Professional Documents
Culture Documents
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Technical Bulletins
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Example:
L1 = 25,500 Feet
R1 = 265.4
T1 = 75F
r = (R1 / L1) x [(302.5) / (234.5 + T1)]
r = 0.01017 /ft
This value of r, should be recorded in the Cable Log Book.
As sections of cable are cut off, the remaining length, L, of cable on the drum can be calculated using the recorded
value of r, the Resistance R of the centre conductor of the remaining length, and the Temperature, T of the
remaining length of cable.
L
Example:
r = 0.01017245 (/ft)
R = 195.4
T = 92F
L = (R / r) x [(302.5) / (234.5 + T)]
L = 17796.7
The length of the cable is now 17,796 feet.
To obtain the best results, it is recommended to use a Fluke or equal quality 4 or 5 digit 1% type Ohmmeter with good
leads. It is Important to use the same Ohmmeter to establish the value of r and later measurements of R.
05/2005
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20,500 feet
220.5 Ohms
165.0 Ohms
325.5 Ohms
Leak Location:
Lw = [ 220.5 + 165.0 325.5 ] x [ 20,500 / 2x220.5 ] = 2,789 feet from whip end
Lt = [ 220.5 + 325.5 165.0 ] x [ 20,500 / 2x220.5 ] = 17,711 feet from truck end
Methods for locating high resistance electrical leaks and eliminating the effects of a wet leak will be covered in later Technical Bulletins.
05/2005
Check and adjust the ZERO on the meter with the small
screw on the meter face.
Plug one test lead into the RED WHIP socket and clip this
lead to the WHIP end of the cable.
Plug one test lead into the BLACK TRUCK socket and clip
this lead to the TRUCK end of the cable,
Plug one test lead into the GREEN ARMOR socket and clip
this lead to the cable ARMOR.
Rotate knob A to read 50.
Connect the AC power cord and turn power ON.
Operation:
With the power on, the meter needle should deflect off
of zero.
If a very small or no deflection occurs, starting with button
1 hold down and observe the deflection of the meter.
If the meter deflects to the left, WHIP, rotate knob A
counter clockwise, until the meter reads zero.
If the meter deflects to the right, TRUCK, rotate knob A
clockwise, until the meter reads zero.
Hold down button 2 until the meter again reads zero.
Repeat this with button 3 held down.
Record the final dial reading, 0.252 in the example
shown below.
Leak Location
Multiply the dial reading, 0.252 by the length of the cable. For
example with a cable length of 20,000 feet, the leak is located at:
0.252 X 20000 = 5040 feet from WHIP end
Setup:
Check that both ends of the cable are free, clean and NOT
connected to anything.
Turn power switch OFF.
Accuracy
This type of instrument will only locate a leak to within +/200 feet.
For maximum accuracy:
1. Burn out the leak to the lowest resistance possible
2. Be sure all test leads fit firmly in sockets
3. The lengths of the WHIP & TRUCK test leads must be equal.
4. The test leads should be as short as possible
Check for a wet leak. This is done by measuring the
resistance of the leak with an Ohm meter and then reversing
the leads of the Ohm meter and see if the leak resistance is
the same. If the leak resistance is the same you are ok. If
there is a significant difference between the two readings,
you need to dry out the leak with a burn out box.
05/2005
(Pay-off)
(Take-up)
05/2005
500F
350
300
300F
250
200
0
10
15
20
(L - d)
(234.5 + Ts)
d
(Tb - Ts)
Hd
2
+d
(234.5 + 68)
(234.5 + 68)
12/2005
Pull on cable to remove all slack and put the cable under strain.
Note and record the indicated depth from the measuring device, (D1).
Note and record the tension in the cable.
Increase the tension exactly 1000 pounds (4.44 kN) & record the indicated depth, (D2).
Calculate the depth of the stuck point: Ds = (D1 - D2) / K (1000 feet).
K is the stretch coefficient of the cable, which is listed in the Wireline Works Catalogue, ft/Kft/Klbs.
