Chapter - 06 Power Cable

Electric Submersible Pumps Mohamed Dewidar 2013
Chapter 6

1
Electric Submersible Power Cable
Table of Content
Section Content Page
1 General concept 3
2 Cable construction 3
2.1 Conductor
2.2 Insulation
2.3 Barrier
2.4 Jacket
2.5 Armor
3 Motor connection options 8
3.1 Potheads
4 General considerations in cable type and
size selection 10
5 Conductors 10
5.1 Definition
5.2 General properties
5.3 Types
5.4 Mil
5.5 Circular mil
5.6 AWG
5.7 Conductivity
5.8 International Annealed Copper Standard
(IACS)
5.9 Resistivity
5.10 Temperature Coefficient
5.11 Number of wire in stranded conductors
6 Voltage drop in ESP cable 19
6.1 Correction of voltage drop for temperature
6.2 Maximum carrying capacity of the cable
7 Method of selecting cable wire size and
type 23
8 ESP cable pulling rates and decompression 24
8.1 Introduction
8.2 Decompression theory
8.3 Material hoop strength
9 Cable test 28
9.1 Types of tests
9.2 Resistance vs. length in ESP cables
9.3 Resistance vs. current
9.4 Resistance vs. wire size
9.5 Resistance vs. shielding
9.6 Industry methods
9.7 Recommended practice
9.8 Megohm correction
9.9 DC Hi-Pot voltage
Chapter 6

2
9.10 DC Hi-Pot leakage current
9.11 Time before test
10 Cable Nomenclature 40
11 Cable families and designation examples 41
Cable selection example 48

Chapter 6

3
Electric Submersible Power Cable
6.1. General Concept
Power is supplied to the electric motor by electric cable.
As mentioned in the previous chapter that the downhole
electric motor is a three phase, accordingly the power cable
has three conductors one for each phase.
The configuration of the electric cables is either flat or
round. Each one of them has different sizes and each size has
different types for different operating conditions.

Round Flat
As an option both Round and Flat include injection tube for
injecting chemicals down hole.

Round and flat cables includes injection tube
6.2. Cable Construction
The cable construction is mainly consists of:
Three copper conductors
Insulation
Barrier
Jacket
Armor
Injection tube (option)

Conductors
Insulation
Barrier
Injection tube
Jacket
Armor
Chapter 6

4

6.2.1. Conductor
The conductors are made of alloy-coated copper. The
alloy coating provides corrosion protection for the copper and
prevents degradation of the adhesive bond between the
conductor and the insulation.
6.2.1.1. Conductor configurations
Conductor is configured in three types,
- SOLID
Smallest diameter / lowest cost
Lower interfacial electrical stress
- Stranded
Greater diameter / higher cost
Greater flexibility
Greater damage resistance
- Compacted
Up to 10% decrease in diameter versus round stranded
conductor

Conductor types
6.2.1.2. Factors to be considered in conductor Selection
Size
Resistance
Flexibility
Cost
6.2.2. Insulation
The purpose of the cable insulation is to provide
protection to the current carrying conductors from attack from
well fluids which will result in a short down-hole circuit. In
addition the insulation can be applied in thicknesses to meet
kv rating required (phase to phase)
6.2.2.1. Insulation types
Polypropylene (Thermoplastic)
(used in cables for lower temperature applications)
Advantages
- Excellent resistance to well fluids
Chapter 6

5
- Excellent electrical properties
- Low cost
Disadvantages
- Upper temperature range, softens at 205F (96C)
- Subject to crazing in certain environments
<205F/96C

>205F/96C

EPDM (Ethylene Propylene Diene Methylene) RUBBER (Thremoset)
(used in cables for higher temperature applications)
Advantages
- Excellent high-temperature stability has been used at up to
550F (288C) in geothermal wells.
- Excellent electrical properties, although higher power
losses than polypropylene.
Disadvantages
- Limited well fluid resistance, oil swells EPDM compounds.
- Susceptible to mechanical damage at elevated temperatures.
6.2.2.2. Thermoplastic vs. Thermoset
Thermoplastic Thermoset
Definite melt point
Limited by temperature
Ease of processing
Simple formulations
Thermal failure is often dramatic
No melting point
Often higher temperature rating
More difficult to process
Complex formulations
Thermal failure is generally gradual
6.2.3. Barrier (tape and braid)
Tapes are added over insulation. A synthetic braid is
woven over the tape. Tape is used as protection against oil
and chemical attack. Braid is used to provide additional
reinforcement and hoop strength (to prevent any swelling and
gas decompression of EPDM insulation) i.e, ensuring superior
performance in wells with hostile environments or wells with
high gas/oil ratios.
6.2.3.1. Barrier Selection
Factors to be considered:
- Temperature
- Chemical environment
- Gas
Chapter 6

6
- Handling
Barrier

6.2.3.2. Barrier Types
- Polyvinyl dine Fluoride Extrusion - 300F (150C)
- TEDLAR tape - 300F (150C)
- TEFLON FEP Extrusion - 350F (175C)
- PROPRIETARY High Temperature tape - 400F (205C)
- Lead - 550F (288C)
6.2.3.3. Tape vs. Extruded Barrier
Tape advantages
- Superior hoop strength
- Higher temperature
Extruded Barrier advantage
- Faster to process
6.2.4. Jacket
The jacket is there mainly to provide mechanical protection
to internal components of the cable.
The jacket also physically binds all three conductor strands
together.
It also allows armor to be applied to the cable without
damaging the conductors.
Control temperature resistance.
6.2.4.1. Factor to be considered
- Temperature
- Chemical environment
- Gas
- Handling conditions
Jacket

