US20180258710A1 - Downhole cables having extruded aluminum encapsulation layers - Google Patents
Downhole cables having extruded aluminum encapsulation layers Download PDFInfo
- Publication number
- US20180258710A1 US20180258710A1 US15/451,935 US201715451935A US2018258710A1 US 20180258710 A1 US20180258710 A1 US 20180258710A1 US 201715451935 A US201715451935 A US 201715451935A US 2018258710 A1 US2018258710 A1 US 2018258710A1
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- United States
- Prior art keywords
- downhole cable
- central core
- extruded aluminum
- cable
- downhole
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 229910052782 aluminium Inorganic materials 0.000 title claims abstract description 60
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims abstract description 60
- 238000005538 encapsulation Methods 0.000 title description 18
- 229910052751 metal Inorganic materials 0.000 claims abstract description 48
- 239000002184 metal Substances 0.000 claims abstract description 48
- 239000013307 optical fiber Substances 0.000 claims abstract description 12
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 11
- 239000010935 stainless steel Substances 0.000 claims description 5
- 229910001220 stainless steel Inorganic materials 0.000 claims description 5
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 4
- 239000004020 conductor Substances 0.000 description 10
- 229920000642 polymer Polymers 0.000 description 6
- 238000001125 extrusion Methods 0.000 description 5
- 238000009413 insulation Methods 0.000 description 4
- 238000000034 method Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004813 Perfluoroalkoxy alkane Substances 0.000 description 2
- 239000004696 Poly ether ether ketone Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229920000840 ethylene tetrafluoroethylene copolymer Polymers 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 229920011301 perfluoro alkoxyl alkane Polymers 0.000 description 2
- 229920006260 polyaryletherketone Polymers 0.000 description 2
- 229920002530 polyetherether ketone Polymers 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- QHSJIZLJUFMIFP-UHFFFAOYSA-N ethene;1,1,2,2-tetrafluoroethene Chemical group C=C.FC(F)=C(F)F QHSJIZLJUFMIFP-UHFFFAOYSA-N 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 229920002313 fluoropolymer Polymers 0.000 description 1
- 239000004811 fluoropolymer Substances 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- -1 polypropylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/20—Flexible or articulated drilling pipes, e.g. flexible or articulated rods, pipes or cables
- E21B17/206—Flexible or articulated drilling pipes, e.g. flexible or articulated rods, pipes or cables with conductors, e.g. electrical, optical
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B47/00—Survey of boreholes or wells
- E21B47/12—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling
- E21B47/13—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency
- E21B47/135—Means for transmitting measuring-signals or control signals from the well to the surface, or from the surface to the well, e.g. for logging while drilling by electromagnetic energy, e.g. radio frequency using light waves, e.g. infrared or ultraviolet waves
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4401—Optical cables
- G02B6/4415—Cables for special applications
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4401—Optical cables
- G02B6/4429—Means specially adapted for strengthening or protecting the cables
- G02B6/443—Protective covering
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
- G02B6/44—Mechanical structures for providing tensile strength and external protection for fibres, e.g. optical transmission cables
- G02B6/4479—Manufacturing methods of optical cables
- G02B6/4486—Protective covering
- G02B6/4488—Protective covering using metallic tubes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/441—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from alkenes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/44—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins
- H01B3/443—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds
- H01B3/445—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes vinyl resins; acrylic resins from vinylhalogenides or other halogenoethylenic compounds from vinylfluorides or other fluoroethylenic compounds
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/20—Metal tubes, e.g. lead sheaths
- H01B7/201—Extruded metal tubes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/20—Metal tubes, e.g. lead sheaths
- H01B7/205—Metal tubes, e.g. lead sheaths composed of aluminium
Definitions
- the present disclosure relates generally to downhole cables, and more particularly to downhole cables having extruded aluminum encapsulation layers.
- downhole cables may include electrical or optical sensors to monitor the well, or may be utilized to support and power equipment or tools connected to an end of the downhole cables.
- optical fibers may utilized for acoustic, strain, temperature, and/or pressure sensing. Such sensing can in some cases be distributed sensing, i.e. along the entire lengths of the fibers.
