APPARATUS, SYSTEMS, AND METHODS FOR STRETCHING CABLES AND MEASURING CABLE STRETCH

Abstract

Systems, apparatus, and methods for stretching wireline cables are provided. Tension is applied to a wireline within an engagement zone, either while the wireline is static or moving. The tension may be stabilized using a capstan. The wireline may be heated, coated, cleaned, stabilized, bent, or combinations thereof.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/539,330, filed on Jul. 31, 2017 (pending), the entirety of which is incorporated herein by reference for all purposes and made a part of the present disclosure. This application is also a Continuation-in-Part (CIP) of International Application No. PCT/US2017/012653, filed on Jul. 1, 2017, the entirety of which is incorporated herein by reference for all purposes and made a part of the present disclosure, which itself claims priority to U.S. patent application Ser. No. 14/991,448, filed on Jan. 8, 2016, the entirety of which is incorporated herein by reference for all purposes and made a part of the present disclosure. This application is also a Continuation-in-Part (CIP) of U.S. patent application Ser. No. 14/991,448, filed on Jan. 8, 2016, the entirety of which is incorporated herein by reference for all purposes and made a part of the present disclosure.

FIELD

The present disclosure relates generally to the use of electromechanical cable, typically logging cable, in the treatment of wells for enhanced production of petroleum products, such as crude oil, natural gas, distillate and other petroleum constituents. More particularly, the present disclosure concerns the use of electromechanical cable to accomplish precision location of the various well tools within wells to provide for well servicing activities. Even more specifically, the present disclosure concerns one or more processes that are employed to prepare an electromechanical logging cable by a cable stretching operation so that the permanent stretch characteristic of the cable is substantially eliminated, thereby permitting a well tool connected with the logging cable to be precisely located at a specified depth or position within a well simply by calculating the elastic stretch of the cable.

The present disclosure also relates to apparatus, systems, and methods for stretching cables and for measuring cable stretch, including wireline cables.

BACKGROUND

It is well known in the well drilling and completion industry that wells being drilled must be logged periodically to determine the characteristics of the earth formation and to confirm the location of the drill bit in the earth formation at any point in time. Well logging is typically accomplished by connecting a logging tool to an electromechanical cable, typically referred to as a logging cable, and running the logging tool into the wellbore. In order to accurately locate the logging tool within the wellbore and with respect to the formation various factors must be calculated including the stretch of the logging cable.

Electromechanical cable is typically manufactured with an inner armor having a left hand lay, which is encompassed by an outer armor having a right hand lay. Newly manufactured electromechanical cable typically has elastic stretch characteristics which can be easily calculated, but also has permanent stretch characteristics which are quite difficult to calculate. Each time the electromechanical cable is run down-hole for logging or other well service activities the permanent stretch characteristics of the cable change to some extent and adversely affect precision use of the cable, especially for well logging operations where logging instruments are employed to precisely measure the depth and location of subsurface formation characteristics. The logging data is then used to precisely locate well tools such as packers, perforation guns and the like with respect to the formation measurements. Consequently, newly manufactured electromechanical cable is not generally deemed to be acceptable for accurate well logging operations since it is difficult to precisely confirm the location of a logging tool within a well. For well logging activities well drilling organizations typically rely on the use of “seasoned” electromechanical cable, i.e., cable that has been run into a deep well and recovered to a spool 10 to 15 or more times.

During each cable run within a deep well a percentage of the permanent stretch characteristics of the cable is depleted and this percentage changes with each cable run. After the cable has been repeatedly run into a deep well and recovered to a cable spool a predetermined number of times, most of the permanent stretch characteristics has been depleted and the cable will have become “seasoned” to the point that only the elastic stretch of the cable need be calculated in order to accurately position a logging tool within a wellbore. Some well drilling companies maintain a deep non-productive well solely for seasoning newly manufactured electromechanical cable. Typically, newly manufactured electromechanical cable must be transported to a designated nonproductive well and run into the well and retrieved a number of times, for example 10 to 12 times, before being transported to a well drilling site for use. Obviously, running and retrieving an electromechanical cable multiple times without achieving income producing work is a time consuming and expensive proposition. Yet, some well drilling organizations maintain a deep well, such as having a depth of 25,000 feet or more, for the sole purpose of facilitating the seasoning of new electromechanical cable to make it ready for accurate well logging and other well service activities.

It is desirable therefore, to provide a method or process and apparatus having the capability of accomplishing accurate and effective seasoning of newly manufactured electromechanical cable in one or more cable processing runs, thus minimizing the time and costs of cable seasoning activities by multiple runs of the cable in designated non-productive wells. Though newly manufactured electromechanical cable can be seasoned by running it over multiple spaced sheaves by application of tension force and heat during cable movement, according to an aspect of the present disclosure, it has been determined by tests that cable seasoning may also be accomplished with a section of the cable engaging multiple sheaves and maintained in static condition within a cable processing arena during cable stretching. Thus, according to the preferred aspect of the present disclosure long sections of electromechanical cable, for example 1000′ to 1,500′ or more, may be positioned statically about multiple sheaves with desired tension force being applied to the static cable section by power energized cable stretching movement of one or more of the sheaves.

A wireline is a cable used to lower tools into wellbores, and to provide electrical power and/or data communication to tools within wellbores (e.g., wireline logging cables). Wirelines may include electrically conductive wires (e.g., copper wires), optically conductive wires (e.g., fiber optic wires), and protective and/or insulating sheaths and/or layers.

During use, a wireline may stretch as a result of, for example, tension on the wireline from tools coupled to the wireline. Stretching of a wireline may be permanent stretching or elastic stretching. Reducing or eliminating permanent stretch of a wireline prior to use may allow for more precise positioning and location of the wireline and any tools coupled thereto within wellbores.

BRIEF SUMMARY

It is a principal feature of the present disclosure to provide a novel method and apparatus for applying controlled stretching and working of a newly manufactured electromechanical cable to remove or dissipate a sufficient amount of the permanent stretch characteristics of the cable to render it suitable for accurate well logging activities.

It is another feature of the present disclosure to provide a novel method and apparatus for processing electromechanical cable by application of controlled tension for cable stretching and controlled application of heat to the cable to temporarily soften polymer insulation of the typically 7 conductors of the cable and permit relative movement of the metal strands of the inner and outer armor.

It is also a feature of the present disclosure to accomplish stretching of significantly long lengths of electromechanical cable, such as 1,000′ to 1,500′ or more, by positioning a selected length of cable about multiple sheaves of a cable processing arena and imparting power energized tension applying movement to one or more of the sheaves so that the selected length of cable is maintained substantially static during stretching activity to achieve substantially permanent stretched or seasoned cable having its permanent stretch characteristics substantially removed.

Briefly, the various objects and features of the present disclosure are realized through the provision of a powered or driven capstan and a braking capstan that are located in spaced relation. Each of the capstans has a pair of spaced sheaves, such as 36″ diameter sheaves, each having an external spiral cable groove receiving multiple wraps, for example 10 to 12 wraps of the electromechanical cable, which prevent slippage of the cable as forces are applied to stretch the cable and remove its characteristics of permanent stretch. The spiral grooves of the capstans the grooves of the cable receiving sheaves have a geometric configuration that is designed to precisely fit the cross-sectional dimension and configuration of the electromechanical cable that is being processed. This feature also prevents slippage of the cable during its processing. Between the driven and braking capstans are located a number of sheaves that are arranged in groups, with the groups being spaced at desired distances for cable stretching. The sheaves can also have a diameter of about 36″, more or less. The groups of sheaves can be spaced in the order of from 1,000′ to about 1,500′ more or less as desired, establishing a cable stretching arena. Most of the sheaves of the groups have fixed positions, with the cable being located about them. One or more of the sheaves of the groups is mounted to a moveable power actuator, such as a hydraulic, pneumatic or electrically driven actuator, so apply stretching force to the statically maintained length of cable. The electromechanical cable is withdrawn from a supply spool that can be mounted on a turntable that is rotated to loosen the outer armor of the cable prior to application of force to stretch the cable. The supply or let-off spool or reel is oriented in spaced relation with the first of the capstans and is recovered by a take-up spool that is also oriented in spaced relation with the last of the capstans. The take-up spool can also be mounted on a turntable that is rotated to re-tighten the outer armor of the cable after the cable has been stretched. Alternatively, where loosening and re-tightening of the outer armor of the cable is not desired, the rotatable turntables may be eliminated and the cable may be fed from the let-off spool directly onto the sheaves of the first of the capstan and may extend from the last of the capstans directly to a take-up reel.

When heating of the cable is desired to render the polymer sheathing flexible before stretching of the cable, one or more cable heating devices are positioned between the spaced sheaves of the first of the capstans or at any other suitable location relative to the cable to be stretched. The cable heating device is preferably electrically energized, though it may be fired by a flammable gas such a propane, natural gas or by any other flammable substance. The cable heater is arranged and controlled to accomplish heating of a predetermined length of the cable to a sufficient temperature above ambient temperature to soften its polymer sheathing so that the cable can be stretched by application of controlled tension force. This feature relaxes the frictional resistance of the polymer insulation with the metal conductor strands of the cable and permits movement of the metal conductors relative to the polymer insulation during the cable stretching process. The cable heater device may be powered electrically for application of radiant heat to the cable as the cable is moved into position for stretching.

After being heated by the cable heater or heaters the cable is stretched and is then permitted to cool to ambient temperature so that the polymer insulation returns to its hardened state. If desired, the heated cable may be moved through a cooler device, such as a water cooler or refrigerated cooler, so that cooling and hardening of the electromechanical cable will occur more rapidly.

According to the preferred aspect of the present disclosure, stretching of selected quite long sections of electromechanical cable is accomplished with the cable being wound about multiple sheaves and with cable stretching tension being applied with the cable being maintained substantially static, rather than being moved through multiple sheaves during stretching activity. Apparatus for cable stretching, including multiple sheaves and power energized sheave moving equipment is provided within the cable stretching arena. A practical length of cable is moved from a cable supply reel into the cable stretch arena around multiple sheaves under low tension, such as under 25% to 35% of the maximum tension for which the cable is designed. Static pull stretching tension is applied to this practical length of cable for a predetermined period of time causing the length of the cable to increase, permanently. This stretching tension may exceed 40% of the published breaking strength of a respective cable size. Tension force is applied to the cable by power energized movement of one or more of the sheaves of the stretching arena, such as by means of hydraulic, electrical or other precisely controllable power apparatus. Preferably the tension force to achieve stretching and permanent elongation of the cable is developed by moving particular sheaves in opposite directions or by moving a particular sheave in relation to the fixed sheaves. The stretching force may be increased or decreased as cable technology changes. After stretching, the tension will be reduced until the amount of stretch can be safely measured and documented.