6.2.4.2. Jacket types
- 185F (85C), HIGH DENSITY POLYETHYLENE (HDPE)
- 275F (135C), NITRILE
*

- >350F (176C), EPDM
* Some manufacturer produce another types of Nitriles worked
at 250 F and 350 F.
Chapter 6

7
6.2.4.2.1. Nitrile Rubber Jacket
- Excellent resistance to oil
- Good physical properties
- Poor electric properties
- Poor resistance to water
- Hardens at temperature above 275
O
F (135
O
C)
- Slow decompression rate

6.2.4.2.2. EPDM Rubber Jacket (>350 F)
- Excellent high temperature stability
- Poor resistance to oil
+ Oil =

Nitrile (NBR) EPDM
Physical properties Good Poor to fair
Oil resistance Good Poor to fair
Water resistance Poor to fair Good
Damage resistance Good Poor
H2S resistance Fair Good
Amine resistance Fair Good
Heat resistance Fair Good
Service temperature up to*
275F/135C
Greater than
350F/176C

HSN is available up to 350 oF

6.2.5. Armor
Cable armor made from steel strips featuring a
galvanized coating on all sides is the standard. The use of
one of many armor options can improve resistance to corrosion
and mechanical damage.
Armor

6.2.5.1. Armor Types
- Standard galvanized armor(GSA, 0.020"/0.51mm and 0.025"/ 0.64
mm thick)
- Heavy galvanize steel (0.034"/0.86mm thick)
+ Water =
Swelled
Swelled
Chapter 6

8
- Stainless steel
- Monel
6.2.5.2. Armor configurations
- Standard crown profile interlocked
- Flat profile interlock
- Flat profile

Standard crown profile interlocked

Flat profile interlocked

Flat profile
6.2.5.3. Factors to be considered in armor selection
- Damage resistance
- Decompression containment
- Corrosion resistance
- Casing and tubing coupling sizes
The following table summarizes the cable construction
Conductors Solid Compacted Stranded
Insulation PPE EPDM
Barriers
Tedlar
tape
FEB
extrusion
High temp. tape Lead
Jacket HDPE Nitrile EPDM
Armor Galvanized HG Double armor SS Monel
6.3. Motor Connection Options
Motor lead extension cable (MLE) (sometimes called Flat
Cable Extension (FCE)) has special configuration designs
provide the optimum combination of installation clearance and
downhole performance due to the following reasons:
1. Size of ESP (always bigger than the tubing coupling)
2. Size of casing
3. Adapt different motor amperes
Chapter 6

9
4. Down-hole temperatures
Example:
- KEOTB - 250
O
F (121
O
C)of Reda
- KELB - 450
O
F (232
O
C)of Reda
- 4KLHT 450
O
F (232
O
C) of Centrilift

K = Polyimide (Kapton ) primary insulation
E = EPDM secondary insulation
O = Nitrile jacket
TB = Tape (probably Tedlar) & braid
4 = # 4 AWG
L = Lead
HT = High Temperature
6.3.1. Potheads
Types:
- Tape-In Pothead - Tape wrapped around individual connector
leads inside motor.
Advantages:
o Most Reliable
o Highest breakdown strength in industry
Disadvantages
o Longer installation time on rig floor

Tape-in design
- Plug-In Pothead - mating block mounted in motor.
Advantages:
o Easy of installation
Disadvantages
Chapter 6

10
o Lower breakdown strength
o Not as reliable as Tape-In
- Direct Connect Pothead - Power cable attached directly to the
Pothead. (Plug-In Type)
6.4. General consideration in cable type and size
selection
- The best cable type for each selection is based on the
environment for each application where the cable will be
utilized and exposed.
- It is important to review all of the data and study these
factors specifically for each well condition to ensure the
cable selected is compatible with the well environment.
- The most critical data values for selecting cable are
temperature considerations and the fluid composition.
- The proper cable size is governed by the amperage, voltage
drop, and space available between the tubing collar and
casing.
- There are many factors which can negatively affect the
performance of cable downhole. Amongst these factors to be
considered are:
Temperature
Pressure changes
Gas oil ratio (GOR)
CO
2

H
2
S
Oil attack
6.5. Conductors
6.5.1. Definition
Conductor is a body so constructed from conducting
material that it may used as a carrier of electric current.
6.5.2. General properties of conductors
Electric current in general possess four fundamental
electric properties, consisting of, resistance, inductance,
capacitance, and leakage conductance. That portion of a
current which is represented by its conductors will also
possess these four properties, but only two of them are
related to the properties of the conductor consider by it
self. Capacitance and leakage conductance depend in part upon
the external dimensions of the conductors and their distance
from one another and from other conducting bodies and in part
upon dielectric properties of the material employed for
insulating purpose.
Inductance is a formation of the magnetic field established by
the current in a conductor but this field is a whole is
divisible into two parts; one being wholly extended to the
Chapter 6

