Submersible Pump Cable Overview Initials8/15/2024INTRODUCTION TO ESP CABLEModular design many optionsInitials8/15/2024REDA Production Systems - LAWRENCERPS Lawrence is part of the Schlumberger GroupLocated in Lawrence Kansas since 1976Manufacturer of electric power cable and rubber molded components for ESPsProducer of more ESP cable than any other manufacturerCertified to ISO 9001 Includes All aspects of Cable ManufacturingInitials8/15/2024Electrical Submersible CablePower is supplied to the electric motor by electric cable.Power CableInitials8/15/2024Cable SelectionElectrical PropertiesPhysical DimensionsEnvironmental ResistanceMechanical StrengthTemperatureHandling ConditionsInitials8/15/2024Cable SelectionThe proper cable size is governed by the amperage, voltage drop, and space available between the tubing collar and casing.Initials8/15/2024Cable SelectionA range of conductor sizes are available to meet application. requirements.Initials8/15/2024Cable SelectionCables are available in either flat or round configurations. FLATROUNDInitials8/15/2024Cables can be installed in wells where bottom hole temperature is excess of 300 degrees Fahrenheit.Cable SelectionInitials8/15/2024CONDUCTORINSULATIONBARRIER INJECTION TUBE (optional)JACKETARMORCable ComponentsInitials8/15/2024SIZEDAMAGE RESISTANCEFLEXIBILITYCOSTConductor SelectionInitials8/15/2024ADHESION & STRAND BLOCKING- Downhole Performance- Gas transmission- Gas entrapment/corrosion- Corona dischargeCoating / AdhesiveCopperAlloy coatingAdhesiveStrand blockALLOY COATING- Chemical resistanceInitials8/15/2024All these calculations are based on extensive research and Finite Element Analysis (FEA) of downhole cable system modelsConductor Size SelectionInitials8/15/2024TEMPERATUREPRESSURE CHANGESGAS TO OIL RATIO (GOR)CARBON DIOXIDE ATTACKOIL ATTACKInsulation SelectionInsulationInitials8/15/2024Definite melt pointLimited by temperatureEase of processingSimple formulationsThermal failure is often dramaticTHERMOPLASTIC vs.THERMOSETNo melting pointOften higher temperature ratingMore difficult to processComplex formulationsThermal failure is generally gradualPolyproylene CoploymerTHERMOPLASTICEthylene Propylene Diene MethyleneTHERMOSETInitials8/15/2024Excellent electrical propertiesLow costAvailable in three different colorsPOLYPROPYLENEADVANTAGES Excellent resistance to well fluidsInitials8/15/2024Upper temperature range, softens at 205F (96C)Subject to crazing in certain environmentsPOLYPROPYLENEDISADVANTAGESInitials8/15/2024Excellent electrical properties, although higher power losses (DLA) than polypropyleneAvailable in three different colorsEPDMADVANTAGES Excellent high-temperature stability, has been used at up to 550F (288C) in geothermal wellsInitials8/15/2024Susceptible to mechanical damage at elevated temperaturesEPDMDISADVANTAGESLimited well fluid resistance, oil swells EPDM compoundsInitials8/15/20243 kV: tested at 20 kV DC, 7 kV AC4 kV: tested at 30 kV DC, 10 kV AC5 kV: tested at 35 kV DC, 13 kV ACVoltage Rating and Selection CriteriaOPERATING VOLTAGEVOLTAGE SPIKES/TRANSIENTSMECHANICAL DAMAGEInitials8/15/2024Surface