressure on the drilling tool; Apparatus for counterbalancing the weight of the rods with flexible drawing means, e.g. cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/14—Insulating conductors or cables by extrusion
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
    • D07B1/147—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising electric conductors or elements for information transfer
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B1/00—Constructional features of ropes or cables
    • D07B1/14—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable
    • D07B1/148—Ropes or cables with incorporated auxiliary elements, e.g. for marking, extending throughout the length of the rope or cable comprising marks or luminous elements
    • D—TEXTILES; PAPER
    • D07—ROPES; CABLES OTHER THAN ELECTRIC
    • D07B—ROPES OR CABLES IN GENERAL
    • D07B2501/00—Application field
    • D07B2501/40—Application field related to rope or cable making machines
    • D07B2501/406—Application field related to rope or cable making machines for making electrically conductive cables

Abstract

An insulated slickline is produced using a compression extrusion technique to apply an insulating polymer layer to a non-roughened surface of a metallic slickline core 4. The insulated slickline may be used for conducting oil or gas wellbore operations. The core may be polished prior to applying the polymer layer such as by electro-polishing 14. The core may be heated 22 before being passed through a compression extrusion die 24 with vacuum being applied to the die inlet. Plural insulating polymer layers may be applied in the same or different dies. The insulted slickline may be oriented vertically while tempering, heating 26 or cooling it. Some of the insulation may be removed or the insulation reshaped, reformed or compressed by passing through a heated reducing die (150, figure 3). A coating applied to the insulating polymer layer or the insulating polymer layer may comprise a composite comprising boron nitride or alumina particles, elongate calcium carbonate elements, whiskers, filaments and/or light-sensitive pigments, powders or particles.

Description

(54) Title of the Invention: Method and system for use in manufacturing an insulated slickline Abstract Title: Method and system for use in manufacturing an insulated Slickline (57) An insulated slickline is produced using a compression extrusion technique to apply an insulating polymer layer to a non-roughened surface of a metallic slickline core 4. The insulated slickline may be used for conducting oil or gas wellbore operations. The core may be polished prior to applying the polymer layer such as by electro-polishing 14. The core may be heated 22 before being passed through a compression extrusion die 24 with vacuum being applied to the die inlet. Plural insulating polymer layers may be applied in the same or different dies. The insulted slickline may be oriented vertically while tempering, heating 26 or cooling it. Some of the insulation may be removed or the insulation reshaped, reformed or compressed by passing through a heated reducing die (150, figure 3). A coating applied to the insulating polymer layer or the insulating polymer layer may comprise a composite comprising boron nitride or alumina particles, elongate calcium carbonate elements, whiskers, filaments and/or light-sensitive pigments, powders or particles.
Figure GB2560563A_D0001
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Figure GB2560563A_D0002
Figure 1
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Figure GB2560563A_D0003
C\J
Figure 2C Figure 2D
102 co
Figure GB2560563A_D0004
Figure 3
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Figure GB2560563A_D0005
Figure 4
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Figure GB2560563A_D0006
Figure 5
METHOD AND SYSTEM FOR USE IN MANUFACTURING AN INSULATED SLICKLINE
FIELD
The present invention relates to a method for use in manufacturing an insulated slickline for use, in particular though not exclusively, for conducting wellbore operations in an oil or gas well. The present invention also relates to a system for use in manufacturing an insulated slickline.
BACKGROUND
It is known to use slicklines for supporting and/or running downhole tools and equipment in oil and gas wells. For example, Figure 5 illustrates the use of a slickline 300 for supporting and/or running a downhole tool 302 in an oil or gas well 304 extending from a surface 306 into a subterranean formation 308. A wellhead arrangement 310 is located at the surface 306 at a head of the well 304. The slickline 300 is attached to the downhole tool 302 and extends to a surface unit 320 including a driven drum 322 at the surface 306 via the wellhead arrangement 310 and one or more sheaves 314. The wellhead arrangement 310 includes a stuffing box 316 which serves to provide one or more seals around the slickline 300 to seal an environment within the well 304 from an environment 312 surrounding the wellhead arrangement 310, whilst also permitting movement of the slickline 300 relative to the stuffing box 316 during wellbore operations.
In use, the drum 322 is driven so as to spool and/or unspool the slickline 300 around the sheaves 314 and through the stuffing box 316. The use of a slickline is generally preferred for simple wellbore operations over the use of more complex types of lines such as wirelines, cables, coiled tubing and the like because the use of a slickline generally requires simpler winching and sealing arrangements at the wellhead, making wellbore operations performed using slickline faster and more efficient than wellbore operations performed when using other more complex types of lines.
The slickline 300 may be a conventional slickline having a metallic core without insulation. Alternatively, the slickline 300 may be an insulated slickline having a metallic core surrounded by an insulating polymer layer to enable the uni- or bidirectional transmission of electrical signals between the downhole tool 302 and the surface unit 320 at limited data rates. Insulated slicklines may permit the real-time transmission of data from downhole tools and equipment to surface and/or the realtime control of the downhole tools and equipment from surface.
