WO2019010804A1 - 一种光电复合缆及其制造方法 - Google Patents

一种光电复合缆及其制造方法 Download PDF

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Publication number
WO2019010804A1
WO2019010804A1 PCT/CN2017/101232 CN2017101232W WO2019010804A1 WO 2019010804 A1 WO2019010804 A1 WO 2019010804A1 CN 2017101232 W CN2017101232 W CN 2017101232W WO 2019010804 A1 WO2019010804 A1 WO 2019010804A1
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Prior art keywords
composite cable
tube
conductive layer
steel pipe
light unit
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PCT/CN2017/101232
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English (en)
French (fr)
Inventor
栗鸣
何仓平
陆杰
缪旭光
薛海军
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中天电力光缆有限公司
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Application filed by 中天电力光缆有限公司 filed Critical 中天电力光缆有限公司
Publication of WO2019010804A1 publication Critical patent/WO2019010804A1/zh
Priority to US16/395,514 priority Critical patent/US10712520B2/en
Priority to US16/889,283 priority patent/US11054603B2/en

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B9/00—Power cables
    • H01B9/005—Power cables including optical transmission elements
    • 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
    • E21B17/003—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings with electrically conducting or insulating means
    • 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
    • G02B6/4416—Heterogeneous cables
    • 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
    • G02B6/44382—Means specially adapted for strengthening or protecting the cables the means comprising hydrogen absorbing materials
    • 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
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or 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
    • H01B13/0016—Apparatus or processes specially adapted for manufacturing conductors or cables for heat treatment
    • 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
    • H01B13/08—Insulating conductors or cables by winding
    • 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
    • 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
    • H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
    • 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
    • H01B7/0009—Details relating to the conductive cores
    • H01B7/0018—Strip or foil conductors
    • 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
    • H01B7/02—Disposition of insulation
    • H01B7/0241—Disposition of insulation comprising one or more helical wrapped layers of insulation
    • 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
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • 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
    • H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
    • H01B7/046—Flexible cables, conductors, or cords, e.g. trailing cables attached to objects sunk in bore holes, e.g. well drilling means, well pumps
    • 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
    • H01B7/207—Metal tubes, e.g. lead sheaths composed of iron or steel
    • 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
    • H01B7/28—Protection against damage caused by moisture, corrosion, chemical attack or weather
    • H01B7/2806—Protection against damage caused by corrosion
    • 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
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
    • 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

Definitions

  • the invention relates to the technical field of optoelectronic composite cables, in particular to an optoelectronic composite cable used in an oil well and a manufacturing method thereof.
  • the detector needs to use the photoelectric composite cable (hereinafter referred to as the oil well cable) for data transmission.
  • the optical fiber sensing system of the detector utilizes the excellent performance of the optical fiber, such as anti-electromagnetic interference and atomic radiation performance, mechanical properties with fine diameter, soft quality, light weight, water resistance, high temperature resistance and corrosion resistance, and overcomes the harsh environment in the underground. High-precision measurement of wellbore and well site environmental parameters.
  • the detector using the fiber optic sensing system has a small cross-sectional area and takes up very little space in the wellbore for ease of use.
  • the detector receives the optical signal and electric energy through the oil well optical cable.
  • the oil well optical cable is placed in the well to collect the sample data, and after the survey is completed, the oil well optical cable is pulled out of the oil well.
  • oil well cables can also be used for other operations downhole.
  • the existing oil well optical cable generally has a plurality of light units wrapped in the central steel pipe and a plurality of circular insulated wires concentrically twisted and disposed in the outer steel pipe of the oil well cable. Due to the outer diameter limitation of the oil well cable, the outer steel pipe wall The thickness is selected according to the downhole pressure requirement. Under the condition of the outer diameter, the inner diameter of the central steel pipe is also a fixed value.
  • the central steel pipe Since the thermal expansion coefficient of the metal is higher than the thermal expansion rate of the optical fiber, the central steel pipe is elongated under the heated condition, and there is not enough in the optical fiber. In the case of excess length, the fiber will be subjected to external tensile stress, which can cause the fiber to attenuate or even break, which affects the life of the fiber.
  • the fiber To satisfy the fiber's sufficient length, there must be enough space for the fiber to be curved.
