Basic ESP Technology and Operation

ESP Downhole System Overview – ESP Power

Cable

SPH Chapter 8
Overview
 Purpose
 Components
 Cable Applications
 Cable Identification Key
 The Power Cable
 Made up of the power cable and motor lead
 Can be made in either round or flat profile
 Is constructed of three insulated & jacketed copper conductors contained by metal
armor
 Proper applications must address electrical, physical size, and operating
temperature requirements

SPH 61
 Conductor Type
 ESP power cable conductor has the following characteristic
for all types
– Material - Copper (Drawn Rod)
 Tinned
 Bare
– Shape
 Solid – Preferred
– Easier to splice
– Smaller size for same amp carrying capacity
 Stranded – used for very large conductors (00 AWG +)
TINNED
COPPER
SPH 61
 Solid vs. Stranded

# 1 AWG SIZE DIFFERENCE

0.289” 0.328” Conventional Same Conductivity with

a Smaller Size
0.322” Compressed
0.302” Compact

SPH 61
 Flat Cable
Components
1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM)
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Low profile to fit in tight clearance
installations

2
3
1

SPH 61
 Round Cable
Components
1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM)
3 - Jacket (Nitrile or EPDM) & Tape
4 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Less current imbalance & runs cooler than
equivalent flat cable
4

1 2

SPH 61
 Motor Lead Extension / Pothead

Components
1 - Conductor (Copper)
2 - Insulation Film (Polyimide)
3 - Insulation (EPDM)
4 - Jacket / Tape & Braid or Lead Sheath (Low Temp or Hi 5
Temp)
5 - Armor (Low Profile Galv, SS, or Monel)
 Benefits: Tape and braid provides added
decompression resistance

4
1&2

SPH 63
 Barrier Cable
Components
1 - Conductor (Copper)
5
2 - Insulation (EPDM)
3 - Extruded Fluorobarrier (Low or Hi Temp)
4 - Jacket (Nitrile or EPDM)
5 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Unlike tapes, the barrier blocks fluid, aids decompression resistance,
and improves electrical properties
4

SPH 62
 Lead Cable
Components
1 - Conductor (Copper)
2 - Insulation (Polypropylene or EPDM) 5
3 - Lead Sheath
4 - Tape or Braid (on EPDM product only)
5 - Armor (Galvanized, Stainless, or Monel)
 Benefits: Lead sheath blocks gasses & protects conductor from
H2S attack 3
 Also available in round profile with EPDM jacket 4

SPH 62
 Capillary Tube Cable
Features & Benefits
 Available with any standard cable
 A variety of capillary tube sizes are utilized
 Available in round or flat profile
 Allows targeted delivery of treatment chemical
 Single or dual capillary designs
 Instrument wire can be inserted in some capillary tube sizes
 An outer layer of armor is applied to protect the capillary tubes

Capillary Tube

SPH 65
 Cable Application

 Proper application of ESP cable

– Profile (round or flat) - based on tubing thread
size vs. casing ID & conductor size
– Voltage rating – based on insulation thickness
– Conductor (AWG) size - limit voltage drop to
less than 15% of motor volts, based on length
and current
– Conductor temperature – function well temp &
voltage drop, drives insulation material
– Armor - based on gas & corrosion tendencies
of the well

SPH 65
 Cable KV Rating (based on insulation thickness)

4 KV 5 KV
3 KV

SPH 65
 Power Cable Voltage Drop

26 volts

16 volts

35 amps
SPH 175-178
 Conductor Temperature

200oF conductor
temperature EPDM insulation
is selected

35 amps

180oF
SPH 175-178
 Cable Temperature Rating

Temperature Ratings of ESP Cables - insulation / covering / jacket (*denotes limiting material)
 Polypropylene* / Nitrile 205o F (96o C)
 Polypropylene* / Lead 257o F (125o C)
 EPDM / Nitrile* (with or w/o Barrier) 280o F (140o C)
 EPDM / Low Temp Barrier* / EPDM 300o F (150o C)
 EPDM / EPDM (with or w/o hi temp Barrier) 400o F (205o C)
 EPDM* / Lead Sheath 450o F (230o C)
 Motor Lead Extension - Low Temp 250o F (120o C)
 Motor Lead Extension - High Temp 400o F (205o C)
 Motor Lead Extension - Lead Sheath 450o F (230o C)

SPH 66
 Cable Identification Key
Cable names are based on the concept of naming the components from the
conductor to the armor, if present. Centrilift uses this convention as illustrated
below, using Centrilift Type CELF : C = Copper, E = EPDM, L = Lead, F = Flat

Typical Description: 1/0 SOL 5kv DL90 T Gal F

 1/0 = # 1/0 AWG
 SOL = # 1/0 AWG Solid Soft Drawn Copper Conductor
 5KV = Voltage rating of the cable
 DL90 = EPDM insulation
 T = Bedding Tape
 GAL = Galvanized Steel Armor
 F = Flat configuration

 See handout for a full listing

SPH 66
Summary
 Purpose
 Components
 Cable Applications
 Cable Identification Key

 Any Questions?