Section II

Technical Manual

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Cased Hole
Brief Summary:
Overview of EM Cable Issues presented in the Electromechanical Cable Cased Hole School with an
overview of the main operational issues.
Introduction:
The electromechanical cable used in oilfield wire-line service operations must perform four basic
functions.
1. Strength Member: The cable must have sufficient strength to carry an instrument
package to any depth. In most cases the weight of a cable itself is the greatest part of
the load.
2. Electrical Power: The conductors in the cable must be adequate to supply electrical
power from the truck to the instrumentation at the bottom of the cable.
3. Electrical Communication: The electrical conductors must be suitable to transmit the
electrical information generated by the down hole instruments to the computer or
recorder in the truck.
4. Depth Measurements: The only method of measuring the depth, at which the down hole
instruments are located (and the corresponding geological beds of interest), is to
measure the length of cable that has been put into the bore-hole. Without accurate
depth information the instrument data is of little value.
Throughout this school we will be referring to the Camesa type 1N32PP cable as an example.
Many wire-line service companies, throughout the world, use this cable for cased-hole logging
operations.
A. STRENGTH
Cable armor wire is classified as "galvanized extra-improved plow steel". It has a tensile range of
from 270 to 300 thousand PSI.
1. Guaranteed Minimum Breaking Strength: The manufacturer's rated minimum breaking
strength applies to a new cable, pulled straight with no rotation allowed. For the
1N32PP type cable this rated breaking strength is 11,000 lbs. Actual factory break tests
performed on each new cable typically result in values greater than 11,500 lbs.

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2. The actual breaking strength for a cable may be less than the guaranteed minimum
breaking strength for the following reasons:
a.
b.
c.
d.
e.
f.
g.
h.

Wear
Corrosion
Bending
Fatigue
Torque
Rotation
Physical damage
Defective tension device

3. Weak Spots: Cables do not have "weak spots" as a result of manufacturing defects . If
they break at tensions below the guaranteed minimum breaking strength, it is for one of
the above reasons. Individual wire breaks can be the result of a weak point or defect in
the wire, but these occur less than one in every 2 million feet of wire. The probability, of
all the wires in a cable having a defect at the same point in the length, is virtually
impossible. Individual wire breaks can occur for all of the above reasons and in addition:
a. Faults or inclusions in the steel structure
b. Butt welds
c. Damage during manufacturing respooling
4. Field Failures: Experience over the years clearly indicates that by far most cable breaks
in field use are the result of:
a.
b.
c.
d.

Physical damage
Rotation
Inaccurate tension device
Cable or tool becomes stuck near the surface

5. Operating Strength: The minimum guaranteed breaking strength of the cable is the
minimum pull the cable will withstand before parting. For normal operations the following
guidelines should be remembered.
a. The cable when properly installed can withstand unlimited pulls to 50% of its rated
strength. This is 5,500 lbs. for the 1N32PP cable.
b. The cable when properly installed and maintained can withstand 75% of rated
strength, (8,250 lbs.) with only minor damage to the cable. Repeated pulls to this
tension over sheave wheels or measuring devices will cause permanent and
irreversible damage.
c. Any pull on the cable above 75% of rated strength will cause serious and unrepairable damage to the cable, which may not show up until several runs after
the cable has been pulled to this tension.
6. Stuck: When "stuck in the hole" the following suggestions are offered.

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a. Check your tension device and depth to stuck point by comparing it to cable
stretch. The cable can be flagged or marked and the change in the length
measured when the tension is increased.
L
T
L
L
T
L
K

=
=
=
=
=
=
=

K L T
L / (K L)
L / (K T)
change of length
change in tension
length to stuck point
stretch coefficient 1.2 ft/1000ft/1000 lbs.

b. Check all devices the cable physically contacts. Be sure the correct sheave wheel
(proper diameter and groove shape) is being used and that trucks and sheave are
properly aligned. Any pinching, bending or scraping of the cable can significantly
reduce the cable strength.
c. Move your "set-up" distance so that the armor wires are not fatigued by repeated
bending in the same area by the sheave wheel or measuring device.
d. Use common sense in "spudding". "Spudding" means using the inertia of the
logging instrument to break through a bridge that is blocking the well bore. The
cable was designed to work in tension - not compression.
7. Splices: Cased hole cables are sometimes spliced. With regard to cable strength the
following points should be remembered.
a. A properly made splice, either shimmed or welded, will develop at least 90% of
the strength of an unspliced cable in a straight pull.
b. Splices will not tolerate spudding. Drastic reductions of strength of a splice can
occur if is put in compression.
c. Splices fatigue rapidly in bending around sheave wheels and measuring devices.
The smaller the sheave diameter, the more rapid the deterioration of the splice.
8. Torsion and Rotation: All logging and perforating generate a specific torque when
subjected to a load. When permitted, the cable will rotate many revolutions. For
1N32PP cable the approximate values are:
a. Torsion: 1.3 ft.-lbs/1000 lbs tension change
b. Rotation: 5 revolutions/1000 ft/1000 lb tension change
When the cable is first put into use it will "spin-out" in response to the tension profile it
experiences. That is, the cable will rotate in the direction of the outer armor layer