Known methods of manufacturing insulated slicklines involve roughening the surface of a metallic slickline core, applying an insulating polymer to the roughened metallic slickline core using a non-compression technique, heating the insulated slickline and then using rollers to shape and/or compress the insulating polymer around the metallic slickline core.
However, an insulated slickline manufactured using such known methods may not be sufficiently robust to reliably withstand the stresses associated with repeated movement of the insulated slickline around the sheaves 314 and through the stuffing box 316 during wellbore operations, especially in demanding wellbore environments such as high temperature, high pressure and/or corrosive wellbore environments. In particular, an insulated slickline manufactured using such known methods may not have sufficient geometrical precision, sufficient robustness and/or the electrical properties required for some demanding wellbore environments.
SUMMARY
It should be understood that any of the features of any one or more of the following aspects or embodiments may apply alone or in any combination in relation to any of the other aspects or embodiments.
According to an aspect or an embodiment of the present invention there is provided a method for use in manufacturing an insulated slickline comprising using a compression extrusion technique to apply an insulating polymer layer to a nonroughened surface of a metallic slickline core.
The metallic slickline core may comprise a metallic alloy such as an austenitic alloy.
The surface of the metallic slickline core may have a surface roughness parameter Ra of 0.05 to 0.90 pm, 0.10 to 0.80 pm or 0.25 to 0.60 pm.
The non-roughened surface of the metallic slickline core may have a surface finish grade of 1K, 2K, 1P or 2P under the EN 10088-2 standard for cold rolled stainless steel and preferably a surface finish grade of 2P under the EN 10088-2 standard for cold rolled stainless steel.
The non-roughened surface of the metallic slickline core may have a surface finish grade of 4, 6 or 7 under the ASTM standard A 480/A 480M, and preferably a surface finish grade of 7 under the ASTM standard A 480/A 480M.
Surprisingly, it has been found that applying an insulating polymer layer to a metallic slickline core having such a non-roughened or polished surface using a compression technique may lead to improved adhesion of the insulating polymer layer to the metallic slickline core. This is thought to be a consequence of reduced fracturing of the insulating polymer layer when applied in this way compared with known methods of manufacturing insulated slicklines which involve roughening the surface of a metallic slickline core, applying an insulating polymer to the roughened metallic slickline core using a non-compression technique, heating the insulated slickline and then using rollers to shape and/or compress the insulating polymer around the metallic slickline core. The increased adhesion of the insulating polymer layer to the metallic slickline core may allow the insulated slickline to reliably withstand the stresses to which the insulated slickline is exposed as the insulated slickline is repeatedly pulled around one or more sheaves and/or through a stuffing box during wellbore operations, especially in demanding wellbore environments such as high temperature, high pressure and/or corrosive wellbore environments.
The method may comprise removing material, for example a thickness of 2 to 40 μίτι and preferably 3 to 10 μίτι of material, from the surface of the metallic slickline core before applying the insulating polymer layer to the surface. Removing material in this way may serve to remove asperities present on the surface of the metallic slickline core or to reduce the degree of sharpness, reduce the degree of acuity and/or reduce or suppress some of the higher spatial frequencies associated with such asperities.
Removing material from the surface of the metallic slickline core may comprise polishing the surface of the metallic slickline core.
Polishing the surface of the metallic slickline core comprises electro-polishing and/or mechanically polishing the surface of the metallic slickline core.
Electro-polishing the surface of the metallic slickline core may comprise passing the metallic slickline core through an electrolyte, electrically coupling the metallic slickline core to form a first electrode, providing a second electrode which is exposed to the electrolyte and applying a voltage between the first and second electrodes and/or driving a current between the first and second electrodes.
Electro-polishing the surface of the metallic slickline core may comprise passing the metallic slickline core through the electrolyte at a speed of 1 to 20 m/min, preferably to 10 m/min. Electro-polishing the surface of the metallic slickline core may comprise applying a voltage of 12 - 18 V DC across the first and second electrodes. Electropolishing the surface of the metallic slickline core may comprise driving a current density of 50 - 240 mA/cm2 between the first and second electrodes. The electrolyte may comprise ortho-phosphoric acid and/or sulphuric acid. The electrolyte may have a temperature in the range of 40 to 60 °C.
Applying the insulating polymer layer to the surface of the metallic slickline core may comprise applying a molten polymer material under pressure to the metallic slickline core as the metallic slickline core passes through a compression extrusion die.
Applying the insulating polymer layer to the surface of the metallic slickline core may comprise preheating the metallic slickline core, for example using an IR oven or an induction heater, before passing the metallic slickline core through the compression extrusion die.
Applying the insulating polymer layer to the surface of the metallic slickline core may comprise reducing air pressure or applying a low vacuum to a slickline inlet of the compression extrusion die.
The method may comprise applying a plurality of insulating polymer layers to the metallic slickline core.
The method may comprise applying the plurality of insulating polymer layers to the metallic slickline core as the metallic slickline core passes through the same compression extrusion die.
The method may comprise applying different insulating polymer layers to the metallic slickline core as the metallic slickline core passes through different compression extrusion dies. The method may comprise orienting the metallic slickline core vertically during the application of the insulating polymer layer to the surface of the metallic slickline core. This may reduce the influence of gravity on the manufacturing process and lead to reduced eccentricity and/or ovality of the insulating polymer layer.
