WO2016175806A1 - Épissure de gaine de câble sous-marin - Google Patents

Épissure de gaine de câble sous-marin Download PDF

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Publication number
WO2016175806A1
WO2016175806A1 PCT/US2015/028391 US2015028391W WO2016175806A1 WO 2016175806 A1 WO2016175806 A1 WO 2016175806A1 US 2015028391 W US2015028391 W US 2015028391W WO 2016175806 A1 WO2016175806 A1 WO 2016175806A1
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WO
WIPO (PCT)
Prior art keywords
polymer
cable
nonmetallic
power cable
jacket
Prior art date
Application number
PCT/US2015/028391
Other languages
English (en)
Inventor
Bradley Matlack
Jason Holzmueller
Mark Metzger
Gregory Howard MANKE
Brandon NEAL
William Goertzen
Original Assignee
Schlumberger Canada Limited
Services Petroliers Schlumberger
Schlumberger Technology B.V.
Schlumberger Technology Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Schlumberger Canada Limited, Services Petroliers Schlumberger, Schlumberger Technology B.V., Schlumberger Technology Corporation filed Critical Schlumberger Canada Limited
Priority to PCT/US2015/028391 priority Critical patent/WO2016175806A1/fr
Publication of WO2016175806A1 publication Critical patent/WO2016175806A1/fr

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Classifications

    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/08—Cable junctions
    • H02G15/18—Cable junctions protected by sleeves, e.g. for communication cable
    • 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
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/14—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for joining or terminating cables
    • H02G1/145—Moulds
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G1/00—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines
    • H02G1/16—Methods or apparatus specially adapted for installing, maintaining, repairing or dismantling electric cables or lines for repairing insulation or armouring of cables
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G15/00—Cable fittings
    • H02G15/003—Filling materials, e.g. solid or fluid insulation
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G9/00—Installations of electric cables or lines in or on the ground or water
    • H02G9/12—Installations of electric cables or lines in or on the ground or water supported on or from floats, e.g. in water

