Al Esps s003 20-04-002 Cable Armor Removal

Operations Global
Artificial Lift
Section 4 - Operations
Effective Date - 14-Nov-2011
Armor Removal
ESP-Cable / AL-ESPS-S003-20-04-002 / A
Armor Removal Cable splicing consists of several key steps and procedures. Follow these
steps in the proper order to achieve a quality splice.
These steps consist of:
1. Cable Identification
2. Armor Removal
3. Cable Preparation
4. Cable Sleeve Crimping
5. Cable Cleaning and Taping
6. Armor Application
7. Cable Field Testing
8. Cable Banding and Clamping
This section assumes that the cable identification has been made and the
armor is now ready to be removed for the splice.
Complete this section before proceeding to the Cable Preparation section.
It would be impractical to cover each possible configuration that is
encountered in the field since there are many manufactures and designs
worldwide.
This document will address only the types of cable that Baker Hughes
manufactures.
Storage Cables should be stored properly for protection against physical damage and
the environment.
Fencing or other barriers may be used to protect cables and reels from
damage by vehicles or other equipment moving about in the storage area.
Reels should be stored upright on their flanges, not stacked.
Handling should be in a manner that prevents deterioration of and physical
damage to the reel and to the cable.
Prior to, during, and after installation, seal the ends of the cables to prevent
contamination while located outdoors or in other wet locations where
contamination is possible. For this same reason, it is best practice to seal
the ends when the cables are not immediately spliced or terminated.
Revision History
Rev. DCR Amendment Detail Initiator Approval Effective Date
Initial Release
A --/-- T. Lewis R. de Long 14-Nov-2011
Approved for OCS
© 2011-2011 BAKER HUGHES INCORPORATED (UNPUBLISHED WORK). All rights reserved. Terms and conditions of use: By accepting this
document, the recipient agrees this document (together with the contents) is confidential and proprietary property of Baker Hughes Incorporated and
includes valuable trade secrets, proprietary information of Baker Hughes (collectively “information”). Baker Hughes retains all rights under copyright
laws and trade secret laws of the United States of America and other countries. The recipient further agrees the documents may not be distributed,
transmitted, copied or reproduced in whole or part by any means, without express written consent of Baker Hughes, and may not be used in any way
detrimental to Baker Hughes.
Operations Global
Artificial Lift
Armor Removal
Armor Removal
Cut or scrape potential
Serious physical injury can occur from what

appears to be a minor cut or scrape.
• Long sleeves, gloves, and eye protection are
required
• Wash hands thoroughly after handling lead
• Do not eat or drink around splicing process
a) Armored Round Armor on round cable can sometime be difficult to remove, but following
Cable these simple instructions should make the job easier.
Before beginning armor removal, ensure that the end of the cable is in good
condition and not smashed or damaged.
If necessary, cut off the end of the cable prior to beginning.
Carefully measure the distance from the end of the cable to the point where
the armor will need removal. These measurements vary depending on the
type or size of cable being spliced.
Armor Armor
Cable Cable
Removal Removal
CPN 20 inches CEBEHT 20 inches
CEN 20 inches CEE 20 inches
CEBN 20 inches CEL 20 inches
CEBE 20 inches
Cable armor when cut with cable cutters or a saw will have a sharp end that
can cause puncture or cutting wounds. Remove this sharp end prior to
working the rest of the splice.
NOTE: Kevlar gloves are used in the following examples.
Remove
Page 2 of 13
Uncontrolled when printed - Please use the latest revision - Company confidential
©2011-2011 Baker Hughes Incorporated
Operations Global
Artificial Lift
Armor Removal
Identifying the Armor Baker Hughes manufactures cable in which thin strips of armor is molded
and wrapped on the outside of the cable jacket to protect the cable during
End Direction transport, installation and to act as containment to provide strength to the
cable.
Depending on which end of the cable is referenced, the strip of armor could
be under the previous strip (closed or secure end) or over the previous strip
(open or loose end).
Procedures have been developed to address each of these configurations.
1. Removing armor from
Loose or Open end of
the Cable
Grasp the end of the armor with
a pair of side cutters. Carefully
unwind the end until the sharp
edge can be cut with side cutters
or tin snips.
Cover end before trimming

Making small cuts of the armor may cause
metal projectiles flying and hitting bystanders
Long sleeves, gloves, and eye protection are
required.
• Cover before trimming
• Wear safety glasses
Page 3 of 13
Operations Global
Artificial Lift
Armor Removal
Trim the corners of the armor to remove sharp points.
A correctly-trimmed end pictured above.