Voltage is higher than motor Voltage (Voltage drop)Energy is required to push current through a cableOhms law; V = I(R+XL) = IrL/A+IXLVoltage DropInitials8/15/2024Voltage Drop GraphInitials8/15/2024TEMPERATURECHEMICAL ENVIRONMENTGASHANDLINGBarrier SelectionInitials8/15/2024Barrier TypesTEDLAR TAPE - 300F (150C)TEFLON FEP EXTRUSION - 350F (175C)PROPRIETARY HIGH TEMPERATURE TAPE - 400F (205C)LEAD - 550F (288C)POLYVINYLEDINE FLUORIDE EXTRUSION - 300F (150C)Initials8/15/2024SUPERIOR HOOP STRENGTHHIGHER TEMPERATURETAPE vs. EXTRUDED BARRIERTAPE ADVANTAGEEXTRUDED BARRIER ADVANTAGES FASTER TO PROCESSInitials8/15/2024TEMPERATURECHEMICAL ENVIRONMENTGASHANDLING CONDITIONSJacket SelectionJacketInitials8/15/2024185F (85C), HIGH DENSITY POLYETHYLENE (HDPE)250F (121C), NITRILE 1275F (135C), NITRILE 2350F (176C), NITRILE 3350F (176C), EPDMJacket TypesInitials8/15/2024EPDM Rubber+ Oil =EXCELLENT HIGH TEMPERATURE STABILITYPOOR RESISTANCE TO OILInitials8/15/2024GOOD PHYSICAL PROPERTIESPOOR ELECTRICAL PROPERTIESPOOR RESISTANCE TO WATERNITRILE RubberEXCELLENT RESISTANCE TO OILHARDENS AT TEMPERATURES ABOVE 275F (135C) SLOW DECOMPRESSION RATEInitials8/15/2024EPDM & NITRILE Jackets Offer Different AdvantagesInitials8/15/2024DAMAGE RESISTANCEDECOMPRESSION CONTAINMENTCORROSION RESISTANCEArmor SelectionInitials8/15/2024HEAVY GALVANIZED STEEL (0.034/0.86mm thick)HEAVY COATING CLASS II GALVANIZED STEELDOUBLE ARMOR (two layers)STAINLESS STEELMONELTWO DIFFERENT ARMOR PROFILES Armor TypesSTANDARD GALVANIZED STEEL (CLASS I)(GSA, 0.020/0.51mm & 0.025/0.64mm thick)Initials8/15/2024Armor Profile TypesFlat profileStandard crown profile interlockedInitials8/15/2024REDA Production SystemsCable OptionsInitials8/15/2024 POLYETHYLENE: 185F (85C)REDA Production SystemsCable Families REDALENE: 205F (96C)POTBPPEOInitials8/15/2024REDA Production SystemsCable Families REDAHOT: 250-350F (121-177C) REDABLACK: 300-400F (149-204C)EERETBEFInitials8/15/2024 REDALEAD: 400-450F (203-232C)KELBREDA Production SystemsCable Families MOTORLEADS: 250-450F (121-232C)Initials8/15/2024FLAT CABLE EXTENSIONS (FCE) (Motorlead Pothead)MOTORLEAD - Typically smaller conductor than power cable, thus runs hotter. - KEOTB - 250F (121C)- KELB - 450F (232C)- KELTB - 450F (232C)Motor Connection OptionsInitials8/15/2024POTHEADS- Tape-In Pothead - Tape wrapped around individual connector leads inside motor. - Plug-In Pothead - mating block mounted in motor.- Direct Connect Pothead - Power cable attached directly to the Pothead. (Plug-In Type)Motor Connection OptionsInitials8/15/2024Tape-In Pothead vs Plug-In PotheadREDA Tape-In DesignAdvantages:Most ReliableHighest breakdown strength in industryDisadvantagesLonger installation time on rig floor Advantages:Ease of installationDisadvantagesLower breakdown strength Not as reliable as Tape-InInitials8/15/2024What does #4/1 KEOTB 0.015M5F represent?#4/1 #4 AWG Solid conductorK Polyimide (Kapton) primary insulationE EPDM secondary insulationO Nitrile jacketTB Tape (probably Tedlar) & braid0.015 Armor thickness (inches)M Monel armor5 5 kV Voltage rating F Flat cableCable NomenclatureInitials8/15/2024