  • the only possibility is to increase the outer diameter of the light unit. In the inner circular space defined by the inner diameter, increasing the outer diameter of the light unit causes the outer diameter of the wire to decrease. The reduction in the outer diameter of the insulation will result in The insulation capacity of the wires is reduced. In a complicated environment, the oil cable may be damaged due to the insulation of the wires.
  • the technical problem to be solved by the present invention is to provide an optical composite cable for oil wells in which a light unit and an insulated wire are coaxially arranged, which can increase the outer diameter of the light unit, and the fiber has sufficient length without affecting the insulation of the wire. performance.
  • the present invention provides a technical composite cable comprising: a light unit, a conductive layer coated on the surface of the light unit, an insulating layer continuously extruded outside the conductive layer, and a package.
  • An outer steel pipe that covers the outside of the insulating layer.
  • the light unit comprises a fiber-reinforced steel tube and a plurality of optical fibers coated in the fiber-reinforced steel tube, and the fiber surface is coated with a fiber paste.
  • the conductive layer is a copper tube which is coated on the surface of the light unit by laser continuous welding.
  • the conductive layer is a copper tube which is coated on the outside of the fiber-reinforced steel tube by laser continuous welding.
  • the conductive layer is a copper alloy tube or an aluminum tube or an aluminum alloy tube.
  • the outer steel pipe is a single-layer steel pipe.
  • the outer steel pipe comprises two layers, respectively an inner layer steel pipe and an outer layer steel pipe, the inner layer steel pipe is coated on the outer side of the insulation layer, and the outer layer steel pipe is wrapped on the outer side of the inner layer steel pipe.
  • the invention also provides a method for manufacturing an optoelectric composite cable, comprising the following steps:
  • the light unit step pulling a plurality of optical fibers into a stack and coating the fiber paste, coating the steel strip with the optical fiber and laser welding into a smooth steel tube to form a light unit, and drawing the steel tube to a desired outer diameter;
  • the step of generating the excess length processing the light unit by using a tension method or a deformation method to generate a residual length of the light unit;
  • Electrical unit step forming a conductive layer on the outside of the above light unit;
  • Insulating step extruding on the outside of the above conductive layer to form an insulating layer
  • External steel pipe step a layer of steel strip is longitudinally wrapped on the outer side of the above insulating layer and laser continuous welding is used to prepare a finished photoelectric composite cable.
  • the conductive layer in the step of the electric unit is a copper tube formed by coating the copper strip on the surface of the light unit by laser continuous welding.
  • the conductive layer in the step of the electric unit is a copper alloy tube or an aluminum tube or an aluminum alloy tube.
  • the invention also provides a method for manufacturing an optoelectronic composite cable, which comprises the following steps:
  • the light unit step pulling a plurality of optical fibers into a stack and coating the fiber paste, coating the steel strip with the optical fiber and laser welding into a smooth steel tube to form a light unit, and drawing the steel tube to a desired outer diameter;
  • the step of generating the excess length processing the light unit by using a tension method or a deformation method to generate a residual length of the light unit;
  • Electrical unit step forming a conductive layer on the outside of the above light unit;
  • Insulating step extruding on the outside of the above conductive layer to form an insulating layer
  • Inner steel pipe step longitudinally wrapping a steel strip on the outer side of the above insulating layer and continuously forming a steel pipe by laser continuous welding;
  • Step of outer steel pipe a layer of steel strip is longitudinally wrapped on the outer side of the inner steel pipe, and the outer steel pipe is formed by laser continuous welding to form a finished product of the photoelectric composite cable.
  • the conductive layer in the step of the electric unit is a copper tube formed by coating the copper strip on the surface of the light unit by laser continuous welding.
  • the conductive layer in the step of the electric unit is a copper alloy tube or an aluminum tube or an aluminum alloy tube.
  • the invention has the beneficial effects that the optical unit and the conductive layer of the photoelectric composite cable of the invention have a coaxial structure, which effectively utilizes the inner space of the photoelectric composite cable, so that the optical fiber can have sufficient space to be added.
  • the excess length of the fiber is adapted to the external tensile stress.
  • the thickness of the insulating layer outside the conductive layer can also be increased to improve the insulating properties of the conductive layer.
  • the use of the copper layer as the conductive layer also has better hydrogen barrier properties, can improve the reliability of the use of the optoelectronic composite cable, and further improve the service life of the optoelectronic composite cable.
