ESP Application Engineering

Section 11

Introduction to ESP Cable

Section 4b Haward Technology Middle East 1

 ESP Application Engineering

Introduction to ESP Cable

Modular design many options

Section 4b Haward Technology Middle East 2

 ESP Application Engineering

Electrical Submergible Cable

 Power is supplied to the electric motor by electric
cable.

Section 4b Haward Technology Middle East 3

 ESP Application Engineering

Cable Configuration
 The proper cable size is governed by the amperage,
voltage drop, and space available between the tubing
collar and casing.

Section 4b Haward Technology Middle East 4

 ESP Application Engineering

Cable Configuration
Various factors are involved in the design and
manufacturing of Electrical Submergible Cable
 Electrical Properties
 Physical Dimensions
 Environmental Resistance
 Mechanical Strength
 Temperature
 Handling Conditions

Section 4b Haward Technology Middle East 5

 ESP Application Engineering

Cable Configuration

 ROUND
• Electrical Properties
• Mechanical Properties

 FLAT
• Clearance

Section 4b Haward Technology Middle East 6

 ESP Application Engineering

Cable Configuration

 Round & Flat Composite Injection Tube Power Cables

 Available In All Cable Types

Section 4b Haward Technology Middle East 7

 ESP Application Engineering

Cable Configuration

The best cable type for each selection is based on the

environment for each application where the cable will be
utilized and exposed. It is important to review all of the
data and study these factors specifically for each well
condition to ensure the cable selected is compatible with
the well environment. The most critical data values for
selecting cable are temperature considerations and the
fluid composition.

Section 4b Haward Technology Middle East 8

 ESP Application Engineering

Section 4b Haward Technology Middle East 9

 ESP Application Engineering

Conductor - Selection

 Size
 Damage resistance
 Flexibility
 Cost

Section 4b Haward Technology Middle East 10

 ESP Application Engineering

Conductor - Types
 SOLID
• Smallest diameter / lowest cost
• Lower interfacial electrical stress
 STRANDED (Round)
• Greater flexibility
• Greater damage resistance
 COMPACTED
• Up to 10% decrease in diameter versus
round stranded conductor

Section 4b Haward Technology Middle East 11

 ESP Application Engineering

Conductor - Types
 ALLOY COATING  ADHESION & STRAND BLOCKING
• Chemical resistance • Downhole Performance
‐ Gas transmission
‐ Gas
entrapment/corrosion
‐ Corona discharge

Section 4b Haward Technology Middle East 12

 ESP Application Engineering

H2S Exposure Comparison

Section 4b Haward Technology Middle East 13

 ESP Application Engineering

H2S Exposure Comparison

Size is determined by the required ampacity,
insulation or jacket type and BHT
 Two equations determine ampacity:
• Maximum conductor temperature, Tc, (°F) = (a x I²)
+Twell
• Conductor heating (Watts) = I²R = I²rL/A

Section 4b Haward Technology Middle East 14

 ESP Application Engineering

Conductor - Size Selection

 All these calculations are based on extensive research
and Finite Element Analysis (FEA) of downhole cable
system models
Temperature
Casing
Equivalency (oF)
Tubing
Tubing
Annular
Fluid

Produced
Fluid

Section 4b Haward Technology Middle East 15

 ESP Application Engineering

Insulation Selection
 Temperature
 Pressure changes
 Gas to oil ratio (GOR)
 Carbon dioxide attack
 Oil attack

Section 4b Haward Technology Middle East 16

 ESP Application Engineering

Insulation Types

 ETHYLENE PROPYLENE DIENE METHYLENE RUBBER

(EPDM,THERMOSET)
 POLYPROPYLENE COPOLYMER (THERMOPLASTIC)

Section 4b Haward Technology Middle East 17


THERMOPLASTIC vs. THERMOSET
THERMOPLASTIC
 Definite melt point
 Limited by temperature
 Ease of processing
 Simple formulations
 Thermal failure is often dramatic
Section 4b
ESP Application Engineering
THERMOSET
 No melting point
 Often higher temperature rating
 More difficult to process
 Complex formulations
 Thermal failure is generally gradual
Haward Technology Middle East 18
 ESP Application Engineering