The method may comprise tempering, for example, heating and/or cooling the insulated slickline after applying the insulating polymer layer to the surface of the metallic slickline core. Tempering the insulated slickline may alter the structure of the insulating polymer. For example, tempering the insulated slickline may alter the crystalline state or level of crystallinity of the insulating polymer.
The method may comprise orienting the insulated slickline vertically during tempering, heating and/or cooling of the insulated slickline. This may reduce the influence of gravity on the manufacturing process and lead to reduced eccentricity and/or ovality of the insulating polymer layer.
The method may comprise reshaping, reforming and/or compressing the insulating polymer layer.
The method may comprise applying heat to the insulating polymer layer.
The method may comprise thermoforming the insulating polymer layer.
Reshaping, reforming and/or compressing the insulating polymer layer and/or thermoforming the insulating polymer layer may reduce thermally induced stresses formed in the insulating polymer layer during the application of the insulating polymer layer to the metallic slickline core during compression extrusion of the insulating polymer layer. This may serve to enhance adhesion of the insulating polymer layer to the to the metallic slickline core.
The method may comprise passing the insulated slickline through one or more heated reducing dies to reshape, reform and/or compress the insulating polymer layer.
The method may comprise removing some of the insulating polymer layer.
The method may comprise passing the insulated slickline through one or more heated reducing dies to remove some of the insulating polymer layer.
The method may comprise controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the reshaping, reforming and/or compressing of the insulating polymer layer. The configuration of the one or more apertures of the one or more reducing dies may include the size and/or shape of the one or more apertures of the one or more reducing dies.
The method may comprise monitoring one or more diameters of the insulated slickline at one or more outputs of the one or more reducing dies and controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the one or more diameters of the insulated slickline. The configuration of the one or more apertures of the one or more reducing dies may include the size and/or shape of the one or more apertures of the one or more reducing dies.
The method may comprise controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the removal of some of the insulating polymer layer. The configuration of the one or more apertures of the one or more reducing dies may include the size and/or shape of the one or more apertures of the one or more reducing dies.
The method may comprise monitoring a weight and/or a volume of polymer removed and controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the weight and/or volume of polymer removed. The configuration of the one or more apertures of the one or more reducing dies may include the size and/or shape of the one or more apertures of the one or more reducing dies.
The method may comprise applying an outer coating to an insulating polymer layer surface.
The insulating polymer layer and/or the outer coating may be formed from a composite material comprising a polymer material having one or more particles and/or one or more elongated elements, fibres, whiskers or filaments embedded therein.
The composite material may comprise the polymer material and boron nitride particles embedded in the polymer material. The boron nitride particles may be cubic boron nitride particles. The boron nitride particles may have a size between 0.05 to 1.25 μητ The boron nitride particles may be present in a concentration of >4wt%.
The composite material may comprise the polymer material and alumina particles embedded in the polymer material.
The composite material may comprise the polymer material and elongated calcium carbonate elements embedded in the polymer material. The calcium carbonate elements may comprise calcium carbonate whiskers. The calcium carbonate elements may have an aspect ratio in the range of 20 to 30.
The composite material may comprise the polymer material and one or more light-sensitive pigments, powders and particles.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may be configured to reduce a permeability of the one or more insulating polymer layers, the outer coating and/or the polymer material to a fluid such as a gas.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may be configured to be impermeable to a fluid such as a gas.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may be configured for abrasion resistance.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may be configured to reduce friction.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may be configured to reduce corrosion.
Any of the one or more insulating polymer layers, the outer coating and/or the polymer material may comprise PEEK or compounded PEEK.
The method may comprise cleaning the surface of the metallic slickline core before applying the insulating polymer layer to the surface.
Cleaning the surface of the metallic slickline core may comprise using a fluid such as air, water and/or a solvent to remove particulates, dirt and/or oil from the surface of the metallic slickline core. Cleaning the surface of the metallic slickline core may comprise treating the surface of the metallic slickline core with a plasma to remove particulates, dirt and/or oil from the surface of the metallic slickline core.
Cleaning the surface of the metallic slickline core may comprise exposing the surface of the metallic slickline core to ultrasonic waves.
The method may comprise sensing a slickline parameter and/or an environmental parameter during any of the steps of the method of slickline manufacture and controlling any of the steps of the method of slickline manufacture according to the sensed slickline parameter value and/or the sensed environmental parameter.
The slickline parameter may comprise at least one of slickline speed, slickline diameter, slickline surface roughness and slickline surface finish grade.
The environmental parameter may comprise at least one of temperature and pressure.
The method may comprise applying one or more markings, graphic symbols, text, numbers, codes, bar codes, and machine-readable codes to the insulating polymer layer or the outer coating.
The method may comprise applying the insulating polymer layer to the metallic slickline core in a first environment. The method may comprise preheating the metallic slickline core in the first environment. The method may comprise tempering the insulated slickline in the first environment.
The method may comprise performing a post-manufacturing treatment step in a second environment which is different to the first environment.