Definitions

  • Power cables for downhole electric submersible pumps are typically rated at 3kV (kilovolts), 4kV, or 5kV and utilize either a flat or round cable profile.
  • Flat cables are more commonly used than round because they prevent spatial clearance issues.
  • a cable-to-cable splice is performed.
  • Splice and repair techniques replace each layer of the cables, such as insulation, dielectric, and jacketing, with the same or similar materials for that layer over the span of the splice or repair site.
  • Conventional splice techniques consist of welds, tape layers, convection wrap molding, and so forth, to ensure that the splice or repair has sufficient integrity to meet downhole operating conditions.
  • the final component of any splice or repair is a conventional metal armor, a layer that protects all of the underlying components.
  • the cable is "armorless," without conventional metal armor.
  • the jacket material used in lieu of metal armor is robust enough to be exposed to hot, corrosive, and abrasive downhole fluids without need for the conventional metal protective armor.
  • An example method includes detecting a gap in a nonmetallic jacket of a cable for powering a downhole electric submersible pump (ESP), and molding a polymer around at least part of the cable to seal the nonmetallic jacket at the gap.
  • ESP downhole electric submersible pump
  • An example method of splicing the power cable for a downhole electric submersible pump (ESP) includes receiving a first power cable and a second power cable, each power cable including a nonmetallic outer jacket, coupling a first conductor of the first power cable to a second conductor of the second power cable to establish an electrical connection between the first power cable and the second power cable, and molding a polymer around at least the electrical connection to create a continuous nonmetallic outer jacket between the first power cable and the second power cable for sealing the electrical connection.
  • ESP downhole electric submersible pump
  • a system for splicing a nonmetallic jacket of a cable includes a mold configured to approximate an outside diameter of a first power cable to be spliced to a second power cable, each of the first power cable and the second power cable comprising a nonmetallic outer jacket, a heat source associated with the mold, and a temperature controller associated with the mold for melting a polymer at a temperature suitable for molding and fusing the polymer to the nonmetallic outer jackets of the first power cable and the second power cable.
  • FIG. 1 is a diagram of an example subsea power cable with a nonmetallic jacket for powering a subsea electric submersible pump (ESP), the subsea power cable having molded polymer splices and a molded polymer repair site.
  • ESP electric submersible pump
  • FIG. 2 is a diagram of an example splice site between two power cables that have nonmetallic jackets and an example repair site on a cable that has a nonmetallic jacket.
  • Fig. 3 is a cross-sectional diagram of an example power cable in a mold or form for injection molding, compression molding, or transfer molding a polymer onto the power cable.
  • Fig. 4 is a diagram of example chemical formulae of a moldable polymer for splicing or repairing a power cable that has a nonmetallic jacket.
  • Fig. 5 is a cross-sectional diagram of an example power cable including a nonmetallic jacket molded from a mix of polymer and additive agents.
  • Fig. 6 is a diagram of an example mold and molding configuration for splicing two power cables that have nonmetallic jackets.
  • Fig. 7 is a diagram of an example power cable that has a molded polymer splice between the nonmetallic jackets of two cable segments and in which the molded polymer has a higher melting point than the nonmetal jackets of two cable segments.
  • Fig. 8 is a flow diagram of an example method of molding a polymer onto a cable to repair a nonmetallic jacket of the cable.
  • Fig. 9 is a flow diagram of an example method of molding a polymer to splice two cable segments that have nonmetallic jackets.
  • This disclosure describes subsea cable jacket splicing and repairs.
  • the splicing, mold, repair materials, and techniques described herein are not limited to subsea environments, but can be applied to armorless cables used in many types of harsh downhole environments.
  • a tough and resistant jacket takes the place of conventional metal armor.
  • the splice or repair can be performed in a shop, and then the spliced or repaired cable can be used downhole.
  • the spliced or repaired part of the jacket maintains strength and durability, and resists to abrasion, high temperatures, and surface penetration of corrosives without needing a conventional metal outer armor.
  • the splice itself can be considered a molded nonmetal armor.
  • the splice is molded onto at least part of each cable, creating a fusion bond or weld with the existing jackets of the cables.
  • the molding process can be, for example, injection molding, compression molding, transfer molding, and so forth.
  • the molding process uses a form, pre-forms, or a mold as well as heat to fuse the polymer being placed.
  • Fig. 1 shows an example power cable 100 being connected to a subsea well 102, and further downhole to an electric submersible pump (ESP) 104 in the well 102.
  • the example power cable 100 is armorless, without an outer metal protective layer.
  • the outer layer of the armorless power cable 100 is a tough polymer jacket.