- Known downhole cables typically include insulated copper wire conductors or optical fiber-containing metal tubes that are belted to a certain diameter with a polymer layer and then processed into a metal pipe.
- the metal pipe can be very expensive depending on the material used. For example stainless steel and nickel-based alloys are frequently utilized, and these materials can be very expensive.
- the pipe is then jacketed with a polymer that is selected based on application. Because of the extreme, high temperature environments in which many downhole cables are utilized, the polymer jacket is typically formed from an expensive polymer such as a flouropolymer. Together, the pipe and jacket make such downhole cables extremely expensive and sometimes unaffordable for the industry.
- downhole cables which are relatively less expensive to produce while being suitably robust for their applications would be advantageous.
- a downhole cable in accordance with one embodiment of the present disclosure, includes a central core.
- the central core includes a metal tube having a plurality of optical fibers therein or a copper wire.
- the downhole cable further includes an extruded aluminum tube surrounding the central core.
- a downhole cable in accordance with another embodiment of the present disclosure, includes a central core.
- the central core includes a metal tube having a plurality of optical fibers therein or a copper wire.
- the downhole cable further includes an extruded aluminum tube surrounding and directly contacting the central core.
- the downhole cable has a maximum outer width of less than or equal to 12 millimeters.
- a downhole cable in accordance with another embodiment of the present disclosure, includes a central core.
- the central core includes a metal tube having a plurality of optical fibers therein or a copper wire.
- the downhole cable further includes an extruded aluminum tube surrounding the central core, and a metal pipe disposed between the central core and the extruded aluminum tube.
- the downhole cable has a maximum outer width of less than or equal to 12 millimeters.
- FIGS. 1-20 illustrate cross-sectional profile views of downhole cables in accordance with embodiments of the present disclosure.
- a downhole cable 10 in accordance with the present disclosure advantageously includes an aluminum encapsulation layer 12 .
- the encapsulation layer 12 surrounds various core components of the downhole cable 10 , such as a central core (which may include optical fibers and/or copper wire, thus providing optical and/or electrical conduction), an optional metal pipe, and an optional belting layer. Further, in some embodiments, the belting layer may additionally be formed from aluminum.
- the aluminum encapsulation layer 12 and optional belting layer may be extruded aluminum layers.
- extruded aluminum layers provide numerous advantages for downhole cables 10 in accordance with the present disclosure.
- the use of aluminum, and in particular extruded aluminum provides significant cost-savings, reducing the overall cost of the downhole cable 10 and providing a robust, cost-effective downhole cable 10 to the relevant industries.
- the use of extruded aluminum allows for formation (via the extrusion process to a wide variety of shapes and volumes, thus advantageously providing improved and an increased number of downhole cable designs 10 .
- the use of aluminum advantageously provides a hydrogen barrier in downhole cables 10 , thus providing improved downhole cable 10 performance.
- Aluminum encapsulation layer 12 and optional belting layer may be extruded using a suitable aluminum extrusion process.
- an aluminum rod may be heated and provided to an extrusion die.
- the extrusion die may include a mandrel therein, and the die and associated mandrel may be utilized to form the aluminum rod into an extruded aluminum tube.
- the formed tube may have the desired shape and size for a desired downhole cable 10 application, or additional post-processing may be performed to adjust the formed tube to the desired shape and size.
- the use of extrusion processes and extruded aluminum tubes in accordance with the present disclosure is particularly advantageous due to the wide variety of available shapes and sizes, the relatively tight tolerances and high accuracies available, and the significant associated cost savings.
- a cable 10 may include, for example, a central core 20 .
- Central core 20 may, for example, have a maximum diameter 21 of less than or equal to 4.6 millimeters, such as less than or equal to 4.4 millimeters, such as less than or equal to 4.2 millimeters, such as between 4.4 millimeters and 2.2 millimeters, such as between 4.2 and 2.4 millimeters.
- the central core 20 may, in some embodiments as illustrated in FIGS. 1 through 10 , include a metal tube 22 . In these embodiments, an outer surface of metal tube 22 may define the maximum diameter 21 .
- One or more optical fibers 24 may be disposed within metal tube 22 .
