A cable containing a conductive outer layer and methods for manufacturing the conductive outer layer and the cable are provided. A cable may include a cable core and a plurality of armor wire strength members that surround the cable core. The cable may also include a conductive outer layer disposed about the plurality of armor wire strength members that physically contacts at least one armor wire strength member of the plurality of armor wire strength members.

A method of manufacturing hybrid cable applicable in oil wells provides an FIMT, a conductor layer formed by continuous laser welding and cylindrically covered the outer surface of the FIMT, the outer cylindrical surface of the conductor layer being covered with a high temperature resistant insulating layer by a continuous extrusion method or by wrapped helically with insulating tapes around the outer surface of the conductor layer and the external steel tube cylindrically covered the outer surface of the insulating layer. The conductor layer is coaxial with the FIMT, the inner space of the hybrid cable to accommodating excess length of the optical fiber to allow for thermal expansions and tensile stress on the optical cable. The thickness of the insulating layer cylindrically covering the outer surface of the conductor layer is able to be increased, improving the insulating property.

A method and method of using 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.

A cable including at least one primary conductor and at least one secondary conductor. A metallic shield element surrounds the primary and secondary conductors. A jacket surrounds the elements of the cable. At least one heating element is disposed under the shield element.

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.

A downhole logging cable includes a core conductor unit and a core optical unit. The core conductor unit may include a conductor and a jacket which surrounds and contacts the conductor. At least one metal tube may surround the core conductor unit and core optical unit, such that the core conductor unit and core optical unit are disposed in an interior of the at least one metal tube. A filler may be provided in the interior surrounding the core conductor unit and core optical unit.

A method of manufacturing hybrid cable applicable in oil wells provides an FIMT, a conductor layer formed by continuous laser welding and cylindrically covered the outer surface of the FIMT, the outer cylindrical surface of the conductor layer being covered with a high temperature resistant insulating layer by a continuous extrusion method or by wrapped helically with insulating tapes around the outer surface of the conductor layer and the external steel tube cylindrically covered the outer surface of the insulating layer. The conductor layer is coaxial with the FIMT, the inner space of the hybrid cable to accommodating excess length of the optical fiber to allow for thermal expansions and tensile stress on the optical cable. The thickness of the insulating layer cylindrically covering the outer surface of the conductor layer is able to be increased, improving the insulating property.

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.

A flange assembly for supporting a cable has a flange body and an armor retainer. The flange body and the armor retainer are configured to support a cable by compressing an armor layer of the cable against the armor retainer. The armor retainer and the flange body are separate pieces, that are removably attachable to one another.

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.