11
conductor and the other being wholly within the conductor,
only the latter portion can be regarded as corresponding to
magnetic properties of the conductor material.
Resistance is strictly a property of the conductor it self.
Both resistance and internal conductance of conductors change
in effective values when the current changes with great
rapidly as in case of high frequency alternating current, this
termed as skin effect.
6.5.3. Types of conductor
In general, conductor consists of solid wire or
multiplicity of wires stranded together, made of conducting
material and use either bare or insulated. Usually conductor
is made of copper or aluminum, but application requiring high
strength such as transmission lines, bronze, steel, and varies
composite construction are made.
Pure copper, rolled, forged, or drawn and then annealed are
always used in power cables (density of 8.89 g/cm
3
at 20
O
C or
8.90 g/cm
3
at 0
O
C).
6.5.4. Mil
Mil is a term universally used to measure wire diameter
and is a unit of length equal to one-thousandth of an inch.
6.5.5. Circular Mil
Is a term universally used to define cross sectional
area, being a unit of area of a circle 1 mil in diameter. Such
circle, however, has an area of 0.7854 (or /4) mil
2
. Thus a
wire 10 mils in diameter has cross sectional area of 100 cmils
or 78.54 mils
2
. Hence, a cmil equals 0.7854 mil
2
.
6.5.6. American Wire Gauge
This gauge has the property, in common with a number of
other gauges that is sizes represent approximately the
successive steps in the process of wire drawing. Also, like
many other gauges, its numbers are retrogressive, a large
number denoting a smaller wire, corresponding to the
operations of drawing. These gauge numbers are not arbitrarily
chosen, as in many gauges, but follow the mathematical law
upon which the gauge is found.
Basic of the AWG is a simple mathematical law. The gauge is
formed by the specification of two diameters and the law that
a given number of intermediate diameters by geometric
progression. Thus, the diameter of No.0000 (4/0 AWG) is
defined as 0.4600 in and of No. 36 AWG is 0.0050 in. There 38
sizes between these two; hence the ratio of any diameter to
the diameter of the next greater number is given by this
expression
1229322 . 1 92
0050 . 0
4600 . 0
39
39
= =
Chapter 6

12
The square of this ratio = 1.2610. The sixth power of the
ratio, that is, the ratio of any diameter to the diameter of
the sixth greater number = 2.0050. The fact that this ratio is
so nearly 2 is the basis of numerous useful relations or short
cuts in wire computation.
In general AWG diameter conventional formula for bare copper
wire is:
Wire diameter in millimeter = (92^((36-AWG)/39))/39)*0.127
Wire diameter in mils = (92^((36-AWG)/39))*5

There are a number of approximate rules applicable to the AWG
which are useful to remember
o An increase of three gauge number (for example No. 10 to 7)
doubles the area and weight and consequently halves the dc
resistance.
o An increase of six gauge numbers (for example No. 10 to 4)
doubles the diameter.
o An increase of ten gauge numbers (for example No. 10 to 1/0)
multiplies the area and weight by 10 and divides the
resistance by 10.
o A No. 10 wire has a diameter of about 0.10 in, an area of
about 10,000 mils, and (standard annealed copper at 20
O
C) a
resistance of approximately 1.0 /1000 ft.
o The weight of No. 2 copper wire is very close to 200 lb/ 1000
ft.
AWG tables for some sized of bare Copper Wire
AWG Dia.(mils) Dia.(mm)
D.C.
ohms/kft
lbs/kft Amps
Max.
Amps
0000 459.99 11.684 0.0501 640.48 282.12 423.18
000 409.63 10.405 0.0631 507.93 223.73 335.6
00 364.79 9.2657 0.0795 402.8 177.43 266.14
0 324.85 8.2513 0.1003 319.44 140.71 211.06
1 289.29 7.348 0.1264 253.33 111.59 167.38
2 257.62 6.5436 0.1593 200.9 88.492 132.74
3 229.42 5.8272 0.2009 159.32 70.177 105.27
4 204.3 5.1893 0.2533 126.35 55.653 83.48
5 181.94 4.6212 0.3195 100.2 44.135 66.203
6 162.02 4.1153 0.4028 79.46 35.001 52.501
7 144.28 3.6648 0.508 63.014 27.757 41.635
8 128.49 3.2636 0.6405 49.973 22.012 33.018
9 114.42 2.9063 0.8077 39.63 17.456 26.185
10 101.9 2.5881 1.018 31.428 13.844 20.765
- AWG: American Wire Gauge size varying from #000m0 to #40 `
- Dia. (mils): Wire diameter in mils (1 mil = 0.001 inches)
Chapter 6

13
- Dia. (mm): Wire diameter in millimeters. This was included to help when
dealing with metric system.
- D.C. ohms/kft: Wire electrical resistance against direct current in ohms
per 1,000 feet
- lbs/kft: Wire section weight in pounds per 1,000 feet
- Amps: Wire conservative current rating in amperes
- Max. Amps: Wire maximum allowable current rating in amperes. Do NOT
exceed this rating.
AWG wire
size (solid)
Area CM*
Resistance
/kft @ 20
0
C
Diameter
inch
0000(4/0) 211600 0.049 0.46
000(3/0) 167810 0.0618 0.40965
00(2/0) 133080 0.0779 0.3648
0(1/0) 105530 0.0983 0.32485
1 83694 0.124 0.2893
2 66373 0.1563 0.25763
3 52634 0.197 0.22942
4 41742 0.2485 0.20431
5 33102 0.3133 0.18194
6 26250 0.3951 0.16202
AWG = American Wire Gauge
Dia Mils = Diameter in Mils (1 Mil = 0.001 inch)
The following cables are the most usable one in oil business:
AWG # 1
o Solid
Conductor size 1 AWG
Area 42.408 mm^2 (square-mm)
Area 83693 CM (circular mil)
Diameter 289.3 mil (1)
Diameter 7.348 mm (1)
DC-resistance 0.000407 Ohm/m
Tensile strength 1272.23 kgf (2)
Weight 377.004 kg/km (Cu)
Weight 114.501 kg/km (Al)
Construction: solid
Note:
1. Diameter of stranded conductor is an approximation.
2. Tensile strength of crimped terminal is about 60 % of
conductor.
o Stranded
Area 83693 CM circular mil)
Chapter 6