  • Figure 1 is a structural view showing a first embodiment of the photoelectric composite cable of the present invention
  • Figure 2 is a cross-sectional view showing a first embodiment of the photovoltaic composite cable of the present invention
  • Figure 3 is a graph comparing the permeation rates of hydrogen in different metals
  • Figure 4 is a structural view showing a second embodiment of the photoelectric composite cable of the present invention.
  • Figure 5 is a cross-sectional view showing a second embodiment of the photovoltaic composite cable of the present invention.
  • the photoelectric composite cable 100 for oil wells of the present invention can be used as an transmission system in an oil well as a transmission medium to withstand harsh environments such as high temperature, high pressure, high acid corrosion, and maintain long-term work.
  • the photoelectric composite cable 100 of the present invention comprises a light unit 10, a conductive layer 20 coated on the surface of the light unit 10, an insulating layer 30 continuously formed by extrusion coating on the outside of the conductive layer 20, and an outer steel tube coated on the outside of the insulating layer 30. 40.
  • the optical unit 10 includes a fiber-reinforced steel tube 101 and a plurality of optical fibers 102 coated in the fiber-reinforced steel tube 101.
  • the optical fiber 102 is coated with a plurality of fiber pastes 103.
  • the optical fiber 102 is a carbon coated optical fiber, which forms a dense carbon layer on the surface of the optical fiber, reduces the high-strength region of the surface of the optical fiber, eliminates the low-strength region, improves the mechanical properties of the optical fiber, and additionally carbon coating.
  • the layer also has excellent hydrogen resistance to avoid fiber loss and strength degradation caused by hydrogen and water.
  • the fiber-reinforced steel tube 101 is longitudinally coated on the outer side of the optical fiber 102 by laser welding using a 316L stainless steel strip.
  • the fiber paste 103 is a hydrogen absorbing fiber paste, and the hydrogen absorbing fiber paste is added with a hydrogen absorbing agent in the fiber paste to have a hydrogen absorption function, thereby preventing hydrogen from harming the fiber.
  • the conductive layer 20 is densely coated on the outside of the fiber-reinforced steel tube 101 by laser continuous welding to form a smooth copper tube.
  • the copper tube has a thickness of less than or equal to 0.15 mm.
  • the copper tube serves as an electrical transmission medium for the photoelectric composite cable of the present invention, and has good electrical conductivity and can meet the power supply requirement of the exploration system.
  • the penetration rate of hydrogen in gold, silver, copper, and aluminum is two orders of magnitude slower than that in iron. Therefore, the copper tube can also act as a hydrogen barrier to reduce the fiber in the oil well cable. The effect of damage reduces the penetration rate of hydrogen in the photoelectric composite cable and improves the service life of the photoelectric composite cable.
  • a copper tube is used as the conductive layer to achieve electrical conductivity.
  • a copper alloy tube, an aluminum tube, or an aluminum alloy tube may be used as the conductive layer to achieve power supply.
  • the insulating layer 30 is made of a polymer material.
  • a polytetrafluoroethylene plastic is used, which has high temperature resistance.
  • other high temperature resistant insulating materials may be used to form an insulating layer according to the ambient temperature. .
  • the outer steel tube 40 is formed by longitudinally wrapping a thick layer of NAS825 alloy steel strip and continuously welding it to the outside of the insulating layer 30.
  • NAS825 alloy is a high-corrosion resistant alloy with high nickel, which has excellent corrosion resistance for oxidizing and non-oxidizing acids. In the harsh environment of the oil well, it plays the role of high temperature resistance and corrosion resistance.
  • the photovoltaic composite cable 100 for oil wells of the present invention comprises a light unit 10, a conductive layer 20 coated on the surface of the light unit 10, an insulating layer 30 formed by continuously extrusion coating on the outside of the conductive layer 20, and an outer layer of the insulating layer 30.
  • External steel tube 40 External steel tube 40.
  • the outer steel pipe 40 is composed of two layers of steel pipes, including an inner steel pipe 50 coated on the outer side of the insulating layer 30 and an outer steel pipe 60 coated on the outer side of the inner steel pipe.
  • the inner layer steel pipe 50 is continuously welded to the outer side of the insulating layer 30 by a longitudinal packing of 316L stainless steel strip, and the 316L stainless steel is a kind of molybdenum-containing stainless steel, which has good heat resistance and corrosion resistance.
  • the outer steel tube 60 is longitudinally wrapped with a thin NAS825 alloy steel strip and continuously welded to the outer side of the inner steel tube 50.