- one or more copper wires or other suitable electrical conductors may be disposed within metal tube 22 .
- Such conductor 26 may include an inner conductor core 27 , and may further include an outer insulation layer 28 .
- Metal tube 22 may, for example, be formed from a stainless steel or a nickel alloy. Alternatively, other suitable metals may be utilized. In some embodiments, metal tube 22 may further include a gel disposed therein. Alternatively, no gel may be included. Further, in alternative embodiments, the metal tube 22 may be an open tube, thus being empty other than the optical fibers 24 and optional conductor(s) 26 .
- the central core 20 may include a single copper wire or other suitable electrical conductor (which may for example be a metal wire) 26 , and an outer surface of this single conductor may define the maximum diameter 21 .
- Such conductor 26 may include an inner conductor core 27 , and may further include an outer insulation layer 28 .
- the outer surface which defines the maximum diameter 21 may be the outer surface of the core 27 if no insulation layer is provided, or may be an outer surface of the outer insulation layer 28 .
- aluminum tube 12 (which in exemplary embodiments is an extruded aluminum tube as discussed herein) surrounds the central core 20 .
- the aluminum tube 12 may directly contact the central core 20 , such as the outer surface of the metal tube 22 or the outer surface of the electrical conductor 26 .
- cable 10 may further include a metal pipe 30 .
- the metal pipe 30 may be disposed between the central core 20 and the aluminum tube 12 .
- Metal pipe 30 may, for example, be formed from a stainless steel or a nickel alloy. Alternatively, other suitable metals may be utilized.
- Metal pipe 30 may have a maximum diameter 31 of less than or equal to 6.45 millimeters, such as less than 6.43 millimeters, such as less than or equal to 6.42 millimeters, such as between 6,43 and 6.37 millimeters, such as between 6.42 and 6.38 millimeters, such as between 6.41 and 6.39 millimeters.
- an empty space may be defined between the metal pipe 30 and the central core 20 (such as the outer surface thereof).
- the metal pipe 30 may contact the outer surface of the central core 20 .
- a belting layer may be provided between the metal pipe 30 and central core 20 .
- the aluminum tube 12 may be a first aluminum tube of the cable 10
- the cable 10 may further include a second aluminum tube 32 (which in exemplary embodiments is extruded as discussed herein).
- the second aluminum tube 32 may be disposed between the metal pipe 30 and the central core 20 , and may further be in direct contact with an outer surface of the central core 20 and an inner surface of the metal pipe 30 .
- the belting layer may be formed from another suitable material such as a suitable polymer or another suitable metal.
- Downhole cable 10 may have an outermost exterior surface 14 .
- Such surface 14 defines a maximum outer width 15 (which may in some embodiments be a maximum outer diameter) of the cable 10 .
- the aluminum tube 12 may include the outermost exterior surface 14 of the cable 10 and thus define the maximum outer width 15 .
- an encapsulation layer 40 may surround the aluminum tube 12 . The encapsulation layer 40 may directly contact the aluminum tube 12 . Further, the encapsulation layer 40 may include the outermost exterior surface 14 of the cable 10 and thus define the maximum outer width 15 .
- Encapsulation layer 40 may be formed from a suitable plastic.
- encapsulation layer 40 may be formed from a polypropylene.
- encapsulation layer 40 may be formed from a fluoropolymer, such as perfluoroalkoxy alkane (“PFA”),
- encapsulation layer 40 may be formed from a polyaryletherketone (“PAEK”), such as polyether ether ketone (“PEEK”).
- PAEK polyaryletherketone
- PEEK polyether ether ketone
- encapsulation layer 40 may be formed from ethylene tetrafluoroethylene (“ETFE”).
- ETFE ethylene tetrafluoroethylene
- Downhole cables 10 in accordance with the present disclosure may have a wide variety of shapes and sizes.
- the downhole cable 10 has a circular cross-sectional profile.
- each layer i.e. the aluminum tube 12 , central core 20 , metal pipe 30 , second aluminum tube 32 , and/or encapsulation layer 40
- cable 10 has a square cross-sectional profile.
- one or more layers of the cable 10 may have square cross-sectional profiles, while one or more other layers of the cable 10 may have circular cross-sectional profiles.