During tension and heat processing a selected length of the cable is maintained in static condition and is engaged within the cable grooves of multiple spaced sheaves. After a section of the cable has been stretched to remove its permanent stretch characteristics the cable is then moved lengthwise by a driven capstan and a braking capstan to position a succeeding length of cable for stretching. The cable stretching activity can be repeated two or more times to ensure removal of virtually all of the permanent stretch of the cable, with the cable being wound on a drum for storage or shipment when the cable stretching operation has been completed.

The section of stretched cable will then be installed onto a take-up reel and a new section of cable will be moved from the supply reel into the cable processing or stretching arena. This process will be repeated as many times as is required to safely remove the permanent stretch from the complete length of cable of the supply reel. Specially designed clamps will be employed to attach starter cables to the cable section that is to be stretched. These clamps are designed to permit significant tension force to be applied to the cable, without causing damage to the cable insulation the electrical conductors or other cable components. These cable clamps ensure that a maximum amount of cable will be present in the stretching arena at any given time, insuring that all of the cable on the shipping reel will be stretched.

The present disclosure provides for a system for stretching wireline cable. The system includes a cable payoff, a cable take-up, a cable positioner, and a cable tensioner. The cable positioner is configured to operatively engage a wireline between the cable payoff and the cable take-up. The cable tensioner is configured to apply a tension to a wireline engaged with the cable positioner. The cable payoff and the cable take-up may each include a payoff twister.

In some aspects of the system include a cable tension measurement device operatively coupled to the cable tensioner, the cable positioner, or combinations thereof. The cable tension measurement device is configured to measure tension on a wireline cable operatively engaged with the cable positioner. In some aspects, the cable tension measurement device includes a string potentiometer operatively coupled to a sheave of the cable positioner via a string, and a string potentiometer computer system in operative and/or data communication with the string potentiometer. The string is responsive to tension applied to any wireline operatively coupled to the sheave, and the string potentiometer is responsive to movement of the string to form data signals.

In some aspects of the system, the cable positioner includes a locking capstan, at least one sheave, and a power capstan. The at least one sheave is positioned between the power capstan and the locking capstan and is operatively coupled to the cable tensioner. The power capstan is configured to pull a wireline through the system. The power capstan and locking capstan are configured to locked in place a wireline coupled there-between within an engagement zone, and the cable tensioner is configured to apply tension only to wireline cable positioned within the engagement zone.

In some aspects of the system, the cable tensioner includes a cylinder operatively coupled to a cylinder rod. The cylinder rod is operatively coupled to a sheave of the cable positioner and is configured to retract into the cylinder to pull the sheave toward the cylinder; thereby stretching any wireline cable coupled to the sheave.

The system may include a heat box configured to heat a wireline prior to the wireline entering an engagement zone of the cable positioner. The heat box includes an insulated box and a heater.

In certain aspects, the cable positioner includes a braking capstan, a power capstan, and at least one sheave operatively positioned between the braking capstan and the power capstan. The braking capstan may also function as the cable tensioner.

Certain aspects of the system include a tension stabilizing capstan positioned between the cable payoff and the braking capstan. The tension stabilizing capstan is configured to apply tension to a wireline even out of the tension on the wireline such that there is no, or substantially no, variation in tension on the wireline in an engagement zone of the cable positioner.

The system may include a cable fluid applicator/cleaner positioned between the cable payoff and the cable take-up. The cable fluid applicator/cleaner is configured to apply a coating to a wireline, clean the wireline, or combinations thereof. The cable fluid applicator/cleaner may be a cart including a trough, spray nozzles and/or hoses, applicators for applying coatings, post-form rollers, or combinations thereof. The cable fluid applicator/cleaner may include high-pressure jets adapted to spray the wireline with a coating substance, water, or combinations thereof. In some aspects, the cable fluid applicator/cleaner includes post-form rollers configured to at least partially bend the wireline in different directions.

The present disclosure also relates to a method for stretching a wireline cable. The method includes positioning a length of wireline cable within an engagement zone and locking the length of wireline cable within the engagement zone. The method also includes applying tension to the length of wireline cable within the engagement zone for a length of time to stretch the length of the wireline cable, releasing the tension form the length of the wireline cable, unlocking the length of wireline cable from the engagement zone, and moving the length of the wireline cable form the engagement zone. The method may be implemented using the system disclosed herein.

Certain aspects of the method include measuring the tension applied to the wireline cable during the stretching.

The method may further include heating the wireline cable prior to stretching the wireline cable.

In some aspects, the method includes stabilizing tension applied to the wireline within the engagement zone. The tension is stabilized using a tension stabilizing capstan positioned between a cable payoff and a braking capstan.

The method may include applying a coating to the wireline cable, cleaning the wireline cable, or combinations thereof. The application of the coating, the cleaning, or both may be performed prior the stretching the wireline cable, after stretching the wireline cable, or combinations thereof. In certain aspects, the method includes at least partially bending the wireline cable in different directions during the applying of the coating to the wireline cable, cleaning the wireline cable, or combinations thereof.

Certain aspects of the present disclosure provide for a method for seasoning a cable. The method includes applying tension to a length of cable within an engagement zone. The tension is applied along a longitudinal axis of the cable.

Some aspects of the present disclosure provide for a stabilized wireline cable. The stabilized wireline cable includes at least one conductor (electrical, optical, or both). An insulator surrounds the at least one conductor. An inner armor layer surrounds the insulator, and an outer armor layer surrounds the inner armor layer. A stabilizing material is positioned to fill void spaces (interstitial spaces) between the inner armor layer and the outer armor layer.

Other aspects of the present disclosure provide for a method for stabilizing a cable. The method includes providing a pre-formed wireline cable. The pre-formed wireline cable may be a fully formed, existing wireline cable. The method includes embedding a stabilizing material into the cable.

U.S. patent application Ser. No. 14/311,183 may provide background and points of reference helpful in the understanding of certain subject matter introduced herein, and is, therefore, hereby incorporated by reference, in its entirety, for all purposes and made a part of the present disclosure.

The foregoing has outlined rather broadly the features and technical advantages of the present disclosure in order that the detailed description that follows may be better understood. Additional features and advantages will be described hereinafter, which form the subject of the claims. It should be appreciated by those skilled in the art that the conception and specific aspect disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the disclosure. The novel features which are believed to be characteristic of the products, systems, and methods, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the features and advantages of the system, products, and/or method so of the present disclosure may be understood in more detail, a more particular description briefly summarized above may be had by reference to the aspects thereof which are illustrated in the appended drawings that form a part of this specification. It is to be noted, however, that the drawings illustrate only various exemplary aspects and are therefore not to be considered limiting of the disclosed concepts as it may include other effective aspects as well.

FIG. 1 is a schematic illustration showing an electromechanical cable processing system embodying the principles of the present disclosure and being arranged to loosen the outer cable armor, apply controlled tension and controlled heat to the cable during its processing for stretching and then re-tighten the outer cable armor after the cable has been stretched;

FIG. 2 is an isometric illustration showing a braking capstan that comprises one of the capstans of the schematic illustration of FIG. 1;

FIG. 3 is an isometric illustration showing a powered or driven capstan that comprises another one of the capstans of the schematic illustration of FIG. 1;

FIG. 4 is an isometric illustration showing a pair of spaced sheaves of a capstan and also showing a multiplicity of cable grooves of the sheaves, with an electromechanical cable being located within the cable grooves of the spaced capstan sheaves;

FIG. 5 is a schematic end view of a single conductor electromechanical cable that is manufactured at the present time by a well-known high-quality cable manufacturer;

FIG. 6 is a schematic end view of a three-conductor electromechanical cable that is being manufactured, sold and used at the present time;

FIG. 7 is a schematic end view of a seven-conductor high quality electromechanical cable that is also being manufactured, sold and used at the present time;

FIG. 8 is a schematic illustration showing an electromechanical cable stretching system embodying the principles of the present disclosure and showing apparatus defining a cable stretching arena having multiple relatively moveable sheaves and power equipment for maintaining a selection of the cable in substantially static condition within a cable processing arena and controllably moving one or more of the sheaves to achieve stretching of the electromechanical cable section;

FIG. 9 is a simplified schematic illustration showing let-off and take-up drums or reels, capstans for cable driving and braking and a power energized sheave for controlled application of tension force to a length of electromechanical cable for normalizing the cable by stretching to remove as much of the permanent stretch characteristics as is practicable;

FIG. 10A depicts a system for stretching cables and for measuring the cable stretch, in accordance with certain aspects of the present disclosure;

FIG. 10B is a schematic of a cable tension measurement device;

FIG. 10C and FIG. 10D are schematics of a locking capstan;

FIG. 11A depicts a system for stretching cables including a heat box, in accordance with certain aspects of the present disclosure, with the system arranged and configured for use in a heat-box static method;

FIG. 11B is a schematic of a heat box;

FIG. 12 depicts a system for stretching cables including a heat box, in accordance with certain aspects of the present disclosure, with the system arranged and configured for use in a heat-box dynamic method;

FIG. 13A depicts a system including a tension stabilizing capstan, in accordance with certain aspects of the present disclosure;

FIG. 13B depicts a tension stabilizing capstan;

FIG. 14A depicts a cable fluid applicator/cleaner, in accordance with certain aspects of the present disclosure;

FIG. 14B is a view within the trough of the cable fluid applicator;

FIG. 15 depicts a system including a cable fluid applicator/cleaner, in accordance with certain aspects of the present disclosure, with the system arranged and configured for use in a dynamic method;

FIG. 16 depicts a system including a cable fluid applicator/cleaner, in accordance with certain aspects of the present disclosure, with the system arranged and configured for use in a static method;

FIG. 17A depicts a stabilizing material applicator;

FIG. 17B depicts a stabilized cable;

FIG. 18A depicts a lateral force applicator;

FIG. 18B and FIG. 18C depict a cable; and

FIG. 19 depicts a system including a stabilizing material applicator and a lateral force applicator.