The post-manufacturing treatment step may comprise thermally curing the insulating polymer layer and/or outer coating.
The post-manufacturing treatment step may comprise using an autoclave to impregnate the insulating polymer layer and/or outer coating with a gas blocking or a gas scavenging substance.
The post-manufacturing treatment step may comprise irradiating the insulated slickline to alter a chain length or chain mobility of a polymer material of the insulating polymer layer and/or outer coating.
The metallic slickline core or the insulated coated slickline may have a diameter of 0.092”, 0.108”, 0.125”, 0.140”, 0.150”, 0.160” or 0.20”.
According to an aspect or an embodiment of the present invention there is provided a system for use in manufacturing an insulated slickline comprising:
a compression extrusion die for applying an insulating polymer layer to a nonroughened surface of a metallic slickline core under pressure as the metallic slickline core passes through the die.
The system may comprise an arrangement for removing material, preferably a thickness of 2 to 40 pm or 3 to 10 pm of material, from the surface of the metallic slickline core before applying the insulating polymer layer to the surface.
The arrangement for removing material from the surface of the metallic slickline core may be configured to polish the surface of the metallic slickline core.
The arrangement for removing material from the surface of the metallic slickline core may comprise an electro-polishing cell.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described by way of non-limiting example only with reference to the following drawings:
Figure 1 is a schematic of a first manufacturing system for an insulated slickline;
Figure 2A is a magnified longitudinal cross-section view of a surface region of an insulating slickline formed by applying an insulating polymer to a metallic slickline core having a rough or roughened surface;
Figure 2B is a magnified longitudinal cross-section view of a surface region of an insulating slickline formed by applying an insulating polymer to a metallic slickline core having a non-roughened surface such as a smooth or polished surface;
Figure 2C is a magnified longitudinal cross-section view of three different surfaces, each surface having the same value of surface roughness parameter Ra;
Figure 2D is a magnified longitudinal cross-section view of five different surfaces, each surface having the same value of surface roughness parameter Ra but a different surface finish grade;
Figure 3 is a schematic of a second manufacturing system for an insulated slickline;
Figure 4 is a schematic of a third manufacturing system for an insulated slickline; and
Figure 5 is a schematic of a slickline in use supporting and/or running a downhole tool in an oil or gas well.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring initially to Figure 1 there is provided a schematic of a first manufacturing system 1 for an insulated slickline 2 including a first reel or drum 6, a second reel or drum 8 and several intermediate wheels or sheaves 10. In use, a metallic slickline core 4 extends from the first reel or drum 6 to the second reel or drum 8.
The manufacturing system 1 includes a first cleaning stage 12, an electropolishing cell 14, a second cleaning stage 16, an ultrasonic cleaning stage 18, a drier 20, a preheater 22, a compression extrusion die 24, a tempering stage 26, a laser marker 28 and a caterpillar haul-off winch 29.
In use, the caterpillar haul-off winch 29 pulls the metallic slickline core 4 at a controlled rate causing the first reel or drum 6 at an input end of the manufacturing system 1 to unspool the metallic slickline core 4 and the second reel or drum 8 is driven to spool the insulated slickline 2 at an output end of the manufacturing system 1.
In the first cleaning stage 12, the metallic slickline core 4 is subjected to cleaning fluid, for example rinsed or exposed to a shower or curtain of cleaning fluid such as air, water and/or a solvent to remove any particulates and/or oil.
The electro-polishing cell 14 includes an electrolyte 30 in the form of a mix of ortho-phosphoric acid and sulphuric acid, an electrical contact 32 electrically coupled to the metallic slickline core 4 so that the metallic slickline core 4 may act as a first electrode, and a second electrode 34 which is exposed to the electrolyte 30. The second electrode 34 may be formed from a metal such as lead, copper or the like. The electro-polishing cell 14 further comprises an electrical source 36 such as a voltage source for applying a voltage between the first and second electrodes 4, 34 and/or driving a current between the first and second electrodes 4, 34. In use, the electrolyte 30 is heated to a temperature in the range 40 - 60 °C, the metallic slickline core 4 is passed through the electrolyte 30 at a speed of 1 - 20 m/min and preferably 5-10 m/min, and the electrical source 36 applies a voltage of 12 - 18 V DC and drives a current density of 50 - 240 mA/cm2 between the first and second electrodes 4, 34. This may result in removal of between 2 and 40 pm and preferably 3 to 10 pm of surface asperity from the surface of the metallic slickline core 4 as illustrated by the magnified view 37 of the surface of the metallic slickline core 4 before the electropolishing cell 14 and the magnified view 38 of the surface of the metallic slickline core 4 after the electro-polishing cell 14.
In the second cleaning stage 16, the metallic slickline core 4 is subjected to a cleaning fluid, for example rinsed or exposed to a shower or curtain of cleaning fluid such as air, water and/or a solvent to remove any particulates. The cleaning fluid may be configured to remove any excess electrolyte 30. The cleaning fluid may be configured to neutralise any excess electrolyte 30. For example, the cleaning fluid may include caustic soda. The metallic slickline core 4 is then subjected to ultrasonic cleaning in the ultrasonic cleaning stage 18 before being dried by the drier 20.
