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Such cushioning might help to preserve the integrity of the metallic shield 750 by way of one or more mechanisms. In such an instance, an extruded cushion layer can achieve a desired hoop stress, low voltage armored power cable which may help the extruded cushion layer to retain its form. As an example, a further cushion layer could also be applied that surrounds assemblies the place the extra cushion layer is considerably circular in its cross-sectional form (e.g., an annular wall about a gaggle of assemblies). For example, the cushion layer 760 can be formed as a tube defined not less than partially by a wall thickness and an interior cross-section dimension (e.g., an internal diameter) and/or an outer cross-section dimension (e.g., an outer diameter). As talked about, a cable can embrace lead (Pb), which could be within the type of a lead (Pb) layer (e.g., a barrier layer). For example, a pump system can include a pump; a submersible electric motor operatively coupled to the pump; and a power cable for delivery of electrical power to the submersible electric motor, the place the power cable features a conductor, a lead (Pb) barrier layer disposed in regards to the conductor, a cushion layer disposed about the lead (Pb) barrier layer where the cushion layer contains crosslinked polyethylene (XLPE), and metallic armor wrapped concerning the cushion layer.

In the geometry of the power cable 702, three assemblies are shown where every assembly includes a conductor 710 (e.g., a considerably pie formed conductor with an arc span of roughly 120 degrees), insulation 730 (e.g., a considerably pie shaped layer of insulation that surrounds the conductor 710), a metallic shield 750 (e.g., a considerably pie shaped layer of lead (Pb) that surrounds the insulation 730, and a cushion layer 760 (e.g., a considerably pie formed layer of fabric that surrounds the metallic shield 750. As proven, the three assemblies will be grouped (e.g., 120 degrees every to form a circular cross-part of 360 degrees) and one or more further layers could be utilized that surrounds the three assemblies the place one or more of such layers can embody armor. In some embodiments, an insulation shield layer could be applied by way of extrusion. In some embodiments, a barrier layer may be formed from a number of fluoropolymers, lead, or another material resistant to downhole gases and fluids.

In some embodiments, a jacket may be constructed from one or more layers of a number of materials (e.g., consider a number of of EPDM, nitrile rubber, HNBR, fluoropolymers, chloroprene, or another materials offering suitable resistance to downhole situations). In some embodiments, a metallic shield layer may serve to electrically isolate the phases of the cable from one another. For example, the metallic shield 750 can have a wall thickness that is less than approximately 1 mm. For example, the cushion layer 760 can include one or more further supplies akin to, for example, talc and/or polypropylene. As an example, a technique can embody crosslinking not less than a portion of polyethylene after armoring and/or crosslinking at least a portion of the polyethylene earlier than armoring. In such an example, the cushion layer can embody clay and/or polypropylene. Talc or talcum is a clay mineral composed of hydrated magnesium silicate, for example, consider one or more of the chemical system H2Mg3(SiO3)4 or Mg3Si4O10(OH)2.

Based on the DMA outcomes, a mix XLPE with PP with no less than roughly 25 wt % may considerably improve the thermal stability and chemical compatibility of uncured XLPE. As talked about, an individual cushion layer may surround an individual considered one of a metallic shield the place such a cushion layer may be substantially circular in form, considerably pie shaped, or one other form. As one instance, the cushion layer 760 will be formed of a material with a shape and dimension that helps to maintain the shape and dimension of the metallic shield 750. In such an example, the shapes could also be considerably circular. As mentioned, a cushion layer could also be of a non-circular form equivalent to substantially pie form. As an example, a considerably circular shaped cushion layer may be extruded a couple of plurality of considerably pie shaped cushion layers which are grouped. In FIG. 7, the power cable 700 includes three conductor assemblies the place every assembly features a conductor 710, insulation 730, a metallic shield 750, a cushion layer 760 and an armor layer 780. In FIG. 7, the ability cable 700 is configured with a flat geometry; whereas, the facility cables 701 and 702 are configured with a round geometry where conductors are considerably pie formed of their cross-part.