Patent Application
20100186990
The present invention relates to electrical cables of the type used in electric submersible well pumps and the like.
Electrical cables are used to interconnect electric motors to submersible pumps or other equipment in oil and gas wells. These cables ordinarily consist of three solid or stranded electrical conductors that are combined into a single cable.
Historically, electrical cables for submersible pumps have been rated for low voltage in the range of 5 kV and most electric submersible pump (ESP) motors have had name plate voltage below 5 kV. With the increasing demand for higher horsepower, ESP motors are now being built with name plate voltages greater than 5 kV requiring manufacturers to design cables with higher rating such as 8 kV. As the voltage of the electrical cables increase, the presence of any voids between the conductors and the insulation in an electrical cable can result in partial discharge. It is important to provide a higher voltage (greater than 5 kV) ESP cable with improved electrical strength and reduced partial discharge characteristics.
A power cable for an electric submersible pump assembly is constructed with improved electrical strength and reduced partial discharge characteristics. One embodiment of the present invention utilizes solid conductors that are uniformly and firmly bonded to the surrounding insulation with a thin bonding layer applied directly over the conductor. The bonding layer has a thickness between 0.00002 inches and 0.005 inches. In a preferred embodiment, the bonding layer is non-conductive. A layer of conductive fabric tape is wrapped tightly around the insulation to form an outer stress control layer. The insulated conductors may be covered with an extruded layer of lead, which may then be wrapped with a fabric tape to protect the lead layer during subsequent processing steps. An armored outer layer is then applied around the insulated conductors. Space between the insulated and wrapped conductors and the armored outer layer may be filled with a jacket material.
Referring to
An outer stress control layer 31 surrounds the conductors 26, bonding layer 27, and insulation 29. In a preferred embodiment, the outer stress control layer 31 is a conductive fabric tape wrapped tightly around the insulation 29. The tape serves to make intimate electrical contact with the insulation 29 thereby greatly reducing or eliminating voids which can cause partial discharge. The fabric tape also serves the function of helping to contain the insulation 29 during decompression of the cable 20. As an alternative to the outer stress control layer 31 of conductive fabric tape, in an alternate embodiment, conductive braids can be wrapped tightly around the insulation 29. Referring to
Referring back to
The conductors 26, bonding layer 27, insulation 29, outer stress layer 31, and lead 33 may be surrounded by a fabric tape 35 to protect the lead layer 33 during subsequent processing steps. The fabric tape 35 is wrapped around the lead layer 33 of the cable 20. A jacket 37 is extruded around the three insulated conductors 26. The center space between the three fully insulated conductors 26 is also filled with the jacket material 37. Insulation 29 and jacket material 37 can be constructed from various polymer compounds, including: EPDM rubber (Ethylene Propylene diene monomer), nitrile rubber, HNBR rubber, aflas rubber, FKM rubber, polypropylene, polyethylene, cross-linked PE or PP, thermoplastic elastomers, fluoropolymers, thermoplastics or thermoset elastomers. Typically, the finished three conductor high voltage ESP cable 20 has an armored outer layer 39, which may be made of metal strip wrapped and formed around jacket 37. The purpose of the jacket material 37 is to support the conductors 26 and keep them tightly held in place by the armor 39.
Using solid conductors with insulation bonded to the conductors by a bonding layer offers several advantages. Unlike stranded conductors, solid conductors do not provide spaces for gasses to collect between the strands, improving the decompression resistance of the cable. Additionally, solid conductors are smaller than stranded conductors, allowing more space for insulation. By bonding the insulation to the solid conductors, the bonding helps prevent damage during splicing operations, improves decompression resistance, and eliminates voids that are a source of partial discharge under high AC voltage conditions. The high bond strength of the bonding layer prevents insulation damage during the handling of the cable, while also improving decompression resistance. The outer stress control layer serves a dual purpose of partial discharge mitigation and decompression containment.
While the invention has been shown in only one of its forms, it should be apparent to those skilled in the art that it is not so limited but is susceptible to various changes without departing from the scope of the invention. For example, although the cable is shown with a round, circular geometry, it could have a flat, rectangular geometry.