  • the example power cable 100 may be made of multiple long cable segments, joined together by at least one splice 106.
  • the power cable 100 may also have at least one site on which a repair 108 has been performed.
  • a repair 108 rejuvenates the power cable 100 against a gap in the nonmetallic outer jacket, and against possible damage to underlying layers of insulation, dielectric, barriers, and filler.
  • Fig. 2 shows an example site 200 for a splice 106 between two example power cables 100 & 100'.
  • Fig. 2 also shows example sites 202 & 204 for repair 108 to the example power cable 100.
  • the splice 106 or repair 108 uses a process of molding a polymeric covering onto the power cable 100, to replace or rejuvenate the nonmetallic outer jacket 206 already in place on the power cable 100 to be repaired or spliced.
  • the splice 106 or repair 108 may also involve coupling electrical conductors 208 and repairing or extending other layers of the cable 100 occurring between the inner electrical conductors 208 and the outer jacket 206, such as insulation 210 and so forth.
  • Fig. 3 shows an example power cable 100 in cross-section.
  • the example power cable 100 is shown within a mold 300 (form or pre-form) for molding the polymer around at least part of the power cable 100.
  • Molds 300 for injection molding, compression molding, or transfer molding are well- described in the respective arts.
  • the example power cable 100 may have one or multiple electrical conductors 208 (wires), for example three electrical conductors 208 for 3- phase AC electrical service to an induction motor of the ESP 104.
  • Each wire or electrical conductor 208 of the example power cable 100 is surrounded by electrical insulation 210.
  • the insulation 210 may be surrounded by various other layers, such as a barrier 302.
  • an inner barrier layer 302 when present, may be made of lead metal or a fluoropolymer.
  • An example splicing process molds a polymer around the electrical conductors 208, the insulation 210, and the other layers, such as the barriers 302, to complete or repair the nonmetallic outer jacket 206 of the example power cable 100.
  • a pair of cable ends can be spliced 106 or repaired 108 by molding an example outer jacket material 206 between the two cable ends, after the conductors 208 and other underlying layers 210 & 302 of the cable 100 have been made continuous between the two cable ends.
  • Such an example splice 106 allows for longer lengths of an armorless power cable 100 to be made and installed downhole, for example in deep well 102 applications.
  • splicing 106 and repairing 108 with the same jacket material as the original cables 100 maintains the same performance of the cable 100 at the splice site 200 or repair locations 202 & 204.
  • a cable 100 can also be repaired 108 using the example polymer molding technique when there is an error or equipment malfunction during manufacture of the cable 100, thereby saving the resources that would be used to make a new, full length of the cable 100.
  • the electrical conductors 208 may be high purity copper and may be solid, stranded or compacted-stranded. Stranded and compacted-stranded conductors offer improved flexibility, which is an advantage in some installations.
  • the conductors 208 may also be coated with a corrosion- resistant coating to prevent degradation of the conductor 208 from the hydrogen sulfide (H 2 S) gas which is commonly present in downhole environments. Examples of such corrosion-resistant coatings include tin, zinc, lead, nickel, silver, and other corrosion-resistant alloys and metals.
  • the conductors 208 can be spliced using a welding technique or copper sleeve.
  • the example power cable 100 may also have a conductor shield, which is a semiconductive layer around each conductor 208 that controls electrical stress in the cable 100 to minimize discharge.
  • This layer can be between 0.002 inches and 0.020 inches thick.
  • the conductor shield layer can be bonded to the conductor 208 and insulation 210 to prevent gas migration, or the conductor shield layer can be made strippable. Whether or not the shield is bonded depends on the application.
  • the conductor shield layer may be made of a semiconductive tape wrap or an extruded semiconductive polymer.
  • the layer may be an elastomer or thermoplastic co-extruded with the insulation 210 allowing the layers to crosslink together.
  • the co-extrusion may eliminate the possibility of voids at the critical conductor shield / insulation interface.
  • Materials used for the conductor shield layer may be semiconductive, having a resistivity less than about 5000 ohm-cm.
  • An elastomer compound such as ethylene propylene diene monomer / terpolymer (EPDM), loaded with conductive fillers may be used for this layer.
  • EPDM ethylene propylene diene monomer / terpolymer
  • PEEK polyether ether ketone
  • the insulation shield and the insulation 210 do not have to use the same base material, however, using the same base material may allow for easier processing.
  • the conductor shield layer may be spliced 106 or repaired 108 using tape layers, shrink tube, or a molding process directly onto the conductor 208.
  • Material for the insulation layer 210 may be EPDM or PEEK.
  • EPDM When EPDM is selected, compound formulations for oil and decompression- resistance may be used.
  • the insulation layer 210 adheres or is completely bonded to the conductor shield, when present.
  • the insulation layer 210 should also be continuous with an insulation shield, if present, but does not have to be completely bonded.