14
Construction: stranded
Note:
conductor.
AWG # 2
o Stranded
Conductor size: 2 AWG
Area: 33.631 mm^2 (square-mm)
Area: 66371 CM (circular mil)
Diameter: 297.6 mil (1)
Diameter: 7.558 mm (1)
DC-resistance: 0.000523 Ohm/m
Tensile strength: 1008.93 kgf (2)
Weight: 298.978 kg/km (Cu)
Weight: 90.803 kg/km (Al)
Note:
1. diameter of stranded conductor is an approximation.
conductor.
o Solid
Construction: solid
Note:
conductor.
AWG # 4
o Solid
Chapter 6

15
Construction: solid
Note:
conductor.
o Stranded
Area 41741 CM (circular mil)
Note:
2. Tensile strength of crimped terminal is about 60 %
of conductor.
6.5.7. Percent Conductivity
Conductivity is an important property of a material
used in electric circuits, which is a measure of its ability
to conduct electricity, the definition of conductivity (o ) is
o =
meter per volt in gradient Potential
meter sq. per ampere in density Current

o = J/E
o = conductivity
-1
/m
J = current density A/m
2
E = Electric field density v/m
o = A/m
2
v/m = A/m
2
x m/v =
-1
/m = Siemens/m (S/m)
The units of conductivity are thus the reciprocal of ohm.meter
or siemens/meter. Typical values of conductivity for good
conductors are 1000 to 6000 s/m. The reciprocal of
conductivity is called resistivity.
Percent conductivity is very common to rate the conductivity
of a conductor in terms of its percentage ratio to the
conductivity of chemically pure metal of the same kind as the
conductor is primarily constituted or in ratio to the
conductivity of the international copper standard. Both forms
of the conductivity ratio are useful for various purposes.
This ratio can also express in two different terms, one where
the conductor cross sections are equal and therefore termed
the volume-conductivity ratio and the other where the
conductor masses are equal and therefore termed the volume-
Chapter 6

16
conductivity ratio.
6.5.8. International Annealed Copper Standard (IACS)
IACS is the international accepted value of the
resistivity of annealed copper of 100% conductivity. This
standard is expressed in terms of mass resistivity as 015328
.g/m
2
or the resistance of a uniform round wire 1 m long and
weight of 1 g at standard temperature of 20
O
C.
Equivalent expressions of the annealed copper standard, in
various units of mass resistivity or volume resistivity are as
follows:
0.15328 .g/m
2
875.2 .lb/mi
2
1.7241 .in @ 20
O
C
1.725x10-8 .mt @ 20
O
C
10.371 .Cmil/ft
0.017241 .mm
2
/m
6.5.9. Electric resistivity of conductor
It is a measure of resistance of a circuit of a unit
quantity of a given material, it may expressed in terms of
either mass or volume
Mass resistivity = c =
2
Rm
/m
Resistance = R =
m
2
c

Volume resistivity = =
RA
.m
Resistance = R =
A

R = Resistance, m = Mass, = Length, and A = Area
Accordingly,
Voltage drop in conductor = IR =
A
I
volts
Voltage drop per meter potential gradient =
A
I
volts
Conductivity =
meter per volt in gradient Potential
meter sq. per ampere in density Current
=
= A/m
2
x m
2
/(A..m) =
-1
m
-1
(Siemens/m)
6.5.10. Temperature coefficient of conductor resistance
The resistance of all pure metals increases with
increase temperature, where as the resistance of carbon,
electrolytes and insulating materials degreases with increase
temperature. For a moderate range of temperature such 100
O
C,
the change of resistance is usually proportional to the change
of temperature, if R
t1
is the resistance at temperature t
1
, and
t1
is the coefficient at that temperature, the resistance at
Chapter 6

17
some other temperature t
2
is expressed by the formula
R
t2
= R
t1
[1+
t1
(t
2
-t
1
)]
Upon assuming the general linear relationship between
resistance and temperature, the new coefficient at any
temperature t within the linear range is expressed
) ( ) / 1 (
1
1 2 t t t
t
+
=
o
o

The coefficient of resistance is the ratio of the increase of
resistance per
O
C rise to resistance at 0
O
C. Alternative the
temperature coefficient of resistance can be defined as the
increase in resistance of 1 at 0
O
C for 1
O
C rise of
temperature.
The variation of resistance of copper for the range over which
copper conductors are usually operated is represented by the
following graph,

If this graph extended backwards, the point of intersection
with the horizontal axis is found to be -234.5
O
C.
Hence, for standard annealed conductor having a resistance of
1 @ 0
O
C, the variation of resistance over 234.5
O
C
(resistance of annealed copper is 0 @ -234.5
O
C) is 1 ,
o 0 = t
=
5 . 234
1
= 0.004264 /
O
C
In general, coefficient of conductor resistance at t
O
C is:
ot
=
t + 5 . 234
1
= 0.004264 /
O
C
Example:

Coefficient at t =15
O
C is
o 15 = t
=
15 5 . 234
1
+
= 0.004008 /
O
C
O
C is
Chapter 6

18
o 20 = t
=
20 5 . 234
1
+
= 0.003929 /
O
C

O
C is
o 25 = t
=
25 5 . 234
1
+
= 0.0038535 /
O
C
From above graph,
1 1
5 . 234 5 . 234
5 . 234
1
1 1
0
1
+ = + =
+
=
t
t t
R
R
o
1 1
5 . 234 5 . 234
2
1
2
0
2
5 . 234
+ = + =
+
=
t
t
t
R
R
o
R
1
= R
0
(1+o t
1
)
R
2
= R
0
(1+o t
2
)
1
1
2
1
2
1
+
+
=
t
t
R
R
o
o

5 . 234
5 . 234
2
1
2
1
+
+
=
t
t
R
R
and, ( )
5 . 234 5 . 234 1
1
2
2 +
=
t
R
R
t