DETAILED DESCRIPTION

Certain aspects of the present disclosure include methods, systems, and apparatus for seasoning cable.

Method and Apparatus for Treating Logging Cable

A method and apparatus for removing permanent stretch characteristics of electromechanical cable by application of predetermined tension to a selected length of electromechanical cable within a cable processing arena. Movement of the cable from a pay-off reel into the cable processing arena and to the take-up reel is controlled by spaced capstans that also secure the length of cable in static position within a cable processing arena during cable stretching. Successive selected lengths of the cable are stretched for dissipating its permanent stretch characteristics and rendering the cable suitable for accurate well logging.

Referring now to the drawings and first to FIG. 1, a schematic illustration of an electromechanical cable processing system, generally at 10, includes a rotary supply reel or drum 12 that is mounted on a turntable 13 containing a length, for example 25,000 feet or more, of a particular type of newly manufactured electromechanical cable 14. The electromechanical cable typically has permanent stretch characteristics that prevent it from be used for logging services in wells. The electromechanical cable is withdrawn from the cable supply or let-off drum 12 and is directed upwardly and over a sheave 15 while the cable loosening turntable is rotated in a direction for loosening the outer spiral wound armor of the cable and consequently tightening the oppositely wound inner armor. As will be described in greater detail below when the finished cable is taken up it is rotated in the opposite direction by a similar turntable, thereby tightening the spiral wound outer armor substantially to its original condition of tightness and loosening the inner armor substantially to its original condition of tightness. This is done to permit the torque characteristics of the cable to remain balanced during its processing so that the torque characteristics of the finished cable will remain substantially the same as when the cable is removed from the cable supply drum 12. The cable extended upwardly from the cable supply drum 12 and is passed over a cable orienting sheave 15 that is supported by a sheave support structure 16. The cable is loosened during its linear travel from the cable supply drum to the cable orienting sheave 15. The electronically marked electromechanical cable 14 is then passed to a braking capstan shown generally at 17 having spaced externally grooved cable drums 18 and 19. The externally grooved cable drums 18 and 19 each have a plurality of external cable grooves that permit a number of cable wraps, for example 10 to 12 wraps, that extend about the spaced drums of the braking capstan. These multiple wraps of cable ensure against slippage of the cable when tension is applied either by braking activity or capstan driving activity or both. Between the spaced externally grooved sheaves 18 and 19 of the braking capstan 17 is located a cable heater 20 that is positioned to accomplish heating of the cable while it is under tension.

The cable may be passed through the cable heater or it may pass in close proximity with the heater so that it is heated to a controlled temperature due to the thermal output of the heater and the speed of substantially continuous cable movement. A tension detecting ohmmeter 21 is located between the braking capstan 17 and a power-driven capstan shown generally at 22 for continuously detecting the tension that is being applied to the cable and transmitting an electronic tension signal to the power-driven capstan 22 for controlling the tension of the substantially continuously moving electromechanical cable 14 that is being applied by the combined tension developing action of the braking capstan 17 and the power-driven capstan 22.

The power-driven capstan 22 has a pair of spaced capstan drums 23 and 24, which, like the braking capstan 17, define multiple closely spaced cable grooves 25 that define multiple passes or wraps of cable within the grooves and about the spaced capstan drums as is evident in FIGS. 2 and 4. Typically, a safety cover, such as is shown in FIGS. 2 and 3, is positioned about each of the capstans to prevent workers from coming into contact with the cable grooves or the moving cable being treated. For purposes of simplicity, the capstan drums and multiple wraps of electromechanical cable are shown with the protective cover removed in FIGS. 1 and 4, so that the cable grooves and multiple wraps of cable can be visualized. At least one of the capstan drums 18 or 19 of the braking capstan 17 is provided with one or more brake members 26, as shown in FIG. 2 which is actuated by a hydraulic unit 28 to restrain rotation of the capstan drum and thereby create a braking action that subjects the electromechanical cable to tension as it traverses the multiple cable grooves of the spaced capstan drums and is subjected to tension by the force of the rotating drums of the powered capstan 22. The hydraulic unit 28 may be provided in the form of a hand-pump variety if desired, or it may be mechanically or electro-mechanically controlled to provide the braking system with accurate brake control for maintenance of predetermined cable tension. Capstan drum support structure 29 provides support for drum bearings 30 that provide for rotatable support for the capstan drums. The bearings are provided with a lubricant supply system and have a central passage 31 through which water or other coolant fluid is fed to and from the internal coolant compartment of the capstan drums.

Since substantially continuous application of capstan braking generates considerable heat, the drums 18 and 19 of the braking capstan 17 are of hollow construction, each defining a coolant compartment that contains a volume of coolant fluid such as water. A coolant supply and a coolant receptacle are in heat controlling communication with the coolant compartment and are controlled to ensure that heating of the braking capstan drum or drums is maintained within a predetermined range of temperature. Coolant to and from the internal coolant compartment is provided by passages that are located centrally of the drum bearings 23 and are connected with a coolant supply manifold 32.

A drive belt 33 is driven by a motor 34, such as a rotary electric motor, pneumatic motor or rotary hydraulic motor, and is received by drive pulleys 35 and 36 for driving the drums 23 and 24 of the powered capstan. The drums 23 and 24 of the powered capstan also have multiple cable grooves to establish multiple wraps of cable that extend about the drums and prevent slippage of the cable. The cable leaving the power-driven drum 23 extends upwardly to a sheave 37 that is supported by a sheave support structure 38 and is then directed to move downwardly for collection by a take-up spool 39. The take-up spool is mounted for rotation by a turntable 40 which is rotated in a direction for tightening the outer armor of the electromechanical cable 14 and returning the cable to the same conditions as when it is removed from the let-off or cable supply drum 12. The driven capstan 30 is also provided with a braking system that is similar or identical, as compared with the braking system of the capstan shown in FIG. 2 and which is operated by a hydraulic actuator 44, such as a hand-pump or powered actuator.

Referring again to FIG. 1, spaced from the braking capstan 20 is a driven capstan shown generally at 30 having spaced externally grooved capstan drums 32 and 34 which may be substantially identical in size and geometry as compared with the braking capstan drums 22 and 24. The capstan drums are rotatably supported by bearings 36 that are in turn supported by a capstan drum support structure 38. At least one of the capstan drums 32 is rotatably driven by a drive belt 40 that is driven by a rotary motor 42, such as an electric motor, hydraulic or pneumatic motor. The driven capstan 30 is also provided with a braking system that is similar or identical, as compared with the braking system of the capstan shown in FIG. 2 and which is operated by a hydraulic actuator 44, such as a hand-pump or powered actuator.

As mentioned above, heating of the electromechanical cable 14 while it is maintained under predetermined tension is also an important aspect of the present disclosure. A predetermined length of the cable is heated to soften the polymer insulation of the conductors so that relative movement of the conductors can occur in response to the tension being applied to the cable by the braking and driven capstans, thereby causing most if not virtually all of the permanent stretch characteristics of the cable to be dissipated, leaving the cable in seasoned condition and ready for use during well logging activities. The cable heater 20 is supported between the rotary cable drums of the braking capstan as shown in FIG. 1 and applies radiant heat for a sufficient period of time, while the cable is continuously moving to achieve predetermined softening of the polymer insulation of the conductors and resulting in conductor movement relative to the softened polymer insulation in response to the continuous application of predetermined tension to the cable. As the treated electromechanical cable 14 leaves the proximity of the heater 20 it is typically cooled by ambient temperature. If desired, the heated and treated cable may be controllably cooled by means of refrigerated air or by passing it through a water bath.

The treated electromechanical cable 14 is then passed about a return sheave 37 that is rotatably supported by a sheave support structure 38. The take-up reel or drum 39 is rotatably supported by a turntable 40 and serves to receive the treated and seasoned electromechanical cable 14. Starting and end portions of the cable will not have been adequately treated by application of tension and heat and thus will need to be discarded or electronically marked so that the treated and seasoned section of the cable can be easily identified as the cable is used for well logging and many other activities where the tensile strength and permanent stretch characteristics must be taken into consideration.

Electromechanical cable for well logging and for other purposes are manufactured in many different forms. FIGS. 5-7 illustrate three forms of electromechanical cable that are currently manufactured and are widely used throughout the well drilling and completion industry. In FIG. 5 the cable has a single conductor 62 that comprises seven strands of metallic conductor wire. Polymer insulation 64 covers the single conductor and is surrounded by inner armor 66 that comprises a number twisted metal wires that are wound about the conductor and an outer armor 68 that also comprises a number of twisted metal wires. As mentioned above, the outer armor typically has a left hand lay while the inner armor has the opposite, or right hand lay. While the electromechanical cable is run into a well the outer armor becomes loosened and the inner armor becomes tightened.

In FIG. 6 a three-conductor electromechanical cable is shown, having three polymer coated conductors 70, 72 and 74 with structural members 76 located in conductor grooves. A water barrier 78 surrounds the polymer coated conductors and the structural members to prevent damage by salt water and other well constituents. The cable is provided with a spiral wrapped inner armor 80 and an oppositely spiral wrapped outer armor 82 that are composed of oppositely twisted wires. As mentioned above, the inner armor is composed of multiple wires having a left hand spiral lay and the outer armor is composed of multiple wires having a right hand spiral lay. It should be borne in mind that loosening the outer armor causes tightening of the inner armor.

In FIG. 7 a seven-conductor electromechanical cable is shown having seven polymer coated electrical conductors 84 which are contained within a water barrier 86. Structural strands 87 are would within external grooves that are defined by the coated conductors 84. An inner armor 86 and an outer armor 88 are oppositely would about the water barrier 86. Many other types of electromechanical cables are manufactured sold and used by the petroleum industry for well logging and other well servicing activities and can be treated by application of tension and heat for permanent stretch dissipation and seasoning.