The cleaned polished metallic slickline core 4 is then heated to a predetermined temperature by preheater 22 before entering the compression extrusion die 24. A molten polymer 40 which includes molten PEEK or compounded PEEK is fed into the compression extrusion die 24 and is applied to the surface of the metallic slickline core 4 under pressure within the compression extrusion die 24 so as to form an insulating layer or jacket of polymer material around the metallic slickline core 4. A low vacuum may be applied at a slickline inlet of the compression extrusion die 24 so as to draw the molten polymer 40 towards the metallic slickline core 4 and promote adhesion between the surface of the metallic slickline core 4 and the polymer 40.
At tempering stage 26, the metallic slickline core 4 and the surrounding insulating polymer layer is subjected to controlled heating and/or cooling in an oven, fridge and/or autoclave to promote adhesion between the insulating polymer layer and the metallic slickline core 4 to provide the insulated slickline 2.
As shown in Figure 1, the manufacturing system 1 is configured so that the metallic slickline core 4 is arranged vertically during the application of the insulating polymer layer to the surface of the metallic slickline core 4 in the compression extrusion die 24 and during tempering. This reduces the influence of gravity on the manufacturing process and leads to reduced eccentricity and/or ovality of the insulating polymer layer.
The molten polymer 40 further includes an additional light-sensitive substance such as a light-sensitive pigment, powder or particles e.g. the molten polymer may be or may comprise an Iriotec 8000 series pigment. The laser marker 28 uses a suitable laser to write or apply one or more markings, graphic symbols, text, numbers, codes, bar codes, and machine-readable codes to the insulating polymer layer.
Without wishing to be bound by theory, it is believed that the use of known insulated slickline manufacturing methods which involve applying an insulating polymer layer 42 to a metallic slickline core 4 having a rough or roughened surface as shown in Figure 2A using a non-compression extrusion technique, heating the insulating polymer layer 42 and subsequently compressing the insulating polymer layer 42 using rollers, may actually be detrimental to the long-term adhesion of the insulating polymer layer 42 to the metallic slickline core 4 because the presence of sharp edge asperities 44 may lead to the formation of fractures 46 in the insulating polymer layer 42 as the insulated slickline is repeatedly pulled around one or more sheaves and/or through one or more seals of a stuffing box at a wellhead of an oil or gas well in and out of demanding wellbore environments such as high temperature, high pressure, corrosive wellbore environments during wellbore operations.
Surprisingly, it has been found that applying an insulating polymer layer 42 to a metallic slickline core 4 having a non-roughened or polished surface as shown in Figure 2B using a compression technique as described with reference to Figure 1 may lead to improved adhesion of the insulating polymer layer 42 to the metallic slickline core 4. Specifically, it has been found that, when used in conjunction with a compression extrusion technique, the use of a metallic slickline core 4 having a non12 roughened or polished surface with a surface roughness parameter Ra in the range of 0.05 to 0.90 pm and a surface finish grade of 1K, 2K, 1P or2P under the EN 10088-2 standard for cold rolled stainless steel or a surface finish grade of 4, 6 or 7 under the ASTM standard A 480/A 480M, may provide sufficient adhesion of the insulating polymer layer 42 to the metallic slickline core 4 to permit the insulated slickline 2 to be used for wellbore operations in demanding wellbore environments. For example, the metallic slickline core 4 may have a non-roughened or polished surface with a surface roughness parameter Ra in the range of 0.10 to 0.80 pm and preferably 0.25 to 0.60 pm. Preferably the metallic slickline core 4 may have a non-roughened or polished surface with a surface finish grade of 2P under the EN 10088-2 standard for cold rolled stainless steel or 7 under the ASTM standard A 480/A 480M.
One of ordinary skill in the art will understand that the roughness of the surface of the metallic slickline core 4 may be specified according to not only the size or amplitude of the variation in the radius of the metallic slickline core 4 as defined by the surface roughness parameter Ra but also in the spatial frequencies associated with the variation in the radius of the metallic slickline core 4 over the surface of the metallic slickline core 4 as defined by the surface finish grade. The difference between the surface roughness parameter Ra and the surface finish grade is illustrated with reference to Figures 2C and 2D. Specifically, the surfaces ‘a’, ‘b’ and ‘c’ of Figure 2C all have the same roughness parameter Ra, but each have a different surface finish grade. In particular, surface ‘a’ has sharp outward surface projections and surface ‘b’ has sharp inward surface recesses, whilst the surface features of surface ‘c’ may be considered to have a degree of sharpness which is intermediate between the sharpness of the surface features of surfaces ‘a’ and ‘b’. Similarly, Figure 2D is a schematic illustration of five different surfaces ‘a’, ‘b’, ‘c’, ‘d’ and ‘e’ all having the same roughness parameter Ra, but each have a different surface finish grade. Of the five different surfaces ‘a’ - ‘e’ of Figure 2D, the surface ‘a’ is preferred because of the reduced sharpness of the edge asperities of surface ‘a’ relative to the sharpness of the edge asperities of surfaces ‘b’ - ‘e’.
