A downhole cable that has a cable core with an inner jacket located about it. The inner jacket has a shell located thereabout, and a pair of strength member layers surrounds the inner shell. Interstitial spaces of the strength member layers are filled with bonding layers. One of the strength member layers is at a contra-helical lay angle to the other. An outer jacket is located about one of the strength member layers, and the outer jacket is bonded with the bonding layers.

Provided is a method of manufacturing a downhole cable, the method including, forming a helical shape in an outer circumferential surface of a metal tube, the metal tube having a fiber element housed therein, and stranding a copper element in a helical space formed by the metallic tube. Also provided is a downhole cable including, a metallic tube having a helical space in an outer circumferential surface thereof, wherein the metallic tube has a fiber element housed therein, and a copper element disposed in a helical space formed by the steel tube. Double-tube and multi-tube configurations of the downhole cable are also provided.

A gas resistant pothead system and method for electric submersible motors. A gas resistant pothead system includes a lead foil wrapped motor lead cable (MLE) extending through a pothead, a sleeve of an insulator block inside the pothead, the sleeve including gold plating and lead-foil wrapping over the gold plating, and a lead-to-gold seal formed between the gold plating of the sleeve and the lead foil wrapping over the gold plating. A method of creating a seal to gas around a power cable connection to a downhole electric submersible motor includes wrapping lead foil around a MLE extending through a pothead, continuing the lead foil wrapping around a gold-plated sleeve of an insulating block inside the pothead, mechanically reinforcing the lead foil with an encapsulant, and bonding the lead foil to the gold plating of the insulating block.

The present disclosure relates to a cable that includes a core, a first armor wire layer surrounding the core, a first polymer layer disposed around the first armor wire layer, where the first polymer layer has a first sensitivity to energy emitted from an energy source, a second armor wire layer that may be disposed at least partially in the first polymer layer, and a second polymer layer disposed around the second armor wire layer, where the second polymer layer has a second sensitivity to the energy emitted from energy source, and the second sensitivity is greater than the first sensitivity.

An electromechanical cable that is crush-resistant and torque balanced is provided as well as a method for manufacturing a crush-resistant and torque balance electromechanical cable. The cable can include a core having a conductor surrounded by a first jacket layer, a second jacket layer surrounding the first jacket layer, a first armor layer surrounding second jacket layer, a third jacket layer surrounding the first armor layer, a second armor layer surrounding the third jacket layer, and a fourth jacket layer surrounding the second armor layer. The first armor layer can be constructed as a plurality of wires and compressed partially into the second jacket layer. The second armor layer can be constructed from a plurality of three-wire strands and/or single wires and compressed partially into the third jacket layer. The three-wire strands can be symmetric or asymmetric and can be compacted or non-compacted.

A cable that has a cable core with a first armor wire layer and a second armor wire layer. The second armor wire layer is segregated from the first armor wire layer, and an outer jacket is disposed about the second armor wire layer.

A technique facilitates construction and operation of a power cable which may be used to deploy an electric submersible pumping system downhole into a wellbore. The power cable is constructed to provide structural support of the electric submersible pumping system while also providing electric power to the electric submersible pumping system when located downhole in the wellbore. The power cable has at least one conductor and a plurality of layers selected and arranged to ensure long-term support and delivery of electrical power in the relatively harsh downhole environment.

A cable (100) is used for running a load between surface and downhole in a well. The cable includes one or more wires (110) composed of a non-metallic material. Each of the one or more wires (110) bears the load from the surface and electrically conducts between the surface and downhole. An insulating material (120) is disposed about the one or more wires (110) and insulates the electrical conduction. The non-metallic material includes a carbon nano-tube wire. A jacket (130) can be disposed about the insulating material (120), and the jacket (130) can be composed of a non-metallic material also, such as carbon nano-tube wire.

A wireline cable includes an electrically conductive cable core for transmitting electrical power, an inner armor layer disposed around the cable core, and an outer armor layer disposed around the inner armor layer, wherein a torque on the cable is balanced by providing the outer armor layer with a predetermined amount of coverage less than an entire circumference of the inner armor layer, or by providing the outer armor layer and the inner armor layer with a substantially zero lay angle.

A stress cone for reducing electrical stresses is disclosed for use on terminated ends of tubing encapsulated power cable used in surface applications in a subsurface well power system employing electric submersible pumps (ESPs). The stress cone comprises an annular section about a longitudinal axis for receiving a terminated end of the TEPC in its first end and for abutting the terminated metal TEPC end against a metal shoulder at its second end therein, and an insulation chamber axially aligned with and connected to the annular section. The chamber comprises a metal interior surface symmetrical about the axis. The insulated TEPC core (without outer metal sheath) passes through the insulation chamber along the axis and then exits. The ID of the TEPC metal sheath and the inside metal surface of the chamber form a smooth ground plane transition surface. Insulation material surrounds the TEPC insulation layer within the insulation chamber.