Session: 13-03-05: General: Mechanics of Solids, Structures and Fluids V

Paper Number: 164780

Numerical Modeling of Wireline Cable Spool Winding 

Wireline logging utilizes electric instruments to continuously measure the properties of a formation. In this process, the wireline cable is wound around a large spool located on the surface. A motor and drive train operate the winch spool to raise and lower the logging equipment into and out of the well. The quality of wireline cable winding on the winch spool is important for wireline operations. Wireline cable usually requires multi-layer winding, where a regular, ordered, and smooth winding is ideal. Common issues with wireline cables winding include reverse climbing, gap formation between consecutive wraps, pileup at the flange or rim of the spool, and cable snagging. These winding issues impact operational efficiency and can cause mechanical damage to the cable on the spool, leading to downtime and unsafe conditions. Understanding the winding process of wireline cables is crucial for designing the winding apparatus such as the spool, the spooling arm, and the cable guide, and for developing effective winding procedures.

This study uses finite element modeling approach to simulate wireline cable winding on a spool. The wireline cable is represented using beam elements with isotropic elasto-plastic material properties, while the spool, sleeve, and cable guide are modeled as rigid components. The model is solved using the ABAQUS nonlinear implicit solver. It accurately predicts the cable winding process and replicates common winding failure modes such as reverse winding and gap formation, where the former occurs when the current winding clamps onto existing wraps, leading to reverse winding or cable pile-up at the rim, and the later refers to the situation that the current winding jumps to the next location, creating gaps in winding.

The developed model is employed to predict the maximum lagging angle beyond which reverse winding occurs, and the results show favorable agreement with test data and analytical equations, validating the model. Subsequently, the model is used in sensitivity studies to investigate the effects of friction, tension, mechanical properties of the cable, spool size, and cable size. Findings indicate that the coefficient of friction, winding diameter, and cable bending stiffness significantly affect the critical leading and lagging angles, which determines the range of permissible fleet angle for good winding. Higher friction, larger winding diameters, and cables with greater bending stiffness tend to reduce this range. Cable tension has a relatively minor impact, especially when bending stiffness is negligible compared to axial stiffness. Cable size has a pronounced effect, with larger cables tending to allow a wider range of permissible fleet angles.

The developed method provides a high-fidelity numerical approach to simulate wireline cable winding, understand the underlying physics, and offers valuable insights for designing wireline cable winding apparatuses and developing effective control procedures.

Presenting Author: Haitao Zhang SLB

Presenting Author Biography: Haitao Zhang received his PhD in Solid Mechanics in 2005 from the Johns Hopkins University. He joined SLB in 2009 and is currently the FEA Domain Manger in the ETD Modeling and Simulation discipline based at HETG in Sugar Land. His expertise is on solid mechanics and finite element modeling.

Authors:

Haitao Zhang SLB
Muhannad Abuhaikal SLB