U.S. patent application number 15/264859 was filed with the patent office on 2017-01-05 for steel armor wire coatings.
The applicant listed for this patent is Schlumberger Technology Corporation. Invention is credited to Evgeny Barmatov, Trevor Hughes, Vadim Protasov, Joseph Varkey, Paul Wanjau.
Application Number | 20170001415 15/264859 |
Document ID | / |
Family ID | 55401487 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170001415 |
Kind Code |
A1 |
Hughes; Trevor ; et
al. |
January 5, 2017 |
Steel Armor Wire Coatings
Abstract
A wire includes a ferrous core. The ferrous core can be coated.
The coatings can include nickel, molybdenum, zinc and Fe. A process
of forming a wire can include placing a metal strip alongside a
ferrous wire core, bending the strip around the core, and seam
welding the strip to form a metal tube around the core. The process
of forming a wire can include applying a metal layer to a ferrous
metal rod to form a plated rod, placing a metal strip alongside the
rod, bending the strip around the rod, and seam welding the strip
to form a metal tube around the rod. The process of forming a wire
can include coating a ferrous wire core with a layer of nickel,
molybdenum or a nickel alloy that circumferentially surrounds the
ferrous wire core.
Inventors: |
Hughes; Trevor; (Cambridge,
GB) ; Varkey; Joseph; (Sugar Land, TX) ;
Protasov; Vadim; (Houston, TX) ; Barmatov;
Evgeny; (Cambridge, GB) ; Wanjau; Paul;
(Missouri City, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Schlumberger Technology Corporation |
Sugar Land |
TX |
US |
|
|
Family ID: |
55401487 |
Appl. No.: |
15/264859 |
Filed: |
September 14, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14470708 |
Aug 27, 2014 |
9446565 |
|
|
15264859 |
|
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 28/021 20130101;
B32B 15/013 20130101; C23C 4/134 20160101; C23C 4/02 20130101; B32B
2311/30 20130101; C25D 3/12 20130101; C23C 2/38 20130101; C22C
18/00 20130101; C22C 27/04 20130101; C22C 30/06 20130101; C25D 3/54
20130101; C23C 4/18 20130101; C23C 2/06 20130101; C23C 28/025
20130101; B32B 2311/20 20130101; C23F 15/00 20130101; B32B 2311/22
20130101; B32B 15/015 20130101; C23C 2/26 20130101; C23C 16/06
20130101; C25D 5/12 20130101; C25D 3/22 20130101; C25D 7/0607
20130101; C23C 2/02 20130101; C25D 3/56 20130101; C23C 4/08
20130101 |
International
Class: |
B32B 15/01 20060101
B32B015/01; C23C 2/06 20060101 C23C002/06; C23C 2/26 20060101
C23C002/26; C23C 2/38 20060101 C23C002/38; C23C 4/02 20060101
C23C004/02; C23C 4/08 20060101 C23C004/08; C23C 4/134 20060101
C23C004/134; C23C 4/18 20060101 C23C004/18; C23C 28/02 20060101
C23C028/02; C23F 15/00 20060101 C23F015/00; C25D 3/56 20060101
C25D003/56; C25D 3/54 20060101 C25D003/54; C25D 3/12 20060101
C25D003/12; C25D 3/22 20060101 C25D003/22; C25D 5/12 20060101
C25D005/12; C25D 7/06 20060101 C25D007/06; C23C 2/02 20060101
C23C002/02 |
Claims
1. A process of forming a wire comprising: coating a ferrous wire
core with an interface layer of nickel, molybdenum or a nickel
alloy, wherein the interface layer circumferentially surrounds the
ferrous wire core; and coating the interface layer with an outer
layer.
2. The process of claim 1, wherein the ferrous wire core is
steel.
3. The process of claim 1, wherein the interface layer has a
thickness of between 2 and 60 microns.
4. The process of claim 1, wherein outer layer has a thickness of
between 1 and 50 microns.
5. The process of claim 1, wherein the outer layer comprises a zinc
alloy, and wherein the zinc allow comprises: binary Zn--Ni or
Zn--Co alloy; or ternary Zn--Ni--Co, Zn--Ni--Mo or Zn--Co--Mo
alloy.
6. The process of claim 1, further comprising an Fe layer, wherein
the Fe layer circumferentially surrounds the interface layer and is
circumferentially surrounded by the outer layer.