Armor is applied in an overlapping fashion to make it easy to remove the
top layer or loose end of the armor.
Measure the correct length
from the end as prescribed
above and wrap at least two
layers of tape around the
armor.
This prevents the armor
from unraveling past the
point where it is to be
removed.
Place one hand on the tape
and the other hand on the
end of the armor. Twist
the armor to loosen.
The armor should gap and
loosen near the taped end.
Continue to hold the armor end and

use your other hand to cut the
armor at the taped end.
Page 4 of 13
Operations Global
Artificial Lift
Armor Removal
Twisting the cut armor will allow it to slide off the end of the cable.
Remove the tape and trim the armor as seen

in the picture to prevent injury.
Cover the end of the cutters before trimming
to prevent flying projectiles of armor striking
bystanders.
Trim the corners of the armor to remove sharp points.
A correctly trimmed end is pictured above.
Wrap two wraps of high modulus tape

around the jacket (under the armor end) to
protect the jacket during the rest of the
splice and then over the armor to prevent
it from unraveling and cover any sharp
ends.
Page 5 of 13
Operations Global
Artificial Lift
Armor Removal
2. Removing Armor from Carefully measure the distance from the end of the cable to the point where
the Closed End of the the armor will need removal. These measurements may vary depending on
Cable the type or size of cable being spliced.
Armor Armor
Cable Cable
Removal Removal
CPN 20 inches CEBEHT 20 inches
CEN 20 inches CEE 20 inches
CEBN 20 inches CEL 20 inches
CEBE 20 inches
Cable armor, when cut with cable cutters or a band saw, will have a sharp
end that can cause puncture or cutting wounds. This sharp end needs to be
removed prior to working the rest of the splice.
NOTE: Kevlar gloves are used in the following examples.
Remove
With a hack saw, cut the armor at about a

45° angle so that at least two crowns of
armor are cut.
Be careful not to cut too deeply and cut
into the jacket or into the insulation of the
cable. If this happens, cut the cable off at
this point and repeat the procedure.
An example of a good cut.
Page 6 of 13
Operations Global
Artificial Lift
Armor Removal
Insert a straight edge screwdriver into

the cut that was made in the armor.
Twist the screwdriver to widen the
split in the armor.
Small area of
armor that needs
to be parted.
Small saw blade cuts will reduce the armor

strength
NOTE Remove to
this point.
Scored or damaged armor can cause

a failure point due to the loss of
containment for the cable.
To alleviate this, pull and cut
additional wraps of armor from
under the previous one until all
scored armor has been removed.
Trim the cut end of the armor to avoid sharp points that could cut into the
cable jacket.
Correctly trimmed end should look like this.
Page 7 of 13
Operations Global
Artificial Lift
Armor Removal
Bend the end down and use the

edge of the screwdriver to push the
edge of the armor back under the
previous wrap. Be careful not to
gouge the jacket with the
screwdriver.
Insert the screwdriver under the lip

and pull up so that tape can be
wrapped under the armor. The tape
prevents damage to the jacket during
the rest of the splice.
Wrap two wraps of high modulus

tape around the jacket (under the
armor end). Then two wraps over
the cut end to protect the jacket and
tapes during the rest of the splice.
Page 8 of 13
Operations Global
Artificial Lift
Armor Removal
Now that all the sharp edges have been trimmed, the armor can be removed
by grasping the end of the armor with one hand near the cut and with the
other hand, near the end, twist to loosen the armor.
Twist with the hand nearest the cut, and hold the armor firmly in place with
the other.
Loosen until the armor can slide off the end. Wiggling the armor back and
forth will help to loosen the armor from the jacket.
The armor section should look like this after it is removed.
b) Armored Flat Cable Flat cable armor removal techniques are similar to the round. The ends of
the armor must be rounded to prevent injury.
Carefully unwind one wrap of armor at the end with the sharp shard. Cut
with side cutters or tin snips.
Armor Armor
Cable Cable
Removal Removal
CTT 18 inches CEE 18 inches
CPN 18 inches CPL 18 inches
CEN 18 inches CEL 18 inches
Page 9 of 13
Operations Global
Artificial Lift
Armor Removal
On the end that is
loose or which
unwraps easily, the
armor can be
twisted upon itself.
As each wrap
loosens, move the
armor towards the unwrapped armor.
If the armor pulls from underneath or is