Referring to Figure 3 there is provided a schematic of a second manufacturing system 101 for an insulated slickline 102. As will be appreciated from Figure 3, the second manufacturing system 101 of Figure 3 shares many of the same features as the first manufacturing system 1 of Figure 1 and, in the interests of brevity, only the differences between the manufacturing system 101 of Figure 3 and the manufacturing system 1 of Figure 1 are described below.
Unlike the compression extrusion die 24 of the manufacturing system 1 of Figure 1, the manufacturing system 101 of Figure 3 includes a compression extrusion die 124 having first and second inlets for molten polymer. A first molten polymer 140a is fed into the first inlet and is applied to the surface of the metallic slickline core 4 under pressure within the compression extrusion die 124 so as to form a first insulating layer or jacket of polymer material around the metallic slickline core 4. A second molten polymer 140b is fed into the second inlet and is applied to the surface of the first insulating layer or jacket of polymer material under pressure within the compression extrusion die 124 so as to form an outer insulating layer or coating of polymer material around the first insulating layer or jacket of polymer material. A low vacuum may be applied at a slickline inlet of the compression extrusion die 124 so as to draw the molten polymers 140a, 140b towards the metallic slickline core 4 and promote adhesion between the metallic slickline core 4 and the polymer materials 140a, 140b. The polymers 140a, 140b may include the same polymer, for example, PEEK or compounded PEEK. Alternatively, the polymers 140a, 140b may be different polymers. In one embodiment, one of the first and second polymers 140a, 140b may include PEEK and the other of the first and second polymers 140a, 140b may include compounded PEEK.
The manufacturing system 101 of Figure 3 further includes a heated reducing die 150 which defines a calibrated aperture for the insulated slickline. In use, the insulated slickline is passed through the calibrated aperture to reshape, reform and/or compress the insulating polymer layer. The slickline diameter may be monitored at an outlet of the reducing die 150 and at least one of slickline speed, a configuration of the aperture and a temperature of the reducing die 150 controlled so as to control the slickline diameter after the reducing die 150. Using the reducing die 150 to thermoform the insulating polymer layers may reduce thermally-induced stress and improve adhesion between the insulating polymer layers and the metallic slickline core 4.
Any excess insulating polymer material may be removed as the insulated slickline is passed through the calibrated aperture of the reducing die 150 and the excess insulating polymer material collected in a receptacle 152. The weight and/or volume of polymer removed may be monitored and at least one of slickline speed, a configuration of the aperture and a temperature of the reducing die 150 controlled so as to control the weight and/or volume of polymer removed.
Referring to Figure 4 there is provided a schematic of a third manufacturing system 201 for an insulated slickline 202. As will be appreciated from Figure 4, the third manufacturing system 201 of Figure 4 shares many of the same features as the first manufacturing system 1 of Figure 1 and the second manufacturing system 101 of Figure 3. In the interests of brevity, only the differences between the manufacturing system 201 of Figure 4 and the manufacturing systems 1, 101 of Figures 1 and 3 are described below.
Unlike the compression extrusion die 124 of the manufacturing system 101 of Figure 3, the manufacturing system 201 of Figure 4 includes two separate compression extrusion dies 224a and 224b. The manufacturing system 201 of Figure 4 further includes two separate tempering stages 226a and 226b, each tempering stage 226a and 226b associated with a corresponding extrusion die 224a and 224b respectively.
Each compression extrusion die 224a, 224b has an inlet for molten polymer. A first molten polymer 240a is fed into the inlet of the first compression extrusion die 224a and is applied to the surface of the metallic slickline core 4 under pressure within the first compression extrusion die 224a so as to form a first insulating layer or jacket of polymer material around the metallic slickline core 4. A second molten polymer 240b is fed into the inlet of the second compression extrusion die 224b and is applied to the surface of the first insulating layer or jacket of polymer material under pressure within the second compression extrusion die 224b so as to form an outer insulating layer or coating of polymer material around the first insulating layer or jacket of polymer material. A low vacuum may be applied at a slickline inlet of one or both of the compression extrusion dies 224a, 224b so as to draw one or both of the molten polymers 240a, 240b towards the metallic slickline core 4 and promote adhesion between the metallic slickline core 4 and the polymer materials 240a, 240b. The polymers 240a, 240b may include the same polymer, for example, PEEK or compounded PEEK. Alternatively, the polymers 240a, 240b may be different polymers. In one embodiment, one of the first and second polymers 240a, 240b may include PEEK and the other of the first and second polymers 240a, 240b may include compounded PEEK.
One of ordinary skill in the art will appreciate that various modifications may be made to any of the foregoing insulated slickline manufacturing methods. For example, a slickline parameter and/or an environmental parameter may be sensed during any of the steps of the method of slickline manufacture and any of the steps of the method of slickline manufacture may be controlled according to the sensed slickline parameter value and/or the sensed environmental parameter. The slickline parameter may, for example, comprise at least one of slickline speed, slickline diameter, slickline surface roughness and slickline surface finish grade. The environmental parameter may comprise at least one of temperature and pressure.

