MXPA06004216A - Methods of manufacturing composite slickline cables - Google Patents

Abstract

Disclosed are wellbore electric cables, and methods of manufacturing such cables, and in one aspect, methods of manufacturing wireline composite slickline cables. Some embodiments are methods which include preparing a slickline cable by providing an inner metallic tube containing at least one conductor (such as an optical fiber), disposing an epoxy/fiber composite strength layer substantially upon the outer periphery of the inner metallic tube, and exposing the combination of the inner metallic tube and composite strength layer to at least one technique for minimizing the variation in diameter and providing a substantially uniform circular cross-sectional shape of the combination. Further, an outer metallic tube is draw around the combination of the composite strength member and the inner metallic tube, to form a wellbore slickline. Cables prepared using such methods are also disclosed.

Description

METHODS FOR MANUFACTURING WIRES OE 1? JEA T.TSA COMPOUNDS BACKGROUND OF THE INVENTION This invention relates to smooth borehole power line cables, and methods for making and using such cables. In one aspect, the invention relates to a method for manufacturing smooth line cables composed of wire line. Generally, geological formations within the earth that contain petroleum and / or petroleum gas have properties that can be linked to the capacity of the formations to contain said products. For example, formations that contain petroleum or petroleum gas have higher electrical resistivity than those that contain water. Formations that usually comprise sandstone and limestone may contain petroleum or petroleum gas. Formations that generally comprise shales, which can also encapsulate oil-containing formations, may have much larger porosities than those of sandstone or limestone, but, because the shale grain size is very small, they may be very difficult to remove oil or gas trapped in it. Consequently, it may be desirable to measure various characteristics of geological formations adjacent to a well before completion to help determine the location of a formation containing petroleum and / or petroleum gas as well as the amount of oil and / or oil gas trapped. within the training. The logging tools, which are generally long, tube-shaped devices, can be lowered into the well to measure these characteristics at different depths along the well. These recording tools can include gamma ray emitters / receivers, calibration devices, resistivity measurement devices, neutron emitters / receivers, and the like, which are used to perceive characteristics of the formations adjacent to the well. A wireline cable, such as a straight-line cable, connects the registration tool with one or more electrical power sources and data analysis equipment on the surface of the earth, as well as provides structural support to the tools of record as they go down and up through the well-usually, the wire line smooth line is unraveled from a drum unit from a truck or offshore installation, on pulleys, and down to the well . Smooth-line cables used in the oilfield industry typically consist of metal tubes containing optical fibers or insulated copper conductors. The tubes are typically made of Iconel! R) which is non-corrosive, but is inherently low in strength ^ This lack of strength prevents these smooth line cables from being used with high tensile strength. Because smooth line cables have metal tubes and are used with relatively small pulleys (40.64 to 50.80 cm (16 to 20 inches) in diameter) they are also prone to yield and fail as they pass over the pulleys - commonly, the Smooth line cable designs use an epoxy / fiber composite sandwiched between two steel tubes with optical fibers contained in the inner tube, As shown in Figure 1A, in some designs, the optical fibers 102 (only one indicated) are placed in a central stainless steel tube 104. The epoxy / long fiber composite 106 is then made to protrude over the tube 104, and an external tube 108 is generally placed over the compound 106. The compound 106 provides a strength member, lightweight, as well as a hydrogen-resistant barrier for single, small fiber optic conductors .. But, since the long fibers in the epoxy / long fiber composite 106 and the metal that form the tub Since 104 have significantly different thermal coefficients, epoxy / long-fired compound 106 tends to deform during thermal curing (from 204 ° to 260 ° C (400 to 500 ° F)) to a slightly irregular oval shape., as indicated by the spaces 110 (only one indicated) as shown in Figure IB, A "external stainless steel tube 108 is then stretched on the outside of the epoxy compound 106. / long length- When the irregular profile, of the epoxy / long fiber composite 106 resulting in spaces 110 is left uncorrected before the external stainless steel tube 108 is applied, that tube 108 becomes especially vulnerable to failure during handling (e.g., at crossover points on drums, or when going on pulleys) and during operations in the field.Also, in some cases, the loose fibers on the surface of epoxy / fiber composite material 106 can accumulate at the inlets to the extrusion tip and lead to stacking / interruption of the manufacturing process line A method to correct the profile of the composite layer 106 is to compressively extrude a polymer layer on the composite layer before applying the external steel jacket. This causes several problems- First, because the profile can be as much as 0.178 to 0.381 mm (7 to 15 mil) out of roundness, an equivalent amount of coating would be required, thus increasing the diameter of the line and, more frequently, there is no space available in smooth line cables to allow coatings of that thickness. Secondly, applying extruded polymer by compression on the epoxy / long fiber compound reheats the epoxy. This overheating releases moisture and other volatile residues, causing the polymer to be extruded. Third, the short fibers or eraser of the epoxy / fiber composite is collected at the back of the tip of the extruder head due to the accumulation of fluff of the cured protruding core. This leads to stacking at the extruder tip and cable breaks, which prevents long-length extrusions. Also, in the manufacturing process, as illustrated in Figure 2, three uncured rectangular "tow" 202 of epoxy / fiber composite are brought together on inner steel pipe 104 of Figure 1, as the pipe 104 enters a pultrusion die. As each of the tow 202 bends around the central metal tube, the greater stress