  • the NAS825 alloy is a high corrosion resistant alloy containing high nickel, for oxidizing and non-oxidizing acids. Its corrosion resistance is excellent. In the harsh environment of the oil well, it has high temperature and corrosion resistance.
  • a thin-walled copper tube is welded on the outer side of the fiber-reinforced steel tube as a conductive layer and a hydrogen-blocking medium on the outer side of the optical unit 10, instead of the conventional copper wire as a current-carrying conductor, and then outside the copper tube. Squeeze a layer of polymer insulation to make the copper tube The edge conductor is used.
  • the laser welding and continuous welding process is used to weld a thin-walled copper tube, which avoids the welding phenomenon that may be caused by other welding methods such as argon arc welding.
  • the continuous length can be several tens or hundreds of kilometers.
  • the thickness of the copper tube is less than or equal to 0.15 mm, and the thickness is selected mainly according to the requirements of the direct current resistance and the insulation performance. Due to the limited outer diameter, the copper tube used in the present invention is thinner than other opto-electric composite cables, effectively utilizing the space inside the tube, and improving the electrical performance, optical performance, and resistance to hydrogen loss of the optoelectric composite cable.
  • the invention also provides a manufacturing method of the photoelectric composite cable, and the steps of the first embodiment are as follows:
  • Light unit step a plurality of optical fibers are discharged from the pay-off rack, gathered together before the steel tube forming mold and coated with the magnetic paste, the 304 steel strip is coated with the optical fiber and laser welded into a smooth fiber-reinforced steel tube, and the protective wire is pulled. Fiber tube to the required outer diameter and increase the strength of the steel tube to form a light unit;
  • the step of generating the excess length processing the above-mentioned light unit by using the tension method, applying tension to the fiber-reinforced steel pipe, the tension is within the elastic range, and then releasing the tension, and utilizing the elastic deformation, the fiber-reinforced steel pipe is retracted, thereby generating the excess length
  • the deformation method can also be used to generate the excess length, and the steel tube is subjected to the micro-deformation, and the plastic fiber tube is retracted by the plastic deformation, thereby generating the excess length.
  • Electrical unit step longitudinally wrapping a copper strip on the outside of the above-mentioned light unit, and forming a conductive layer by laser welding to form a smooth and dense copper tube.
  • a copper alloy tube, an aluminum tube or an aluminum alloy tube may also be used as the conductive layer;
  • Insulation step extruding a layer of polytetrafluoroethylene plastic as an insulating layer on the outer side of the above conductive layer, the insulating layer enables the copper tube to be used as an insulated conductor; in other embodiments, other high temperature resistant materials may be selected according to the use environment.
  • the insulating material is made of a polymer insulating material.
  • External steel pipe step a layer of NAS825 alloy steel strip is longitudinally wrapped on the outer side of the above insulating layer, and a laser is continuously welded to form a dense outer steel pipe to form a finished photoelectric composite cable.
  • the NAS825 high-alloy stainless steel belt can resist the high temperature and high acidity environment in the harsh environment of the oil well, ensuring the normal operation of the photoelectric composite cable.
  • Inner steel pipe step longitudinally wrapping a layer of 316L stainless steel strip on the outside of the insulating layer and using laser continuous welding to form a dense inner steel pipe.
  • the 316L stainless steel strip is a kind of molybdenum-containing stainless steel with good high temperature resistance and corrosion resistance;
  • Outer steel pipe step a thin layer of NAS825 alloy steel strip is longitudinally wrapped on the outer side of the inner steel pipe, and a laser is continuously welded to form a dense outer steel pipe to form a finished photoelectric composite cable.
  • the NAS825 high alloy stainless steel belt is in the oil well. In the harsh environment, it can resist the high temperature and high acidity environment and ensure the normal operation of the photoelectric composite cable.
  • the manufacturing method of the photoelectric composite cable of the invention has the advantages of simple steps and short process flow, and the electric unit and the optical unit of the produced photoelectric composite cable are coaxial structures, and the inner space of the photoelectric composite cable is effectively utilized, so that the optical fiber can have sufficient space.
  • the fiber length can be increased to accommodate external tensile stresses.
  • the thickness of the insulating layer outside the electric unit can also be increased, the insulation strength of the electric unit is improved, and the insulation performance of the photoelectric composite cable is ensured.
  • the hydrogen absorption fiber paste is used to protect the optical fiber from hydrogen loss.