As mentioned above, it has been determined by tests that cable seasoning may also be accomplished with the cable being controllably stretched while being maintained in substantially static condition. The following aspect of the present disclosure, illustrated diagrammatically in FIG. 8 shows long sections of electromechanical cable, for example 1000′ to 1,500′ more or less, being positioned statically about multiple sheaves with desired tension force being applied to the cable by power energized movement of one or more of the sheaves. FIG. 8 shows a cable tension processing system for electromechanical cable, generally at 90 having a payoff or supply reel 92 supporting a quantity of newly manufactured electromechanical cable 94 to be mechanically stretched and seasoned by application of controlled tension force. A capstan 96 having braking capability receives the newly manufactured cable 94 from the supply reel 92 in readiness for cable stretching and can employ a cable clamp to secure a selected length 98 of the cable, 1,000′ to 1,500′ more or less, against significant movement during the stretching process. It should be noted that the selected length of cable is the cable that extends from the braking capstan 96 over multiple sheaves and is received by a power capstan 104 that also has braking capability. From the power capstan 104 the selected length 98 of the cable, after having been stretched and seasoned is taken up by a take-up reel 106 that will serve during transportation and storage of the seasoned cable in readiness for use.

A cable stretching arena is generally defined by the space or area between a primary sheave support 100 and a secondary sheave support 102. The sheave and power support frame 100 defines a pair of generally parallel slide tracks 108 and 110 that provide support and guidance for sheave mount members that are moved by power actuators 112 and 114. Within the spirit and scope of the present disclosure, the power actuators may take the form of a pair of hydraulic cylinder motors as shown in FIG. 8 or may have the form of pneumatic cylinder motors, mechanical or electrical motors or any other powered apparatus that accomplishes substantially linear sheave movement for application of tension to the selected length of cable. The power actuators 112 and 114 accomplish linear movement of moveable sheave mount members 113 and 115 to which sheaves are mounted. The sheave mount members are secured to the power actuators by force transmitting connectors and slide along the slide tracks 108 and 110 when tension force or tension relaxing movement occurs. A central sheave mount structure 116 of the power support frame 100 provides independent support for interior sheaves 118 and 120 each having independent sheave support shafts.

Each of the sheaves has a diameter in the range of about 36″, though the diameter can be larger or smaller depending on the desires of the user. The sheaves are provided with a cable groove 125, as shown in FIG. 9 that is designed to receive an electromechanical cable of a particular size range. Typically, the sheave wheels 122 are composed of a durable metal, such as steel, and define an outer peripheral sheave groove 124 to which is molded or bonded a protective coating or groove lining 126 that is composed of a suitable polymer material or composite such as NYLON®, NYLETRON®, TEFLON® or any one of a number of suitable durable polymer materials that provide protection for the polymer shielding components of the cable during the cable stretching process. The groove lining material 126 defines a cable groove 125 that is particularly designed to receive electromechanical cable of a particular design and cross-sectional dimension.

The power support frame 100 defines external sheave support structure 128 and 130 having sheave support receptacles 132 and 134 within which are moveably received exterior sheaves 136 and 138. These sheaves are each supported by independent sheave axle shafts to provide for independent sheave movement during the cable stretching operation. The large size of the sheaves and the independent sheave rotation movement permits the electromechanical cable engaging the sheave grooves to be stretched to substantially the same extent as the cable extending distance D between the sheaves so that all of the selected length of cable 98 will be evenly stretched and the permanent stretch will have been removed.

The sheave support block 102 is located a sufficient distance from the power support frame 100 so that a selected distance D, for example 1,000′, is established between the spaced sheaves so that each run of electromechanical cable to be stretched will be about 1,000′ in length. If the cable is passed around 9 sheaves within the stretching arena, including substantially equal cable lengths from the payoff reel to the first sheave and from the last sheave to the take-up reel, then the length of cable being statically stretched during each cable stretching cycle will amount to about 10,000′. The sheave support block 102 is fixed during the cable stretching operation but may be set at any desired distance D from the sheaves of the power support frame 100 to accomplish stretching of a desired length of the cable. The sheave support block 102 has a plurality of sheave support flanges 140 having sheave grooves 142 within which a plurality of sheaves 144 are located. Each of the sheaves is supported for free rotation by an independent sheave axle so that each sheave will be rotated by the cable engaging it to cause even distribution of the tension force that is being applied to the selected cable length at any point in time.

With reference to FIG. 9, a schematic illustration of a cable processing arena is shown generally at 150 which embodies the principles of the present disclosure. A supply of electromechanical cable is provided on a supply or let-off reel 152 and the cable 154 is moved from the let-off reel by tension force that is applied by a first capstan 156 that is both a cable driving and cable braking capstan. The cable is received by the cable grooves of substantially fixed sheaves 158 and 160 that are each rotatable about independent sheave axle shafts of a sheave support. A moveable sheave member 162 receives the electromechanical cable and has an independent axle shaft 164 that is moved and positioned by a power actuator 166, such as a hydraulic or pneumatic actuator that is mounted by a connector 168 to an actuator support member 170 that is positioned substantially immovably within the cable processing arena. As shown and described above in connection with FIG. 8, from the last sheave member 160 the electromechanical cable 150 is retrieved or stabilized by the tension force of a second capstan 172, which is a braking capstan, but may also have a rotary driving capability as well.

Typically, the braking systems of the first and second capstans are energized to prevent linear movement of the electromechanical cable during its processing by stretching activity. The selected length of cable that is located within the cable processing arena is maintained substantially static by the braking activity of the first and second capstans and tension force is applied to the cable by power energized movement of the sheave 162 by means of the power actuator 166. After having been stretched to remove the permanent stretch characteristics of the cable, the cable is moved to a take-up reel 174. If desired, depending on the type and size of the electromechanical cable being processed, the cable may be subjected to the normalization process two or more times to ensure removal of virtually all of the permanent stretch characteristics.

The Cable Seasoning Process

According to the aspect of FIG. 1 a length of electromechanical cable is provided on a supply or payoff reel or drum 12 that is mounted for rotation by a turntable 13. As the cable is pulled from the supply drum 12 upwardly about the cable direction sheave the turntable 13 is rotated in a direction for loosening the outer armor. The outer cable armor which is composed of multiple wires that are wrapped in spiral fashion about the insulation or other wires of the cable with the spiral having a right hand lay. After the cable has been retrieved from the supply reel and loosened by rotation of the turntable 13, multiple wraps of the cable are positioned within the external cable grooves of the spaced drums of a braking capstan.

As the last wrap of electromechanical cable is pulled from the first cable drum of the braking capstan a cable heater located between the drums of the braking capstan heats a section of the cable to sufficient temperature for softening of the polymer insulation of the conductors of the cable. The braking action of the braking capstan and the pulling force of the power-driven capstan cause this predetermined section of the cable to be subjected to tension, thus subjecting the loosened cable to stretching activity to remove substantially all of the permanent stretch characteristics of the cable.

Loosening of the electromechanical cable together with the application of controlled heating in the loosened condition of the cable enhances the cable stretching capability. Subsequent cooling of the heated section of cable will permit the polymer insulation to harden to its original condition, thus stabilizing the stretched cable so that the resulting treated cable will remain with its characteristic of permanent stretch removed. The multiple external cable grooves of each pair of spaced cable drums of the braking and power-driven capstans effectively prevents slippage of the cable during the precisely controlled cable stretching process. The cable is loosened to start the tension and heat responsive seasoning process.

The electromechanical cable is supplied on a let-off drum that is mounted for rotation by being supported by a rotary turntable. As the electromechanical cable is paid out from the let-off or cable supply drum the turntable is rotated in a direction for loosening the spiral wound outer armor of the cable and for tightening the oppositely wound inner armor. The leading end of the electromechanical cable is contacted by a tension control sheave and is looped about a return sheave and is connected to a take-up reel or drum. The electromechanical cable is also passed through or in close proximity with a heater unit that is located between the drums of the braking capstan and may also be passed through or in close proximity with a cable cooling unit the is located downstream from the heater unit. The cable remains torque balanced during the stretching or seasoning process so that the torque characteristics of the finished cable are substantially the same as when the cable seasoning process is started.

With the brake of the braking capstan set for application of predetermined tension to the electromechanical cable and with the heater unit in operation, the driven capstan is actuated to move the cable substantially continuously and to apply predetermined tension to the cable as it is moved through or in close proximity with the heater unit to soften the polymer insulation of the conductors and permit relative movement of the conductors with respect to the polymer insulation surrounding the conductors. The application of heat and tension to the cable causes the permanent stretch characteristics of the cable to be virtually dissipated, leaving the cable seasoned for accurate and efficient use during well logging activities.

Though a pair of double drummed capstans are preferably employed for applying controlled tension to the electromechanical cable during processing for dissipation of the permanent stretch characteristics of the cable, it is to be understood that the present disclosure is not restricted or limited to this particular arrangement of cable stretching apparatus. The present disclosure is practiced by employing any suitable apparatus for application of controlled tension to the electromechanical cable and by applying predetermined heat to the cable while it is under tension to thus permit cable stretching for the purpose of removing or dissipating the permanent stretch characteristics of the cable. controlled movement of the cable conductors relative to the polymer coating that is present and then causing hardening of the polymer coating while the cable is maintained under tension. As the cable is being processed the torque characteristics of the cable remains balanced. As the cable seasoning process is completed the cable is passed about tension control and return sheaves and is then recovered to a take-up spool or drum, thus readying the cable for shipment to a site for use in well logging or other well servicing activities.

According to the aspect of the present disclosure shown in FIG. 8, the sheave support block 102 is positioned at a desired distance D, for example 1,000′ to 1,500′ from the axes of the array of multiple cable stretching sheaves that are supported by the sheave support frame 100. The position of the sheave support block 102 is preferably fixed during the cable stretching process, though its position may be adjusted to establish desired distance of the cable stretching sheaves 142 from the moveable sheaves of the support frame 100. To initiate the cable stretching process a desired length of the electromechanical cable 94 is fed or pulled from the payoff reel 92, such as being pulled by the powered capstan 96, which has a braking system for cable payout tension control. The length of electromechanical cable 94 is passed through the cable groove of each sheave of the array of multiple cable stretching sheaves 142 and the moveable sheaves of the support frame 100, with the forward end of the selected length of cable being passed through the powered capstan 104 and positioned to be received by the take-up reel 106. The powered capstans are controlled during the cable threading process so that a small tension force, such as from 20% to 40% of the designed cable stretching force is continuously supplied to maintain proper orientation of the cable relative to the various sheaves.