Claims (36)

1. A method for use in manufacturing an insulated slickline comprising using a compression extrusion technique to apply an insulating polymer layer to a nonroughened surface of a metallic slickline core.
2. A method according to claim 1, wherein the non-roughened surface of the metallic slickline core has a surface roughness parameter Ra of 0.05 to 0.90 qm, 0.10 to 0.80 μηι or 0.25 to 0.60 μητ
3. A method according to claim 1 or 2, wherein the non-roughened surface of the metallic slickline core has a surface finish grade of 1K, 2K, 1P or 2P under the EN 10088-2 standard for cold rolled stainless steel or a surface finish grade of 4, 6 or 7 under the ASTM standard A 480/A 480M, and preferably a surface finish grade of 2P under the EN 10088-2 standard for cold rolled stainless steel or a surface finish grade of 7 under the ASTM standard A 480/A 480M.
4. A method according to any preceding claim, comprising removing material, for example a thickness of 2 to 40 μηι and preferably 3 to 10 μηι of material, from the surface of the metallic slickline core before applying the insulating polymer layer to the surface.
5. A method according to claim 4, wherein removing material from the surface of the metallic slickline core comprises polishing the surface of the metallic slickline core.
6. A method according to claim 5, wherein polishing the surface of the metallic slickline core comprises electro-polishing the surface of the metallic slickline core.
7. A method according to claim 6, wherein electro-polishing the surface of the metallic slickline core comprises:
passing the metallic slickline core through an electrolyte;
electrically coupling the metallic slickline core to form a first electrode;
providing a second electrode which is exposed to the electrolyte;
applying a voltage between the first and second electrodes and/or driving a current between the first and second electrodes; and at least one of:
passing the metallic slickline core through the electrolyte at a speed of 1 to 20 m/min, preferably 5 to 10 m/min;
applying a voltage of 12 - 18 V DC across the first and second electrodes; and driving a current density of 50 - 240 mA/cm2 between the first and second electrodes.
8. A method according to claim 7, wherein the electrolyte comprises orthophosphoric acid and/or sulphuric acid and/or wherein the electrolyte has a temperature in the range of 40 to 60 °C.
9. A method according to any preceding claim, wherein applying the insulating polymer layer to the surface of the metallic slickline core comprises applying a molten polymer material under pressure to the metallic slickline core as the metallic slickline core is passed through a compression extrusion die.
10. A method according to claim 9, wherein applying the insulating polymer layer to the surface of the metallic slickline core comprises at least one of:
preheating the metallic slickline core, for example using an IR oven or an induction heater, before passing the metallic slickline core through the compression extrusion die; and reducing air pressure or applying a low vacuum to a slickline inlet of the compression extrusion die.
11. A method according to any preceding claim, comprising applying a plurality of insulating polymer layers to the metallic slickline core.
12. A method according to claim 11, comprising applying the plurality of insulating polymer layers to the metallic slickline core as the metallic slickline core passes through the same compression extrusion die.
13. A method according to claim 11, comprising applying different insulating polymer layers to the metallic slickline core as the metallic slickline core passes through different compression extrusion dies.
14. A method according to any preceding claim, comprising orienting the metallic slickline core vertically during the application of the insulating polymer layer to the surface of the metallic slickline core.
15. A method according to any preceding claim, comprising tempering, for example, heating and/or cooling the insulated slickline after applying the insulating polymer layer to the surface of the metallic slickline core.
16. A method according to claim 15, comprising orienting the insulated slickline vertically during tempering, heating and/or cooling of the insulated slickline.
17. A method according to any preceding claim, comprising reshaping, reforming and/or compressing the insulating polymer layer.
18. A method according to any preceding claim, comprising removing some of the insulating polymer layer.
19. A method according to claim 17 or 18, comprising passing the insulated slickline through one or more heated reducing dies to reshape, reform and/or compress the insulating polymer layer and/or to remove some of the insulating polymer layer.
20. A method according to claim 19, comprising controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the reshaping, reforming and/or compressing of the insulating polymer layer.
21. A method according to claim 19 or 20, comprising monitoring one or more diameters of the insulated slickline at one or more outputs of the one or more reducing dies and controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the one or more diameters of the insulated slickline.
22. A method according to any one of claims 19 to 21, comprising controlling at least one of slickline speed, a configuration of an aperture of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the removal of some of the insulating polymer layer.
23. A method according to claim 22, comprising monitoring a weight and/or a volume of polymer removed and controlling at least one of slickline speed, a configuration of one or more apertures of the one or more reducing dies and one or more temperatures of the one or more reducing dies so as to control the weight and/or volume of polymer removed.
24. A method according to any preceding claim, comprising applying an outer coating to an insulating polymer layer surface.
25. A method according to claim 24, wherein the insulating polymer layer and/or the outer coating are formed from a composite material comprising a polymer material having one or more particles and/or one or more elongated elements, fibres, whiskers or filaments embedded therein.