To convert from metres to feet: 1 foot = 0.3048 metres
OD-Inches
ft / Kft / Klbs
3/16
3.0
7/32
2.2
1/4
1.9
9/32
1.6
5/16
1.2
3/8
1.0
7/16
0.70
15/32
0.77
0.49
0.60
Example
Cable type-Dakota 1-R-322-FAH, 5/16 Mono-cable ; K = 1.2
Cable becomes stuck at an indicate depth of, D1 = 16500 ft.
With the cable under strain the line tension is = 3,300 lbs.
The tension is then increased to 4,300lbs and the indicated depth is D2= 16480 ft.
Ds = (D1 - D2)/K = (16500-16480) / 1.2 ( 1000 ft) = 16,600 feet
In this example the stuck point depth is close to the indicated tool depth, so it is the tool that has become stuck.
Depth Corrections
If a more accurate stuck point is important, then the following factors can be considered:
The stretch, ( D2-D1) when measured at the truck includes the stretch in the cable from the truck to the well head. A
more accurate method of measuring the stretch is to mark the cable at the well head an then measure the stretch
when the tension is increased.
If the rig-up distance is known, it can be subtracted from the calculated depth based on measurements of stretch at
the truck.
For well seasoned cables the stretch coefficient should be reduced by 5%.
In very deep hot holes the effective value of K can increase by 10%.
If there are reasons not to increase the tension by 1000 lbs, then just increase the tension by 500 pounds and then
take the value of Ds. calculated using the above formula.
05/2005
result from allowing the cable to free fall into the hole and
coming out of the hole at speeds that cause excessive high
tensions; improper sheave grove size or sheave alignment can
also contribute to loosening the outer armor. When the outer
armor has become loose it is important to have a cable shop
normalize and post-form the cable to tighten the outer
armor and restore its normal breaking strength.
Oilfield cables are constructed with two layers of contrahelically applied armor wires. Under load each layer of wires
develop torque. The torque developed by the inner armor is in
opposition to the torque of the outer armor. The torque
developed by each layer of armor wires is determined
primarily by the total area of steel in each layer and the
distance of the wires from the cable center. The outer armor
wires are always further from the cable center than the inner
armor and for practical reasons the outer armor layer has a
greater area of steel. The outer armor layer, therefore,
develops much greater torque than the than the inner armor
layer. This imbalance in torque can be partially but not
completely offset by adjusting the lay angles of the inner and
outer armor wires.
If a cable under load is free to rotate, such as a cable hanging
in a vertical cased hole, the dominant torque of the outer
armor wires will cause the cable to rotate in such a direction
as to unwind the outer armor and reduce its stress. As the
outer armor wires unwind, the inner armor wires are forced to
wind tighter and this increases the stress in the inner armor. If
allowed, this unwinding will continue until the torque
between the layers is equal and when this occurs the stress in
the inner armor is much higher than in the outer armor. When
a cable is free to rotate or is forced to unwind by improper
operating conditions the breaking strength is significantly
reduced and when it does break, the inner armor will break
first. and then the outer armor wires will stretch out before
they break.
In normal operations, with proper tensions going in and out
of the well, the lower portion of the cable, if free to rotate
will unwind in proportion to the tension but due to friction in
the borehole, there is less unwinding near the surface, so the
cable breaking strength at the surface is close to ends fixed
strength. The breaking strength will be reduced further by
field operations that force the cable to unwind. This includes:
trying to control pressure with a tight pack-off instead of
using more flow tubes; wide cable tension variations that
05/2005
Drum Crush
The term drum crush refers to a cable electrical failures that occur as a result of the cable being crushed, smashed or
distorted to such an extent that the armor wires press and distort the plastic insulation and in some cases cut through the
insulation and contact the conductor. It is possible to have the conductor insulation distorted to such an extent that it
affects the signal transmission characteristics of the cable with out an actual electrical short. These failures are caused by
cables at high tension being spooled over cable spooled at abnormally low tension, cable installed with an incorrect
tension profile or cable that is operated in a manner to cause excessive rotation. For these reasons a more correct term for
this type of failure would be Cable Crush Failure, ( CCF).
CCF, never occurs on the whip end of the cable. Typically the failures are found at a minimum of 4 or 5 layers down and
more commonly deeper than that. Failures can and often do occur in layers of cable that have never or not recently been
off the drum.