  • An advantage of PEEK in this instance is improved mechanical properties that allow for improved damage resistance during cable installation and cable operation.
  • the much higher stiffness of PEEK also allows for much greater ease in sealing over the cable members at cable termination points (motor potheads, well connectors, feed-th roughs, and so forth). This is an important factor in improving reliability not only of the cable 100, but of the system.
  • the insulation layer 210 can be spliced 106 or repaired 108 using tape layers, shrink tube, or a molding process directly onto each conductor 208.
  • An insulation shield may be applied over the insulation 210 as a semiconductive layer to minimize electrical stresses in the cable 100.
  • the insulation shield may be bonded to the insulation 210 or may be strippable. Some adhesion between the layers is ideal to prevent voids and defects in the cable 100.
  • the material for the insulation shield can be a semiconductive tape or a semiconductive polymer, for example having a resistivity less than 5000 ohm-cm. Like the conductor shield, the insulation shield can be co- extruded with the insulation 210 to ensure complete contact between the surfaces. The same material can be used for the insulation shield as for the conductor shield. Conversely, a different material can also be used if the different material is more workable.
  • the insulation shield layer can be repaired 108 or spliced 106 using tape layers, shrink tube, or a molding process directly onto the conductor 208.
  • a conductive layer can optionally be applied to serve as an electrical ground plane outside of the insulation shield. This conductive layer can isolate the effects of the different electrical phases of the cable 100 from each other. Copper, aluminum, lead, or another conductive material, tape, braid, paint, or extrusion can be applied over the insulation shield to provide the conductive layer.
  • the conductive layer may also serve as a barrier to downhole gases and fluids, protecting the inner cable layers.
  • the conductive layer can be repaired 108 or spliced 106 using tape layers, shrink tube, or a molding process directly onto the conductor 208.
  • the barrier layer 302 can protect the cable 100 from corrosive downhole gases and fluids. Additional barrier layers 302 may then be applied if needed.
  • the barrier layer 302 can be made up of extruded or taped layers of fluoropolymers, lead, or other material sufficient for protection against well fluids. A combination of extruded and taped layers may also be used.
  • This barrier layer 302 can be repaired 108 or spliced 106 using tape layers, shrink tube, welding, or a molding process directly onto the conductor 208.
  • the cable jacket 206 takes the place of conventional metal armor, so the polymer selected for the nonmetallic outer jacket 206 has characteristics of toughness and resistance to harsh downhole environments.
  • the nonmetallic outer jacket 206 may have a metal filler agent or metal atoms as part of a polymer mix. So the descriptive term “nonmetallic” just means that the nonmetallic outer jacket 206 is an extrudable and moldable polymer that avoids the disadvantages of being a conventional metal armor, but “nonmetallic” does not mean that metallic agents are avoided in the polymer jacket 206 at all costs.
  • the nonmetallic jacket 206 is continually extruded with no gaps, holidays, or voids in the jacket layer 206 that allow for ingress of fluids.
  • the polymeric makeup of the nonmetallic jacket 206 imparts excellent fluid and gas resistance at the surface of the jacket 206, low surface energy to prevent adhesion of fluids during retrieval out of hole, and high mechanical properties, preferably with low cost and good workability.
  • the polymeric jacket 206 could be spliced 106 or repaired 108 using tape layers or shrink tubing, but because the nonmetallic jacket 206 is in contact with moving well fluid, which can contain abrasives, tapes or elastomers with low mechanical strength are easily damaged, resulting in early failure of the splice 106 or repair 108.
  • the cable jacket 206 is molded with a polymeric splice between the two cables 100 & 100' being spliced 106, preferably using the same materials as the jackets 206 of the two cables 100 & 100'. This allows creation of long lengths of the cable 100 and enables repair 108 if there is damage or errors in manufacturing, without reducing the overall quality of the cable.
  • the splice 106 or repair 108 is made by molding a polymer derived from a high-strength resin to the cable 100, for example, an ethylene tetrafluoroethylene (ETFE), such as TEFZEL (DuPont Corporation, Wilmington, Delaware).
  • ETFE ethylene tetrafluoroethylene
  • a copolymer of polyvinyl idene fluoride (PVDF) and hexafluoropropylene (HFP) can be used for the splice 106 or repair 108 of the cable jacket 206 by molding this copolymer combination over the conductors 208.
  • PVDF polyvinyl idene fluoride
  • HFP hexafluoropropylene
  • the high crystallinity of the PVDF component gives high strength and stiffness, but can tend toward environmental stress cracking in some oilfield conditions. Incorporation of a size disparate copolymer such as HFP disrupts the crystallinity, creating amorphous regions where crack propagation is stopped.
  • the inclusion of HFP in the polymer structure also improves the fluid resistance of the jacket surface, while reducing the likelihood of crack propagation.