occurs at the edges of the profiled profile 204, causing the fibers to move in half, to a lower tension area-This causes that each of the tows be distorted as shown at 204. As a result, after leaving the pultrusion die on the inner steel tube 206 and contents thereof, the completed profile 208 of the epoxy / composite layer assumes a shape of "clover leaf". Said cloverleaf shape not only has significant variation in diameter around the periphery, but also varying domains of relative fiber / epoxy concentrations which can result in additional weakening by making the rope less durable. Thus, there is a need for safe and efficient methods for manufacturing smooth line cables consisting of an epoxy / fiber composite with improved circular profile consistency and fiber distribution in the composite, and where the cable remains substantially round in size. cross-sectional shape while the cable is in use. Said need is filled at least in part by the following invention-COMPENDIUM OF THE INVENTION This invention relates to smooth borehole line electrical cables, and methods for making and using said bores, and in one aspect, methods for manufacturing cables. Smooth line wire line composites. In some embodiments, the methods of the invention include preparing a smooth line cable providing an internal metallic tube containing at least one conductor (such as an optical fiber), dispose an epoxy / fiber composite resist layer substantially on the outer periphery of the inner metallic tube, and expose the combination of the inner metallic tube and composite resist layer to at least one technique to reduce the minimum the variation in diameter and provide a substantially uniform circular cross-sectional shape of the combination- In addition, an outer metallic tube is attracted around the combination of the composite resistance member and the inner metallic tube, to form a smooth wellbore line. probed Any appropriate technique to minimize the variation in diameter and provide a substantially uniform circular cross-sectional shape of the combination of the composite resistance member and the inner metallic tube may be employed. In one embodiment, this technique may include passing the combination through three progressively smaller diameter dies and liquid epoxy baths, then extruding a thin layer of epoxy over the combination at a sufficient viscosity to maintain a rounding profile before and after during exposure to UV radiation. Another technique involves passing the combination of the tube and composite layer through an infrared heater to remove volatiles from the epoxy, and then passing the combination through an extrusion die by polymer counterflow compression. Yet another technique used for the inner tube / composite combination where the compound is applied from the shape of a tow, includes passing the combination of the inner metallic tube and composite resistance tops (which can be coated with liquid epoxy) through of a first clover leaf shape die, passing the combination through a second circular shaped die, and then passing the combination through the third slightly smaller circular configuration die- Still another embodiment, including making pass the combination of the inner metallic tube and composite resistance layer through a first and second splitting die, where an epoxy layer is applied over the combination as the combination passes through the first dividing die- Likewise, some modalities can use two or more different techniques in series to help minimize variation in diameter and providing a substantially uniform circular cross-sectional shape of the combination of the composite resistance member and the inner metallic tube. In embodiments where epoxy / fiber tow is used to form the composite pipe, the tow can be applied to an inner metal pipe by passing the tow through channels in a configuration guide, and contacting a metal pipe in the pipe. tip of the guide. Some embodiments may also include arranging a fiberglass ribbon over the combination of the inner tube and composite layer before passing the combination through an infrared heat source to help maintain the diameter and the circular shape. invention also includes smooth line cables prepared in accordance with the methods described, as well as methods for using a smooth line cable deployed in a borehole to measure the properties of underground formations. BRIEF DESCRIPTION OF THE DRAWINGS The invention can be understood by reference to the following description taken in conjunction with the accompanying drawings, in which - Figures 1A and IB graphically show by cross section representation, the designs 1A common smooth line cable and some problems encountered with smooth line cables manufactured in accordance with methods 2B of the previous branch. Figure 2 illustrates by cross-sectional representation, the problems presented as smooth line cables are prepared in accordance with methods of the previous branch - Figure 3 illustrates a method for manufacturing a smooth line cable using a series of dies of progressively smaller diameter, liquid epoxy baths, a pressurized extrusion die, and a UV radiation source to cure the epoxy. Figures 4A and 4B show a polymer backflow compression extrusion die as used in a method for manufacturing a smooth line cable. Figures 5A, 5B, 5C and 5D illustrate the use of a trefoil pattern setting die in concert with circular dies in the manufacture of a smooth line cable. Figures 6A, 6B and 6C depict the use of first and second split dies and the application of an epoxy layer as used in the manufacture of a smooth line cable - Figures 7A, 7B and 7C illustrate how the member guides of resistance set are used in the manufacture of a smooth line cable- Figure 8 indicates how a fiberglass ribbon can be rolled over an epoxy / fiber composite tube- Figure 9, Figure 10 and Figure 11 illustrate some total processes to place epoxy / fiber composite on a pipe in a production line, of smooth line cable, which can be used in accordance with the invention. Figure 12 depicts how ultraviolet-cured shell fiber optic lines can be used in the manufacture of a straight line cable. DETAILED DESCRIPTION The description and examples are presented solely for the purpose of illustrating the preferred embodiments of the invention and should not be construed as limiting the scope and capability of application of the invention-While some embodiments of the invention are described herein as comprising certain materials, it should be understood that the composition could optionally comprise two or more different materials.