7. The process of claim 6, wherein the Fe layer has a thickness of
between 2 and 20 microns.
8. The process of claim 1, further comprising a galvanized zinc
coating.
Description
TECHNICAL FIELD/FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to steel armor wire strength
member coating compositions, structures, and processes.
BACKGROUND OF THE DISCLOSURE
[0002] Armor wire strength members used in wireline cables for
oilfield applications are often composed of galvanized improved
plow steel (GIPS). In GIPS armor wire strength members, the steel
substrate is coated with zinc via a hot dip galvanization process.
The hot dip galvanization process involves immersion of the steel
substrate in molten zinc at a temperature of around 860.degree. F.
(460.degree. C.).
[0003] The strength and hardness of unalloyed zinc are greater than
those of tin or lead, but less than those of aluminum or copper.
Except when very pure, zinc is brittle at ambient temperatures, but
zinc becomes ductile at around 100.degree. C. Pure zinc rapidly
recrystallizes after deformation at ambient temperature because of
the high mobility of the atoms within the lattice. Thus, zinc
typically cannot be work-hardened at ambient temperature.
[0004] Hot dip zinc coatings provide corrosion protection in a
range of atmospheric and low temperature aqueous environments such
as humid atmospheric conditions, natural weathering conditions,
soil environments, salt-spray testing conditions and under low
temperature aqueous/brine immersion conditions. This corrosion
protection may be relevant when GIPS armor wire components of
wireline cables are stored between wireline logging operations.
[0005] Zinc-based coatings may fall into several categories: pure
zinc, zinc-iron, zinc-aluminum, zinc-nickel and zinc composites. In
terms of manufacturing methods, zinc coatings are produced by
hot-dipping, electroplating, mechanical bonding, sherardizing and
thermal spraying. The hot-dip methods are further divided into two
processes: (1) the continuous process in which long strands of
sheet, wire or tubing are continuously fed through a bath of molten
zinc; and (2) the batch process in which fabricated parts such as
fasteners, poles or beams are dipped into molten zinc, either
individually or in discrete batches. Similarly, zinc electroplating
can be performed in a continuous or batch mode.
SUMMARY
[0006] The present disclosure provides a wire and a process of
forming a wire.
[0007] Embodiments of the wire can include a ferrous wire core, an
interface layer circumferentially surrounding the ferrous wire
core, and an outer layer circumferentially surrounding the
interface layer. The interface layer can include nickel, molybdenum
or a nickel alloy, for example. The outer layer can include zinc or
a zinc alloy, for example.
[0008] Embodiments of the wire can include a ferrous wire core, an
inner zinc layer circumferentially surrounding the ferrous wire
core, an Fe layer circumferentially surrounding the inner zinc
layer, and an interface layer circumferentially surrounding the Fe
layer. The interface layer can include nickel or molybdenum, for
example.
[0009] Embodiments of the wire can include a ferrous wire core and
a layer circumferentially surrounding the ferrous wire core. The
layer circumferentially surrounding the ferrous wire core can
include nickel, molybdenum or a nickel alloy. The layer
circumferentially surrounding the ferrous wire core can be present
without an overlying zinc or zinc alloy layer. The layer including
nickel, molybdenum or a nickel alloy can act as a protective layer
in oil and gas downhole conditions and in surface storage
conditions.
[0010] Embodiments of the process of forming a wire can include
placing a metal strip alongside a ferrous wire core. The metal
strip can include Zn, Ni, Mo, or Fe, for example. The process can
include bending the metal strip circumferentially around the
ferrous wire core. The process can include seam welding the metal
strip to form a metal tube around the ferrous wire core.
[0011] Embodiments of the process of forming a wire can include
applying a metal layer to a ferrous metal rod to form a plated rod.
The metal layer can include Zn, Ni, or Mo, for example. The process
can include placing a metal strip alongside the plated rod. The
metal strip can include Zn, Ni, Mo, or Fe, for example. The process
can include bending the metal strip circumferentially around the
plated rod. The process can include seam welding the metal strip to
form a metal tube around the plated rod.
[0012] The process of forming a wire can include coating a ferrous
wire core with a layer of nickel, molybdenum or a nickel alloy. The
layer can circumferentially surround the ferrous wire core. The
layer circumferentially surrounding the ferrous wire core can be
present without an overlying zinc or zinc alloy layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present disclosure can be understood from the following
detailed description when read with the accompanying figures. It is
emphasized that, in accordance with the standard practice in the
industry, various features are not drawn to scale. In fact, the
dimensions of the various features may be arbitrarily increased or
reduced for clarity of discussion.