With the electromechanical cable in place within the cable grooves of the various sheaves, essentially as shown in FIG. 8, the power actuators 112 and 114 of the cable stretching apparatus will be activated, moving the sheaves 136 and 138 toward the support frame 100 or to the left as shown in FIG. 8, applying substantially equal tension force to each of the cable runs of the selected length 98 of cable. The cable stretching apparatus is provided with sensor apparatus and accurate controls to ensure that the tension force being applied to the cable 98 is accurately measured and recorded. Apparatus is also provided to mark measured lengths of the cable, such as by laser printing after the cable stretching operation has been completed. These features permit the ultimate customer to be provided with precision documentation of the processed cable that has been received and permits customers to select the parameters of the cable stretching process when cable stretching is ordered.

Device for the Measurement of Cable Stretch

Certain aspects of the present disclosure include apparatus, systems, and methods for stretching cables and for measuring cable stretch, including wireline cables.

FIG. 10A depicts system 1000a. System 1000a is configured for stretching wireline 101 and for measuring the stretch of wireline 101. System 1000a includes, but is not limited to, a cable payoff (payoff twister 1100a); a cable positioner (here shown as including locking capstan 200, sheaves 300a-300c, and power capstan 400); cable tensioner 600; cable tension measurement device 611; and a cable take-up (take-up twister 500). As shown, wireline 101 is operatively coupled with each of payoff twister 1100a, locking capstan 200, sheaves 300a-300c (e.g., turn around sheaves), power capstan 400, and take-up twister 500.

In operation, to stretch wireline 101, wireline 101 is operatively engaged with the cable positioner of system 1000a. To operatively engage wireline 101 with the cable positioner, wireline 101 is fed from payoff twister 1100a, which may be a spool, and run through locking capstan 200, such as about a barrel of locking capstan 200. From locking capstan 200, wireline 101 extends to operatively engage about sheave 300a. From sheave 300a, wireline 101 extends to operatively engage about sheave 300b (e.g., a cylinder sheave). From sheave 300b, wireline 101 extends to operatively engage about sheave 300c. From sheave 300c, wireline 101 extends to run through power capstan 400. From power capstan 400, wireline 101 extends to take-up twister 500, which may be a spool, and is operatively engaged therewith. With wireline 101 engaged with the cable positioner of system 1000a, wireline may be pulled from payoff twister 1100a, and through locking capstan 200 and sheaves 300a-300c, via power capstan 400. For example, and without limitation, power capstan 400 may include a motor operatively coupled with a barrel of power capstan 400 and configured to rotate the barrel, thereby pulling wireline 101.

After engagement of wireline 101 with the cable positioner of system 1000a, when a desired length of wireline 101 is moved into position, extending between and operatively engaged with locking capstan 200 and power capstan 400, power capstan 400 and locking capstan 200 are locked in place, such that barrels of the capstans are configured to not rotate. As used herein “engagement zone” refers to the operative zone of system 1000a between locking capstan 200 (or braking capstan) and power capstan 400. “Engagement zone” may also be referred to as the “engagement arena”, “stretching zone” or “stretching arena.” For example, wireline 101 extending between and operatively coupled to power capstan 400 and locking capstan 200 is positioned within the engagement zone of system 1000a, as used herein. With power capstan 400 and locking capstan 200 locked in place, additional length of wireline 101 upstream of locking capstan 200 and downstream of the power capstan 400 (i.e., outside of the engagement zone) is prevented from entering the engagement zone of system 1000a, and wireline 101a within the engagement zone is prevented from leaving the engagement zone (i.e., the wireline within the engagement zone is maintained in a static configuration). In some aspects, wireline is only stretched when in a static configuration, and is not stretched when moving. In some aspects, prior to being stretched in the static configuration, the wireline has not been previously stretched. As used herein, “upstream” with reference to a method step refers to a step that occurs temporally and/or spatially prior to another step. For example, cleaning of the wireline may be performed “upstream” of the tensioning of the wireline, with the cleaning apparatus (e.g., apparatus 3100, discussed below) positioned to engage the wireline prior to the wireline entering the engagement zone (see, e.g., FIGS. 14 and 15). Also, as used herein, “upstream” with reference to a system refers to a component of the system that is positioned to operatively engage with the wireline temporally and/or spatially prior to another component. For example, the tension stabilizing capstan (e.g., capstan 2100, discussed below) is positioned to operatively engage the wireline prior to the wireline operatively engaging with the braking capstan (see, e.g., FIGS. 13A and 13B).

With wireline 101 locked in place and static within the engagement zone (i.e., power capstan 400 and locking capstan 200 are locked in place), cable tensioner 600 is used to apply a tension onto wireline 101 to stretch wireline 101. Cable tensioner 600 includes cylinder 610 operatively coupled to cylinder rod 620, which is in-turn operatively coupled to sheave 300b, such as via sheave coupling 615. Cylinder rod 620 retracts into cylinder 610; thereby pulling sheave 300b towards cylinder 610, and in-turn pulling wireline 101 towards cylinder 610. Pulling wireline 101 results in the stretching of the length of wireline 101 that is positioned within the engagement zone of system 1000a. In some aspects, one or more sheaves move to pull the wireline, while one or more additional sheaves do not move. In certain aspects, only one sheave (e.g., sheave 300b) moves to pull the wireline, while all other sheaves (e.g., sheaves 300a and 300c) remain static.

Cable tension measurement device 611 includes string potentiometer 640 operatively coupled to sheave coupler 615 via string 630 and string coupler 625. Cable tension measurement device 611 also includes string potentiometer computer system 650, which is in operative and/or data communication with string potentiometer 640 via power and/or data cable 645. String 630 is responsive to tension applied to wireline 101 and sheave 300b. String potentiometer 640 is responsive to movement of string 630 to form data signals, which are transmitted to string potentiometer computer system 650 for storage thereon. String potentiometer computer system 650 may include a processor and non-transitory data storage medium (e.g., hard drive), which may have various computer instructions stored thereon. String potentiometer computer system 650 may include computer instructions to use an equation to process the data signals from string potentiometer 640 to determine the amount of stretch wireline 101 has achieved. Cable tension measurement device 611 may take measurements continuously, continually, or intermittently, for example.

Once the desired tension on wireline 101 has been reached, wireline 101 may be maintained at the desired tension for a length of time. After the length of time has passed, cylinder rod 620 is extended from cylinder 610, releasing the tension from wireline 101. String potentiometer 640 may operate to record the movement sheave 300b and wireline 101, when cylinder rod 620 is extended. When cylinder rod 620 is extended, locking capstan 200 and power capstan 400 are unlocked, allowing wireline 101 to move out of the engagement zone by being driven by power capstan 400, such that the already stretched length of wireline 101 may be taken up into take-up twister 500, allowing a new length of wireline 101 to be moved into the engagement zone of system 1000a. All data collected by string potentiometer 640 during the stretching of wireline 101 may be stored on string potentiometer computer system 650 for contemporaneous or subsequent use.

The system disclosed herein and components thereof are not limited to the particular aspects shown in the Figures. For example, the sheaves may be replaced with another component capable of operatively coupling with a wireline and allowing a wireline to move thereabout.

Cable Stretch Measurement

Certain aspects of the present disclosure include a device for the measurement of cable stretch, systems incorporating the same, and methods using the same. With reference to FIGS. 10A and 10B, cable tension measurement device 611, and the use thereof, will be described in further detail.

In operation, string potentiometer 640 records the movement of hydraulic cylinder, including rod 620 and base 610, as the hydraulic cylinder pulls sheave 300b. Wireline logging cable 101 is held stationary in the stretching arena between locking capstan 200 and power capstan 400, between which cable 101 passes over multiple sheaves including sheave 300b. Cable 101 in the stretching arena is stationary and unable to move. As the hydraulic cylinder rod 620 is pulled back, the cable 101 is stretched under tension.

One end of string 630 is connected to string potentiometer 640, which is fixed to the base of the hydraulic cylinder, and the other end of the string 630 is fixed to the end of the cylinder rod 620 via coupler 625. Rod 620 is connected to sheave 300b via coupling 615. In operation, as the cylinder rod 620 moves, the string 630 retracts or extends. The movement of the string 630 is electronically recorded and, through the use of an equation based on the properties of the cable 101 and properties of the stretching arena, the movement of the string 630 is translated into the stretch per 1,000 ft. of cable.

All data of the string 630 movement is recorded and stored electronically via computer system 650. This data can be used to determine the amount of inelastic or permanent stretch removed from the cable 101 through the use of the stretching process, as well as the cable stretch coefficient for the elastic stretch of the cable 101.

Using such integrated, optionally automated, cable stretch measurement reduces or eliminates the need for manual measurement of cable stretch, which has the potential for human error and my put users in danger of injury and prevents the need for a mechanical device to be placed directly on the cable which opens up the possibility to damage the cable.

Locking Capstan

Certain aspects relate to a device for locking a wireline capstan in place for tension stabilization, a capstan including such a device (i.e., a locking capstan), to systems incorporating the same, and to methods of using the same.

Some capstans include brake bands to create tension on a cable passing therethrough (i.e., a braking capstan). In aspects with relatively high-tension applied to the cable, such brake bands are not capable of holding the barrels of the capstan in place, resulting in a drop of tension being applied to the cable.

Certain aspects of the present disclosure provide for a locking capstan, which may replace a braking capstan in the systems and methods described herein. With reference to FIGS. 10A, 10C, and 10D, locking capstan 200 is depicted. In operation, a wireline 101 is pulled into the stretching arena as described with reference to FIG. 10A. Once a sufficient length of the wireline has been pulled into the arena, the locking capstan 200 and power capstan 400 are both locked in place, resulting in the barrels of the capstans no longer being able to turn.

The locking of the capstans 200 and 400 is accomplished through the use of a physical restraint on the drums, which block rotation of the drums. As shown in FIGS. 10C and 10D, locking bar 210, which may be a hinged locking bar, may be the physical restraint on locking capstan 200. Locking bar 210 may be connected to support frame 212 of locking capstan 200. In operation, as locking barrel 214 (e.g., a grooved locking barrel having cable grooves 215) rotates, locking bar 210 engages locking plates 216. The locking plates 216 are affixed to locking barrel 214 and, upon engagement with locking bar 210, halt rotation of the barrels of the locking capstan 200. Halting of the rotation of the barrels locks the wireline in place, preventing more wireline from traveling into the stretching arena when tension is placed on the section of wireline in the stretching arena.

The locking bar 210 may be moved through the use of an actuated cylinder apparatus, including actuated hydraulic brake unit 220 and actuated hydraulic locking nut 222, allowing control of the movement of the system remotely.