- the aluminum tube 12 defines the maximum outer width 15 .
- the aluminum tube 12 has a circular cross-sectional profile.
- the central core 20 and optional metal pipe 30 and second aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles.
- the aluminum tube 12 has a square cross-sectional profile.
- the central core 20 and optional metal pipe 30 and second aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles.
- the encapsulation layer 40 may define the maximum outer width 15 . In some of these embodiments, as shown in FIGS.
- the encapsulation layer 40 has a circular cross-sectional profile.
- the central core 20 , aluminum tube 12 , and optional metal pipe 30 and second aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles.
- the encapsulation layer 40 has a square cross-sectional profile.
- the central core 20 and optional metal pipe 30 and second aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles.
- the aluminum tube 12 may have a circular cross-sectional profile, while in other embodiments, as shown in FIGS. 3, 6, 13, and 16 , the aluminum tube 12 may have a square cross-sectional profile.
- the maximum outer width 15 may be less than or equal to 12 millimeters, such as less than or equal to 11.5 millimeters, such as between 12 millimeters and 10 millimeters, such as between 11.5 millimeters and 10.5 millimeters.
- width refers to, in the case of a circular or oval cross-sectional profile, the maximum diameter, and in the case of a square or rectangular cross-sectional profile, the maximum conventional width from side to opposite side, excluding diagonal measurements.
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Abstract
A downhole cable includes a central core. The central core includes a metal tube having a plurality of optical fibers therein or a copper wire. The downhole cable further includes an extruded aluminum tube surrounding the central core.
Description
- The present disclosure relates generally to downhole cables, and more particularly to downhole cables having extruded aluminum encapsulation layers.
- In industries such as the oil and gas industry, wells are utilized to provide access to raw materials. A variety of cables may be utilized in the wells, and various of these cables, termed downhole cables, may perform specified functions. For example, downhole cables may include electrical or optical sensors to monitor the well, or may be utilized to support and power equipment or tools connected to an end of the downhole cables. In some cases, for example, optical fibers may utilized for acoustic, strain, temperature, and/or pressure sensing. Such sensing can in some cases be distributed sensing, i.e. along the entire lengths of the fibers.
- Known downhole cables typically include insulated copper wire conductors or optical fiber-containing metal tubes that are belted to a certain diameter with a polymer layer and then processed into a metal pipe. The metal pipe can be very expensive depending on the material used. For example stainless steel and nickel-based alloys are frequently utilized, and these materials can be very expensive. The pipe is then jacketed with a polymer that is selected based on application. Because of the extreme, high temperature environments in which many downhole cables are utilized, the polymer jacket is typically formed from an expensive polymer such as a flouropolymer. Together, the pipe and jacket make such downhole cables extremely expensive and sometimes unaffordable for the industry.
- Accordingly, improved downhole cables are desired in the art. In particular, downhole cables which are relatively less expensive to produce while being suitably robust for their applications would be advantageous.
- Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.
- In accordance with one embodiment of the present disclosure, a downhole cable is provided. The downhole cable includes a central core. The central core includes a metal tube having a plurality of optical fibers therein or a copper wire. The downhole cable further includes an extruded aluminum tube surrounding the central core.
- In accordance with another embodiment of the present disclosure, a downhole cable is provided. The downhole cable includes a central core. The central core includes a metal tube having a plurality of optical fibers therein or a copper wire. The downhole cable further includes an extruded aluminum tube surrounding and directly contacting the central core. The downhole cable has a maximum outer width of less than or equal to 12 millimeters.
- In accordance with another embodiment of the present disclosure, a downhole cable is provided. The downhole cable includes a central core. The central core includes a metal tube having a plurality of optical fibers therein or a copper wire. The downhole cable further includes an extruded aluminum tube surrounding the central core, and a metal pipe disposed between the central core and the extruded aluminum tube. The downhole cable has a maximum outer width of less than or equal to 12 millimeters.
- These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.