  • molding the jacket splice 106 or jacket repair 108 into place eliminates the need for a protective metal armor layer at the splice site 200 or the repair sites 202 & 204.
  • Using the same polymeric material as the original cable jacket enhances the reliability of this example method.
  • the physical and chemical properties of a PVDF-HFP copolymer may be selected by adjusting the copolymer ratio of HFP to PVDF in the PVDF-HFP copolymer.
  • the copolymer ratio of HFP to PVDF in the PVDF-HFP copolymer may be selected by adjusting the copolymer ratio of HFP to PVDF in the PVDF-HFP copolymer.
  • an optimized copolymer of PVDF-HFP that is predominantly PVDF with a small copolymer ratio or proportion of HFP provides a splice 106 or repair 108 with high tensile strength and modulus yet excellent toughness and resistance to environmental stress cracking.
  • a KYNAR FLEX grade of PVDF copolymer resin may be used (Arkema, Colombes France).
  • PVDF-HFP copolymer jacket 206 provides a cost-effective jacket material
  • other materials may be used, such as a fluorinated ethylene propylene (FEP), a polyvinyl fluoride (PVF), a polypropylene (PP), a polyalkyletherketone, a polyaryletherketone, a polyamide, nylon 12, and so forth.
  • Fig. 5 shows the example power cable 100 with additive agents 500 included with the molding polymer.
  • additive agents 500 can be fillers that provide a beneficial property.
  • the additive agents 500 can be incorporated into a thermoplastic jacketing material, for example, to improve or manipulate properties such as tensile strength, abrasion resistance, thermal conductivity, resistance to surface penetration, and other key properties.
  • the additive agent 500 may be a barrier agent 500 or a reinforcement agent 500 added to the polymer to be molded around at least part of the cable to seal the nonmetallic jacket at a gap.
  • the barrier agent 500 or the reinforcement agent 500 can consist of glass fibers, carbon fibers, carbon nanotubes, carbon black, graphene, boron nitride, an aluminum oxide (for example, alumina or aluminum (III) oxide), a clay, a mica, a silica, and so forth.
  • an aluminum oxide for example, alumina or aluminum (III) oxide
  • a clay for example, a mica, a silica, and so forth.
  • FIG. 6 shows an example splice 106 or repair 108 scenario in which the splice site 200 or repair site 204 of the cable 100 is placed into a form, pre-form, or mold 300 for injection-molding, compression molding, or transfer molding. Underlying layers of the cable 100, such as insulation 210 or barriers 302 are repaired or extended as needed, before the selected polymer is molded onto a section of nonmetallic outer jacket 206.
  • the selected polymer for the splice 106 or repair 108 is introduced into the mold 300 according to the molding operation selected.
  • the molded polymer fusion- bonds or welds to the existing jackets 206 on the cables being spliced 100 & 100'.
  • the molded polymer may also bond or at least adhere to the underlying insulation layer 210 or barrier layer 302.
  • An example mold 300 for splicing the existing nonmetallic jackets 206 of two cables 100 can be configured to approximate an outside diameter of the cables 100.
  • a heat source melts or achieves the fusion temperature of the polymer being used to splice the jackets 206 of the cables 100.
  • a temperature controller for precise adjustment can be useful in controlling the degree and the quality of the fusion bond achieved between the polymer selected for the splice and the nonmetallic jackets 206 of two cables 100.
  • the mold 300 may utilize an induction heat source for rapid heating of the polymer and the nonmetallic outer jackets 206, and for precise control of the extent of the fusion bond or weld between the molded polymer and the nonmetallic outer jackets 206 of the cables 100.
  • the induction heating source may include a conductor 302 near or constituting the barrel 304 of the mold 300 where the splice takes place.
  • An induction coil 306, or electromagnet causes heating in the conductor 302 through electromagnetic induction using high-frequency alternating current (AC).
  • the example mold 300 may also have a cooling assembly 308 including, for example, cooling tubes, that circulates a fluid such as water or oil. The cooling assembly 308 rapidly reduces the temperature after molding for achieving a reduced cycle time, a higher mold throughput, and control of the extent of the fusion bond between the molded polymer and the nonmetallic outer jackets 206 of the cables 100.
  • the induction heating also improves energy efficiency for the molding process. Since heat is generated directly in the barrel 304 of the example mold 300, warm-up and energy consumption are reduced.
  • the induction coil 306 can reside outside of thermal insulation to operate at low temperatures, for increased lifespan.
  • Terminated cable sections constituting cable ends to be spliced 106 may be surface-prepared so that the molded polymer bonds well to the jackets of the terminated cable sections. Mechanical abrasion, plasma treatment, or etching of the preexisting jacket surfaces of the cables 100 & 100' to be spliced 106 or repaired 108 ensure reliable bonding with the molded polymer of the splice 106 or repair 108.
  • Fig. 7 shows example cables 100 & 100' spliced 106 with a molded polymer 700.
  • the molecular structure of the molded polymer 700 is adjusted, e.g., by varying the proportion of a copolymer or by including additive agents 500, to provide a slightly higher melting temperature of the molded polymer 700.