The brake bands 213, when placed under tension, create friction on the barrels of locking capstan to slow movement thereof. The brake bands 213 may be used as a failsafe system in case of catastrophic failure of the locking system.

Locking capstan 200 also includes grooved barrel 230, capstan safety barrier 240, and barrel bearings 250 supplied with coolant from barrel coolant supply system 260.

Heat Box—Static Method Layout

FIG. 11A depicts system 1000b for stretching wireline 101, with system 1000b arranged and configured for use in a static method, including use of a heat box. As used herein a “static method” refers to a method in which the wireline is maintained in a static configuration during stretching thereof. System 1000b is similar to system 1000a, with like reference numerals indicating like elements. However, in system 1000b, payoff twister 1100a is replaced with payoff twister 1100b. Also, while system 1000b is not shown as including cable tension measurement device 611, one skilled in the art would understand that system 1000b could also include such a cable tension measurement device.

System 1000b operates in substantially the same manner as system 1000a, with the exception that payoff twister 1100b includes heat box 700, which may be insulated, and heater 700. In operation, wireline 101 is engaged with payoff twister 1100b, and heat box 700 is closed; thereby enclosing wireline 101 within heat box 700. Heater 710 is turned on to the desired temperature, and wireline is left stationary in payoff twister 1100b for a predetermined amount of time before starting the stretching process, as described with reference to FIG. 10A, above.

Heat Box

Some aspects of the present disclosure relate to devices for maintaining wireline cable at a desired temperature before it is deployed into a stretching arena (engagement zone), to systems incorporating the same, and to methods of using the same. With reference to FIGS. 11A and 11B, heat box 700, and the operation thereof, will be described in further detail. Heat box 700 includes an insulated box 712 defining a cavity 714 within the interior thereof. In some aspects, as shown in FIG. 11A, payoff twister or drum (1100b) is positioned within the cavity 714. Heat box 700 includes heater 710 positioned to transfer thermal energy into cavity 714. Heater 710 is shown as including heating elements or coils 716. However, heater 710 may be any device configured to provide heat to cavity 714. With a payoff twister positioned within cavity 714, heater 710 may provide heat within cavity 714 to heat any wireline cable on the payoff twister. Heat box 700 includes cable exit 720, which may be a series of insulated strips with spaces therebetween through which wireline cable may exit cavity 714.

Seasoning (cable stretching) of wireline cable while a cable is a warm or hot may achieve a more sufficient degree of stretching of the wireline cable in comparison to when the wireline cable is at a cooler temperature. To heat wireline cable prior to stretching, insulated hot box 712 may be placed around the payoff stand or twister. Insulated heat box 712 may include removable or movable walls that allow wireline cable on payoff stand to be loaded therein. Once in place, the heater 710 may operate to heat the wireline cable. In some aspects, heater 710 is an electric heater or another controllable heating apparatus. In some aspects, one or more thermometers 722 within heat box 700 monitor the temperature therein and relay the temperature data to the heater 710 via hard wire or wireless communication. Heater 710 may adjust the temperature within heat box 700 automatically or through manual action of an operator.

Insulated heat box 712 fully encloses the payoff stand and cable therein and is insulated to prevent heat loss. The front of insulated heat box 712 includes opening, exit 720, that allows the wireline cable to exit, and travel on to the capstan (e.g., the locking capstan). Exit 720 is constructed in such a way as to minimize the area open to the outside environment. This may be achieved through the use of a panel that follows the movement of the cable back and forth as it is payed-off from the reel of payoff stand, or by the use of strips of insulated material allowing the least possible amount of the interior of insulated heat box 712 to be exposed while the cable passes through the exit 720, or through another means that minimizes the amount of open area in the hot box wall 721.

Heat Box—Dynamic Method Layout

FIG. 12 depicts system 1000c for stretching wireline 101, including heat box 700, with system 1000c arranged and configured for use in a dynamic method. As used herein a “dynamic method” refers to a method in which the wireline is moved (optionally continuously moved) though the engagement zone during stretching thereof. System 1000c is similar to system 1000b, with like reference numerals indicating like elements. However, in system 1000c, locking capstan 200 is replaced with braking capstan 800. Also, system 1000c only includes a single sheave, sheave 300d, and does not include cable tensioner 600 or cable tension measurement device 611. In operation of system 1000c, wireline 101 is placed in payoff twister 1100b, then heat box 700 (e.g., a door thereof) is closed, enclosing wireline 101 within heat box 700. Heater 710 is then turned on to the desired temperature, and wireline 101 is left stationary in payoff twister 1100b for a predetermined amount of time before starting the stretching process. After the predetermined amount of time, wireline 101 is taken from payoff twister 1100b and run through braking capstan 800. From braking capstan 800, wireline 101 engaged about sheave 300d, from sheave 300d wireline 101 engages with power capstan 400, and from power capstan 400 wireline 101 engaged with take-up twister 500. As with systems 1000a and 1000b, wireline 101 is pulled through system 1000c by power capstan 400. Wireline 101 is continuously run through the engagement zone of system 1000c, between braking capstan 800 and power capstan 400, with a predetermined amount of tension placed thereon from braking capstan 800.

Tension Stabilizing Capstan Layout

When a wireline cable is pulled from a reel (e.g., a wooden shipping reel) situated in a payoff twister, the wireline may fluctuate in tension. Such fluctuation in tension may continue even after traveling through a braking capstan. As changes from a set amount of tension may be detrimental to the stretching of the wireline cable, it may be desirable to dampen or eliminate such fluctuation in tension. In some aspects, a tension stabilizing capstan may be used to reduce or eliminate such fluctuations in tension. The tension stabilization capstan may operate to prevent surges in tension on wireline cable and/or fluctuations in the tension on wireline cable as the wireline cable enters the engagement zone by applying a relatively low (relative to the tension applied within the engagement zone) and steady tension to the wireline cable. In some applications, if such tension fluctuations on the wireline cable are not reduced or eliminated via use of the tension stabilizing capstan, such tension is transferred to the wireline cable as the wireline cable exits the engagement zone, causing fluctuations of tension, including relatively high and low tensions, to be applied to the wireline cable exiting the engagement zone. Thus, in operation, the tension stabilizing capstan is used to stabilize the tension applied to the wireline cable, and the braking and locking capstans are drive capstans used to apply a tension to the wireline cable that is sufficient to remove the inelastic stretch from the wireline cable. The braking capstan uses friction from brake bands thereof to slow the braking capstan barrels as they turn, and the driving capstan pulls on the wireline cable by rotating the barrels of the driving capstan.

FIG. 13A depicts system 1000d including tension stabilizing capstan 2100, in accordance with certain aspects of the present disclosure. System 1000d is similar to system 1000c, with like reference numerals indicating like elements. The tension stabilizing capstan 2100 may be positioned and engaged with the wireline outside of the engagement zone, such as “upstream” of the braking capstan 800.

In system 1000d, wireline 101 is run through tension stabilizing capstan 2100 prior to running wireline 101 through braking capstan 800. In some aspects, tension stabilizing capstan 2100 is the same or similar in construction to braking capstan 800 but may have fewer grooves in which wireline 101 is wound. Tension stabilizing capstan 2100 may be used to apply a lower amount of tension to wireline 101 than does braking capstan 800, such as less than 1,000 pounds of tension. One skilled in the art would understand that the amount of tension applied to wireline 101 by tension stabilizing capstan 2100 may be varied depending upon the particular application and may be more or less than 1,000 pounds of tension. Uses of tension stabilizing capstan 2100 may result in an evening out of the tension on wireline 101, such that, once wireline 101 has gone through the braking capstan 800 and into the engagement zone between braking capstan 800 and power capstan 400, there is no, or substantially no, variation in tension on wireline 101.

In the operation of system 1000d: (1) wireline 101 is operatively engaged with payoff twister 1100a; (2) wireline 101 is taken from payoff twister 1100a and run through tension stabilizing capstan 2100; (3) wireline 101 is then ran from the tension stabilizing capstan 2100 through braking capstan 800; (4) wireline 101 is then run from braking capstan 800 about turn around sheave wheel 300d; (5) from sheave 300d, wireline 101 is run through power capstan 400; and (6) from power capstan 400, wireline 101 is taken up in take-up twister 500. Wireline 101 is pulled through the system via power capstan 400. Wireline 101 is continuously run through the engagement zone with a predetermined amount of tension placed on wireline 101 by use of braking capstan 800.

FIG. 13B depicts tension stabilizing capstan 2100 in isolation from the remainder of the system. Tension stabilizing capstan 2100 includes grooved barrels 2110a and 2110b, each rotatably supported via barrel bearings 2112a and 2112b, respectively, which are, in-turn, supported via tension stabilizing capstan support frame 2114. Each barrel 2110a and 2110b includes cable grooves 2116a and 2116b, respectively, for receipt and guidance of wireline cable therethrough.

Device for the Application of Fluids and/or Cleaning a Cable During Stretching

Cable fluid applicator/cleaner 3100 is shown in FIGS. 14A and 14B. Cable fluid applicator/cleaner 3100 may be used during the stretching of a wireline cable. In some aspects, use of cable fluid applicator/cleaner 3100 during the stretching of a wireline cable may assist in the “seasoning process” of the wireline cable by applying one or more substances onto the wireline cable, by cleaning the wireline cable (e.g., removing debris) prior to the stretching of the wireline cable, or combinations thereof. Cable fluid applicator/cleaner 3100 may be a cart including a trough 3101 supported by a frame 3103, spray nozzles 3113 and/or hoses 3115 contained therein, applicators for applying coatings 3117, post-form rollers (such as the rollers shown in FIG. 18A), or combinations thereof. Lid 3105 is engaged over trough 3101, defining exit 3107 through which cable may exit trough. One skilled in the art would understand that, while not shown, an entry for cable may be formed in substantially the same way as exit 3107. The cable fluid applicator/cleaner 3100 is not limited to the particular aspects shown in the Figures, and may be any structure, mechanism, or component capable of applying liquid (water, cleaning solution, coating, lubricant, etc.) to a wireline.

Cable Fluid Applicator/Cleaner Dynamic Stretching Method

FIG. 15 depicts system 1000e including cable fluid applicator/cleaner 3100, in accordance with certain aspects of the present disclosure. System 1000e is similar to system 1000e, with like reference numerals indicating like elements.