- A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:
-
FIGS. 1-20 illustrate cross-sectional profile views of downhole cables in accordance with embodiments of the present disclosure. - Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
- Referring now to
FIGS. 1-20 , various embodiments ofdownhole cables 10 in accordance with the present disclosure are provided. Adownhole cable 10 in accordance with the present disclosure advantageously includes analuminum encapsulation layer 12. Theencapsulation layer 12 surrounds various core components of thedownhole cable 10, such as a central core (which may include optical fibers and/or copper wire, thus providing optical and/or electrical conduction), an optional metal pipe, and an optional belting layer. Further, in some embodiments, the belting layer may additionally be formed from aluminum. - More particularly, in exemplary embodiments as discussed herein, the
aluminum encapsulation layer 12 and optional belting layer may be extruded aluminum layers. Use of extruded aluminum layers provided numerous advantages fordownhole cables 10 in accordance with the present disclosure. For example, the use of aluminum, and in particular extruded aluminum, provides significant cost-savings, reducing the overall cost of thedownhole cable 10 and providing a robust, cost-effective downhole cable 10 to the relevant industries. Further, the use of extruded aluminum allows for formation (via the extrusion process to a wide variety of shapes and volumes, thus advantageously providing improved and an increased number ofdownhole cable designs 10. Still further, the use of aluminum advantageously provides a hydrogen barrier indownhole cables 10, thus providing improveddownhole cable 10 performance. -
Aluminum encapsulation layer 12 and optional belting layer may be extruded using a suitable aluminum extrusion process. For example, an aluminum rod may be heated and provided to an extrusion die. The extrusion die may include a mandrel therein, and the die and associated mandrel may be utilized to form the aluminum rod into an extruded aluminum tube. The formed tube may have the desired shape and size for a desireddownhole cable 10 application, or additional post-processing may be performed to adjust the formed tube to the desired shape and size. The use of extrusion processes and extruded aluminum tubes in accordance with the present disclosure is particularly advantageous due to the wide variety of available shapes and sizes, the relatively tight tolerances and high accuracies available, and the significant associated cost savings. - A
cable 10 may include, for example, acentral core 20.Central core 20 may, for example, have amaximum diameter 21 of less than or equal to 4.6 millimeters, such as less than or equal to 4.4 millimeters, such as less than or equal to 4.2 millimeters, such as between 4.4 millimeters and 2.2 millimeters, such as between 4.2 and 2.4 millimeters. Thecentral core 20 may, in some embodiments as illustrated inFIGS. 1 through 10 , include ametal tube 22. In these embodiments, an outer surface ofmetal tube 22 may define themaximum diameter 21. One or moreoptical fibers 24 may be disposed withinmetal tube 22. Further, in some embodiments, one or more copper wires or other suitable electrical conductors (which may for example be metal wires) 26 may be disposed withinmetal tube 22.Such conductor 26 may include aninner conductor core 27, and may further include anouter insulation layer 28. -
Metal tube 22 may, for example, be formed from a stainless steel or a nickel alloy. Alternatively, other suitable metals may be utilized. In some embodiments,metal tube 22 may further include a gel disposed therein. Alternatively, no gel may be included. Further, in alternative embodiments, themetal tube 22 may be an open tube, thus being empty other than theoptical fibers 24 and optional conductor(s) 26. - In other embodiments as illustrated in
FIGS. 11 through 20 , thecentral core 20 may include a single copper wire or other suitable electrical conductor (which may for example be a metal wire) 26, and an outer surface of this single conductor may define themaximum diameter 21.Such conductor 26 may include aninner conductor core 27, and may further include anouter insulation layer 28. The outer surface which defines themaximum diameter 21 may be the outer surface of the core 27 if no insulation layer is provided, or may be an outer surface of theouter insulation layer 28. - As shown, aluminum tube 12 (which in exemplary embodiments is an extruded aluminum tube as discussed herein) surrounds the