  • the copper tube is used as the conductive layer and has good hydrogen barrier performance, which can improve the reliability of the use of the photoelectric composite cable, thereby improving the service life of the photoelectric composite cable.

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Abstract

本发明提供了一种油井用光电复合缆，包括光单元，包覆于光单元表面的激光连续焊接形成的导电层，于导电层外连续挤塑形成的耐高温绝缘层以及包覆于该耐高温绝缘层外的外部钢管。本发明光电复合缆的光单元与导电层为同轴结构，有效利用了光电复合缆的管内空间，使得光纤能够有足够的空间可以增加光纤余长以适应光缆的热膨胀伸长或外部的拉应力。同时，导电层外的绝缘层厚度亦可以增加，可以提高导电层的绝缘性能。本发明还提供一种光电复合缆的制造方法。

Description

一种光电复合缆及其制造方法 技术领域
本发明涉及光电复合缆技术领域，特别是涉及一种用于油井内的光电复合缆及其制造方法。
背景技术
油井勘测中，探测器需要使用油井用光电复合缆(下称油井光缆)进行数据传输。其中探测器的光纤传感系统利用光纤优异性能，如抗电磁干扰和原子辐射的性能，径细、质软、质量轻的机械性能，耐水耐高温、耐腐蚀的化学性能，克服井下恶劣环境，高精度地测量井筒和井场环境参数。而且，利用光纤传感系统的探测器横截面积小，在井筒中占据空间极小，使用方便。探测器通过油井光缆接收光信号和电能，使用时将油井光缆放入井下收集样本数据，勘测完成后将油井光缆拉出油井。当然，油井光缆也可用于井下其他作业。
在油井中超过120℃、100MPa高压力、高化学腐蚀的恶劣环境中应用，不但要选择相应温度等级的特种光纤，保护光纤的光缆结构设计也非常重要。现有的油井光缆一般是将若干包裹在中心钢管内的光单元和若干圆形的绝缘导线同心绞合设置于油井光缆的外层钢管中，由于油井光缆的外径限制，外层钢管的壁厚根据井下压力要求选择，在外径一定的情况下，中心钢管的内径尺寸也是一个定值，由于金属的热膨胀率高于光纤的热膨胀率，在受热条件下中心钢管伸长，在光纤没有足够的余长的情况下，光纤会受到外部拉应力，可使光纤衰减上升甚至断裂，影响光纤寿命。
要满足光纤具有足够的余长，则必须有足够的空间使光纤呈弯曲状，唯一的可能就是增加光单元的外径。而在内径尺寸限定的内圆空间里，增加光单元外径会导致导线的绝缘外径减小。绝缘外径的减小会造 成导线的绝缘能力下降，在复杂环境下，油井光缆可能因导线的绝缘层受到破坏从而无法供电。
发明内容
本发明主要解决的技术问题是提供一种将光单元与绝缘导线同轴设置的油井用光电复合缆，既能增加光单元的外径，使光纤具有足够的余长，又不影响导线的绝缘性能。
为解决上述技术问题，本发明提供的一种技术方案是：提供一种光电复合缆，包括光单元、包覆于光单元表面的导电层、于导电层外连续挤塑形成的绝缘层以及包覆于该绝缘层外的外部钢管。
其中，光单元包括护纤钢管及包覆于护纤钢管内的若干根光纤，光纤表面涂覆纤膏。
其中，导电层是将铜带采用激光连续焊接的方式包覆于光单元表面的铜管。
其中，导电层是将铜带采用激光连续焊接的方式包覆于护纤钢管外侧的铜管。
其中，导电层是铜合金管或铝管或铝合金管。
其中，外部钢管为单层钢管。
其中，外部钢管包括两层，分别为内层钢管及外层钢管，内层钢管包覆于绝缘层外侧，外层钢管包覆于内层钢管外侧。
本发明还提供了一种光电复合缆的制造方法，包括以下步骤：
光单元步骤：将若干光纤拉出汇成一缕并涂覆纤膏，将钢带包覆光纤并用激光焊接成光滑的钢管，形成光单元，拉拔该钢管至所需外径；
