An electric submersible pumping system includes a motor, a pump driven by the motor, and a cable that provides electrical power to the motor. The cable includes a conductor and an insulator surrounding the conductor. The insulator includes a first layer surrounding the conductor and a second layer surrounding the first layer. The insulator may include an H.sub.2S scavenger and an H.sub.2S reactant in the first or second layers surrounding the conductor. The cable optionally includes a sub-insulator layer that includes a metal or nitride coating applied directly to the conductor.

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 cable having a cable core for use in fracturing zones in a well, wherein the cable core includes an optical fiber conductor. The optical fiber conductor has a pair of half-shell conductors. An insulated optical fiber located between the pair of half-shell conductors. The insulated optical fiber is coupled with the pair of half-shell conductors. An optical fiber conductor jacket is disposed about the pair of half-shell conductors.

An optical cable can include one or more graphenic elements disposed about one or more optically transmissive fibers. A graphenic element can be a coating of graphene or amorphous graphite, a ribbon of graphene or amorphous graphite, or fibers of graphene or amorphous graphite. The graphenic element provides a path for electrical conduction while the optically transmissive fiber provides a path for optical transmission. An optical cable as disclosed herein can include a plurality of electrical and optical paths with a much smaller diameter and weight than traditional cables.

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.

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 embodiment of a wellbore cable comprises a cable core, at least a first armor wire layer comprising a plurality of strength members and surrounding the cable core, and at least a second armor wire layer comprising a plurality of strength members surrounding the first armor wire layer, the second armor wire layer covering a predetermined percentage of the circumference of the first armor wire layer to prevent torque imbalance in the cable.

A motor lead extends alongside an electrical pump assembly for supplying electrical power to the motor. The motor lead has electrical power wires positioned side-by-side in a sub assembly. Each of the electrical power wires has an electrical conductor encased in an insulation layer, which in turn is encased in a lead sheath. A metallic band armor wraps around the sub assembly. A thermal barrier layer is located between an inward facing side of the sub assembly and the pump assembly. The thermal barrier layer is formed of thermal insulation material and has a width at least equal to a width of the sub assembly. The motor lead is free of any thermal barrier layers on the outward facing side of the sub assembly to as to allow heat within the sub assembly to dissipate outward.

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.

Electric submersible pumping systems are exposed to harsh chemicals in the downhole environment. Conductors used in the electric submersible pumping system must be shielded against these chemicals. To improve the resistance of conductors to hydrogen sulfide and other aggressive chemicals, an improved insulation system includes an interior layer applied to the conductor, a first outer layer, and an intermediate layer between the interior layer and the first outer layer. The intermediate layer can be a nano-composite layer that includes a mixture of nanoparticles in a polyether ether ketone (PEEK) polymer.