Over moderate range of temperature, the change of resistance is
usually proportional to the change of temperature. Resistivity
is always expressed at standard temperature, usually 20
O
C (68
O
F).
The coefficient of copper less than standard conductivity
(100%) is proportional to the actual conductivity, expressed
as decimal percentage. Thus if n is the percentage
conductivity (95% = 0.95), the temperature coefficient will be
t
= n
t
, where
t
(0.00393) is the coefficient of the
annealed copper standard at 100% conductivity.
) 20
1
1
( )] 00393 . 0 ( * / 1 [
1
+
=
t
n
o

Example:
Coefficient of annealed copper conductor of 95% conductivity
at 20 OC is
00373 . 0
( )] 00393 . 0 ( * 95 . 0 / 1 [
1
) 20
20
20
=
+
=
o

Coefficient of annealed copper conductor of 95% conductivity
at 25 OC is
00367 . 0
( )] 00393 . 0 ( * 95 . 0 / 1 [
1
) 20
25
25
=
+
=
o

6.5.11. Number of wires in stranded conductors
Each successive layer in a concentrically stranded
conductor contains six more wires than the proceeding one. The
total number of wires in conductor for 1-wire core
Chapter 6

19
construction (1,7,9,.etc) is

N = 3n(n+1)+1
Where n is number of layers over core, which is not counted as
layer.
if n = 1 then N = 7

If n = 2 then N = 19

6.6. Voltage drop in the ESP cables
The voltage drop per 1000 ft (kft) length of cable is
published as a chart for each manufacture at certain
temperature. For cables operating at conductor temperatures,
the value obtained from voltage drop chart must be multiplied
by correction factor (issued by manufacturer) Although the
actual conductor temperatures varies along the length of the
cable, an acceptable industry practice is to assume that the
conductor temperature is equivalent to the maximum well
temperature.
The voltage drop formula used for a given length of cable ia
as follows:

(
+ = sin
60
cos 732 . 1
f
X R
x l I drop Voltage
L ac

Where:
I = current in ampere,
l = length of cable in 1000 ft
R
ac
= ac resistance at specified conductor temperature in
/kft.
Cos = Power factor
X
L
= Inductive reactance
f = Frequency c/s

Layer 1
Layer 2
Core
Layer 1
Core
Chapter 6

20
p.f cos sin
--- ----- -----
80% 0.80 0.600
85% 0.85 0.527
90% 0.90 0.436
95% 0.95 0.312
For the inductive reactance X
L
(/kft) each manufacturer issued
values of each of their cables. For example the following
values are for Philips cables (/kft @ 60 hz)
AWG # Round Flat
----- ----- -----
1 0.033 0.042
2 0.034 0.044
4 0.036 0.047
6 0.039 0.050
In case if the frequency is other than 60, the above mentioned
values should multiply by (f/60).
For example, cable size AWG #2, motor amps is 100 A, cable
length is 8000 ft, the PF = 0.85 and conductor resistance at
77
O
F is 0.1708 so, The voltage drop =
=
(
|
.
|
\
|
+ = 527 . 0
60
50
034 . 0 85 . 0 1708 . 0 1 100 732 . 1 ..D V 27.73 volts

Each manufacturer issues the voltage drop curves for their
cables conductor at certain temperature, the following curves
represent an example (Reda),
Voltage Drop for Reda Cables @ 77
O
F
0
10
20
30
40
50
60
0 20 40 60 80 100 120 140
Motor Amps
V
o
l
t
a
g
e

D
r
o
p

v
o
l
t
s
/
k
f
t
AWG #6 AWG #4 AWG #2 AWG #1

For example, if the motor amperage (name plate) is 100 amp so,
The voltage drop of conductor size AWG# 1 is 17.75 volts.
Chapter 6

21
Definitions
Maximum Well Temperature: It is defined as the ambient
temperature surrounding the cable during steady state
operation. This temperature depends on the initial bottom
hole temperature, the heat rise from the operating
submersible equipment, and the heat generated by the power
losses in the cable.
Conductor temperature: It is defined as the temperature on
the surface of the current carrying conductor during steady
state operation.
Maximum conductor temperature: It is the highest temperature
at which the cable can continuously operate without causing
significant degradation of cable dielectric material.
6.6.1. Correction of voltage drop for temperature:
The issued voltage drop curves (by manufacturers) are at
certain temperature (20
O
C [68
O
F] or 25
O
C [77
O
F), so the
voltage drop must be corrected to the conductor temperature.
The following steps are used for the corrections:
- Calculate the conductor temperature using the motor amperage
and the maximum well temperature,

T I
a
T well C
+ =
2
*
O
F
Where:
T
C
= Conductor temperature
I = Motor amperage
a = Factor for each cable size (issued by manufacturer)
T
well
= Maximum well temperature
- Adjust the voltage drop at maximum well temperature from the
following equation using the voltage drop have got from the
manufacturer chart at motor amperage, cable size, and
conductor temperature calculated in the previous step
)) 77 ( 00214 . 0 1 ( + =
T V V C a adj

Where:
V
adj
= Adjusted voltage drop
V
a
= Voltage drop from the curve
Example:
I = 50 A, T
well
= 200
O
F, cable is AWG# 4 Reda hot type
a = 0.00117 (from Reda issued table)
T
c
= 0.00117 x (50)
2
+ 200 = 229
O
F
V
adj
= 22 x (1+0.00214(229-77)) = 29 volt/1000
Note:
Most of the cable manufacturers issue tables of
temperature correction factor which can be used directly
Chapter 6

