Various cables for cable deployed electric submersible pumping systems and methods of manufacturing such cables are provided. The cable includes a power cable core and coiled tubing formed around the power cable core. The power cable core includes one or more conductors, insulation surrounding each conductor, and an elastomeric jacket extruded around the insulated conductors. Various mechanisms, systems, and methods are described to anchor the power cable core in the coiled tubing and to transfer weight from the power cable core to the coiled tubing.

A method for a down-hole cable is provided. The down-hole cable includes an insulated conductor portion. A filler layer abuts and encapsulates the insulated conductor portion, wherein the filler layer is substantially formed with a foamed fluoropolymer. An armor shell is applied to the exterior of the foamed fluoropolymer filler layer.

A wireline cable, method, and system for broadband communications and data transfer. The wireline cable comprises insulated conductors, arranged such that circumferentially spaced conductors surround a central conductor. One or more of the conductors is insulated with a magnetic permeable insulation configured to reduce electrical interference with an adjacent conductor.

A power cable can include a conductor; an insulation layer disposed about the conductor where the insulation layer includes a first polymeric material; and a shield layer disposed about the insulation layer where the shield layer includes a second polymeric material where a solubility parameter of the first polymeric material is less than a solubility parameter of the second polymeric material.

A high-power low-resistance electromechanical cable constructed of a conductor core comprising a plurality of conductors surrounded by an outer insulating jacket. Each conductor has a center conductor element surrounded by a plurality of copper wires, wherein the plurality of copper wires is compacted to have a non-circular cross-section. The center conducting element may be one of a fiber optic strand, a copper wire having an indented outer surface, or a twisted conductor pair. Each conductor also includes a conductor insulating jacket encapsulating the plurality of copper wires and center conducting element. A first armoring layer of a plurality of strength members is wrapped around the outer insulating jacket. A second armoring layer of a plurality of strength members may also be wrapped around the first layer. A polymer jacket layer may encapsulate the first and/or second armoring layers of strength members.

A power cable for an electric submersible pump (ESP) includes an electrical conductor in the power cable; an elastomeric insulation layer around the electrical conductor; a fluoroplastic barrier layer around the elastomeric insulation layer; and a bonding layer between the elastomeric insulation layer and the fluoroplastic barrier layer, the bonding layer formulated to prevent a dielectric breakdown of the power cable and a rapid gas decompression breakdown of the power cable.

A small-diameter, continuously bonded cable and a method for manufacturing the same includes at least one longitudinally extending inner metallic component with a tie layer of an amended polymer material surrounding and bonded thereto in steps of heating and extruding. A longitudinally extending outer metallic component is radially spaced from the at least one inner metallic component and incased in a polymer material jacket layer in heating and extruding steps. The polymer materials insulate the metallic component for conducting electrical power and/or data signals.

A load carrying bundle of elongate elements combined with a fiber optic cable for integration with an elongated structure to perform global strain monitoring using fiber optic strain sensors is described. The load carrying bundle is made up by a number of individual elongated strength elements, which individual elongated strength elements are laid in a helix around the, in the bundle, centrally located fiber optic cable sensor. The elongated strength elements are laid adjacent to each other enabling to perform both a protective enclosure of the fiber optic cable sensor and to provide frictional bonding between the fiber optic cable sensor and the elongated strength elements.

A cable assembly, well system, and method of use. A cable assembly may comprise a protective covering and a cable disposed in the protective covering. The cable may comprise a center conductor, an insulator. The insulator may be disposed about the center conductor. The cable may comprise an extra conductive layer, where the extra conductive layer may comprise copper and may be disposed about the insulator, and an outer conductive casing. A well system may comprise a cable assembly, which may comprise a protective covering, and a cable. The well system may further comprise downhole equipment disposed in a wellbore, wherein the downhole equipment may be connected to the cable assembly. A method for using a cable assembly in a well may comprise providing the cable assembly, inserting the cable assembly in the well, and sending a signal current through the cable assembly from the surface to downhole equipment.

Systems and methods of the disclosed embodiments may include a coiled tubing locatable in a wellbore, a power and communications cable positioned along the coiled tubing. The power and communications cable may include an electromagnetic waveguide, an inner metallic tubular surrounding the electromagnetic waveguide, an electrically conductive material surrounding the inner metallic tubular, an electrically insulating material surrounding the electrically conductive material, and an outer metallic tubular resistant to corrosion and abrasion surrounding the electrically insulating layer. The example system may include an electrical device locatable in the wellbore and coupleable to the cable and a control unit coupleable to the cable and operable to supply power to and communicate with the electrical device via the power and communications cable.