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 power cable assembly supplies power to and suspends in a well an electrical well pump. The assembly includes metal tubing having a longitudinal tubing center line and a cylindrical side wall. Power cable has an exterior delta shape when viewed in a cross-section. The delta shape defines three exterior side surfaces that face radially outward and join each other at corners. Power cable has three insulated power conductors wrapped helically with a metal strip. The power cable is located in the tubing with the corners deformed against an inner diameter of the tubing.

Disclosed are composite cables suitable for use in conjunction with wellbore tools. One cable may include a polymer composite that includes dopants dispersed in a polymer matrix and continuous fibers extending along an axial length of the cable through the polymer matrix, wherein the cable is characterized by at least one of the following: (1) at least a portion of the cable having a density greater than about 2 g/cm.sup.3, wherein at least some of the dopants have a density of about 6 g/cm.sup.3 or greater, (2) at least a portion of the cable having a density less than about 2 g/cm.sup.3, wherein at least some of the dopants have a density of about 0.9 g/cm.sup.3 or less, (3) at least some of the dopants are ferromagnetic, or (4) at least some of the dopants are hydrogen getters.

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.

An electrical power cable for high temperature environments comprises two or more sheathed conductors; each sheathed conductor comprising an electrical conductor, an electrical insulator surrounding the electrical conductor, and a sheath surrounding the electrical insulator; and a bonding material interconnecting the sheaths of the two or more sheathed conductors positioned adjacent to one another to form a cable.

A wireline cable includes an electrically conductive cable core for transmitting electrical power. The wireline cable further includes an inner layer of a plurality of first armor wires surrounding the cable core and an outer layer of a plurality of second armor wires surrounding the inner layer, wherein a diameter of the outer layer of the plurality of second armor wires is smaller than a diameter of the inner layer of the plurality of first armor wires.

A high-temperature cable and a method of making the same is provided. The high-temperature cable includes at least one conductor. An inorganic tape is wrapped around the at least one conductor. An armor shell is applied exterior of the inorganic tape.

A cable that includes a cable core. The cable core has an inner armor wire layer disposed thereabout. The inner armor wire layer has an outer armor wire layer disposed thereabout. The inner armor wire layer and outer armor wire layer have torque removed therefrom during manufacturing.

Cables that include a conductor and an optical fiber. In some embodiments, the cable can include an optical fiber loosely disposed within an enclosure. A conductor layer can be disposed about the enclosure. An insulation layer can be disposed about the at least one conductor layer. An inner layer of armor strength members can be helically disposed about the insulation layer. An outer layer of armor strength members can be helically disposed about the inner layer of armor strength members. The armor strength members in the outer layer of armor strength members can be at an opposite helix compared to the armor strength members in the inner layer of armor strength members. An outer jacket can be disposed about the outer layer. In other embodiments, the cable can include an optical fiber in a coupled electro-optical package, where the conductor layer can be disposed about the electro-optical package.

An electrical submersible pump (ESP) power cable includes a sheathing including a body that includes at least one conductor bore formed therethrough; and at least one power conductor threaded through the at least one conductor bore. The power cable has a density sufficient for the power cable to be at least substantially neutrally buoyant in a wellbore fluid in a wellbore.