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winding. Once the cable has "spun-out", there will be a torque generated and
tendencies for the cable to rotate only when there is a change in the tension profile.
The cable experiences a change in tension profile every time it goes into and comes out
of the well as a result of the frictional drag on the tool and cable. If the cable were
lowered and pulled out at a uniformly slow speed, there would be virtually zero frictional
drag. Under those conditions, a seasoned cable would have no tendency to rotate.
Under practical operating conditions the tension going into the hole is several hundred or
even several thousand pounds less than the tension coming out. This results in
significant torque and rotation in the cable during every round trip into and out of a well.
There in no limit to the speed at which the cable can be spooled except as how it affects
the tension in the cable and the resulting torque and rotation.
To avoid any cable problems resulting from cable torque, the tension at any given depth
should never be less than 1/2 of the tension going into the hole at that same depth
coming out of the hole. When the tension drops to 1/3, there is loss of contact between
the inner and outer armor layers, in this condition, the cable can accumulate wellbore
material between the armor layers, develop high wires, or bird caging of the arm can
occur.

B. ELECTRICAL POWER
One of the main functions of the EM Cable is to transfer electrical power from surface panels to
down-hole logging instruments. In order to determine which is the best cable for the job the
following issues should be considered.
1. Voltage Rating: The voltage rating of a new 1N32PP cable is 1500 volts D.C. All new
cables are tested at twice the rated maximum voltage rating for 5 minutes before they
leave the factory. The specified maximum voltage is a conservative rating. The reason
for this conservative rating is to take into account some of the stresses that the cable
can be exposed to during normal operations. These stresses include splices, physical
abuse the cable will normally experience in field use, and the effects of temperature and
pressure.
The voltage ratings are not reduced by temperature within the temperature rating of the
cable. Since the voltage ratings are conservative, the ratings can be applied to used
Camesa cables, provided that splices are done carefully and physical abuse to the cable
is not excessive.
2. Power Handling: The combination of cable maximum voltage rating and the conductor
electrical resistance are the factors that limit the conductor current.
Another factor, which needs to be considered, is the heat generated by high current
applications. Passing several amps through the conductor for several hours, with a
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portion of the cable tightly wound on the drum, can cause a significant amount of heat to
build up. With the cable tightly wound on the drum the conductor can not dissipate the
heat and the cable on the drum acts as a big heating coil. Sustained high currents, in
such situations, can cause sufficient heating to melt the plastic insulation around the
conductor.
3. Insulation Leakage: All plastic insulation used in logging cables are such an excellent
dielectrics that in an un-spliced cable there should be no measurable leakage in any
conductor. To check cable insulation be sure:
a. Cable is disconnected from collector (slip-rings)
b. Cable is disconnected from the head or bridle cable
c. The insulation at both ends has been cleaned and all conductive coating material
is removed.
Under the above conditions there should be no measurable leakage once the conductor
is fully charged. This leakage will not vary with surface temperatures. The insulation
resistance is so high, over 1.5 x 105 megohms/1000 ft, that even though it decreases
slightly with temperature to the range of 104 or 103 megohms/1000 ft., the decrease is of
no significance. Most generally, low insulation resistance is caused by rubber, neoprene,
or similar type boots in contact with the connector pins.
4. Insulation Defects: If any leakage can be observed after taking the above precautions it
will be due to:
a.
b.
c.
d.

Manufacturing defects
Mechanical damage to cable
Splice in conductor
Z-kinks

Methods of locating leaks will be discussed later under service, but experience clearly
indicates that most electrical failures are associated with mechanical damage to the
cable. One form of mechanical damage can be caused by perforating, especially in an
under-balanced well condition.. This can result in the formation of "Z" kinks in the
conductors near the cable end.
5. Conductor Resistance: The maximum electrical resistance of the cable conductors is
listed in the catalog. For the 1N32PP, the maximum electrical resistance is 3.1
ohms/Kft. at 68 degrees F. A 1N32PP line typically has 2.8 ohms/Kft. at 68 degrees F.
The conductor is made of copper and therefore the resistance of the conductor varies
with temperature as
For T in degrees Centigrade
(.9214 + .00393 T2 )
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RT2

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= RT1 ------------------------------(.9214 + .00393 T1 )

For T in degrees Fahrenheit

RT2

(.8515 + .00218 T2 )
= RT1 ------------------------------(.8515 + .00218 T1 )

RT = Resistance at temperature
T = Temperature at which RT was measured
More specifically, for a 1N32PP cable with a typical resistance of 2.8 ohm/kft. at 68
degrees F,
For T in degrees Centigrade:
RT = (2.58 + .0.011 T) ohm/1000 ft.
For T in degrees Fahrenheit:
RT = (2.38 + .00611T) ohm/1000 ft.
At 274 degrees C (526 F) the resistance of copper is double its value at 20 degrees C
(68 F).
This demonstrates the significant effect of temperature on conductor resistance. Of
course, as the resistance increases, the ability of the cable to transmit power and return
signals decreases!
As a cable is lowered into the hole the total conductor resistance for the 1N32PP cable
will be
For T in degrees Centigrade:
RL

= (2.58 + .011 TS )L + [2.58 + .0055 (TB - TS )]D ohms

For T in degrees Fahrenheit

RL
Where:
RL
L
TS

= (2.38 + .00611 TS )L + [2.38 + .00305 (TB - TS )]D ohms

= total conductor resistance - ohms
= total length of cable on truck winch - units of 1000 ft.
= surface temperature

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D
TB

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= depth of tool - units of 1000 ft.