22
instead of using the previous equation. For example, the
following table is issued by Centrilift for their cable:
Conductor V.D. Temp. factor @ 77
O
F
Temp.
O
F Corr. factor Temp.
O
F Corr. factor
50 0.95 221 1.31
59 0.96 230 1.33
68 0.98 239 1.35
77 1.00 248 1.37
86 1.02 257 1.39
95 1.04 266 1.40
104 1.06 275 1.42
113 1.08 284 1.44
122 1.10 293 1.46
131 1.12 302 1.48
140 1.13 311 1.50
149 1.15 320 1.52
158 1.17 329 1.54
167 1.19 338 1.56
176 1.21 347 1.58
185 1.23 356 1.60
194 1.25 365 1.62
203 1.27 574 1.64
212 1.29 383 1.65
6.6.2. Maximum carrying capacity of the cable (I
max
)
The maximum carrying capacity of a cable can be
calculated using the following equation:
a
BHT
T
I
C

=
max
max

Where:
max
TC
= Maximum conductor temperature
O
F
BHT = Bottom hole temperature
O
F
a = Current temperature factor (an example here is below Reda
current temperature factor table for their cables)

Current temperature factor (a) table for Reda cables
Cable Type
Conductor Size (AWG)
6 4 2 1 1/0 2/0
Redablack Flat (EEF) 0.0275 0.0167 0.0086 0.0064 0.005 0.0039
Redablack Round (EER) 0.0199 0.0115 0.0058 0.0043 0.0032 0.0025
Redalead Flat (ELB) 0.0281 0.0169 0.0086 0.0064 0.005 0.0039
Redalead Round (ELBE) 0.0202 0.0116 0.0058 0.0042 0.0031 0.0025
Redablack Round (ETBE-300) 0.0199 0.0115 0.0058 0.0043 0.0032 0.0025
Redablack Flat (ETBE-300F) 0.0275 0.0167 0.0086 0.0064 0.005 0.0039
Redahot Round (ETBO) 0.02 0.0117 0.0062 0.0046 0.0034 0.0027
Motorlead (KELB) 0.0281 0.0169 0.0086 0.0064 0.005 0.0039
Low Temperature Motorlead (KEOTB) 0.0275 0.0169 0.009 0.0068 0.0053 0.0042
Redalene Flat (POTB) 0.0281 0.0176 0.0097 0.007 0.0048 0.0038
Chapter 6

23
Redalene Round (PPEO) 0.0199 0.0112 0.0062 0.0045 0.0031 0.0025

Current temperature factor (a) table for Centrilift cables
Cable type Max.
O
F AWG 6 AWG 4 AWG 2 AWG 1
CPNF 205 0.0261 0.0155 0.0091 0.0065
CPNR 205 0.0222 0.0132 0.0077 0.0056
CENF 260 0.0289 0.0171 0.01 0.0072
CENR 260 0.0195 0.0115 0.0068 0.0049
CEBNR 280 0.0195 0.0092 0.0054 0.0039
CEBER 300 0.0195 0.0092 0.0054 0.0039
CEBER-HT 400 0.0156 0.0092 0.0054 0.0039
CEEF 400 0.0272 0.0161 0.0095 0.0068
CEER 400 0.0156 0.0092 0.0054 0.0039
CELF 450 0.0272 0.0161 0.0095 0.0068
Example:
The maximum current carrying capacity for Reda black
round 400
O
F (ETBE) size AWG #2 at bottom hole temperature 200
O
F is:
a
BHT
T
I
C

=
max
max
=
0058 . 0
200 400
= 185.7 amps
for size AWG #4 I
max
is:
=
0115 . 0
200 400
= 131.9 amps
6.7. Method of selecting Cable wire size and type
1. From the voltage drop (VD) chart, select a cable gauge that
results in a three phase voltage less than 30 volts per 1000
ft at motor name plate amps. For example at the motor
amperage 100 the VD of size AWG 4 is 42.29 volts and size
AWG 2 is 28.59 volts, accordingly, size AWG 2 is selected as
is VD is <30 volts/kft. This VDs are at 77
O
F.
Note:
VD = 1.732 x R x I in case if the p.f is 1.00 i.e. cos =1
VD = 1.732 x 0.176 x 100 = 30.48 v/kft for AWG 2.
At VD = 28.59 v/kft the p.f is 0.86 (=30.7
O
) and inductance
reactance is 0.027 ohm/kft at 50 hz and 77
O
F.

Chapter 6

24

2. Adjust VD for the selected cable to the down hole well
temperature, suppose that the average DHT is 200
O
F, then,
)) 77 ( 00214 . 0 1 ( + =
T V V C a adj

V
adj
= 28.59 x (1+0.00214(200-77)) = 36.1 volt/1000
V
adj
>

30 volts/kft, accordingly, the bigger size should be
selected (lower AWG), so size AWG 1 is selected, VD of AWG 1
is 17.75 volts/kft,
)) 77 ( 00214 . 0 1 ( + =
T V V C a adj

V
adj
= 17.75 x (1+0.00214(200-77)) = 22.4 volt/1000

3. Adjust conductor temperature based on the well DHT as
follows,

T I
a
T well C
+ =
2
*
O
F
=0.0058 x 100
2
+ 200 = 258
O
F
AWG 1, Reda Hot 275
O
F (maximum cable temperature) is a good
choice.
6.8. ESP cable pulling rates and decompression
6.8.1. Introduction
When discussing cable handling techniques one area of
concern is the effect of pulling rates on the internal
components of the cable. Unfortunately, this is not simple
issue and there are not definitive means for determining
optimum pulling rates. The intent of this part, however, is to
discuss the factors involved in decompression of the cable,
whether it is due to pulling of the downhole equipment or
simply drawdown of the fluid.
6.8.2. Decompression theory
When a cable is initially installed in the oil well it
is exposed to an external pressure created by gas pressure and
Chapter 6