26. A method according to claim 25, wherein the composite material comprises the polymer material and at least one of the following:
boron nitride particles embedded in the polymer material, and optionally, wherein the boron nitride particles are cubic boron nitride particles, and optionally, wherein the boron nitride particles have a size between 0.05 to 1.25 pm, and optionally, wherein the boron nitride particles are present in a concentration of >4wt%;
alumina particles embedded in the polymer material;
elongated calcium carbonate elements embedded in the polymer material, and optionally, wherein the calcium carbonate elements comprise calcium carbonate whiskers, and optionally, wherein the calcium carbonate elements have an aspect ratio in the range of 20 to 30; and one or more light-sensitive pigments, powders and particles.
27. A method according to any one of claims 24 to 26, wherein any of the one or more insulating polymer layers, the outer coating and/or the polymer material are configured to be impermeable to a gas, configured for abrasion resistance, and/or configured to reduce friction.
28. A method according to any one of claims 24 to 27, wherein any of the one or more insulating polymer layers, the outer coating and/or the polymer material comprises PEEK or compounded PEEK.
29. A method according to any preceding claim, comprising cleaning the surface of the metallic slickline core before applying the insulating polymer layer to the surface, optionally wherein cleaning the surface of the metallic slickline core comprises using a fluid such as air, water and/or a solvent to remove particulates, dirt and/or oil from the surface of the metallic slickline core, and optionally wherein cleaning the surface of the metallic slickline core comprises exposing the surface of the metallic slickline core to ultrasonic waves.
30. A method according to any preceding claim, comprising sensing a slickline parameter and/or an environmental parameter during any of the steps of the method of slickline manufacture and controlling any of the steps of the method of slickline manufacture according to the sensed slickline parameter value and/or the sensed environmental parameter, and optionally wherein the slickline parameter comprises at least one of slickline speed, slickline diameter, slickline surface roughness and slickline surface finish grade, and optionally wherein the environmental parameter comprises at least one of temperature and pressure.
31. A method according to any preceding claim, comprising applying one or more markings, graphic symbols, text, numbers, codes, bar codes, and machine-readable codes to the insulating polymer layer or the outer coating.
32. A method according to any preceding claim, comprising applying the insulating polymer layer to the metallic slickline core in a first environment, and performing a postmanufacturing treatment step in a second environment which is different to the first environment, wherein the post-manufacturing treatment step comprises at least one of:
thermally curing the insulating polymer layer and/or outer coating;
using an autoclave to impregnate the insulating polymer layer and/or outer coating with a gas blocking or a gas scavenging substance; and irradiating the insulated slickline to alter a chain length or chain mobility of a polymer material of the insulating polymer layer and/or outer coating.
33. A method according to any preceding claim, wherein the metallic slickline core or the insulated slickline has a diameter of 0.092”, 0.108”, 0.125”, 0.140”, 0.150”, 0.160” or 0.20”.
5
34. A system for use in manufacturing an insulated slickline comprising:
a compression extrusion die for applying an insulating polymer layer to a nonroughened surface of a metallic slickline core under pressure as the metallic slickline core passes through the die.
10
35. A system according to claim 34, comprising an arrangement for removing material, preferably a thickness of 2 to 40 pm or 3 to 10 pm of material, from the surface of the metallic slickline core before applying the insulating polymer layer to the surface.
15
36. A system according to claim 35, wherein the arrangement for removing material from the surface of the metallic slickline core is configured to polish the surface of the metallic slickline core, and optionally wherein the arrangement for removing material from the surface of the metallic slickline core comprises an electro-polishing cell.
Intellectual
Property
Office
Application No: GB1704175.7 Examiner: Tim James
GB1704175.7A 2017-03-16 2017-03-16 Method and system for use in manufacturing an insulated slickline Active GB2560563B (en)

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Application Number Priority Date Filing Date Title
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Application Number Priority Date Filing Date Title
GB1704175.7A GB2560563B (en) 2017-03-16 2017-03-16 Method and system for use in manufacturing an insulated slickline

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GB2560563A true GB2560563A (en) 2018-09-19
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CN111161924A (en) * 2020-04-08 2020-05-15 潍坊智新电子股份有限公司 A automation equipment for pencil processing

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US20060242824A1 (en) * 2005-04-29 2006-11-02 Varkey Joseph P Methods of manufacturing enhanced electrical cables
US20070000682A1 (en) * 2005-06-30 2007-01-04 Varkey Joseph P Electrical cables with stranded wire strength members
US20090038149A1 (en) * 2007-08-06 2009-02-12 Joseph Varkey Methods of Manufacturing Electrical Cables
US20120155813A1 (en) * 1995-09-28 2012-06-21 Fiberspar Corporation Composite Spoolable Tube

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US20120155813A1 (en) * 1995-09-28 2012-06-21 Fiberspar Corporation Composite Spoolable Tube
US20060242824A1 (en) * 2005-04-29 2006-11-02 Varkey Joseph P Methods of manufacturing enhanced electrical cables
US20070000682A1 (en) * 2005-06-30 2007-01-04 Varkey Joseph P Electrical cables with stranded wire strength members
US20090038149A1 (en) * 2007-08-06 2009-02-12 Joseph Varkey Methods of Manufacturing Electrical Cables

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN111161924A (en) * 2020-04-08 2020-05-15 潍坊智新电子股份有限公司 A automation equipment for pencil processing

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