POLYPROPYLENE
ADVANTAGES
 Excellent resistance to well fluids
 Excellent electrical properties
 Low cost
 Available in three different colors

Section 4b Haward Technology Middle East 19

 ESP Application Engineering

POLYPROPYLENE
DISADVANTAGES
 Upper temperature range, softens at 205°F (96°C)
 Subject to crazing in certain environments

Section 4b Haward Technology Middle East 20

 ESP Application Engineering

EPDM
ADVANTAGES

 Excellent high-temperature stability, has been used at

up to 550°F (288°C) in geothermal wells
 Excellent electrical properties, although higher power
losses (DLA) than polypropylene
 Available in three different colors

Section 4b Haward Technology Middle East 21

 ESP Application Engineering

EPDM

DISADVANTAGES

 Limited well fluid resistance, oil swells EPDM

compounds
 Susceptible to mechanical damage at elevated
temperatures

Section 4b Haward Technology Middle East 22

 ESP Application Engineering

Typical Thermostat Design

 Up to 15 ingredients used, for example:
• Polymer system
• Filler system
• Plasticizer system
• Activator system
• Accelerator system
• Antidegradent system
• Cure system
• Miscellaneous ingredients
 Formulations can be changed to meet the desired properties

Section 4b Haward Technology Middle East 23

 ESP Application Engineering

Voltage Rating
 3 kV: tested at 20 kV DC, 7 kV AC
 4 kV: tested at 30 kV DC, 10 kV AC
 5 kV: tested at 35 kV DC, 13 kV AC

Section 4b Haward Technology Middle East 24

 ESP Application Engineering

Voltage Selection
 Operating voltage
 Voltage spikes/transients
 Mechanical damage

Section 4b Haward Technology Middle East 25

 ESP Application Engineering

Voltage Drop
 Surface Voltage is higher than motor Voltage (Voltage
drop)
 Energy is required to push current through a cable
 Ohm's law; V = I(R+XL) = IrL/A+IXL

X, 000
ft

Section 4b Haward Technology Middle East 26

 ESP Application Engineering

Voltage Drop Graph

Section 4b Haward Technology Middle East 27

 ESP Application Engineering

Barrier Selection
 Temperature
 Chemical environment
 Gas
 Handling

Section 4b Haward Technology Middle East 28

 ESP Application Engineering

Barrier Types
POLYVINYLEDINE FLUORIDE EXTRUSION - 300°F (150°C)
 Tedlar™ tape - 300°F (150°C)
 Teflon™ FEP extrusion - 350°F (175°C)
 Proprietary high temperature tape - 400°F (205°C)
 Lead - 550°F (288°C)

Section 4b Haward Technology Middle East 29

 ESP Application Engineering

Tape vs. Extruded Barrier

 Tape advantage
• Superior hoop strength
• Higher temperature
 Extruded barrier advantages
• Faster to process

Section 4b Haward Technology Middle East 30

 ESP Application Engineering

Jacket Selection
 Temperature
 Chemical environment
 Gas
 Handling conditions

Section 4b Haward Technology Middle East 31

 ESP Application Engineering

Jacket Types
 185°F (85°C), High density polyethylene (HDPE)
 250°F (121°C), Nitrile 1
 275°F (135°C), Nitrile 2
 350°F (176°C), Nitrile 3
 >350°F (176°C), EPDM

Section 4b Haward Technology Middle East 32

 ESP Application Engineering

EPDM Rubber
 Excellent high temperature stability
 Poor resistance to oil

Section 4b Haward Technology Middle East 33

 ESP Application Engineering

NITRILE Rubber
 Excellent resistance to oil
 Good physical properties
 Poor electrical properties
 Poor resistance to water

Section 4b Haward Technology Middle East 34

 ESP Application Engineering

EPDM & NITRILE Jackets Offer

Different Advantages

Section 4b Haward Technology Middle East 35

 ESP Application Engineering

Armor Selection
 Damage resistance
 Decompression containment
 Corrosion resistance