[0014] FIG. 1 is a first cross sectional view of steel armor wire
consistent with at least one embodiment of the present
disclosure.
[0015] FIG. 2 is a second cross sectional view of steel armor wire
consistent with at least one embodiment of the present
disclosure.
[0016] FIG. 3 is a third cross sectional view of steel armor wire
consistent with at least one embodiment of the present
disclosure.
[0017] FIG. 4 is a fourth a cross sectional view of steel armor
wire consistent with at least one embodiment of the present
disclosure.
[0018] FIG. 5 depicts a gas plasma coating system consistent with
at least one embodiment of the present disclosure.
[0019] FIG. 6 depicts an electrolytic plasma coating system
consistent with at least one embodiment of the present
disclosure.
[0020] FIG. 7 depicts an electroplating system consistent with at
least one embodiment of the present disclosure.
[0021] FIGS. 8a-8d depict a method of forming a wire consistent
with at least one embodiment of the present disclosure.
[0022] FIGS. 9a-9e depict a method of forming a wire consistent
with at least one embodiment of the present disclosure.
[0023] FIG. 10 depicts a hot dip galvanizing process consistent
with at least one embodiment of the present disclosure.
DETAILED DESCRIPTION
[0024] It is to be understood that the following disclosure
provides many different embodiments, or examples, for implementing
different features of various embodiments. Specific examples of
components and arrangements are described below to simplify the
present disclosure. These are, of course, merely examples and are
not intended to be limiting. In addition, the present disclosure
may repeat reference numerals and/or letters in the various
examples. This repetition is for the purpose of simplicity and
clarity and does not in itself dictate a relationship between the
various embodiments and/or configurations discussed.
[0025] Wireline is a single-strand or multi-strand wire or cable
for intervention in oil or gas wells. A wireline is commonly used
in association with electric logging and cables incorporating
electrical conductors. In certain circumstances, it may be
desirable to augment the wire or cable to provide it with
additional strength or resistance to adverse temperature or other
environmental conditions. Such augmented wireline is termed "armor
wire."
[0026] FIG. 1 depicts wire 100 consistent with at least one
embodiment of the present disclosure. Wire 100 includes ferrous
wire core 110. One non-limiting example of a ferrous wire core is a
steel wire. Interface metal layer 120 circumferentially surrounds
ferrous wire core 110. Interface metal layer 120 may be composed
of, for instance, nickel, molybdenum, or nickel-rich alloy. In
certain embodiments, interface metal layer 120 may have a thickness
of between 2 and 60 microns. Outer layer 130 circumferentially
surrounds interface metal layer 120. Outer layer 130 may be
composed of zinc or a zinc alloy. The zinc alloy may include, but
is not limited to, a binary Zn--Ni or Zn--Co alloy or a ternary
Zn--Ni--Co, Zn--Ni--Mo or Zn--Co--Mo alloy. In certain embodiments,
outer layer 130 may have a thickness of from about 1 to about 50
microns. Without being bound by theory, it is believed that the
interposition of the interface metal layer 120 between ferrous wire
core 110 and outer layer 130 acts as a barrier protection for the
ferrous wire core 110 when wire 100 is exposed to harsh temperature
and other environmental conditions, such as those that exist
downhole in oil and gas fields. Further, without being bound by
theory, it is believed that the zinc or zinc alloy in outer layer
130 provides sacrificial protection of the underlying layers during
storage, such as wireline cable storage conditions between
successive wireline logging jobs.
[0027] FIG. 2 depicts wire 200 consistent with at least one
embodiment of the present disclosure. Wire 200 includes ferrous
wire core 110. One non-limiting example of a ferrous wire core 110
is a steel wire. Interface metal layer 120 circumferentially
surrounds ferrous wire core 110. Interface metal layer 120 may be
composed of nickel or molybdenum. In certain embodiments, interface
metal layer 120 may have a thickness of from about 2 to about 50
microns. Without being bound by theory, interface metal layer 120
may serve as a stop layer for corrosion if the outer layer 130
(described below) is compromised. In the embodiment depicted in
FIG. 2, Fe layer 140 circumferentially surrounds interface metal
layer 120. In certain embodiments, Fe layer 140 may have a
thickness of from about 2 to about 20 microns. Without being bound
by theory, it is believed that nickel contact with the environment
may increase brittleness, and Fe layer 140 may reduce such contact
and increase the longevity of wire 200. Outer layer 130
circumferentially surrounds Fe layer 140. Outer layer 130 may be
composed of zinc or a zinc alloy. The zinc alloy can include, but
is not limited to, a binary Zn--Ni or Zn--Co alloy, or a ternary
Zn--Ni--Co, Zn--Ni--Mo or Zn--Co--Mo alloy. In certain embodiments,
outer layer 130 may have a thickness of between 1 and 50
microns.