An important characteristic of CCF is that the failure frequently does not occur immediately. For a failure to occur the
plastic insulation must cold flow under pressure and this can be a slow process. A CCF condition in some cases may have
been setup several jobs, days or even weeks before the actual failure does occur. It is this time lag that makes it difficult to
always identify the actual cause of the failure.
Factors that can contribute to CCF include:
1. Poor drum cable entry hole.
2. Irregular drum core.
3. Spreading of drum flanges.
4. Incorrect tension profile on initial cable installation.
5. Single break cable installation.
6. Loss of normal cable tension in field operations.
7. Excessive cable rotation.
8. Low or non uniform cable inner armor coverage.
A further explanation of these failures:
1. A rough or bad angle of the cable entry hole in the drum can result in a CCF from the pressure of all the wraps on the
drum. This is a special case and is easily identified.
2. Irregularities in the diameter of the drum core results in irregularities in the spooling pattern which causes pressure
points on the cable and distorts its shape. When the cable shape is distorted, it generates gaps in the inner armor
permitting easier cold flow of the plastic.
3. When the drum flanges spread there is as much as half of the diameter of the cable on each side of the top layer then
there is a situation where the cable can cut in. When this occurs, the cable shape is distorted resulting in easier plastic
cold flow.
4. There is no one size fits all when it comes to installing a cable on the drum. The correct tension profile that should be
used depends on the type of cable, the cable length and expected depth of operations. In general after the bed layer is
established the spooling tension is increased each layer for 3 or 4 more layers up to a tension of about 1/3 of the cable
breaking strength. This tension is maintained for half the cable length after which the tension is reduced each
successive layer. This is just a very general rule and experienced cable service men in each area know how to adjust
these tensions for best spooling. If too much installation tension is used in shallow hole areas, then the cable will not
spool properly at the low tensions in shallow operations. If the installation tension is too low, when installing a cable to
be used in deep hole operations, then the problem is more serious as CCF can result. When the installation tension is
low, and the spooling tension coming out of the hole is high it can result in a CCF. The failure will typically occur several
layers down on the drum and at a cable cross over between wraps or at the flange where the cable moves from one
layer to the next.
5. When a cable is spooled on a drum the cable must move over one diameter distance for each wrap. If this move is
accomplished at one point in the wrap it is called a single break spooling. All qualified cable spoolers now use the
double break spooling method, which moves the cable half a cable diameter midway around each wrap. The single
break results in a more sever distortion of the cable armor making it more susceptible to a CCF by over laying layers.
6. One frequent causes of a CCF resulting from field operations is re-spooling cable back on the drum after loss of normal
cable tension. A common cause of loss of cable tension is over running the hole bottom. When this occurs it results in
several wraps of the cable going back on the drum at low tension, followed by the high tension of cable when pulled
off of TD. This problem has become more frequent because of deviated holes, where it is necessary to approach TD very
05/2005
05/2005
05/2005
Vb
Battery
DMM
*Measure at cable ends on the conductor
Vw
Collector End
+
Battery
Battery
05/2005
Breaking Strength
The breaking strength of any Dakota cable can be found on both the Cable Specification Sheet and
in the Catalogue. These can either be found on the website www.wirelineworks.com or call your
Wireline Works Representative to send you physical copies. These values of breaking strength are
theoretical values assuming the cable is in new physical condition, and the cable is pulled straight
without rotating. Dakota cables are regularly tested to verify that the breaking strength exceeds the
catalogue values.
There are many factors which can effect the breaking strength of a cable after it has been in the
field which include:
Physical wear on the cable which reduces the diameter of the outer armor wires; hence,
reducing the breaking strength of the cable
Corrosion of the cable will reduce the effective diameter of both the inner and outer armor
wires and again reduce the breaking strength
H2S exposure can embrittle the steel and drastically reduce its breaking strength, as it bends
over the sheave wheel.
CO2 exposure will also cause accelerated corrosion
Excessive rotation of the cable, caused by improper operating tensions or hydraulic packers
can reduce the breaking strength by as much as 30%
Splices if done properly can withstand loads over 90% of the cables breaking strength.