central core 20. In some embodiments, as illustrated inFIGS. 4-6, 9-10, 14-16, and 19-20 , thealuminum tube 12 may directly contact thecentral core 20, such as the outer surface of themetal tube 22 or the outer surface of theelectrical conductor 26. In alternative embodiments, as illustrated inFIGS. 1-3, 7-8, 11-13, and 17-18 ,cable 10 may further include ametal pipe 30. Themetal pipe 30 may be disposed between thecentral core 20 and thealuminum tube 12.Metal pipe 30 may, for example, be formed from a stainless steel or a nickel alloy. Alternatively, other suitable metals may be utilized.Metal pipe 30 may have a maximum diameter 31 of less than or equal to 6.45 millimeters, such as less than 6.43 millimeters, such as less than or equal to 6.42 millimeters, such as between 6,43 and 6.37 millimeters, such as between 6.42 and 6.38 millimeters, such as between 6.41 and 6.39 millimeters. - In some embodiments, an empty space may be defined between the
metal pipe 30 and the central core 20 (such as the outer surface thereof). In alternative embodiments, themetal pipe 30 may contact the outer surface of thecentral core 20. In other alternative embodiments, a belting layer may be provided between themetal pipe 30 andcentral core 20. For example, in exemplary embodiments as shown inFIGS. 1-3, 7-8, 11-13, and 17-18 , thealuminum tube 12 may be a first aluminum tube of thecable 10, and thecable 10 may further include a second aluminum tube 32 (which in exemplary embodiments is extruded as discussed herein). Thesecond aluminum tube 32 may be disposed between themetal pipe 30 and thecentral core 20, and may further be in direct contact with an outer surface of thecentral core 20 and an inner surface of themetal pipe 30. Alternatively, however, the belting layer may be formed from another suitable material such as a suitable polymer or another suitable metal. -
Downhole cable 10 may have an outermostexterior surface 14.Such surface 14 defines a maximum outer width 15 (which may in some embodiments be a maximum outer diameter) of thecable 10. In some embodiments, as shown inFIGS. 7-10 and 17-20 , thealuminum tube 12 may include the outermostexterior surface 14 of thecable 10 and thus define the maximumouter width 15. In other embodiments, as illustrated inFIGS. 1-6 and 11-16 , anencapsulation layer 40 may surround thealuminum tube 12. Theencapsulation layer 40 may directly contact thealuminum tube 12. Further, theencapsulation layer 40 may include the outermostexterior surface 14 of thecable 10 and thus define the maximumouter width 15.Encapsulation layer 40 may be formed from a suitable plastic. For example, in some embodiments,encapsulation layer 40 may be formed from a polypropylene. Alternatively,encapsulation layer 40 may be formed from a fluoropolymer, such as perfluoroalkoxy alkane (“PFA”), Alternatively,encapsulation layer 40 may be formed from a polyaryletherketone (“PAEK”), such as polyether ether ketone (“PEEK”). Alternatively,encapsulation layer 40 may be formed from ethylene tetrafluoroethylene (“ETFE”). Alternatively, other suitable polymers may be utilized. -
Downhole cables 10 in accordance with the present disclosure may have a wide variety of shapes and sizes. The use of extruded aluminum tube, in particular, advantageously facilitates the ease of formation of accurately sized and shapescables 10 in accordance with consumer demands. - For example, in some embodiments, as shown in
FIGS. 1, 4, 7, 9, 11, 14, 17, and 19 , thedownhole cable 10 has a circular cross-sectional profile. For example, in exemplary embodiments, each layer (i.e. thealuminum tube 12,central core 20,metal pipe 30,second aluminum tube 32, and/or encapsulation layer 40), may have a circular cross-sectional profile. In other embodiments, as shown inFIGS. 2, 3, 5, 6, 8, 10, 12, 13, 15, 16, 18, and 20 ,cable 10 has a square cross-sectional profile. In these embodiments, one or more layers of thecable 10 may have square cross-sectional profiles, while one or more other layers of thecable 10 may have circular cross-sectional profiles. For example, as discussed, in some embodiments, thealuminum tube 12 defines the maximumouter width 15. In some of these embodiments, as shown inFIGS. 7, 9, 17, and 19 , thealuminum tube 12 has a circular cross-sectional profile. Thecentral core 20 andoptional metal pipe 30 andsecond aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles. In other of these embodiments, as shown inFIGS. 