[0028] FIG. 3 depicts wire 300 consistent with at least one
embodiment of the present disclosure. Wire 300 includes ferrous
wire core 110. One non-limiting example of ferrous wire core 110 is
a steel wire. Inner zinc layer 150 circumferentially surrounds
ferrous wire core 110. In certain embodiments of the present
disclosure, inner zinc layer 150 is between 2 and 50 microns in
thickness. In the embodiment depicted in FIG. 3, Fe layer 140
circumferentially surrounds inner zinc layer 150. In certain
embodiments, Fe layer 140 may have a thickness of between 2 and 20
microns. Interface metal layer 120 circumferentially surrounds Fe
layer 140 and may be composed of nickel or molybdenum. In certain
embodiments, interface metal layer 120 may have a thickness of from
about 2 to about 50 microns.
[0029] FIG. 4 depicts a cross sectional view of wire 1000. Wire
1000 includes ferrous wire core 110. Wire 1000 includes a layer
1120, such as a Ni, Mo, or Ni alloy coating, circumferentially
surrounding the ferrous wire core 110. The layer 1120
circumferentially surrounding the ferrous wire core 110 can be
present without an overlying zinc or zinc alloy layer. The layer
1120 can act as a protective layer in oil and gas downhole
conditions and in surface storage conditions.
[0030] The successive metal layers depicted in FIGS. 1-4 may be
deposited by any number of methods, including but not limited to
gas plasma, electrolytic plasma, electroplating, electrodeposition,
cladding, or a combination of such methods.
[0031] In certain embodiments, the metal to be deposited is plated
onto the surface of the wire or other metal object via gas plasma
coating. As depicted in FIG. 5, gas plasma coating system 500
includes infrared heat source 410. Prior to processing, wire or
other metal object 220, such as a metallic tool, is passed through
infrared heat source 410 to increase the temperature of wire or
other metal object 220 to enhance bonding. Gas plasma coating
system 500 applies positive and negative energy to two metal wires
240 as the metal wires 240 are fed through gun head 230. As the
positive and negative metal wires 240 arc, the metal in the two
metal wires 240 becomes molten and is then sprayed using dry
compressed air 250 onto wire or other metal object 220. Molten
droplets from the two metal wires 240 may interlock and bond to
each other and the treated wire or other metal object 220,
roughening the surface of the wire or other metal object 220.
[0032] In certain other embodiments, the metal to be deposited is
plated onto the surface of the wire or other metal object 220 via
electrolytic plasma coating. As depicted in FIG. 6, electrolytic
plasma coating system 600 includes infrared heat source 510. Prior
to processing, wire or other metal object 220 is passed through
infrared heat source 510 to increase the temperature of wire or
other metal object 220 to enhance bonding. An electrical charge is
applied to wire or other metal object 220 as it passes through
liquid bath 310 containing metals with an opposite electrical
charge. At the surface of the wire or other metal object 220, the
opposite electrical charges of the metal create plasma layer 320
that deposits metals from liquid bath 310 to create a bonded
roughened surface on wire or other metal object 220. As one of
ordinary skill in the art will appreciate, although FIG. 6 depicts
the charge imparted on wire or other metal object 220 as positive
and the metals in liquid bath 310 as negative, the charges could be
reversed.
[0033] In yet other embodiments, the metal to be deposited is
plated onto the surface of the wire or other metal object 220 via
electroplating. As depicted in FIG. 7, in electroplating system
400, an electrical charge is applied to wire or other metal object
220 as it passes through liquid bath 610. Liquid bath 610 is an
aqueous solution of an oppositely charged electrolyte containing
the metal to be electroplated. The metal in the solution bonds
electro-statically to wire or other metal object 220, and forms a
solid coating over wire or other metal object 220. As one of
ordinary skill in the art will appreciate, although FIG. 7 depicts
the charge imparted on wire or other metal object 220 as positive
and the metals in liquid bath 610 as negative, the charges could be
reversed.