产生余长步骤：运用张力法或形变法对上述光单元进行加工，使光单元产生余长；
电单元步骤：在上述光单元外侧形成导电层；
绝缘步骤：在上述导电层外侧挤塑形成绝缘层；
外部钢管步骤：在上述绝缘层外侧纵包一层钢带并采用激光连续焊接，制成光电复合缆成品。
其中，电单元步骤中导电层是将铜带采用激光连续焊接的方式包覆于光单元表面形成的铜管。
其中，电单元步骤中导电层是铜合金管或铝管或铝合金管。
本发明还提供另一种光电复合缆的制造方法，其特征在于，包括以下步骤：
光单元步骤：将若干光纤拉出汇成一缕并涂覆纤膏，将钢带包覆光纤并用激光焊接成光滑的钢管，形成光单元，拉拔该钢管至所需外径；
产生余长步骤：运用张力法或形变法对上述光单元进行加工，使光单元产生余长；
电单元步骤：在上述光单元外侧形成导电层；
绝缘步骤：在上述导电层外侧挤塑形成绝缘层；
内层钢管步骤：在上述绝缘层外侧纵包一层钢带并采用激光连续焊接形成内层钢管；
外层钢管步骤：在上述内层钢管外侧纵包一层钢带，并采用激光连续焊接形成外层钢管，制成光电复合缆成品。
其中，电单元步骤中导电层是将铜带采用激光连续焊接的方式包覆于光单元表面形成的铜管。
其中，电单元步骤中导电层是铜合金管或铝管或铝合金管。
本发明的有益效果是：区别于现有技术的情况，本发明光电复合缆的光单元与导电层为同轴结构，有效利用了光电复合缆的管内空间，使得光纤能够有足够的空间可以增加光纤余长以适应外部的拉应力。同时，导电层外的绝缘层厚度亦可以增加，提高导电层的绝缘性能。另外，采用铜层作为导电层亦具有较好的阻氢性能，可以提高光电复合缆的使用可靠性，进而提高光电复合缆的使用寿命。
附图说明
图1是本发明光电复合缆的第一实施方式的结构图；
图2是本发明光电复合缆的第一实施方式的截面图；
图3是氢在不同金属中的渗透速率比较图；
图4是本发明光电复合缆的第二实施方式的结构图；
图5是本发明光电复合缆的第二实施方式的截面图。
具体实施方式
下面将结合本发明实施例中的附图，对本发明所提供的各个示例性的实施例的技术方案进行清楚、完整地描述。在不冲突的情况下，下述各个实施例及其技术特征可以相互组合。
请参阅图1及图2，为本发明光电复合缆的第一实施方式的结构图及截面图。本发明油井用光电复合缆100，可使用于油井中的勘探系统，作为传输介质以抵御井下高温、高压、高酸腐蚀等恶劣环境并保持长期工作。
本发明光电复合缆100包括光单元10，包覆于光单元10表面的导电层20，于导电层20外连续挤压包覆形成的绝缘层30以及包覆于该绝缘层30外侧的外部钢管40。
所述光单元10包括护纤钢管101、包覆于该护纤钢管101内的若干根光纤102，该光纤102表面涂覆若干纤膏103。在本实施方式中，光纤102为碳涂层光纤，其是在光纤表面形成一层致密的碳层，降低光纤表面的高强度区也消除了低强度区，提高光纤的机械性能，另外碳涂层还具有优异的抗氢性能，可以避免氢气和水引起的光纤损耗和强度衰退。护纤钢管101是采用316L不锈钢带经过激光焊接纵向包覆于光纤102外侧。纤膏103为吸氢纤膏，吸氢纤膏是在纤膏中加入吸氢剂使其具有吸氢功能，防止氢气对光纤的危害。
所述导电层20是将铜带采用激光连续焊接的方式致密地包覆于护纤钢管101的外侧形成一层光滑的铜管。该铜管的厚度小于或等于0.15mm，该铜管作为本发明光电复合缆的电传输介质，具有良好的导电性能，可以满足勘探系统的供电需求。
另外，油井井下会存在大量氢气及游离氢，氢气或游离氢能够渗过金属保护层进入光纤纤芯，会与纤芯中的晶格缺陷或掺杂元素发生化学反应形成OH键，也可以以氢分子状态积存在纤芯内部，上述两种现象 都会引起光纤损耗的增加，影响光纤的传输性能。
请参照图3，氢在金、银、铜、铝中的渗透速度要比在铁中的渗透速率慢2个数量级，所以铜管还可以作为氢气阻挡层，可降低油井光缆中光纤受“氢损”影响，降低氢在光电复合缆中的渗透速率，提高光电复合缆的使用寿命。