8, 10, 18, and 19 , thealuminum tube 12 has a square cross-sectional profile. Thecentral core 20 andoptional metal pipe 30 andsecond aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles. In other embodiments, as discussed, theencapsulation layer 40 may define the maximumouter width 15. In some of these embodiments, as shown inFIGS. 1, 4, 11 , and 14, theencapsulation layer 40 has a circular cross-sectional profile. Thecentral core 20,aluminum tube 12, andoptional metal pipe 30 andsecond aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles. In other of these embodiments, as shown inFIGS. 2, 3, 5, 6, 12, 13, 15, and 16 , theencapsulation layer 40 has a square cross-sectional profile. Thecentral core 20 andoptional metal pipe 30 andsecond aluminum tube 32 may, in these embodiments, have circular cross-sectional profiles. In some of these embodiments, as shown inFIGS. 2, 3, 12, and 15 , thealuminum tube 12 may have a circular cross-sectional profile, while in other embodiments, as shown inFIGS. 3, 6, 13, and 16 , thealuminum tube 12 may have a square cross-sectional profile. - As discussed,
cable 10 is a downhole cable. Accordingly,cable 10 may be sized for such downhole applications. In exemplary embodiments, for example, the maximumouter width 15 may be less than or equal to 12 millimeters, such as less than or equal to 11.5 millimeters, such as between 12 millimeters and 10 millimeters, such as between 11.5 millimeters and 10.5 millimeters. It should be noted that “width” as utilized herein refers to, in the case of a circular or oval cross-sectional profile, the maximum diameter, and in the case of a square or rectangular cross-sectional profile, the maximum conventional width from side to opposite side, excluding diagonal measurements. - This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.
Claims (20)
1. A downhole cable, comprising:
a central core, the central core comprising a first metal tube having a plurality of optical fibers therein or a copper wire therein;
a first extruded aluminum tube surrounding the central core;
a second metal tube surrounding the first extruded aluminum tube; and
a second extruded aluminum tube surrounding the second metal tube, wherein the second extruded aluminum tube comprises an outermost exterior surface of the cable.
2. The downhole cable of claim 1 , wherein the downhole cable has a maximum outer width of less than or equal to 12 millimeters.
3. The downhole cable of claim 1 , wherein the downhole cable has a circular cross-sectional profile.
4. The downhole cable of claim 1 , wherein the downhole cable has a square cross-sectional profile.
5. The downhole cable of claim 1 , wherein the first extruded aluminum tube directly contacts the central core.
6-9. (canceled)
10. The downhole cable of claim 1 , wherein each of the first metal tube and the second metal tube comprises a stainless steel or a nickel alloy.
11. (canceled)
12. A downhole cable, comprising:
a central core, the central core comprising a first metal tube having a plurality of optical fibers therein or a copper wire therein;
a first extruded aluminum tube surrounding and directly contacting the central core,
second metal tube surrounding and directly contacting the first extruded aluminum tube; and
a second extruded aluminum tube surrounding and directly contacting the second metal tube;
wherein the second extruded aluminum tube comprises an outermost exterior surface of the cable and the downhole cable has a maximum outer width of less than or equal to 12 millimeters.
13. The downhole cable of claim 12 , wherein the downhole cable has a circular cross-sectional profile.
14. The downhole cable of claim 12 , wherein the downhole cable has a square cross-sectional profile.
15. (canceled)
16. (canceled)
17. A downhole cable, comprising:
a central core, the central core comprising a first metal tube having a plurality of optical fibers therein or a copper wire therein;
a first extruded aluminum tube surrounding the central core;
a metal pipe disposed between the central core and the first extruded aluminum tube; and
a second extruded aluminum disposed between the metal pip and the first extruded aluminum tube;
wherein the first extruded aluminum tube comprises an outermost exterior surface of the cable and the downhole cable has a maximum outer width of less than or equal to 12 millimeters.