tucked under at the end, it will need to be
scored with a hacksaw, as with the round
cable. Then un-wrap the opposite way as
above.
When cutting the armor on a flat cable

with a hacksaw, be extremely careful
not to cut too deeply into the armor to
NOTICE the point that the lead or insulation is
cut. If this occurs, Cut the cable off at
this point and begin the splice again.
Insert a flat blade screwdriver under the cut

end of the armor and carefully pry the
armor up.
Remove the rest of the cut armor until

there are no score marks in the armor that
might cause loss of armor strength.
Page 10 of 13
Operations Global
Artificial Lift
Armor Removal
Cut excess armor and prepare the end so

that it does not gouge or cut the cable.
Using a screwdriver, carefully push the cut

end of the armor under the wrapped end.
By carefully twisting the loose end of the

armor in the opposite direction from the
factory wrap, the armor will form a
triangular shape that will slide off the end
of the cable.
It should look something like the photo to

the left.
If care is taken, the cable armor will stay
together throughout the entire process. If it
starts to unravel, just cut off the loose
portion and continue as above.
After the armor is removed

and the end of the armor is
trimmed, wrap two layers of
high modulus tape around
the three phases. Then wrap
the armor to protect the
phases from damage when
the phases are bent during the splice.
Page 11 of 13
Operations Global
Artificial Lift
Armor Removal
c) High Density The polyethylene cable jacket, sometimes refered to as unarmored cable, is
Polyethylene Cable difficult to remove.
Care should be taken to ensure that the cable insulation is not damaged.
Armor Armor
Cable Cable
Removal Removal
CBM 18 inches CPE 18 inches
Sharp cutting tools will be required for this cable
Polyethylene jacket is difficult to remove and

sharp cutting tools will be required.
• Always wear cut-resistant gloves when
removing the jacket material.
• Always cut away from yourself
The best practice is to score

the jacket at the proper
removal length by using a
sharp blade to cut into the
jacket 360° around the
jacket.
Take care not to cut so
deeply that you cut into the
insulation.
Now, score the cable jacket

lengthwise, taking care not to
cut so deeply that you cut
into the insulation.
Page 12 of 13
Operations Global
Artificial Lift
Armor Removal
Apply heat in areas where a heat gun can be used, heat the entire portion of
the jacket to be removed.
In areas where a heat gun cannot be used, the end of the cable can be placed
under the heater in your vehicle.
Starting from the loose end

of the cable, peel back the
jacket at the point where it
was scored.
Use a pair of pliers to get it
started if necessary, but you
should be able to continue
the tear without the pliers.
This is a very difficult
process and will require time
and patience to accomplish
the task.
There are also specialty tools that can be used to aid in removing the jacket.
These tools have an adjustable blade depth and can be spirialed around the
cable in a corkscrew fashion to score the cable for removal. Make sure the
blade depth is properly set so that it only scores the jacket and does not cut
through the jacket.
Above are two examples from GREENLEE®

The prepared splice should be ready to for the next portion of the splicing
procedure, Cable Preparation.
Page 13 of 13

Al Esps s003 20-04-002 Cable Armor Removal

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Operations Global

Cut or scrape potential

Serious physical injury can occur from what

Cover end before trimming

A correctly-trimmed end pictured above.

Continue to hold the armor end and

Remove the tape and trim the armor as seen

Trim the corners of the armor to remove sharp points.

A correctly trimmed end is pictured above.

Wrap two wraps of high modulus tape

With a hack saw, cut the armor at about a

An example of a good cut.

Insert a straight edge screwdriver into

Small saw blade cuts will reduce the armor

Scored or damaged armor can cause

Correctly trimmed end should look like this.

Bend the end down and use the

Insert the screwdriver under the lip

Wrap two wraps of high modulus

The armor section should look like this after it is removed.

If the armor pulls from underneath or is

When cutting the armor on a flat cable

Insert a flat blade screwdriver under the cut

Remove the rest of the cut armor until

Cut excess armor and prepare the end so

Using a screwdriver, carefully push the cut

By carefully twisting the loose end of the

It should look something like the photo to

After the armor is removed

Sharp cutting tools will be required for this cable

Polyethylene jacket is difficult to remove and

The best practice is to score

Now, score the cable jacket

Starting from the loose end

Above are two examples from GREENLEE®

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