However they loose much of their strength if put into compression (spudding), and tend to
deteriorate quickly when run over sheaves frequently. Shims used in splicing need to be
inspected regularly for wear.
Fatigue of armor wires occurs when the cable is yo-yoed at high tension. When it is
necessary to yo-yo a cable, then at every 10 or 20 cycles the upper sheave wheel or truck
should be moved so that a fresh section of cable is passing under the measuring head and
over the sheave wheels.
Physical Damage such as kinks, armor scratches, dents, etc. to the cable can result in a much
reduced breaking strength
Operating Strength of a cable is expressed as the percent of ends fixed breaking strength (BS) of the
cable. For GIPS cables Wireline Works recommends an Operating Strength of 60% of the breaking
strength. Sour service cables should not normally be operated over 50% of there breaking strength.
The cable will operate an unlimited number of tension cycles to its Operating Strength without
permanent damage to the cable. When the cable is stressed to above the operating strength, there
may be permanent irreversible damage. Above the recommended operating strength there can be
plastic forced out of the gaps in the inner armor resulting in less electrical insulation between the
conductor and armor. There may also be additional elongation of the cable and when tension is
released Z kinks may begin to form in the copper conductor. If these high tensions are repeated it
will lead to electrical failure.
05/2005
Use plenty of the pressure control grease, Liquid O Ring 4-I, ( or equal).
Use the National Association of Corrosion Engineers guide lines, for allowable H2S.
Get in and out of the hole as quickly as possible, within correct operating speeds.
If your operating conditions do not fall within these guidelines, then an alloy cable should be used. H2S and alloy
armored, MP35 & stainless steel, cables will be covered in another technical bulletin.
05/2005
08/2005
Example #1:
Length of cable in the hole is 20,000 feet; therefore, Lh = 20;
Length of cable on the drum is 5,000 feet; therefore, Ld = 5;
The Voltage required at the tool Vb = 700;
The cable voltage rating Vmax= 1200, (from Wireline Works
Catalogue)
Total cable loop resistance, Rc = (4.0 x 5) + (4.0 x 20) +
(4.4 x 20) = 188 Ohms
Total allowable Voltage drop, Vd = Vmax Vb = 1200 700
= 500 Volts
Current = Voltage /Resistance
Maximum current that can be supplied is Imax = Vd / Rc =
500 / 188 = 2.6 amps.
Now consider the heating effect of the cable on the drum.
Power = (Current)2 x Resistance = Current x Current x
Resistance
Power (watts) dissipated in drum cable, Pd = (Imax x Imax) x
(4.0 x Ld) = (2.6 x 2.6) x (4.0 x 5) = 135 Watts. In this example
the heat from 135 watts, a typical light bulb, dissipated in the
500 pounds of cable on the drum plus the steel drum will have
little effect on the cable temperature.
Example #2:
Lh =5; Ld = 20; Vb = 700; Vmax = 1200; Calculate Imax
Rc = (4.0 x 20) + (4.0 x 5) + (4.4 x 5) = 122 Ohms
Vd = 1200 700 = 500 Volts
Imax = 500 / 122 = 4.1 amps
Now consider the heating effect of the cable on the drum
Pd = (Imax x Imax) x Rd
Rd = 4.0 x Ld
Pd = (4.1 x 4.1) x (4.0 x 20) = (16.8 x 80) = 1,344 watts.
This is nearly 10 times the wattage of the other example but
still not a serious problem for short periods. 1,344 Watts is
about the power of a kitchen hot plate. It would take a very
long time to heat up a 2,000 pound cable on the drum plus a
steel drum with a kitchen hot plate. This example does
however, illustrate that the problem of maximum current
becomes more serious when most of the cable is on the drum.
There are too many variables to calculate the maximum
allowable time limit, including: ambient temperature, layers of
cable on the drum, air circulation, spooling tensions, etc.
Experience has indicated that cable on the drum can tolerate,
without damage, 1/10 watt per foot for periods of 24 hours. In
this example that would be 1,250 watts.