In addition, the composition may also comprise some components other than those already mentioned - In the summary of the invention and this detailed description, each numerical value must be read once as modified by the term "around" (unless it is already expressly so already modified), and then read again as otherwise modified unless otherwise indicated in the context. The invention relates to smooth borehole well line power lines, and methods for making and using said boreholes, and particularly methods for manufacturing composite smooth line cables. The methods of the invention provide efficient, safe methods for manufacturing smooth line lines consisting of an epoxy / fiber composite layer with a consistent circular profile sandwiched between two metal tubes (inner and outer tube), with the optical fibers contained Inside the inner tube - The epoxy / fiber composite material restricts tube breakage when the cable is pulled on pulleys and also contributes to a superior weight-to-weight ratio for the cable. The method of the invention produces durable smooth line boreholes with minimum variation in diameter and substantially uniform circular cross sectional shape through their length, the cable formed of low resin content epoxy / fiber compound disposed between internal and external metallic tubes, wherein the inner tube contains at least one conductor, such as an electrical conductor, an optical fiber, or a combination of the same- Variations in the diameter and cross-sectional shape of the combination of the compound and Internal tube combination results in a variation in the diameter and shape of the finished smooth line cable, which can lead to resistance, durability and / or deployment issues of the cable- Variations in diameter and cross-sectional shape due to differences in Thermal expansion between the cable elements can be minimized by means such as instant curing of the outer surface of the composite using infrared heating, arrange a tape (such as a glass fiber citation for example) on the composite; use a UV curable epoxy shell for the compound, or any combination thereof. Variations due to stress differences in the fibers during pultrusion can be minimized by using a die arrangement including a clover leaf die followed by circular dies, circular dies arranged in a sequence with varied die diameters (i.e. , diameters of die exit ports), coat the composite surface with polymer backflow, apply thin epoxy coating after the compound is at least partially cured, or any combination thereof - The surface layer distortions Composite due to fibers protruding above the surface of the composite (also called "fluff") can also result in variation in diameter and non-circular cross-sectional shape. Lint formation can be improved by using, for example, polymer backflow during extrusion, epoxy back coating after the compound is fully cured and / or semi-cured, UV curable epoxy counterflow, or any feasible combination thereof. . Any of the techniques described above for minimizing the variation in diameter and non-circular cross-sectional shape can be used either alone or in any suitable combination. When a fiber or optical fibers are used, they may be single-mode or multi-mode fibers, or mixtures thereof, with a pitch index or a graduated index fiber type. The fibers are preferably multi-mode, high temperature fiber. Even more preferably, the fibers are sized 50/125/400/700 um fibers manufactured with Si / PFA, such as those materials, manufactured by Sumitomo-Dichas, fibers have a resistance classification of approximately 100 kpsi, a classification of high temperature, and an attenuation of 1 kb / km at 1300 nm, 400 MHz- The fibers can have a layer intermediate protective or a hydrogen cleaning layer, if desired. While fiber is typically used in well monitoring to transmit data between two devices (from a downhole sensor to a processor above the well), the fiber itself can serve as a sensor. said practice, a surface device sends a signal down the fiber even when it is not terminated to a device at the other end. Partially, reflected bits of the signal return by echo above the line and the same surface device collects this data. Well conditions affect the properties of the fiber, fiber causes variations in the reflected signal, and these variations can provide information valuable about the well. The inner metallic tube, which works at least to protect the contents, can have an outer diameter of about 0.762 mm (0.03 inches) to about 10.16 mm (0.4 inches) and made of any suitable material, including stainless steel, such as a 304SS, 316SS, or an alloy such as INC0NEL. { R) A615, A825 or G31, which are high strength austenitic nickel-chromium iron alloys which have exceptional corrosion and heat resistance properties. A pipe made of any of these materials can withstand pressures in excess of about 1054-5 to about 1406 kg / cm2 (15,000 to 20,000 psi) and will have minimum bend radii of at least about 20.32 cm (8 inches), depending on the size / dimensions of the tube. The tubes can also be strong enough to finish in electrical applications, as if they were regular conductive wires. - The outer metallic tube can be welded around the set composed of insulated tube. While any suitable tube material can be employed, the most commonly used tubes are based on 316SS or A825, and preferably is about 3.175 mm (0.125 inches) in outside diameter (OD) with, for example but not limited to Wall thicknesses of around 0-559, 0.711, 0.889 or 1.244 mm (0.022, 0.028, 0.035 or 0.049 inches). More preferably, the tube is approximately 3-175 mm (0-125 inches) OD, about 0.559 mm (0.022 inches) wall thickness, A825, A825 