Downhole connection assemblies include a connector to receive a conductor and pin at opposite ends. The connector includes a first electrical collet, a separate second electrical collet and a sleeve. The first collet includes a first recess in a first end to receive the conductor and a second recess in a second end to receive the pin. The second collet is positioned around the pin and separated from the first collet. The sleeve is positioned around the pin, first collet and the second collet. Downhole cables include a center electrical conductor, a first insulator positioned around the center conductor, a second insulator positioned around the first insulator, and a pressure tube surrounding the second insulator. The cable further includes one or more slots extending axially along a length of the second insulator, or one or more slots extending axially along an inner diameter of the pressure tube.

Downhole connection assemblies include a connector to receive a conductor and pin at opposite ends. The connector includes a first electrical collet, a separate second electrical collet and a sleeve. The first collet includes a first recess in a first end to receive the conductor and a second recess in a second end to receive the pin. The second collet is positioned around the pin and separated from the first collet. The sleeve is positioned around the pin, first collet and the second collet. Downhole cables include a center electrical conductor, a first insulator positioned around the center conductor, a second insulator positioned around the first insulator, and a pressure tube surrounding the second insulator. The cable further includes one or more slots extending axially along a length of the second insulator, or one or more slots extending axially along an inner diameter of the pressure tube.

A cable assembly includes a plug receiver, a conductor interface, a metal shell encasing the conductor interface and a portion of a cable of the cable assembly, a metal foil that wraps conformably around an exterior of the metal shell, wherein the metal foil covers substantially all of the exterior of the metal shell and extends beyond the metal shell onto a cable shielding layer. The cable assembly further includes a solder layer disposed about the metal foil, wherein the solder layer bonds and electrically couples the first foil portion to itself, the second foil portion to cable shielding at the location on the plurality of conductors that is proximate to the conductor interface, and the third foil portion to the plug receiver. The cable assembly further includes an electrically insulating layer that encases the metal shell, the metal foil, and the solder layer.

A terminal-formed electrical wire includes a core wire, a sheath that exteriorly covers a sheath target portion, a portion other than a core wire exposed portion, of the core wire, a metallic tubular member that accommodates the core wire exposed portion inside and is integrated with the core wire exposed portion to form a terminal unit. The core wire exposed portion has a flat board portion in the shape of a flat board thinner than the sheath target portion. The tubular member has a first wall and a second wall in the shape of a flat board sandwiching the flat board portion from respective flat surfaces of the flat board portion.

A terminal-formed electrical wire includes a core wire, a sheath that exteriorly covers a sheath target portion, a portion other than a core wire exposed portion, of the core wire, a metallic tubular member that accommodates the core wire exposed portion inside and is integrated with the core wire exposed portion to form a terminal unit. The core wire exposed portion has a flat board portion in the shape of a flat board thinner than the sheath target portion. The tubular member has a first wall and a second wall in the shape of a flat board sandwiching the flat board portion from respective flat surfaces of the flat board portion.

A power cable (1) for an electric submersible pump (ESP) system, and systems and methods thereof are described herein. The power cable (12) is a weight-bearing three-phase power cable comprising a core (8) having an outer diameter and comprising three insulated conductors (2) substantially embedded in a polymeric bedding (3); and a multi-layered armor comprising an inner steel-based continuous tube (4) surrounding and in direct contact with the core (8), and an outer steel-based continuous tube (5) surrounding and in direct contact with the inner steel-based continuous tube (4). The inner steel-based continuous tube (4) and the outer steel-based continuous tube (5) are mechanical congruent with each other as a result of a roll reducing technique.

A shield conduction path that includes a wire; and a pipe with a circular cross-section that accommodates the wire. The pipe is formed by combining a first divided body and a second divided body that are divided in a diameter direction using, as boundaries, divided surfaces that extend in an axial direction of the pipe. The first divided body and the second divided body include a metal material that can be held in a combined state through welding, and a circumferential length of the first divided body is set to be longer than a circumferential length of the second divided body.

A shield conduction path that includes a wire; and a pipe with a circular cross-section that accommodates the wire. The pipe is formed by combining a first divided body and a second divided body that are divided in a diameter direction using, as boundaries, divided surfaces that extend in an axial direction of the pipe. The first divided body and the second divided body include a metal material that can be held in a combined state through welding, and a circumferential length of the first divided body is set to be longer than a circumferential length of the second divided body.

Disclosed is an electrical cable for vertical applications, comprising a core having a length L, a sheath surrounding the core and extending through the whole length L and a reinforcing jacket surrounding the sheath and in direct contact therewith. The reinforcing jacket is made of concentric layers comprising a first layer longitudinally extending from a first cable end (the proximal or upper cable end, in use) towards a second cable end (the distal or lower cable end, in use) substantially along the whole length L. The reinforcing jacket also comprises at least one further layer longitudinally extending from the first cable end towards the second cable end for a length shorter than L. At least one layer of the reinforcing jacket is a circumferentially closed metal tube. Also disclosed is a process for manufacturing such cable.

An aluminum wire includes a strand main body, an inner layer, and an outer layer. The strand main body includes aluminum wire or an aluminum alloy wire. The inner layer includes Zn, a Zn alloy, Ni, or an Ni alloy and covers the outer circumferential surface of the strand main body. The outer layer includes Sn or an Sn alloy and covers the outer circumferential surface of the inner layer. In the aluminum wire, the pinhole ratio in the outer layer is no more than 4% and/or the thickness of the inner layer is at least 0.3 μm.