In operation of system 1000e: (1) wireline 101 is operatively engaged with payoff twister 1100a; (2) wireline 101 is taken from payoff twister 1100a and run through cable fluid applicator/cleaner 3100; (3) within cable fluid applicator/cleaner 3100, wireline 101 is subjected to application of a desired coating and/or cleaning substance, such as a lubricant and/or water to coat and/or clean wireline 101; (4) while wireline 101 travels through cable fluid applicator/cleaner 3100, wireline 101 travels through post-form rollers of cable fluid applicator/cleaner 3100, which may at least partially bend wireline 101 in different directions in order to assist in the application/cleaning process (e.g., applicator 5000, discussed below); (5) wireline 101 is then ran from the cable fluid applicator/cleaner 3100 through braking capstan 800; (6) wireline 101 is then run from braking capstan 800 about turn around sheave wheel 300d; (7) from sheave 300d, wireline 101 is run through power capstan 400; and (8) from power capstan 400, wireline 101 is taken up in take-up twister 500. Wireline 101 is pulled through the system via power capstan 400. Wireline 101 is continuously run through the engagement zone with a predetermined amount of tension placed on wireline 101 by use of braking capstan 800. While cable fluid applicator/cleaner 3100 is shown as located between payoff twister 1100a and braking capstan 800, cable fluid applicator/cleaner 3100 may be placed in a different position within system 1000e as needed or desired. Furthermore, multiple cable fluid applicator/cleaners 3100 may be used in system 1000e at sequential or non-sequential locations within system 1000e.

Cable Fluid Applicator/Cleaner Static Stretching Method

FIG. 16 depicts system 1000f including cable fluid applicator/cleaner 3100, in accordance with certain aspects of the present disclosure. System 1000f is similar to system 1000b, with like reference numerals indicating like elements. In operation of system 1000f: (1) wireline 101 is placed in payoff twister 1100a; (2) wireline 101 is taken from payoff twister 1100a and run through cable fluid applicator/cleaner 3100, which operates in the same manner as described above with respect to FIG. 15; (3) after cleaning and/or applying coating to wireline 101 in cable fluid applicator/cleaner 3100, wireline 101 is run through locking capstan 200; (4) from locking capstan 200, wireline 101 is run about sheaves 300a, 300b, and 300c; (5) from sheave 300c, wireline 101 is run through power capstan 400; and from power capstan 400, wireline 101 is taken up via take-up twister 500. Wireline 101 is pulled through system 1000f via power capstan 400. The stretching of wireline 101 is performed in the same manner as described with respect to FIGS. 10A and 11A, by locking a length of wireline 101 in the engagement zone between power capstan 400 and locking capstan 200 and using cable tensioner 600.

Cable fluid applicator/cleaner 3100 may be placed in a different position within system 1000f as needed or desired. Furthermore, multiple cable fluid applicator/cleaners 3100 may be used in system 1000g at sequential or non-sequential locations within system 1000f. Cable fluid applicator/cleaner 3100 may be positioned and engaged with the wireline outside of the engagement zone, such as “upstream” of the braking capstan.

Stabilization of Cable Armor

When a wireline cable is used in field operations, the wireline cable is placed under tension, resulting in the rotation of the cable. In some such applications, rotation of the cable results in torque on the inner and outer armor wire layers of the wireline cable. The torque on the inner armor wire layer is in the opposite direction as the torque on the outer armor wire layer. Over time, such torque can become imbalanced, which can result in various negative effects on the cable. Additionally, free rotation of the cable while under tension can result in at least some loss of the permanent stretch induced in the wireline cable during the stretching process.

Certain aspects of the present disclosure provide for systems, methods, devices, and apparatus for stabilizing the armor of a cable, such that the cable is capable of retaining a greater degree of permanent stretch imparted thereto in comparison to an otherwise identical cable without stabilized armor. In some such aspects, stabilizing material is provided between the inner and outer armor wire layers. In some aspects, the stabilizing material is or includes grit, such as particles of sand, particles of stone, or combinations thereof.

In some aspects, systems, methods, and apparatus for applying stabilizing material (e.g., grit) to the wireline cable is provided. For example, in some such aspects, the stabilizing material is applied to the wireline cable as a solution or suspension (e.g., a solution or suspension of grit). The solution or suspension may be injected, sprayed, or otherwise applied to the wireline cable.

With reference to FIGS. 17A, 17B and 19, injection system 4000 for application of stabilization material to wireline cable 10, and the operation thereof within system 1000g, will be descried. Injection system 4000 includes trough 4010 positioned and arranged to receive wireline cable 10. Trough 4010 may include inlet 4012 for entry of wireline cable 10 therein and outlet 4014 exit of wireline cable 10 therefrom. Trough 4010 may be supported by trough support frame 4016. Trough 4010 may be formed of one or more walls that define an interior space 4018 within which wireline cable 10 passes through between inlet 4012 and outlet 4014. While not shown, trough 4010 may include a lid, the same or similar to applicator 3100 described herein.

Injection chamber 4020 is positioned and arranged within interior space 4018 to receive wireline cable 10 passing through trough 4010. Injection chamber 4020 is fluidly coupled with reservoir 4022, such as via conduit 4026. Reservoir 4022 contains stabilizing material medium 4024, which may be in the form of a solution or suspension. For example, stabilizing material medium 4024 may be in the form of a suspension of particles of sand and/or stone in water or other suspension medium.

In operation, wireline cable 10 passes from payoff twister 1100b, through inlet 4012, and into injection chamber 4020. Within injection chamber 4020, stabilizing material medium 4024 is applied to wireline cable 10. In some such aspects, stabilizing material medium 4024 is applied to wireline cable 10 under pressure (i.e., above ambient and/or atmospheric pressure). For example, stabilizing material medium 4024 may be pumped from reservoir 4022, through conduit 4026, and into injection chamber 4020 under such pressure. In some aspects, conduit 4026 provides stabilizing material medium 4024 to one or more nozzles or other spay apparatus within injection chamber 4020 for applying stabilizing material medium 4024 to wireline cable 10 under pressure. After exiting injection chamber 4020, wireline cable 10 passes through cable wiper 4030. Cable wiper 4030 cleans wireline cable by removing at least some excess stabilizing material medium 4024 therefrom. As described in reference to other such systems herein, wireline cable 10 may then pass through tension stabilizing capstan 2100, locking capstan 200, turn around sheaves 300a-300c, power capstan 400, and cable fluid applicator/cleaner 3100 to take-up twister 500. As described in reference to other such systems herein, wireline cable 10 is pulled through system 1000g via power capstan 400, such that wireline cable 10 continuously moves through the stretching arena with a predetermined amount of tension placed on wireline cable 10 by use of locking capstan 200.

Thus, in some aspects, the stabilizing material is applied to wireline cable 10 prior to (upstream of) the pre-stretching/seasoning of wireline cable 10. That is, the stabilizing material is applied to wireline cable 10 upstream of locking capstan 200 and, therefore, upstream of the stretching arena (defined between locking capstan 200 and power capstan 400).

As a result of contact between the stabilizing material and wireline cable 10 within injection system 4020, stabilizing material medium 4024 is forced, under pressure, into wireline cable 10, such that at least some of the stabilizing material occupies voids (interstitial spaces) between the inner and outer armor wires of the cable. With reference to FIG. 17B, the wireline cable shown in FIG. 5 is reproduced, with the addition of stabilizing material 4050 occupying voids between the inner armor wires 66 and outer armor wires 68 thereof. Stabilizing material 4050 may occupy voids between individual, adjacent wires of layer 66; voids between individual, adjacent wires of layer 68; voids between individual, adjacent wires of layer 66 and 68; or combinations thereof. The positioning of stabilizing material 4050 within such voids results in a stabilizing, resistive force within the wireline cable, reducing the movement of each individual wire in each layer (layers 66 and 68) relative to other individual wires in each layer and reducing the movement of each layer (layers 66 and 68) relative to the other layer. Reduction in such relative movement of the individual wires and layers of armor results in the retention of more of applied permanent stretch in the wireline cable.

Additionally, by occupying the space that would otherwise be void space, stabilizing material 4050 prevents the ingress of other materials (e.g., contaminates) into the space that would otherwise be void space. For example, in some applications the wireline cable is in contact with oils. Stabilizing material 4050 prevents the ingress of such oils or other contaminates into wireline cable. In some such applications, when oil ingresses into wireline cable, the oil acts as a lubricant, which increases the relative rotation and movement of the layers (e.g., the armor wire lays) of the wireline cable. Thus, stabilizing material 4050 can reduce or prevent the occurrence of such oil-induced rotation and movement.

As such, application (e.g., injection) of stabilizing material 4050 (e.g., a grit solution or suspension) within wireline cable facilitates the retention of permanent stretch subsequently imparted to the wireline cable, such as via any of the pre-stretching processes disclosed herein.

While shown and described as including a trough cart having an injection chamber, one skilled in the art would understand that stabilizing material applicator, system, apparatus, and method is not limited to the particular arrangement, as shown in FIGS. 17A and 19, so long as stabilizing material is incorporated into the void space between the armor wires of the armor wire layers. In some such aspects, the stabilizing material is incorporated into the void space between the armor wires of the armor wire layer after manufacturing of the wireline cable, including after application of the armor wire layers (both inner and outer) to the wireline cable.

Lateral Stretching

With reference to FIGS. 18A, 18B, 18C, and 19, in certain aspects, the tension applied to the wireline cables disclosed herein, within the stretching zone or arena between the locking capstan 200 and the power capstan 400, is applied along the longitudinal axis 6000 of the wireline cable 10, or at least substantially along the longitudinal axis 6000 of the wireline cable 10. That is, such tension is applied along the direction of longitudinal extension of the wireline cable 10 from one longitudinal end 6010 to another longitudinal end 6010 of the cable 10.

Certain aspects of the present disclosure provide for systems, methods, devices, and apparatus for applying at least some force (lateral force) to the wireline cable 10 that is at least partially, if not entirely, perpendicular to the force (tension) applied along longitudinal axis 6000. Such force may be applied to wireline cable 10 along any direction that is perpendicular to longitudinal axis 6000, such as along lateral axis 6020 or lateral axis 6030.