is preferred because of its strength and corrosion resistance, yet at elevated temperatures. As seen in the industry, most downhole components are required to meet standards such as NACE MR-0175 (for corrosion), and A825 fills this standard even at elevated temperatures where many grades of stainless steel do not will qualify. A825 is also readily available and welds more easily than some of the more exotic steel alloys. The tube can serve as a shield to protect the internal / composite tube combination, and it can also serve as a return path to complete the electrical circuit between an above-ground computer, core conductors, and downhole sensor- according to the invention are useful for producing smooth line cables deployed in boreholes consisting of a compound, such as an epoxy / fiber compound of low resin content, sandwiched between two metal tubes, any practical epoxy relationship. fiber can be used. However, preferably from about 30 to about 50% by weight of epoxy is mixed with from about 70% to about 50% by weight of fibers, both based on the weight of total compound; more preferably, from about 35 to about 45% by weight of epoxy is mixed with from about 65% to about 55% by weight of fibers, both based on total weight of compound. The fiber filaments may have a coating that reacts with the epoxy thereby allowing chemical as well as mechanical bonding between the fibers and epoxies. The smooth line cables prepared according to the invention may have any diameter effect which requires very high tolerances ( ± 2 mils) in the pultruded compound - Preferably, the diameter is up to about 1.27 cm (0.5 inches), more preferably up to about 5.08 mm (0-2 inches), even more preferably up to about 2.54 mm (0.1 inch), In some embodiments, the diameter can still vary from about 2794 mm to about 3 ^ 302 m. (O-11 to 0-13 inches), such as around 3.175 rom (0.125 inches), These diameter tolerances are very difficult to achieve due to the different coefficients of thermal expansion of the individual components, voltage differences in the carbon fibers when their profile changes from rectangular to curvilinear during pultrusion, or loose fibers or fluff that accumulate on the pultruded rod causing subsequent processing difficulties. The methods according to the invention improve the variation in diameter, thus making possible the preparation of cables within said narrow diameter tolerances. The described preferred designs and processes solve the problem of thermal expansion differences using one or more of the following techniques: instantaneous cure of the outer shell of the composite layer using infrared heating, employing the use of a wrapping glass fiber ribbon in the composite layer, or by integrating a UV-curable epoxy shell into the composite layer. The problem of tension differences in the fibers during pultrusion can be minimized by using a clover leaf die followed by circular dies, multiple circular dies, coating the composite layer with polymer backflow, or even applying thin epoxy coating After the compound is fully cured or semi-cured, the lint formation in subsequent processing can be improved by using one or more of the following polymer backflow techniques during extrusion, epoxy back coating after the compound is completely cured or Semi-cured, or counter-flow of UV curable epoxy material. In a first embodiment of the invention, a method for manufacturing a smooth line cable that improves the ovality interests, thereby providing a substantially uniform circular cross-sectional shape, and helps prevent stacking during cable fabrication is illustrated in Figure 3. This method begins by providing a tube, such as a stainless steel tube containing optical fibers having an epoxy / heat cured fiber resistance layer spread over the stainless steel tube to form a tube 302. compound. To prevent the accumulation of loose fibers in the extrusion tip 304, the tube 302 passes through a series of progressively smaller diameter dies 306, 308 and 310, as well as liquid epoxy baths 312. The first die 306 is about 25 thousand greater in diameter than the diameter of the tube 302. Some loose fibers 314 are removed by the first die 306 and fall to the filter 316 below, which is placed above the container 318 to contain and recirculate through 320, a mixture of Epoxy and fibers not cured. The composite coating tube 302 then passes through a first epoxy tank 312. At the end of the first bath there is a die 308 with a diameter 15 thousand greater than the diameter of the tube 302. Any loose fibers collected by the die will accumulate on the filter 316 below the toilet instead of a dieThe tube 302 then runs through a second epoxy bath 312 before entering the final extrusion die 310, to a diameter approximately 3 thousand greater than the diameter of the tube 302. The final pressure extrusion die 304 applies a layer of Epoxy 326 from 2 mil to tube 302. This epoxy 326 is at a sufficient viscosity to maintain the round profile as the tube 302 is exposed to UV radiation, such as UV lamps, at 328 where the epoxy 326 is at least partial or completely cured. The external stainless steel tube is welded and stretched over the epoxy / cured fiber composite after passing under the UV radiation source. Referring again to Figure 3, circulating epoxy bath tanks 318 provide extended contact time to saturate the epoxy towards the cured composite surface. The accumulated loose fibers 314, 322, 324 are gradually removed as tube 302 passes through increasingly smaller dies 306, 308, 310 and are collected in filter 316 in recirculation tank 322- This prevents fibers loose ones accumulate in the extrusion tip 304 and stack in