在本实施方式中采用铜管作为导电层来实现导电性能，在其他实施方式中还可以采用铜合金管、铝管或铝合金管作为导电层来实现供电。
绝缘层30为高分子材料制成，在本实施方式中采用聚四氟乙烯塑料，具有耐高温特性，在其他实施方式中，也可以根据使用环境温度，选用其他耐高温的绝缘材料制作绝缘层。
外部钢管40是采用一层较厚的NAS825合金钢带纵包并连续焊接于绝缘层30外侧形成。其中NAS825合金是含高镍的高级耐腐蚀合金，对氧化性以及非氧化性的酸而言其耐腐蚀的性能优秀。在油井恶劣的环境中，起到耐高温、耐腐蚀的作用。
请参阅图4及图5，为本发明光电复合缆的第二实施方式的结构图及截面图。本发明油井用光电复合缆100，包括光单元10、包覆于光单元10表面的导电层20、于导电层20外连续挤压包覆形成的绝缘层30以及包覆于该绝缘层30外侧的外部钢管40。与第一实施方式的不同之处在于，外部钢管40由两层钢管组成，包括包覆于绝缘层30外侧的内层钢管50及包覆于内层钢管外侧的外层钢管60。
其中，该内层钢管50是采用316L不锈钢带纵包连续焊接于绝缘层30外侧，316L不锈钢是含钼不锈钢种，具有良好的耐热性及耐腐蚀性能。该外层钢管60是采用较薄的NAS825合金钢带纵包并连续焊接于内层钢管50的外侧，NAS825合金是含高镍的高级耐腐蚀合金，对氧化性以及非氧化性的酸而言其耐腐蚀的性能优秀。在油井恶劣的环境中，起到耐高温、耐腐蚀的性能。
在本发明中，光单元10外侧采用激光连续焊接的工艺在护纤钢管外侧焊接一层薄壁铜管作为导电层及阻氢介质，代替传统的铜电线作为通电导体，然后在铜管外再挤包一层高分子绝缘层使得铜管可以作为绝 缘导体使用。采用激光焊接，且连续焊接的工艺焊接一层薄壁铜管，避免了其它焊接方式如氩弧焊中途必须更换电极可能导致的漏焊现象，可生产的连续长度达几十或上百公里。
本发明中铜管的厚度小于或等于0.15mm，厚度的选择主要依据直流电阻要求及绝缘性能要求。因外径受限，相对于其它光电复合缆，本发明中所用铜管厚度更薄，有效利用了管内的空间，提高了光电复合缆的电气性能、光学性能以及耐受氢损影响的能力。
本发明还提供一种光电复合缆的制造方法，第一实施方式步骤如下：
光单元步骤：将若干根光纤由放线架放出，在进入钢管成型模前汇聚在一起并涂覆纤膏，将304钢带包覆光纤并用激光焊接成光滑的护纤钢管，拉拔该护纤钢管至所需外径并提高钢管的强度，形成光单元；
产生余长步骤：运用采用张力法对上述光单元进行加工，通过给护纤钢管施加张力，其张力在弹性范围之内，然后释放张力，利用弹性形变使得护纤钢管回缩，从而产生余长；在其他实施方式中，还可以采用形变法产生余长，通过对钢管进行微缩变形，利用塑性变形使得护纤钢管回缩，从而产生余长。
电单元步骤：在上述光单元外侧纵包一层铜带，并通过激光焊形成光滑致密的铜管形成导电层。在其他实施方式中也可以采用铜合金管、铝管或铝合金管作为导电层；
绝缘步骤：在上述导电层外侧挤塑一层聚四氟乙烯塑料作为绝缘层，该绝缘层使得铜管可以作为绝缘导体使用；在其他实施方式中，还可以根据使用环境，选用其他耐高温的高分子绝缘材料制作绝缘层。
外部钢管步骤：在上述绝缘层外侧纵包一层NAS825合金钢带，并采用激光连续焊接形成致密的外部钢管，形成光电复合缆成品。该NAS825高合金不锈钢带在油井的恶劣环境中，能够抵抗高温、高酸腐的环境，保证光电复合缆的正常工作。
本发明光电复合缆的制造方法的第二实施方式与第一实施方式不同之处在于，所述外部钢管步骤包括如下两个步骤：
内层钢管步骤：在绝缘层外侧纵包一层316L不锈钢带并采用激光连续焊接形成致密的内层钢管，该316L不锈钢带是含钼不锈钢种，具有良好的耐高温及耐腐蚀性能；
外层钢管步骤：在上述内层钢管外侧纵包一层较薄的NAS825合金钢带，并采用激光连续焊接形成致密的外层钢管，形成光电复合缆成品，该NAS825高合金不锈钢带在油井的恶劣环境中，能够抵抗高温、高酸腐的环境，保证光电复合缆的正常工作。