25
the static head of the fluid. The cable components, however,
undergo a pressure equalization process whereby the insulation
and jacket compress and gases and fluids migrate into the
material. The rate at which this migration occurs, however, is
highly variable.
Two general factors control the permeation rate,
1. The diffusion between molecular chains.
2. The stability the permeant (the migrating fluid or gas) in
the polymer (the insulation and jacket).
The diffusion is dependent on pressure and concentration
factors; for liquids this referred to as the concentration
gradient and for gas as the partial pressure (total pressure
multiplied by gas concentration). Other parameters affecting
the above two factors include the temperature at which the
cable is operating (high temperature increase the permeation
rate), jacket and insulation thickness, intermolecular chain
forces, degree of cross-linking, molecular size, and chemical
similarity between the permeant and the polymer.

Once the internal components of the cable have reached the
same pressure as the well through the diffusion and physical
compression, the cable has reached equilibrium. Once the
fluids are drawdown, however, or the equipment is pulled, a
pressure differential is created with the high pressure
existing in the cable insulation and jacket material
themselves. The material will physically expand to relieve
some of this pressure, much as they compressed under an
external pressure. The problem arises, though, due to gas
which dissolved in the polymer. Give sufficient time this
gas will migrate back out the material without imparting any
permanent damage to the cable. In some instances, however, the
polymer are not given sufficient time to outgas thereby
causing the pressure differential to exceed the strength of
the material causing a blowout which appears as a bubble or
cavity in the insulation or jacket.

6.8.3. Material hoop strength

6.8.3.1. Insulation

A fundamental property when dealing with decompression
is the hoop strength of the cable material. Hoop strength of
tubing reflects the amount of internal pressure that the tube
can contain without yielding the tube material. Likewise, the
hoop strength of an insulation would approximate the pressure
differential that could be maintained across the insulation
without yielding the insulation material. The equation of hoop
strength is as follows:
D
t
P
H o
2
=

Chapter 6

26
Where
P = Internal pressure psi
o
H
= Yield or tensile strength (hoop strength) of material psi
t = Thickness of material inch
D = Diameter over insulation inches
Hoop Strength =
t
PD
H
2
=
o

Or
P = Internal pressure Mpa
S = Yield or tensile strength (hoop strength)of material Mpa
t = Thickness of material mt
D = Diameter over insulation mt

Example 1
P (internal pressure) = 6.6 Mpa
D (outside diameter) = 6.6 mt
t (thickness) = 18.5 mm
Hoop strength = 3 . 1177
0185 . 0 2
6 . 6 6 . 6
=

=
o H
Mpa = 170.75 psi
281 . 3 0185 . 0 2
89974 . 6
6 . 6
281 . 3 6 . 6

(

=
o H
= 170.75 psi

Example 2
Assume we are looking at a polypropylene insulated, 3
kv rated, AWG #4 conductor as a Redalene type cable. The
tensile strength of polypropylene is approximately 3500 psi,
the insulation thickness on a 3kv rated cable is 0.075, and
the diameter over the insulation is 0.354, therefore,
354 . 0
75 . 0 3500 2
= P = 1483 psi
Unfortunately, the above tensile strength is at room
temperature and since polypropylene is a relatively low
temperature thermoplastic and softens at higher temperature,
Internal
Pressure
t
D
Chapter 6

27
the hoop strength is considerably reduced at normal operating
temperature. Here are below tables of the calculated hoop
strengths for polypropylene insulated conductors for different
conductor sizes and voltage ratings, at two different
temperatures.
Hoop strength of polypropylene at 115
O
F conductor temperature

kV AWG #4 psi AWG #2 psi
3 112 90
4 124 101

Hoop strength of polypropylene at 160
O

3 28 22
4 31 25

EPDM insulation, on the other hand, by its nature as a
thermoset or cross linked compound has much better temperature
stability than polypropylene so that it retains a fairly
constant tensile strength in the 212-300
O
F temperature range
for which the following data was calculated.

Hoop strength of EPDM at 212-300
O

3 390 312
4 431 351
The above shows first that EPDM insulations may provide
greater decompression resistance than polypropylene, but
second that neither provides sufficient decompression strength
on stand alone basis to prevent cable blowout.
6.8.3.2. Tape and Braid
The incorporated of tape and braid over the
insulation provides two advantages to the cable when
considering decompression. First, the tap acts as a barrier to
migration of the well fluids and gases into the insulation,
preventing the absorption of agents which would latter have to
migrate out of the insulation upon decompression. Second, both
the tape and braid provide additional hoop strength to the
insulation. Rough calculations indicate that the additional
hoop strength provided by the poly-vinyl-fluoride (PVF) tape
and nylon braid is approximately 25 psi at 160
O
F.
6.8.3.3. Lead jacket
The use of a lead jacket goes one step beyond the
protection provided by the tape and braid and provides a
totally impervious barrier to migration of well fluids or
gases, thereby totally insulating the insulation from the
chemical environment in the well. Therefore, the initial
pressure equalization is accomplished entirely through the
build up of compressive forces in the lead jacket and the
Chapter 6

28
insulation which are easily relieved during compression ; with
the lead jacket there are no trapped gases which must permeate
out of the insulation. Thus the lead jackets are the best
means of preventing decompression damage.
6.8.3.4. Armor
Not surprisingly, the primary cable component for
preventing decompression damage in non-leaded cables is the
armor. The jacket provides additional hoop strength, but
generally just transfers stresses from the insulation to the
armor. Provided below the hoop strengths for a single wrap of
0.025 galvanized steel armor (GSA) with an interlocked
profile; due to the temperature vs strength relationship for
steel, these values would essentially be constant across the
range of operating temperature.
Hoop strength of 0.025 GSA
3 1260 1074
4 1190 1064