the extrusion line. Referring now to Figure 4A and Figure 4B, in another embodiment of the invention, there is disclosed a method for manufacturing a smooth line cable using a polymer backflow compression extrusion die. In this embodiment, the loose 404 fibers are removed from the epoxy / cured fiber composite. outside the tube 402 containing the optical fibers allowing a small amount of polymer 406 to flow out of the back of the extrusion tip 408, small holes, evenly spaced around the body of the tip 408 allow about 10 at about 15% of the polymer 406 flows out of the back of the tip 408, opposite the direction that the tube 402 is moving- The polymer 406 lodges moving backward through the tip leads away any loose fibers 404 and prevents those fibers from accumulating at the point of entry to the tip- Polymer 406 that leaves the back of 1 point 408 falls away and can be collected as waste. This design provides an effective method to prevent the accumulation of fiber from bunching in the extrusion line. The contact time with the polymer is also high so that even when out of any ovality of the composite profile, and give about 1 to about 2 mil thick the polymer prior to the cured compound. Preventing the blistering of the thermoplastic during compression extrusion, an infrared heater 412 preheats at least partially the epoxy / fiber composite (which may be partially or completely cured) to remove moisture and volatiles from the epoxy / fiber composite before to get in contact with any hot melt thermoplastic. In another embodiment of the invention, as illustrated in Figures 5A, 5B, 5C and 5D, a method for manufacturing a smooth line cable using a trefoil pattern setting die, the design consists of a series of dies 504 , 506, 508 of configuration to improve the profile uniformity of the composite tow coated on tube 502, the composite formed of three tow 510 (only two shown). Figure 5D shows the process and cross-sectional shape of tube 502 below, as it passes through dies 504, 506, 508, Referring now to Figure 5D, in a first step, die 504 forms Shamrock leaf is crazy and spins a. 120 degree deflection angle from the cloverleaf shape of the three uncured 510 traps loaded into the tube, This first 504 die imposes additional force in the low-stress areas in the middle of the tow, thereby forcing the fibers to remain at the upper tension edges of the tow profiles. The first clover leaf die 504 and second circular die 506 are bevelled at the inlet to facilitate movement of the tube 502 through the dies 504 and 506. A third circular die 5Q8, slightly smaller without an inlet angle further improves the profile circular. The clover leaf die 504 allows the tension differences in the fibers in different positions of the tow to be minimized by allowing the fibers of the rectangular tow to move at different distances to reach the circular profile. the front of the cloverleaf die 504 allows the excess epoxy to be removed from the composite. The composite flute-coated tube 502 enters the die in the trefoil sheet profile, tapering down to a circular profile at about 60.degree. % of the length of the die from the inlet, The second die 506 also has an inlet angle and maintains a circular profile through the die length- The third die 508 with a circular profile is added that has no entry angle, and serves to minimize or prevent communication of the fiber tension difference at the entrance of the trefoil leaf die 504 and the output of the third die 508-La accumulated friction of tube 502 coated with composite tow against the three dies causes this effect and helps to minimize the oval quality of the final product due to the voltage difference. As an option, the clover leaf die 504 on the front of the configuration die series could be replaced by an additional circular die at the end of the series. This die would have no entrance angle and a complete circular profile. Here, the accumulated friction between the cable and the three dies would serve to minimize the communication of the fiber voltage difference to the input of the first die and the output of the third or last die. In another embodiment of the invention, a method for manufacturing a smooth line cable using split dies with spring clamps is provided and illustrated in Figures 6A, 6B and 6C. Figure 6C shows the overall configuration while the Figures 6A_ and 6B are side views of the divided dies. The method presents another type of circular profile configuration die. This spring-loaded split design prevents piling up by expanding to allow abnormalities to pass through the die. 604 and 606 divided are held together with a spring clamp system 608, which includes springs 610 (only one indicated) and screws 612 (only one indicated). Any major anomalies in the cable profile will cause the clamps to expand momentarily instead of jamming the process line. The first die 604 is bevelled to the front to facilitate the cable (composite tube) 602 between the series of split dies loaded spring loaded. A foam layer of the epoxy used in the epoxy / cured fiber composite is extruded, or applied onto the cable 602 near the front of the first split die 604 spring loaded through the gate 614 to fill in any cracks or abnormalities in the partially cured epoxy / resin strength members. This thin epoxy coating can perform any of the following functions reduces the oval quality of the cable; removes loose fibers that accumulate on the composite surface; repairs cracks in the compound created in the compound by differences in thermal coefficient; results in finer tolerance laser micrometer readings; and / or prevents excessive wear in the dimension dies and the extrusion tip- The