Armor Specifications
15 X15 Construction
Larger outer armor wires wear longer.
Larger outer wires are stiffer and therefore easier to
thread through flow tubes.
Larger outer wires do not become crossed over as
easily during re-heading.
Smaller inner wires will corrode to brittleness faster,
reducing cable life.
The larger Torque Factor means this type of cable,
especially when new, will try to unwind more , which
can result in loose outer armor wires.
The outer armor of the 15 X 15 construction will
require more frequent trips to a service center for
normalization and post forming, to tighten the
outer armor.
12 X 18 Construction
Larger inner armor wires will not corrode and become
brittle as fast.
The smaller Torque Factor means the cable will not
unwind as easily, so the outer armor will stay tight
longer, requiring less service.
The outer and inner armor wires are the same
diameter making a better head termination.
09/2005
Armor Package
Cable Diameter - inches
Diameter Inner Wires inches
12 inner X 18 outer
15 inner X 15 outer
0.224 +.005/-.002
0.224 +.005/-.002
0.0310
0.0245
0.0310
0.0358
0.009056
0.007070
0.013585
0.015098
0.022641
0.022168
5,600
5,600
2.2
3.2
(patent pending)
If the original length of the cable, L is 25,000 feet then the increase
of the inner armor length, li is:
li = ( 25,000 )(0.0044) = 110 feet
The outer armor in contact with the inner armor layer experiences
the same reduction in diameter but this is a smaller fraction of its
original diameter, so the elongation, lo, of the outer armor is less
than the inner armor:
lo = L[(Dc-Dc)/( Dc+2di +do)]X[Tan Ao]^2 =
L[(0.008)/(0.243+2*0.0535+0.067)](Tan 19)^2 =L[ 0.0023]
lo = (25,000)(0.0023) = 58 feet.
It is conventional cable manufacturing practice to embed the inner
armor in the core to season it by subjecting the finished cable to
a prestressing operation. This operation typically applies a tension
of about 1/3 of the cable rated breaking strength as it passes
between two capstans. The tension in the cable is lost as it leaves
the final capstan and goes on the shipping reel.
If the tension in this standard prestressing operation has embedded
the inner armor in the core, then when the tension is removed, the
inner armor, now wound around a smaller core, would like to be
longer than the outer armor as the above calculations demonstrate.
Because of the friction between the inner and outer layers the
outer armor can not shrink back over the inner armor . Since the
shorter outer armor has much greater strength, it will push back on
the inner armor, which will reduce the pressure on the core.
The nature of plastics is that they have a memory and though the
prestressing operation may have initially fully embedded the inner
armor into the plastic core, when the inner armor pressure is
reduced the core will start to recover its original shape. When this
occurs, the cable is not fully seasoned and will have excessive
inelastic stretch.
Wireline Works Inc. has a proprietary cable seasoning process
known as Compound Pre-StressingTM (patent pending). With this
procedure the inner armor, core assembly is first pre-stressed with
sufficient tension to fully embed the inner armor wires into the
core. After pre-stressing the inner armor, the outer armor is then
applied to the already embedded and elongated inner armor. This
permits the outer armor to add rather than reduce the pressure on
the core ensuring a fully seasoned cable.
To allow for full embedment the initial core diameter required is:
Dc = [ (0.243 + 0.0535)^2 (16 / 2Cos22 )( 0.0535)^2]^1/2
= 0.251
Dc- Dc = 0.251 - 0.008 is the core compression.
This shows that the diameter of a newly assembled cable of this
type will decrease 8 thousandths of a inch when the inner armor is
fully embedded in the core. Since the inner armor wires are
helically wrapped around this smaller effective core diameter the
length of the embedded inner armor layer will be longer. This
increase in length, li, can be calculated :
li = L[ (Dc- Dc ) /( Dc + di)] X [ Tan Ai]^2 = L[ 0.008 /
(0.243 + 0.0535)] X [Tan22]^2 = L[0.0044]
02/2006
Figure 1
Figure 2
Dc
Voids
Dc
Armor Coverage
Armor coverage is a very important property of
electromechanical wireline cables. Proper design and armor
coverage permits cables to operate under tough operating
conditions of high temperatures and high tensile loads. The
term armor coverage refers to how close the armor wires
are together. If a layer of armor wires were to have 100%
coverage, it would mean that all of the armor wires in that
layer were touching their adjacent wires.