[0034] FIGS. 8a-8d depict a method of forming a wire consistent
with at least one embodiment of the present disclosure. In steel
wire cladding process 700, ferrous wire core 110 is provided, as
depicted in FIG. 8a. Metal strip 710 is placed alongside ferrous
wire core 110, as depicted in FIG. 8b. Metal strip 710 may be
composed of, for instance, Zn, Ni, Mo or Fe. Metal strip 710 is
bent around ferrous wire core 110 and seam-welded to form a tube
which is drawn down to fit tightly over ferrous wire core 110 as
shown in FIG. 8c to form metal-covered rod 720. The metal-covered
rod 720 diameter may then be reduced, such as for example, by
drawing or passing the metal-covered rod 720 through a series of
sizing rollers 730 as shown in FIG. 8d, to the desired final
diameter. In certain embodiments, as shown in FIG. 8d, the
orientation of sizing rollers 730 may alternate. Metal-covered rods
720a-720d depict the reduction in diameter of metal-covered rod 720
as it passes through sizing rollers 730.
[0035] FIGS. 9a-9e depict a method of forming a wire consistent
with at least one embodiment of the present disclosure. In steel
wire cladding process 800, a thin layer of Zn, Ni, or Mo is applied
using gas plasma coating, electrolytic plasma, or electroplating as
described above to form plated rod 810, as shown in FIG. 9a. The
thin layer can be from 2 to 10 microns in thickness, for example.
Metal strip 820 is placed alongside plated rod 810, as shown in
FIG. 9b. Metal strip 820 may be formed from Zn, Ni, Mo, or Fe, for
instance. Metal strip 820 is bent around plated rod 810 and
seam-welded to form a tube, as shown in FIG. 9c. The tube is drawn
down to fit tightly over plated rod 810 as shown in FIG. 9d to form
metal-covered rod 830. The metal-covered rod 830 diameter may then
be reduced, such as for example, by drawing or passing the
metal-covered rod 830 through a series of sizing rollers 840, as
shown in FIG. 9e, to the desired final diameter. In certain
embodiments, as shown in FIG. 9e, the orientation of sizing rollers
840 may alternate.
[0036] Metal-covered rods 830a-830d depict the reduction in
diameter of metal-covered rod 830 as it passes through sizing
rollers 840.
[0037] In certain embodiments, the outer layer 130 of zinc in wires
100 and 200, and the inner zinc layer 150 of wire 300 may be
deposited by hot-dipping, electroplating, mechanical bonding,
sherardizing or thermal spraying. Hot-dip methods include a
continuous process in which long strands of sheet, wire or tubing
are continuously fed through a bath of molten zinc. Hot-dip methods
also include batch processes in which fabricated parts, including
such parts as fasteners, poles or beams, are dipped into molten
zinc either individually or in discrete batches. Similarly, zinc
electroplating can be performed in a continuous or batch mode.
[0038] In certain embodiments of the present disclosure, wire 100,
wire 200, wire 300, wire 1000, metal-covered rod 720, and
metal-covered rod 830 may be galvanized, such as through hot dip
galvanizing process 900 as shown in FIG. 10. Wire 910 (which may
include, for example, wire 100, wire 200, wire 300, wire 1000,
metal-covered rod 720, or metal-covered rod 830) may be passed
through molten Zn bath 920 to form galvanized-coated wire 930.
Galvanized-coated wire 930 is wire 910 with an additional layer of
hot-dip Zn galvanization.
[0039] The foregoing outlines features of several embodiments so
that a person of ordinary skill in the art may better understand
the aspects of the present disclosure. Such features may be
replaced by any one of numerous equivalent alternatives, some of
which are disclosed herein. One of ordinary skill in the art should
appreciate that they may readily use the present disclosure as a
basis for designing or modifying other processes and structures for
carrying out the same purposes and/or achieving the same advantages
of the embodiments introduced herein. One of ordinary skill in the
art should also realize that such equivalent constructions do not
depart from the spirit and scope of the present disclosure and that
they may make various changes, substitutions, and alterations
herein without departing from the spirit and scope of the present
disclosure.
* * * * *