second die 606 has a slightly smaller circular profile and is rotated 90 annular degrees from the first 604, this second die 606 provides a second cleaner rub to the coated epoxy - In yet another embodiment of the invention, a method for manufacturing a smooth line cable is disclosed incorporating shaped resistance member guides, wherein the guide channels and forms uncured epoxy / composite to its place As they are placed on an inner tube containing optical fibers, see Figures 7A, 7B and 7C. Figure 7A is a front view, and Figure 7C is a side view of the guide 702. The conductor or tube runs through a hole (hole) 704 in the center of the guide 702, the epoxy / composite tow 706 rectangular uncured (only one indicated) move through guide 702 and are configured to final curvilinear dimensions. The guide 702 is cone-shaped with the base 708 of the cone where the rectangular tows enter the guide and the tip 710 where the curvilinear tows 706 exit the guide 702 into the tube. The smooth line cable in Figure 7B (shown in cross section) then enters a pultrusion die where the tows are further configured and consolidated on the tube. In some embodiments of the invention, illustrated in Figure 8, a glass fiber ribbon 804 can be wound on, or otherwise disposed on, the tube 802 of epoxy / fiber composite. In this approach, the thermosetting epoxy / pultruded fiber composite is wrapped in a glass fiber ribbon 804 to maintain the round profile during thermal curing. The tape 804 is placed at a laying angle and can be lapped if desired. The tape can also be epoxy coated to bond with the epoxy / fiber composite. This design is applied to the uncured pulsed form 802 after the pultrusion dies have applied the tow to the inner metal tube. In addition, to retain the profile during thermal curing, the tape 804 also reduces the likelihood of long fibers with a lay angle of 0 degrees from the split as the members pull on the pulleys under tension, the tape could be apply immediately after the initial series of pultrusion dies, such as those described above - In accordance with the invention, any of the general embodiments described above can be used, either alone or in combination to form line cables smooth Figure 9, Figure 10 and Figure 11 illustrate some total processes for placing epoxy / fiber compound on a pipe in a smooth line cable production line, which can be used in accordance with the invention. In the embodiment illustrated in Figure 9, three or more epoxy / fiber strength members (or tows) are joined together on an inner tube comprising optical fibers to form the composite tube 902 immediately prior to entering the trefoil leaf die 904. , one of a series of configuration dies, similar to 504, 506 and 508 of Figure 5. The trefoil leaf die 904 forms the three epoxy / fiber resistance members on the conductor to compensate for the voltage difference that occurs due to the change from a rectangular to a curvilinear shape. The cable (co-installed tube) 902 then moves through two more circular configuration dies 906, 908 before passing through an infrared heat source 910 at least partially curing or consolidating the epoxy resin. The infrared heater 910 quickly cures the external surface of the composite before allowing significant expansion of the tube contained in compound 902. Then the wire passes through a series of heating furnaces 912- during this time the epoxy It can be cured almost 90%, The composite tube can then be cooled. Then the composite tube 902 passes through a spring clamp split die 914 (such as that described in Figure 6) where a layer of epoxy foam is applied to fill any voids on the surface of the composite tube 902. The cable (tube) 902 then passes through a second spring clamp die 916 (such as that described in Figure 6), then a source 918 of final infrared heat to quickly cure the epoxy so that it does not run. , deform, ovale, flatten or drip when exposed to heat. The composite tube 902 can then pass through a second optional set of spring clamp dies 920 and 922. Represented in Figure 10, a configuration guide installation can be used in place of the trefoil sheet die arrangement of Figure 9, to provide a process such as that described in Figure 9- Referring to Figure 9 , the clover leaf die 904 and circular configuration dies 906 and 908 are replaced with a pair of pultrusion dies 1006, 1008, and are used with a guide 1004 of similar configuration with that illustrated in Figure 7. The tow epoxy / uncured rectangular compounds are moved through the guide 1004 and an inner tube is inserted through the hole in the configuration guide 1004. The tows are formed on the tube to form the composite tube 902. The tube 902 then enters a first pultrusion die 1006 and second pultrusion die 1008 where the tows are further configured and consolidated into the tube. The tube 902 then passes through a source 910 of infrared heat to at least partially cure or consolidate the epoxy resin. The cable (or tube) 902 passes through a series of heating furnaces 912 and then the rest of the process as described in Figure 9. This mode can also use three dies with the option of the clover leaf as the first die to further minimize the tension difference in the fibers in a single tow. Figure 11 illustrates the same process of Figure 10 with the addition of the glass tape applied to the epoxy / fiber composite before the smooth line cable enters the first infrared heater, similar to that illustrated in Figure 8. in Figure 10, the tows run through the guide 1004 and an inner tube is inserted through the hole in the configuration guide 1004, the tows formed on the tube to form the composite tube 902. The tube 