There are a number of very important reasons why the armor
coverage of both the inner and outer armor layers must be
carefully controlled. If the coverage on either layer were
100%, the cable would be so stiff it would not be able to
bend around a sheave wheel without forcing one of the wires
out of the layer, creating a high wire. If the armor coverage is
too low a premature electrical short could result under high
temperature and high load conditions.
The range and requirements for the coverage of the inner and
outer armor layers is quite different. To calculate coverage
there are at least 4 good formulas. In the case of oil field
electro mechanical cables (wirelines), there is little difference
in the calculated coverage values using any of these formulas.
The formula that has been accepted by the major oil field
service companies and Wireline Works is:
di
% Ci =
% Co =
Ci
Co
di
do
Ni
No
i
o
Dc
=
=
=
=
=
=
=
=
=
do
x100
x100
06/2006
di
di = 0.0405;
do = 0.040;
Dc = 0.288;
Ni = 12;
i =
180
19.5
Ci = 99.1%
(100);
Do
No do2 to Sin [o]
2
Qi
Di
2
To off set the dominant outer armor torque, the lay angle of
the inner armor is increased. From cable design we know
there is an angle of maximum torque for the inner armor. This
is because the portion of cable tension carried by the inner
armor decreases as the inner armor lay angle is increased.
Therefore; even though the larger lay angle will result in
increasing the component of tension that generates torque, if
the tension is decreased excessively, the torque will also
decrease. The result is an angle of maximum torque for the
inner armor, which in turn is the angle that results in the
minimum cable torque. ( Q =Qo-Qi ).
The minimum torque angle for a cable with a 12/18 armor
package is about 25 to 26 degrees. Again in cable design there
are compromises to be made. As the lay angle of the inner
armor is increased to reduce cable net torque, it also reduces
the breaking strength. The best compromise between
breaking strength and cable torque is an inner armor lay
angle of 23 degrees.
Cable Torque, inch-pounds/pound
0.017
0.0165
0.016
0.0155
0.015
15
20
25
Inner Armor Lay Angle ia
cos2 ( oa)
06/2006
cd = 0.322
noa = 18
cd dia 2 doa
dia2 +
dia = 0.0445
aia = 23
qcc = 0.0151162
cd doa
35
30
cd doa
doa = 0.0445
aoa = 19
nia = 12
pr = 0.47
Wireline Torque
Electromechanical Wireline Cables are designed and
manufactured to minimize the inherent torque in the cable,
see Technical Bulletin Minimizing Cable Torque during
Design". However, all cables inherently have some torque
and will develop a need to rotate relative to the tension
applied during operations. This is generally not a problem
as long as the cable is allowed to rotate freely. In todays
complex oilfield there are a lot of variables that affect and
restrict cable rotation. If the cable is not allowed to rotate
in proportion to tension, torque build up will begin to occur
in certain areas of the cable depending on what is
restricting it from rotating properly. For example, the packoff will restrict the cable from rotating and the cable will
accumulate torque as the cable passes through pack-off.
This results in torque build up and loose outer armor.
Cable rotation can be restricted and torque imbalance may
occur from the following operations:
Deviated or crooked well bores.
Going in and out too fast and not observing the 80/120
tension rule, (see Technical Bulletin #9).
Pulling out of a well at high speeds that result in
excessive tension.
Centralized and decentralizing tools.
Heavy and viscous drilling mud and completion fluids
affect the tension of the cable.
Grease heads or pack-offs used to wipe or
control pressure.
Pulling out of a rope socket under high load conditions.
Low fluid bypass conditions.
Field experience has shown that almost always loose outer
armor is caused from the torque imbalance resulting from
improper running conditions. During the seasoning or
breaking in period for new cables there will generally be
some areas in the cable that become loose. These areas do
not cause problems under everyday use; however, it would
be good insurance to normalize (tighten loose areas) a
standard GIPS cable after 20 to 30 runs. This would tighten
any loose outer armor that may have occurred due to the
core embedment of a new cable.