In some aspects lateral force applicator 5000 is used to apply lateral force to wireline cable 10 at at least one location between locking capstan 200 and power capstan 400. As shown, lateral force applicator 5000 is positioned downstream of sheaves 300a-300c and upstream of power capstan 400. However, one skilled in the art would understand that the present disclosure is not limited to this particular arrangement, and that lateral force applicator 5000 may be positioned within system 1000g at another point between locking capstan 200 and power capstan 400, such as upstream of sheaves 300a-300b and downstream of locking capstan 200.

Lateral force applicator 5000 includes one or a series of lateral force sheaves positioned and arranged to apply lateral force to wireline 10 at at least one point within the engagement zone (also referred to as the stretching zone or arena). As shown, lateral force applicator 5000 includes four lateral force sheaves, including two lateral force sheaves 5010a and 5010b positioned and arranged to apply lateral force to wireline 10 along a first lateral axis, and two lateral force sheaves 5012a and 5012b positioned and arranged to apply lateral force to wireline 10 along a second lateral axis that is perpendicular to the first lateral axis. Lateral force applicator 5000 may operate to apply lateral force onto wireline cable 10 while wireline cable 10 is under tension via operation of locking capstan 200, power capstan 400, and sheaves 300a-300c. Applicants have found that, a result of the application of such lateral force to wireline cable 10 during the pre-stretching process is an increase in the amount of permanent stretch that is removed from wireline cable 10.

In operation, wireline cable 10 is fed from payoff twister 1100b to tension stabilizing capstan 2100, optionally, after having passed through injection system 4000. Wireline cable 10 then passes through locking capstan 200, and then through sheaves 300a-300c. From sheaves 300a-300c, wireline cable 10 passes through one or a series of lateral force sheaves 5010a, 5010b, 5012a, and 5012b. While wireline cable 10 is under tension, from operation of locking capstan 200 and power capstan 400, and is moving in and through the engagement zone, lateral force sheaves 5010a, 5010b, 5012a, and 5012b apply lateral forces on to wireline cable 10. In some aspects, lateral force sheaves 5010a, 5010b, 5012a, and 5012b are positioned such that each lateral force sheave 5010a, 5010b, 5012a, and 5012b applies lateral force on wireline cable 10 at a different angle than does the other of the lateral force sheave 5010a, 5010b, 5012a, and 5012b. For example, in some applications the orientation of the lateral force applied by each lateral force sheave is at a 90-degree relative to the lateral force applied by the preceding and subsequent lateral force sheave. Such an exemplary arrangement of lateral force sheaves 5010a, 5010b, 5012a, and 5012b as is shown in FIG. 19A, where the lateral force applied to wireline 10 by lateral force sheave 5010a is at a 90-degree angle to the lateral force applied to wireline 10 by lateral force sheave 5012a, the lateral force applied to wireline 10 by lateral force sheave 5012a is at a 90-degree angle to the lateral force applied to wireline 10 by lateral force sheave 5010b, and the lateral force applied to wireline 10 by lateral force sheave 5010b is at a 90-degree angle to the lateral force applied to wireline 10 by lateral force sheave 5012b. One skilled in the art would understand that the angles at which the lateral forces are applied are not limited to be 90-degrees relative to one another. Also, one skilled in the art would understand that the lateral force applicator is not limited to having four lateral force sheaves and may have more or less than four of such sheaves.

In some aspects, the diameters of lateral force sheaves 5010a, 5010b, 5012a, and 5012b are sized such that bending lateral force applied to wireline cable 10 by lateral force sheaves 5010a, 5010b, 5012a, and 5012b is maintained within a proscribed bending radius of wireline cable 10 (i.e., does not exceed the proscribed bending radius of wireline cable 10).

In certain applications where more than one lateral force sheave is used, the lateral force sheaves are spaced apart from one another, along the longitudinal length of wireline cable 10, a sufficient distance such that wireline cable 10 is not damaged from application of the lateral forces thereto.

After exiting lateral force applicator 5000, wireline cable 10 passes through power capstan 400 and to take-up twister 500, optionally, passing through cable fluid applicator/cleaner 3100 therebetween. As discussed with reference to other such systems described herein, wireline cable 10 is pulled through system 1000g via power capstan 400, such that wireline cable 10 is continuously run through the engagement zone with a predetermined amount of tension being applied thereto via locking capstan 200.

Without being bound by theory, Applicant have found that applying lateral force (e.g. a controlled amount of lateral force) perpendicular to the longitudinal axis of a wireline cable, while the wireline cable is moving through the engagement zone under tension, provides for an increase in the amount of permanent stretch removed from the wireline cable during such pre-stretching processes.

One skilled in the art would understand that the various methods, apparatus, and systems disclosed herein may be combined in various ways. For example, the systems and methods described herein may include the use of: the heat box; the cable fluid applicator/cleaner; the stabilizing material applicator; the lateral force applicator; the tension stabilizing capstan; the cable tensioner; the cable measurement device; or any combination thereof via either the static stretching method using the locking capstan or the dynamic stretching method using the braking capstan.

Although the present aspects and advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the disclosure. Moreover, the scope of the present application is not intended to be limited to the particular aspects of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding aspects described herein may be utilized according to the present disclosure. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Claims

1. A system for stretching wireline cable, the system comprising:

a cable payoff;

a cable take-up;

a cable positioner, the cable positioner positioned to engage a cable between the cable payoff and the cable take-up; and

a cable tensioner, the cable tensioner positioned to apply a tension to a cable engaged with the cable positioner.

2. (canceled)

3. The system of claim 1, further comprising a heat box positioned to heat a cable prior to entering an engagement zone of the cable positioner.

4. (canceled)

5. (canceled)

6. (canceled)

7. (canceled)

8. (canceled)

9. (canceled)

10. (canceled)

11. The system of claim 1, wherein the cable positioner includes:

a locking capstan, at least one sheave, and a power capstan, wherein the at least one sheave is positioned between the power capstan and the locking capstan, and wherein the at least one sheave is coupled to the cable tensioner; or

a braking capstan, a power capstan, and at least one sheave positioned between the braking capstan and the power capstan, and wherein the braking capstan is the cable tensioner.

12. (canceled)

13. (canceled)

14. (canceled)

15. The system of claim 11, wherein the cable tensioner includes a cylinder coupled to a cylinder rod, the cylinder rod coupled to at least one sheave of the cable positioner, wherein the cylinder rod is retractable into the cylinder to pull the at least one sheave toward the cylinder, thereby stretching a cable coupled to the at least one sheave.

16. (canceled)

17. (canceled)

18. (canceled)

19. (canceled)

20. (canceled)

21. The system of claim 1, further comprising a tension stabilizing capstan positioned between the cable payoff and the cable positioner, wherein the tension stabilizing capstan is positioned to apply a stabilizing tension to a cable.

22. (canceled)

23. The system of claim 1, further comprising a cable tension measurement device coupled to the cable tensioner, the cable positioner, or combinations thereof, wherein the cable tension measurement device is positioned to measure tension on a cable engaged with the cable positioner.

24. (canceled)

25. (canceled)

26. The system of claim 1, further comprising a cable fluid applicator positioned between the cable payoff and the cable take-up, the cable fluid applicator positioned to apply a fluid onto a cable passing therethrough.

27. (canceled)

28. The system of claim 1, further comprising a stabilizing material applicator positioned to apply a stabilizing material to a cable prior to the cable entering an engagement zone of the cable positioner.

29. (canceled)

30. (canceled)

31. (canceled)

32. (canceled)

33. (canceled)

34. (canceled)

35. (canceled)

36. (canceled)

37. The system of claim 1, further comprising a lateral force applicator positioned and arranged to apply lateral force to a cable within an engagement zone of the cable positioner.

38. (canceled)

39. (canceled)

40. (canceled)

41. (canceled)

42. (canceled)

43. A stabilized wireline cable, the stabilized wireline cable comprising:

at least one conductor;

an insulator surrounding the at least one conductor;

an inner armor layer surrounding the insulator; and

an outer armor layer surrounding the inner armor layer;

wherein a stabilizing material is positioned to fill void spaces between the inner armor layer and the outer armor layer.

44. The stabilized wireline cable material comprises grit.

45. (canceled)

46. A method for seasoning a cable, the method comprising applying tension to a length of cable within an engagement zone, wherein the tension is applied along a longitudinal axis of the cable.

47. (canceled)

48. (canceled)

49. (canceled)

50. (canceled)

51. (canceled)

52. (canceled)

53. (canceled)

54. (canceled)

55. (canceled)

56. (canceled)

57. (canceled)

58. The method of claim 46, further comprising stabilizing tension applied to the cable using a tension stabilizing capstan positioned upstream of the engagement zone.

59. (canceled)

60. (canceled)

61. The method of claim 46, further comprising applying a coating to the length of cable, cleaning the length of cable, or combinations thereof.

62. (canceled)

63. (canceled)

64. The method of claim 46, wherein the length of the cable is stretched while the length of the cable is maintained static within the engagement zone, wherein, prior to being maintained static and stretched within the engagement zone, the length of the cable is an unstretched length of cable.

65. (canceled)

66. (canceled)

67. (canceled)

68. (canceled)

69. The method of claim 46, further comprising, prior to applying the tension to the length of cable, applying a pre-stretching tension to the length of cable using a tension stabilizing capstan.

70. (canceled)

71. (canceled)

72. (canceled)

73. (canceled)

74. (canceled)

75. (canceled)

76. (canceled)

77. (canceled)

78. (canceled)

79. (canceled)

80. (canceled)

81. The method of claim 46, further comprising, prior to applying the tension to the cable, applying a stabilizing material to the cable.

82. (canceled)

83. (canceled)

84. (canceled)

85. (canceled)

86. (canceled)

87. (canceled)

88. (canceled)

89. (canceled)

90. (canceled)

91. (canceled)

92. The method of claim 46, further comprising applying a lateral force to the cable.

93. (canceled)

94. (canceled)

95. (canceled)

96. (canceled)

97. A method for stabilizing a cable, the method comprising:

providing a pre-formed wireline cable; and

embedding a stabilizing material into the cable.

98. The method of claim 97, wherein the stabilizing material is embedded within void space between inner and outer armor wire layers of the cable.

99. (canceled)

100. (canceled)

101. A system for stretching wireline cable, the system comprising:

a locking capstan or a braking capstan positioned to receive a cable; and

a power capstan positioned to receive the cable from the locking capstan or the braking capstan, wherein an engagement zone is defined between the power capstan and the locking capstan or the braking capstan.