902 then enters a first pultrusion die 1006 and second pultrusion die 1008. Then a fiberglass ribbon 1102 can be wound onto the epoxy tube (or cable) 902. The tube 902 then passes through a source 910 of infrared heat, through a series of heating furnaces 912, and then the rest of the process as described in Figure 9. This installation could also use three dies with the choice of cloverleaf as the first die to further reduce the minimum the tension difference in fibers within a single tow - In another embodiment of the invention, ultraviolet-cured shell fiber optic lines are used. In this method, as illustrated in Figure 12, long fibers 1202 are pultruded in an epoxy thermoset onto an inner tube to form a composite tube, similar to the composite tube 302 illustrated in Figure 3 above. The epoxy resin 1204 ter, the internal metallic tube 1206, and long optical fibers 1202 are introduced into the pultruded assembly 12Q8. the outlet thereof being the composite tube 1210, the composite tube 1210 then passes through the pressure-extrusion system illustrated in Figure 3 whose loose fibers are removed from the outside of the line and UV curable epoxy is applied may be using pressure . After the extrusion tip comes out, the uncured epoxy / fiber composite tube 1210 is then exposed to UV Lamp 121 where the outer epoxy shell is cured in a consistent round profile. The composite tube 1210 then passes through the furnace 1213 where the epoxy / fiber composite is cured using heat. The UV-cured outer shell prevents the profile from being deformed into an oval shape during subsequent thermal curing processes - The large arrows in Figure 3, Figure 4, Figure 5, Figure 6, Figure 9, Figure 10, Figure 11, and Figure 12 represent the direction in which the cable (had) moves in the particular process. The particular embodiments described above are illustrative only, since the invention can be modified and practiced in different but apparent ways to those experts in the field who have the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design shown herein, other than as described in the claims below. Therefore it is evident that the particular embodiments described above can be altered or modified and all these variations are consider within the scope and spirit of the invention. Accordingly, the protection sought herein is set forth in the claims below-

Claims (1)

1. CLAIMS 1.- A method to prepare a smooth line cable that includes: a. provide an inner metallic tube containing at least one conductor, b- dispose an epoxy / fiber composite resistance layer substantially on the outer periphery of the inner metallic tube to form the combination of the inner metallic tube and composite resistance layer, c. exposing the combination of the inner metallic tube and composite resist layer to at least one means for minimizing the variation in diameter and providing a substantially uniform circular cross-sectional shape of the combination of the composite resistance member and the inner metallic tube, and d- stretching an outer metallic tube around the combination of the composite resistance member and the inner metallic tube. 2 - The method according to claim 1, wherein the variation in diameter of the smooth line cable is approximately + 2 mils or less. 3 - The method according to claim 1, wherein the at least one conductor is an optical fiber. 4. The method according to claim 1, wherein the inner metallic tube and the outer metallic tube are stainless steel or nickel-chromium-iron alloy tubes. 5. The method according to claim 1, wherein the diameter of the smooth line cable is approximately 12.7 mm (0.5 inches) or less. 6-- The method according to claim 5, wherein the diameter of the line cable smooths up to about 5.08 mm (0.2 inches) preferably up to about 2.54 mm (0.1 inches), more preferably about 2.794 mm ( 0.11 inches) to around 3,302 mm (0.13 inches). 7 - The method according to claim 1, wherein at least one means for minimizing the variation in diameter and providing a substantially uniform circular cross section shape comprises passing the combination of the inner metallic tube and the composite resist layer through three dies of progressively smaller diameter and liquid epoxy baths, where a first die is about 25 thousand in diameter larger than the diameter of the combination, a second die is about 15 thousand in diameter greater than the combination, and a third die is about 3 mil in diameter larger than the combination, before stretching the outer tube thereon. 8 - The method according to claim 7, further comprising arranging a layer of 2 thousand epoxy on the combination of the inner metallic tube and the composite strength layer after the combination passes through a third die, exposing the epoxy layer to UV radiation, before stretching the outer tube thereon. 9. The method according to claim 1, wherein at least one means for minimizing the variation in diameter and providing a section shape. substantially uniform circular cross-section comprising passing the combination of the inner metallic tube and the composite resistance layer through an infrared heater to pre-cure the epoxy, and then passing the combination through a counterflow backflushing extrusion die. polymer before stretching the outer tube on it. 10. The method according to claim 1, wherein at least one means for minimizing the variation in diameter and providing a substantially uniform circular cross-sectional shape passing the combination of the inner metallic tube and the composite resist layer. through a first clover-leaf shaped die, pass the combination through a second circular-shaped die, and then pass the combination through a third