= bottom hole temperature

C. ELECTRICAL COMMUNICATION
A variety of signals are transmitted from down-hole instruments to the surface by means of the
cable conductors and armor. These signals vary in frequency for DC to 60 - 100 KHZ. At 100KHZ
the attenuation of a 1N32PP cable is in the range of 0.68 db/kft @ 10khz and 2.28 db/kft @ 60 hz.
A plot of attenuation versus frequency is shown in the attached graph.
1. Capacitance and Resistance: The cable is basically a R-C network for most of the
frequencies used on the cable. Therefore, to improve signal transmission, it is desirable
to reduce capacity and resistance. Unfortunately as the conductor diameter is increased
to reduce electrical resistance, the electrical capacitance of the conductor (with respect
to armor) increases.
For the 1N32PP cable, the D/d ratio of 2.1 results in a nominal characteristic impedance
in the range of 30 to 50 ohms for the frequencies normally used. The characteristic
impedance varies with frequency starting at the DC value and asymptotically
approaching a high frequency value.
2. Dielectric Materials: Signal attenuation in different dielectric materials varies due to the
differences in dielectric constants.
a.
b.
c.
d.

Poly Propylene
Tefzel
FEP Teflon
PFA Teflon

2.3
2.6
2.1
2.1

The dielectric losses for all of these materials is so low over the frequencies involved
that it can be ignored.
3. Temperature Effects: For all practical purposes the dielectric constant of all the plastic
materials is unchanged up to the maximum operating temperature. On the other hand
the resistance of the copper conductors goes up rapidly and therefore so does the
attenuation of the cable. At 526 F. the resistance of copper is double its value at 68 F.
Therefore that portion of a cable at 526 F. will have double the attenuation of that
portion of the same cable at 68 F.

D. TEMPERATURE RATING
The temperature ratings given in the cable catalog are the temperatures at which the cable will
perform satisfactorily under normal operating conditions.

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1. Temperature gradually increases with depth.

2. The principal load carried by the cable will be the cable weight.
Temperature rating specifications are absolute maximums for the insulation material used in the
cable. Routine operation or operation for extended periods of time at the absolute maximum
temperature ratings are not recommended.
Cables can fail at temperatures less than rated due to:
1. Excessive tension
2. Low inner armor coverage
3. Corrosive materials in the bore-hole in contact with conductor insulation.
E. SPECIAL CABLE PROBLEMS
1. Sour gas
2. Acid
3. Water and gas in conductors
a. Pull out of cable head
b. Cracks in insulation
c. Diffusion through insulation
F. CABLE SERVICE
1.
2.
3.
4.
5.
6.

Proper installation to prevent drum crush

Loose armor
Broken armor wire
Splices
Corrosion
Electrical insulation break down

G. REVERSING A LINE
There is often a desire to reverse a line or turn it end for end so that the virgin portion of the line
can be used. This practice is not recommended for the following reasons:
1. Problems of overlap of the new tension-rotation profile with the previous tension-rotation
profile can result in loose armor or high wires.
2. Z-kink formation when the tension is lowered from operational tensions to shipping reel
spooling tensions.
3. Corrosion rate accelerated due to used portion of cable not being flexed.
4. Cable weak point no longer guaranteed to be at the cable-head.
5. Potential problems with spooling due to smaller diameter of used section of line.

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ATTACHMENT I

Attenuation vs. Frequency

1N32PP Cond vs. Armor (25,000 ft.)

Attenuation (-db)

60
50
40
30
20
10
0
0 10 20 30 40 50 60 70 80 90 100
Frequency (khz)

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ATTACHMENT II
ELECTRICAL FAULT LOCATION

Fault
Location

Cable
Drum End

Cable
Head End

RC

RH

RD

L
F
RH
RD
RC
RF

= Total cable Length (ft.)

= Distance to cable fault from cable head end (ft.)
= Resistance of conductor to armor from cable head end (ohms)
= Resistance of conductor to armor from drum end (ohms)
= Resistance of total conductor, end to end (ohms)
= Resistance of fault (ohms)

RH - RD + RC
2RC

*L

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ATTACHMENT III
Derivation of Fault Detection Formula
L
(RC*F/L)

(RC-RC*F/L)

RC

(L-F)

RH

RF

RH
RD

= RF
+ RC*F/L
= RF + RC - RC*F/L

RH + RD
RF

= 2RF + RC
= RH + RD - RC
2
= RH - RF = RH -

RC*F/L
RC*F/L
F

RD

RH + RD -RC
2

= RH - RD + RC
2
= RH - RD + RC
2RC

* L

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ATTACHMENT IV

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