18. The downhole cable of claim 17 , wherein the downhole cable has a circular cross-sectional profile.
19. The downhole cable of claim 17 , wherein the downhole cable has a square cross-sectional profile.
20. (canceled)
21. (canceled)
22. The downhole cable of claim 17 , wherein the metal pipe comprises a stainless steel or a nickel alloy.
23. (canceled)
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15/451,935 US20180258710A1 (en) | 2017-03-07 | 2017-03-07 | Downhole cables having extruded aluminum encapsulation layers |
PCT/US2018/019084 WO2018164842A1 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
CA3054059A CA3054059A1 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
US16/491,918 US11536096B2 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US15/451,935 US20180258710A1 (en) | 2017-03-07 | 2017-03-07 | Downhole cables having extruded aluminum encapsulation layers |
Related Child Applications (1)
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US16/491,918 Continuation US11536096B2 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
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US20180258710A1 true US20180258710A1 (en) | 2018-09-13 |
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US15/451,935 Abandoned US20180258710A1 (en) | 2017-03-07 | 2017-03-07 | Downhole cables having extruded aluminum encapsulation layers |
US16/491,918 Active 2037-10-31 US11536096B2 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
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US16/491,918 Active 2037-10-31 US11536096B2 (en) | 2017-03-07 | 2018-02-22 | Downhole cables having extruded aluminum encapsulation layers |
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US (2) | US20180258710A1 (en) |
CA (1) | CA3054059A1 (en) |
WO (1) | WO2018164842A1 (en) |
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WO2022236759A1 (en) * | 2021-05-10 | 2022-11-17 | 信达科创(唐山)石油设备有限公司 | Packaging tube cable having color recognition tape and preparation method therefor |
Families Citing this family (2)
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EP4295189A1 (en) | 2021-02-18 | 2023-12-27 | CommScope Technologies LLC | Communications panel system |
US11971598B2 (en) | 2021-02-18 | 2024-04-30 | Commscope Technologies Llc | Tray arrangements for cassettes |
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JPS54134449A (en) * | 1978-04-11 | 1979-10-18 | Kokusai Denshin Denwa Co Ltd | Photoofiber submarine cable |
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WO2004066000A2 (en) * | 2003-01-15 | 2004-08-05 | Sabeus Photonics, Inc. | System and method for deploying an optical fiber in a well |
US7646953B2 (en) | 2003-04-24 | 2010-01-12 | Weatherford/Lamb, Inc. | Fiber optic cable systems and methods to prevent hydrogen ingress |
US7024081B2 (en) * | 2003-04-24 | 2006-04-04 | Weatherford/Lamb, Inc. | Fiber optic cable for use in harsh environments |
US7805046B2 (en) * | 2007-07-06 | 2010-09-28 | Weatherford/Lamb, Inc. | Termination of fiber optic cable |
US9074462B2 (en) * | 2011-03-09 | 2015-07-07 | Shell Oil Company | Integrated fiber optic monitoring system for a wellsite and method of using same |
CN103814321B (en) * | 2011-09-20 | 2018-01-02 | Lios技术有限公司 | Connectorized fiber optic cabling |
US20150129751A1 (en) * | 2013-11-12 | 2015-05-14 | Baker Hughes Incorporated | Distributed sensing system employing a film adhesive |
EP3064974A1 (en) * | 2015-03-03 | 2016-09-07 | Nexans | Cable for downhole well monitoring |
US9915798B2 (en) * | 2015-12-28 | 2018-03-13 | Prysmian S.P.A. | Downhole cable with reduced diameter |
-
2017
- 2017-03-07 US US15/451,935 patent/US20180258710A1/en not_active Abandoned
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2018
- 2018-02-22 US US16/491,918 patent/US11536096B2/en active Active
- 2018-02-22 WO PCT/US2018/019084 patent/WO2018164842A1/en active Application Filing
- 2018-02-22 CA CA3054059A patent/CA3054059A1/en active Pending
Patent Citations (1)
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US6602633B1 (en) * | 1999-09-13 | 2003-08-05 | Hosiden Corporation | Crush type pressure detecting device, rechargeable battery with pressure detecting device, and portable electronic device |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2022236759A1 (en) * | 2021-05-10 | 2022-11-17 | 信达科创(唐山)石油设备有限公司 | Packaging tube cable having color recognition tape and preparation method therefor |
Also Published As
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US20210140248A1 (en) | 2021-05-13 |
WO2018164842A1 (en) | 2018-09-13 |
US11536096B2 (en) | 2022-12-27 |
CA3054059A1 (en) | 2018-09-13 |
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