Section 4b Haward Technology Middle East 36

 ESP Application Engineering

Armor Types
 Standard galvanized steel (Class I)
(Gsa, 0.020"/0.51mm & 0.025"/0.64mm thick)
 Heavy galvanized steel (0.034"/0.86mm thick)
 Heavy coating class II galvanized steel
 Double armor (two layers)
 Stainless steel
 Monel
 Two different armor profiles

Section 4b Haward Technology Middle East 37

 ESP Application Engineering

Armor Profile Types

Section 4b Haward Technology Middle East 38

 ESP Application Engineering

Cable Nomenclature

In naming the cable, always start from the inside and work
outward. The first step is the size and type of conductor

#/1 = AWG # / Solid conductor

#/7 = AWG # / Stranded (round) conductor
#/7 C/S = AWG # / Compacted strand conductor

Section 4b Haward Technology Middle East 39

 ESP Application Engineering

Cable Nomenclature

The insulation is the second step and will generally be:

PPE or P = Polypropylene /ethylene

E = EPDM (ethylene propylene dienemethylene)
K = Polyimide (Kapton™)
T = Semi-conductive tape(Surface)
or
S = Special

Section 4b Haward Technology Middle East 40

 ESP Application Engineering

Cable Nomenclature
The next step will be a protective chemical barrier, either
tape or extruded, with a unique letter for each type
S = Extruded polyvinylidene fluoride (PVDF or Solef™)
TB-300 = Tape & braid polyvinyl fluoride (PVF or
Tedlar™)
F = Extruded fluoropolymer (FEP)
TB-400 = Proprietary high temperature tape/braid
L = Lead

Section 4b Haward Technology Middle East 41

 ESP Application Engineering

Cable Nomenclature

The next step will be the type of jacket

PE = High density polyethylene (HDPE)

O = Nitrile (Oil resistant nitrile rubber compound)
E = EPDM (EPDM rubber compound)

Section 4b Haward Technology Middle East 42

 ESP Application Engineering

Cable Nomenclature
The next step will be the armor
G = Galvanized steel
HG = Heavy galvanized steel
GG = Double galvanized (two layers)
SS = Stainless steel
M = Monel™
= Standard interlocking profile
FP = Flat profile armor
Armor thickness can range from 0.015" to 0.034" (0.38 mm to 0.86 mm) thick
Galvanized steel armor is available as Class I, II or III (Zinc coating thickness)

Section 4b Haward Technology Middle East 43

 ESP Application Engineering

Cable Nomenclature

The final step will be the voltage rating and cable

geometry

3, 4, 5, 8 = Voltage rating (kV)

F = Flat cable configuration
R = Round cable configuration

Section 4b Haward Technology Middle East 44

 ESP Application Engineering

Cable Nomenclature
What does #4/1 KEOTB 0.015M5F represent?
#4/1 #4 AWG Solid conductor
K Polyimide (Kapton™ ) primary insulation
E EPDM secondary insulation
O Nitrile jacket
TB Tape (probably Tedlar™) & braid
0.015 Armor thickness (inches)
M Monel armor
5 5 kV Voltage rating
F Flat cable

Section 4b Haward Technology Middle East 45

 ESP Application Engineering

Cable Families

 Polyethylene: 185°F (85°c)

 Lene: 205°F (96°c)

Section 4b Haward Technology Middle East 46

 ESP Application Engineering

Cable Families

 Hot: 250-350°F (121-177°C)

 Black: 300-400°F (149-204°C)

Section 4b Haward Technology Middle East 47

 ESP Application Engineering

Cable Families

 Lead: 400-450°F (203-232°C)

 Motorleads: 250-450°F
(121-232°C)

Section 4b Haward Technology Middle East 48

 ESP Application Engineering

Motor Connection Options

 Flat cable extensions (FCE) (Motorlead & pothead)
 Motorlead - typically smaller conductor than power
cable, thus runs hotter.
• Keotb - 250°F (121°c)
• Kelb - 450°F (232°c)
• Keltb - 450°F (232°c)

Section 4b Haward Technology Middle East 49

 ESP Application Engineering

End of this
Section

Section 4b Haward Technology Middle East 50