slightly smaller circular-shaped die, before stretching the tube external on it, where the combination is a tube lined with tow-11, - The method according to claim 1, wherein at least one means for minimizing the variation in diameter and providing a substantially uniform circular cross section shape comprises passing the combination of the inner metallic tube and the composite resist layer. through a first and second split die before stretching the outer tube thereon, wherein an epoxy layer is applied over the combination as the combination passes through the first divided die. 12. The method according to claim 1, wherein the inner metallic tube containing at least one conductor passes through an orifice of a configured resistance member guide, the epoxy / fiber composite resistance layer is it substantially rests on the outer periphery of the inner metal tube by passing at least three tows through channels in the guide and making contact with the metal tube at the tip of the guide. 13. - The method according to claim 12, wherein the combination of the inner metallic tube and composite resist layer is passed through a first means to minimize the variation in diameter and provide a substantially uniform circular cross section shape , the first means comprising a first clover-leaf shaped die, a second circular-shaped die, and a third slightly circular-shaped die, then passing the combination through an infrared heat source to pre-cure the epoxy , then curing the epoxy, then passing the combination through a second means to minimize the variation in diameter and provide a substantially uniform circular cross-sectional shape, the second means comprising a first divided die and a second divided die. 14. The method according to claim 12, wherein the combination of the inner metallic tube and composite resistance layer is passed through a first means to minimize the variation in diameter and which provides a cross-sectional shape substantially uniform circular, the first medium comprising a first pultrusion die, and a second pultrusion die, then passing the combination through an infrared heat source to pre-cure the epoxy, and then curing the epoxy. The method according to claim 14, further comprising arranging a fiberglass ribbon over the combination of the inner metallic tube and composite resist layer before passing the combination through an infrared heat source, 16. - The method according to claim 1, wherein the variation in diameter of the combination of the inner metallic tube and composite resist layer before stretching the outer tube thereon is about + 2 mils or less 17, - The method according to claim 1, further comprising disposing a fiberglass ribbon over the combination of the inner metallic tube and composite resist layer before stretching the outer tube thereon. 18. A smooth line cable prepared in accordance with the method of claim 1. 19. A method for preparing a smooth line cable comprising: a. providing an inner metallic tube containing at least one conductor, b- arranging a resistive layer, composed of epoxy / fiber substantially on the outer periphery of the inner metallic tube to form a combination of the inner metallic tube and composite resistance layer, c. pass the combination of the inner metallic tube and composite resistance layer through an infrared heater to pre-cure the epoxy, and then pass the combination through an extrusion die by polymer counterflow compression before stretching the outer tube on it, and d. stretching a metal tube around the combination of the composite resistance member and the inner metal tube; wherein the composite resist layer restricts the breakage of the outer metal tube when pulled on pulleys during deployment of the cable into a borehole. 20. A method for using a smooth line cable deployed in a borehole to measure the properties of an underground formation, the smooth line cable by a method that comprises a. providing an inner metallic tube containing at least one conductor, b- arranging an epoxy / fiber composite resist layer substantially on the outer periphery of the inner metallic tube to form a combination of the inner metallic tube and composite resist layer, c, exposing the combination of the inner metallic tube and composite resist layer to at least one means for minimizing variation in diameter and providing a substantially uniform circular cross-sectional shape of the combination of the composite resistance member and the inner metallic tube, and d. stretching an outer metallic tube around the combination of the composite resistance member and the inner metallic tube; wherein the composite resist layer restricts the breaking of the outer metal tube when pulled on pulleys during deployment of the cable into a borehole. TESTING HESUMEN Borehole electrical cables, and methods for manufacturing such cables, and in one aspect, methods for making smooth line cables of wireline composites are described. Some embodiments are methods that include preparing a smooth line cable by providing an inner metallic tube containing at least one conductor (such as an optical fiber), arranging an epoxy / fiber composite resist layer substantially on the outer periphery of the tube. internal metallic, and expose the combination of the inner metallic tube and composite resist layer to at least one technique to minimize the variation in diameter and which provides a substantially uniform circular cross-sectional shape of the combination- In addition, an outer metallic tube it stretches around the combination of the composite resistance member and the inner metal tube, to form a smooth borehole line. Cables prepared using these methods are also described.