Increase design freedom and tool reliability with small, mechanically robust hook-up wires
Today’s oil and gas industry is demanding smaller downhole tools with improved signal integrity and higher signal density. At the same time, the downhole environment is becoming increasingly challenging with high pressures, extreme temperatures, and vibration.
Whether the function is power or signal, GORE Hook-Up Wires for oil and gas downhole equipment are engineered specifically to withstand extremely harsh conditions without compromising the mechanical and electrical performance of the tools (Table 1). The small size and enhanced mechanical performance of GORE Hook-Up Wires simplify the complex design challenges that can affect equipment life and reliability in extreme temperatures.
Increased Design Freedom
The increased electrical requirements and smaller size of downhole tools have reduced the amount of available space for wire bundles and pathways. GORE Hook-Up Wires deliver outstanding mechanical and electrical performance in smaller wire sizes, which improves flexibility when designing new tools.
Because of the optimized insulation in GORE Hook-Up Wires, they require less space — more than 30 percent less space — than a NEMA HP3 Type E AWG 24 wire (Figure 1). This smaller diameter, along with the improved dielectrics of these wires, enable you to increase the number of conductors in a given space or reduce the amount of space required for the wires — all of which translates to more design freedom.
Added Durability for Easy Installation and Longer Tool Life
Sharp edges and routing through small spaces can damage the conductor insulation during installation. Therefore, wires can fail during use if the damage is undetected. Engineered for superior cut-through and abrasion resistance, GORE Hook-Up Wires have a unique mechanical and dielectric performance (Figure 2). The improved durability of the dielectric and the abrasion-resistant construction increases first-pass yields and reduces the risk of tool failures due to insulation damage. The smaller diameter and added durability increases flexibility with a smaller bend radius that makes it easier to route wires through tighter spaces during installation. It also reduces re-work caused by damage from sharp edges.
Benefits of GORE Hook-Up Wires
- Increased design options with smaller diameters and more durable construction
- Superior electrical and mechanical performance in extreme environments with temperatures up to 260°C
- Longer tool life with abrasion-resistant and low-creep wire insulation
- Reliable installation due to cut-through resistance that eliminates damage from sharp edges or burrs
- Easy routing with smaller, more flexible wire
Figure 1: Size Comparison of NEMA HP3 Type E Wires and GORE Hook-Up Wires
Figure 2: Dynamic Cut-Through Resistance at High Temperatures
GORE Hook-Up Wires are available in a variety of standard sizes (Table 2).
Increased Tool Reliability
With the increased cost of oil and gas exploration, the industry expects downhole tools to operate reliably over multiple well logging cycles without failure. The conditions to which the wires are exposed can easily compromise many wires. For example, exposure to extreme temperatures and vibration may lead to failure due to material creep that is common in most state-of- the-art thermoplastic insulation materials.
GORE Hook-Up Wires maintain consistent signal integrity and reduce the risk of abrasion and cut-through because of the unique engineered fluoropolymer insulation. The materials used in these wires are chemically inert, which reduces reaction to fluids such as those found in downhole environments. GORE Hook-Up Wires also withstand extreme temperatures ranging from -60°C to 260°C.
Table 1: Cable Properties of 24 AWG GORE ® Hook-Up Wires
|Voltage Rating (RMS)||600 V|
|Wrapback Test (AC)||3 kV|
|Wire Insulation||Engineered fluoropolymer|
|Insulation Wall Thickness mm (inch)||0.140 (0.0055)|
|Conductor||SPC / NPC|
|Color Coding||White, grey, red, yellow, green, orange,
blue, brown, black, purple
|Dynamic Cut-Through Resistance (ASTM D 3032 / 22)
at 21°C (70°F)
at 200°C (392°F)
at 260°C (500°F)
> 48 N
> 17 N
> 12 N
|Abrasion Resistance (ASTM D 1676 / 850 g [1.87 lbs])
Abrasion Resistance ( MIL-DTL-17 / 335 g [0.74 lbs])
|> 148 cycles
> 30 cycles
|Tensile strength (insulated wire)||> 100 N|
|Temperature Range °C (°F)||SPC: -65 to 200 (-85 to 392)
NPC: -65 to 260 (-85 to 500)
|Thermoplastic Flow °C (°F)
24 AWG (07/32) SPC tested per ANSI/NEMA MW 1000-2012
|> 300 (> 572)|
Table 2: Specifications for Standard Products
|Part Number||Gauge Size AWG||Strands||Conductor Plating||Nominal Outer Diameter
|Max. Operating Temp. °C (°F)
-65 up to 260 (-85 up to 500)
|Max Operating Temp. °C (°F)
-65 up to 200 (-85 up to 392)
Contact Gore if you need a customized hook-up wire or cable, such as shielded versions, pairs, triads, etc.
Standard versions with voltage ratings of 250 V and 1000 V are available as well