本发明光电复合缆的制造方法，步骤简单，工艺流程较短，生产的光电复合缆的电单元与光单元为同轴结构，有效利用了光电复合缆的管内空间，使得光纤能够有足够的空间可以增加光纤余长以适应外部的拉应力。同时，电单元外的绝缘层厚度亦可以增加，提高电单元的绝缘强度，保证了光电复合缆的绝缘性能。另外，采用吸氢纤膏保护光纤免受氢损，采用铜管作为导电层的同时具有较好的阻氢性能，可以提高光电复合缆的使用可靠性，进而提高光电复合缆的使用寿命。
以上所述仅为本发明的实施方式，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构或等效流程变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (13)

  1. 一种光电复合缆，其特征在于，包括：光单元，包覆于光单元表面的导电层，于导电层外连续挤塑形成的绝缘层，包覆于该绝缘层外的外部钢管。
  2. 如权利要求1所述的光电复合缆，其特征在于，所述光单元包括护纤钢管及包覆于护纤钢管内的若干根光纤，所述光纤表面涂覆纤膏。
  3. 如权利要求1所述的光电复合缆，其特征在于，所述导电层是将铜带采用激光连续焊接的方式包覆于所述光单元表面的铜管。
  4. 如权利要求2所述的光电复合缆，其特征在于，所述导电层是将铜带采用激光连续焊接的方式包覆于所述护纤钢管外侧的铜管。
  5. 如权利要求1所述的光电复合缆，其特征在于，所述导电层是铜合金管或铝管或铝合金管。
  6. 如权利要求1所述的光电复合缆，其特征在于，所述外部钢管为单层钢管。
  7. 如权利要求1所述的光电复合缆，其特征在于，所述外部钢管包括两层，分别为内层钢管及外层钢管，所述内层钢管包覆于所述绝缘层外侧，所述外层钢管包覆于所述内层钢管外侧。
  8. 一种光电复合缆的制造方法，其特征在于，包括以下步骤：
    光单元步骤：将若干光纤拉出汇成一缕并涂覆纤膏，将钢带包覆光纤并用激光焊接成光滑的护纤钢管，形成光单元，拉拔该护纤钢管至所需外径；
    产生余长步骤：运用张力法或形变法对上述光单元进行加工，使光单元产生余长；
    电单元步骤：在上述光单元外侧形成导电层；
    绝缘步骤：在上述导电层外侧挤塑形成绝缘层；
    外部钢管步骤：在上述绝缘层外侧纵包一层钢带并采用激光连续焊接，制成光电复合缆成品。
  9. 如权利要求8所述的光电复合缆的制造方法，其特征在于，所述电单 元步骤中所述导电层是将铜带采用激光连续焊接的方式包覆于所述光单元表面形成的铜管。
  10. 如权利要求8所述的光电复合缆的制造方法，其特征在于，所述电单元步骤中导电层是铜合金管或铝管或铝合金管。
  11. 一种光电复合缆的制造方法，其特征在于，包括以下步骤：
    光单元步骤：将若干光纤拉出汇成一缕并涂覆纤膏，将钢带包覆光纤并用激光焊接成光滑的护纤钢管，形成光单元，拉拔该护纤钢管至所需外径；
    产生余长步骤：运用张力法或形变法对上述光单元进行加工，使光单元产生余长；
    电单元步骤：在上述光单元外侧形成导电层；
    绝缘步骤：在上述导电层外侧挤塑形成绝缘层；
    内层钢管步骤：在上述绝缘层外侧纵包一层钢带并采用激光连续焊接形成内层钢管；
    外层钢管步骤：在上述内层钢管外侧纵包一层钢带，并采用激光连续焊接形成外层钢管，制成光电复合缆成品。
  12. 如权利要求11所述的光电复合缆的制造方法，其特征在于，所述电单元步骤中所述导电层是将铜带采用激光连续焊接的方式包覆于所述光单元表面形成的铜管。
  13. 如权利要求11所述的光电复合缆的制造方法，其特征在于，所述电单元步骤中导电层是铜合金管或铝管或铝合金管。
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