  • the higher melting temperature of the molded polymer 700 improves the fusion bond between the jackets 206 of the terminated cable ends and the molded polymer 700 that makes up the splice section 106.
  • the melting temperature of the molded polymer 700 is selected to be below the melting temperature of the lead jacket (approximately 320-327 °C). This is because during the molding process the lead jacket can be exposed to the molten polymer 700, and if the molten polymer 700 is hot enough it can melt the lead layer.
  • the melting point of the molded polymer 700 selected is less than 320 °C, to provide a safety factor for the thermal vulnerability of the lead layer.
  • an ETFE polymer with a melting temperature in the range of 240-260 °C may be used.
  • a polymer such as polyether ether ketone (PEEK), with a melting point of -335 °C, should be avoided for use as a molten polymer over a cable 100 that has an underlying lead layer.
  • PEEK polyether ether ketone
  • Fig. 8 shows an example method 800 of molding a polymer to repair a nonmetallic jacket of a cable. In the flow diagram, operations are shown in individual blocks.
  • a gap is detected in a nonmetallic jacket of a cable for powering a downhole electric submersible pump (ESP).
  • ESP downhole electric submersible pump
  • a polymer is molded around at least part of the cable to seal the nonmetallic jacket at the gap.
  • Molding the polymer around at least part of the cable to seal the nonmetallic jacket at the gap may further comprise molding a thermoplastic polymer or a thermosetting polymer around at least part of the cable by applying a molding process, such as an injection molding process, a compression molding process, or a transfer molding process.
  • a molding process such as an injection molding process, a compression molding process, or a transfer molding process.
  • the polymer may be an ethylene tetrafluoroethylene (ETFE) polymer or a poly(vinylidene fluoride-co- hexafluoropropylene) (PVDF-HFP) copolymer, for example.
  • ETFE ethylene tetrafluoroethylene
  • PVDF-HFP poly(vinylidene fluoride-co- hexafluoropropylene) copolymer
  • PVDF-HFP poly(vinylidene fluoride-co-hexafluoropropylene) copolymer
  • PVDF-HFP poly(vinylidene fluoride-co-hexafluoropropylene) copolymer
  • the method 800 may further include molding the polymer around at least part of the cable to seal the nonmetallic jacket at the gap, wherein the polymer is formulated to be suitable for protecting the cable from a downhole environmental attack, such as a subsea environment, a high temperature environment, a corrosive environment, a hydrogen sulfide-rich environment, or an abrasive environment, and the polymer may be a fluorinated ethylene propylene (FEP), a polyvinyl fluoride (PVF), a polypropylene (PP), a polyalkyletherketone, a polyaryletherketone, a polyamide, or a nylon, such as nylon 12.
  • FEP fluorinated ethylene propylene
  • PVF polyvinyl fluoride
  • PP polypropylene
  • a polyalkyletherketone a polyaryletherketone
  • a polyamide such as nylon 12.
  • the method 800 may further include adding a barrier agent or a reinforcement agent to the polymer to be molded around at least part of the cable to seal the nonmetallic jacket at the gap.
  • the barrier agent or the reinforcement agent may be glass fibers, carbon fibers, carbon nanotubes, carbon black, graphene, boron nitride, an aluminum oxide (e.g., alumina), a clay, a mica, or a silica.
  • the polymer may be formulated by adjusting a copolymer ratio to provide a polymer melting temperature for properly fusing to the cable.
  • the polymer melting temperature can be incrementally higher than a jacket melting temperature of the nonmetallic jacket already in place on the cable to enhance the fusion bond or weld between the nonmetallic jacket and the molded polymer.
  • a polymer may be selected for molding to the cable that has a melting temperature lower than the melting point of lead metal at approximately 320-327 °C.
  • the surface of the nonmetallic jacket may be prepared for bonding to the molded polymer by mechanical abrasion of the nonmetallic jacket surface, plasma treatment, or etching the nonmetallic jacket surface.
  • Fig. 9 shows an example method 900 of molding a polymer to splice a nonmetallic jacket between two cable ends. In the flow diagram, operations are shown in individual blocks.
  • a first power cable and a second power cable are received, each power cable including a nonmetallic outer jacket.
  • a first conductor of the first power cable is coupled to a second conductor of the second power cable to establish an electrical connection between the first power cable and the second power cable.
  • a polymer is molded around at least the electrical connection to create a continuous nonmetallic outer jacket between the first power cable and the second power cable for sealing the electrical connection.
  • the method 900 may further include extending one or more underlying layers of the respective power cables across the electrical connection by applying a respective material of each underlying layer across the electrical connection, the underlying layers occurring between the respective inner conductors and the respective nonmetallic outer jackets of the power cables.
  • the moldable polymer may be an ethylene tetrafluoroethylene (ETFE) polymer or a poly(vinylidene fluoride-co-hexafluoropropylene) (PVDF- HFP) copolymer.
  • the moldable polymer can also be a fluorinated ethylene propylene (FEP), a polyvinyl fluoride (PVF), a polypropylene (PP), a polyalkyletherketone, a polyaryletherketone, a polyamide, or a nylon, such as nylon 12.