06/2006
If a cable has been run into a well bore with any condition
that may prevent free rotation or cause torque imbalance,
the cable will need attention to keep it from failing. The
standard approach is to normalize the cable to be sure the
outer armor is tight. If you feel or see your cable trying to
curl up while laying on the ground during rig ups it has
excessive torque. Running the cable in this condition will
risk breaking, or getting a strand cross-over which can cause
the cable to strand at deeper depths. Remember every bird
cage you see is caused by getting too much slack in one
location of the cable. It is a good idea to rehead, when
possible, with inner armor strands on the cables that are
using grease heads because they are lubricated and can
torque up relatively easily.
Lack of tension means low rotation is required, and high
tensions means a lot of rotations required to prevent torque
build up. If you come out of a well with very high tension
and torque in the cable, the next time you go into a well
with very little tension, there will be a lot of torque in the
cable wanting to be released. Armor separation, high
strands, or bird caging are not the only issues to worry
about with torque build up, you may also experience early
pullouts, cable breaks, and excessive compression on the
conductor which can short out the cable. The more you
understand the affects of torque the better off you are in
preventing cable failures and/or well site disasters.
The torque generated at maximum working load for
standard cables has been calculated as follows:
TYPE
LOAD
Z-224
R-224
R-288
R-322
R-380 R-425
(pounds)
3360
3360
6000
6720
8600 11700
55.5
40.7
93.5
116.7
176.5
TORQUE
(Inch-pounds)
268.3
Cable Rotation
By design, wireline cables develop torque when subjected to
load, see Technical Bulletin Minimizing Cable Torque During
Cable design. The load on the wireline cable is a result of the
weight of the tool, the weight of the cable and any dynamic
friction due to running conditions. If the tool end of the cable is
free to rotate, the cable will try to rotate to reduce this torque.
All cables used in oil field service operations are built with the
torque of the outer armor dominant over the opposing torque
of the inner armor. To balance the torque the cable will unwind
in a direction to loosen the outer armor, which will tighten the
inner armor. If the cable is free to rotate, this unwinding or
rotation will continue until the torque in the inner armor equals
the torque of the outer armor. The number of revolutions, Nf
(per 1000 ft per 1000 lb), that the end of the cable will make to
equalize the torque can be calculated as follows:
Nf = 48 x 106 (cd doa) ( cd + dia + 2 doa)
dia2 (cd 2 (dia + doa)) nia pr sin3 ( ia) + dia2 ( cd + dia + 2 doa) nia cos2 ( ia) sin ( ia) +
doa2 noa sin ( oa) (cd doa) cos2 ( oa) + (2 (dia + doa) cd) pr sin2 ( oa)
dia2 doa2) nia noa 2 ym ((doa cd) cos ( ia) sin ( oa) (cd dia 2 doa) cos ( oa) sin ( ia))
1
(cd dia 2 doa) (cd doa)2 sin(2 oa) cos2 ( ia) +
2
sin( ia) ((cd doa) ( cd + dia + 2 doa)2 cos2 ( oa) +
cd3 + (4 dia + 6 doa) cd2 5 dia2 cd + 8 doa3) pr sin2 ( oa) cos ( ia) +
pr cd (cd2 4 doa cd + doa (4 dia + 5 doa) cos ( oa) sin ( oa) sin2 ( ia) +
dia cd2 + doa2 (dia + doa) sin (2 oa) sin2 ( ia) +
dia3 + 5 doa dia2 + 8 doa (doa cd) dia 6 cd doa2 sin (2 ia) sin2 ( oa)
06/2006
R-224
48
R-288
22
R-322
17
R-380
10
R-425
7
07/2006
ARMOR
Z-224
R-224
R-258
R-288
R-322
R-380
R-425
POT-lbs
1200
1200
1600
2700
2800
3500
4600
cp-psi/lb
4.00
4.10
3.10
2.49
1.98
1.43
1.14
cp Tool-psi
1200
1230
930
747
594
429
342
cp-at POT-psi
4800
4920
4960
6723
5544
5005
5244
07/2006
wires as they are wrapped around the plastic core before the
assembly enters the closing dye. The closing dye and
following pinch rollers press the evenly spaced armor wires
into the plastic core to insure they will stay evenly spaced
during subsequent manufacturing operations (as shown in
the picture below).
Conclusions
As new plastics become available, Wireline Works evaluates
them by testing them under simulated tension and
temperature conditions. If these new materials perform well
in these simulated tests, then a limited number of cables are
manufactured using the new material and their performance
closely monitored. If there are no problems with the new
materials in the initial field trials, then additional cables will
be put into field service for continued evaluation.
By carefully choosing and testing all core plastic materials and
precisely controlling the inner armor coverage and spacing,
Wireline Works cables will operate at or above the maximum
temperature rating for all routine operations.
Sheave Selection
There is probably more material available on sheave selection
than any other piece of cable equipment. By summarizing and
analyzing all this data it will give the operator greater choice in
judging the proper size sheave for an operation.
There are two important characteristics of sheaves that must be
considered. These are the sheave groove and sheave diameter.
Of these two, running a cable with an improper groove shape
can do more damage to a cable faster than running with the
wrong diameter. Correct sheave groove shape and size is more
important when running multi-conductor cable, as the core is
easily deformed and the thin conductor insulation can be
damaged more easily.
Sheave Groove
The groove of a new sheave should
have a diameter 5% greater than the
cable diameter.
Cables should not be run over sheaves if
the sheave groove diameter is 10%
greater than the cable diameter.
The sheave groove should be machined
to support from 135 to 150 degrees of
the cable diameter.
Sheaves should NEVER be used on 2
different diameter cables
Dc
Ds
135 to 150
Sheave Diameter
There are two rules of thumb that are published in cable
literature that indicate the minimum sheave diameter that
should be used for operating a cable up to its rated Maximum
Working Load. The first rule states that the minimum sheave
diameter, SD, should be 60 times the cable diameter, D, and the
second rule states that the minimum sheave diameter should be
400 times the outer armor wire diameter, d.
Wireline
Works Cable
Type
1-R-100
1-R-125
1-S-185
1-S-207
1-Z-224
1-R-224
1-R-258
1-R-288
1-R-322
1-R-380
1-R-425
7-Y-380
7-Y-428
7-K-464
7-Y-474
7-Y-484
09/2006
Cable
Diameter
D - inches
Cable
Diameter
D - inches
Outer Wire
Diameter
d - inches
1/10
1/8
3/16
13/64
7/32
7/32
1/4
9/32
5/16
3/8
7/16
3/8
7/16
15/32
Slammer
Slammer
0.101
0.125
0.185
0.207
0.224
0.224
0.258
0.288
0.322
0.380
0.425
0.378
0.428
0.464
0.474
0.484
0.014
0.0175
0.0358
0.0390
0.0358
0.0310
0.0358
0.0400
0.0445
0.0525
0.0585
0.0525
0.0585
0.0495
0.0655
0.0670
Sheave
Sheave
Diameter
Diameter
SD=
SD=
60 x D - inc. 400 x d - in
6.1
7.5
11.1
12.4
13.5
13.5
15.5
17.3
19.3
22.8
25.5
22.7
25.7
27.8
28.5
29.0
5.6
7.0
14.3
15.6
14.3
12.4
14.3
16.0
17.8
21.0
23.4
21.0
23.4
19.8
26.2
26.8
Sheave Alignment
It is important that proper sheave alignment is attained during
well site set up. When the sheaves are not properly aligned, the
cable will attempt to crawl up the sides of the sheave wheel
grooves. This action can result not only in distorting the sheave
grooves but can also introduce additional torque in the cable.
The materials used in the construction of sheaves has changed
over the years. The most popular sheaves are now the
Composite Sheaves. These composite sheaves have become
standard with most major service companies. These sheaves have
the wheels and guards manufactured from synthetic materials,
which has resulted in a 40% reduction in the weight. When
manufactured, these sheaves have the correct groove size and
shape to properly support the cable. In use however the
composite sheave groove can be quickly damaged from poor
sheave alignment.