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Abstract

L'invention concerne une épissure de gaine de câble sous-marin. Des matériaux et des techniques donnés à titre d'exemple peuvent être appliqués à des câbles non armés qui sont utilisés dans de nombreux environnements hostiles, tels que des applications sous-marines. Selon un mode de réalisation, un polymère est moulé et lié par fusion à des câbles d'alimentation pour épisser ou réparer une gaine polymère non métallique pour une utilisation en continu dans des environnements hostiles. L'épissure permet de créer des câbles non armés beaucoup plus longs. Le polymère peut être un tétrafluoroéthylène (ETFE), un poly(fluorure de vinylidène-co-hexafluoropropylène) (PVDF-HFP) avec un rapport de copolymère ajusté, un éthylène-propylène fluoré (FEP), un fluorure de polyvinyle (PVF), un polypropylène (PP), une polyalkyléthercétone, une polyaryléthercétone, un polyamide, ou un nylon. Des agents de barrière ou de renforcement peuvent également être ajoutés au polymère pour une meilleure résistance à la traction, une meilleure résistance à des fluides chauds, et une meilleure résistance à la pénétration d'agents corrosifs.
PCT/US2015/028391 2015-04-30 2015-04-30 Épissure de gaine de câble sous-marin WO2016175806A1 (fr)

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EP4113762A1 (fr) * 2021-06-28 2023-01-04 NKT HV Cables AB Dispositif de pressurisation et de chauffage et procédé de restauration du système d'isolation d'un câble électrique

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US6664476B2 (en) * 1998-03-04 2003-12-16 Pirelli Cavi E Sistemi S.P.A. Electrical cable with self-repairing protection
US6676422B1 (en) * 2002-10-01 2004-01-13 Drilltec Patents & Technologies Co., Inc. Power cord composite threaded sealing cap
US20080087466A1 (en) * 2006-10-17 2008-04-17 Emerson Tod D Splice for down hole electrical submersible pump cable
US20120097444A1 (en) * 2010-10-26 2012-04-26 M.C. Miller Co. Method of splicing electrical cables
US20130140726A1 (en) * 2011-12-06 2013-06-06 Tyco Electronics Uk Ltd Cable termination, joint and repair system

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US6664476B2 (en) * 1998-03-04 2003-12-16 Pirelli Cavi E Sistemi S.P.A. Electrical cable with self-repairing protection
US6676422B1 (en) * 2002-10-01 2004-01-13 Drilltec Patents & Technologies Co., Inc. Power cord composite threaded sealing cap
US20080087466A1 (en) * 2006-10-17 2008-04-17 Emerson Tod D Splice for down hole electrical submersible pump cable
US20120097444A1 (en) * 2010-10-26 2012-04-26 M.C. Miller Co. Method of splicing electrical cables
US20130140726A1 (en) * 2011-12-06 2013-06-06 Tyco Electronics Uk Ltd Cable termination, joint and repair system

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4113762A1 (fr) * 2021-06-28 2023-01-04 NKT HV Cables AB Dispositif de pressurisation et de chauffage et procédé de restauration du système d'isolation d'un câble électrique

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