Obviously these values will quickly decrease if armor
corrosion is problem. Various armor packages are available to
increase the degree of containment provided by the armor.
These include the use of 0.034 armor strip instead of the
standard 0.025 strip on round cables, the use of second wrap
of armor applied over the first, the use of flat profile armor
configuration, and finally the use of higher strength, more
corrosion resistant alloys such as 316 stainless steel.
6.8.3.5. Recommendation
The key, therefore, is to be aware of the role of the
different cable component and after choosing the appropriate
cable type, to monitor its decompression performance; this
information should be then fed back into the cable selection
criteria. This of course means being aware of the downhole
conditions when the cable is pulled, as well as the pulling
rates themselves.
In terms of cable choices, three key things should be
evaluated:
1. The insulation and jacket polymer type being used.
2. Is a barrier tape or lead jacket being used to prevent the
migration of gases into the insulation?
3. What type of armor is being used and is corrosion negating
the containment role of the armor?
6.9. ESP Cable Test
A variety of test devices and procedures are used in an
effort to determine the quality of cable. Even when using the
same test device, different interpretations and widely
divergent values are used by various companies.
Chapter 6

29
Reuse of cable is a serious consideration in the economic
evaluation of a well. A cable may present up to one-third of
the equipment cost of an installation. Even more important is
the fact that premature cable failure may well result in
pulling the well before payout of the installation.
Where pulling costs are extremely expensive, many many
producers opt to avoid reuse of cable because of risk. Junking
a $30,000 cable that may be perfectly good, has been
determined to be economically prudent in these conditions.
There must be better way of evaluating ESP cable for use.
6.9.1. Types of tests
Various test are used to determine the performance of
cable. The most common are volt-ohmmeter (VOM), insulation
resistance (IR), and high potential dc test (dc hi-pot). As
with most things worth doing, more valuable information is
obtained from the more expensive and difficult tests.
6.9.1.1. VOM
Since volt-ohmmeter is common, inexpensive, safe, easy
to use, it is very popular. Although useful for some
application, the volt-ohmmeter is virtually useless for
evaluating cable insulation. The instrument usually relies on
a 9 volt battery to energize the cable.
This test is only used for an initial indication of cable
condition while it still in the well. About the best that can
be said about a VOM test is that if the reading indicates bad,
then the cable or some other component of the electric system
is bad. However, if it indicates good, little or nothing is
known about the quality of the cable.
6.9.1.2. IR
The megohmmeter is a portable, moderately expensive
test device that provides limited information about cable
quality. The instrument usually contains a 1000 volt supply to
energize the cable. Some machines are rated up to 5000 volts.
The higher voltage can help determine the basic performance
level of the cable. However, the meter readings are subjected
to so any variations that consistent results are seldom
achieved.
6.9.1.3. Hi-pot
The high potential dc tester is an expensive test machine
which, given the present state of the art, provides the most
information about cable quality. It typically can apply up to
35,000 volts to energize the cable. Some machines at research
facilities are rated up to 200,000 volts or more.
The higher voltage can be used to cause virtually any cable to
fail at weakest point. However, it is very difficult to find a
way to interpret the readings so that the quality of cable can
be determined without taking the cable to destruction.
Chapter 6

30
Experience, skill, and knowledge of local conditions taken in
conjunction with test results are major aids in analyzing the
suitability of cable for reuse.
6.9.2. Resistance vs. Length in ESP cables
Cable insulation is essentially a large resistor that I
spread over along distance. Using finite element analysis, the
insulation ca modeled as numerous resistors. Each resistor
represents a unit length. All the resistors between the
conductors and ground are then connected in parallel to obtain
the total insulation resistance as shown as the following
figure.

Based on the relationship for parallel resistors, the total
resistance will always be lower than the lowest resistor
anywhere on the cable. In addition, the value will lower
exponentially as the length increases.
R R R R R n t
1
..........
1 1 1 1
3 2 1
+ + + + =
The reciprocal of the total resistance, R
t,
is equal to the sum
of the reciprocals of all individual resistances along the
length of the cable.
End effects, associated with where the conductors are exposed
to air, constitute two additional resistors. These are also in
parallel with insulation resistance.
The concept of parallel resistances is important in gaining an
appropriate understanding of the total leakage current, the
insulation resistance, and leakage conductance. These have a
pronounced effect on the mega-ohmmeter and dc hipot leakage
current test leakage.
6.9.3. Resistance vs current in ESP cables
The insulation resistance R in megohms and the leakage
current I in microamps are related by Ohms low.
V = R * I
It is apparent that the test voltage V plays a role in the
relation ship. For cable insulation, the resistance varies
with the length. As the length increases, the megohm value
decreases. This is a non linear change. For a fixed test
voltage, the leakage current must increase exponentially as
the length increases.
During varies tests, we have observed that the leakage current
R1 R2 R3 Rn
Grounded shield
Energized conductor
Chapter 6

31
and megohm values vary over a wide range. For a particular
group of conditions, one value of leakage current and
insulation resistance might be appropriate, but no single
number satisfies all conditions. Some of the conditions
influencing both leakage current and insulation resistance
include length, temperature, material, moisture, and oil
gravity.
Cable length has to be incorporated in Ohms law relationship.
If the resistance is multiplied by length the appropriate
units are megohm-thousand feet (M-kft). The reciprocal is
called conductance and has units of micromhos per thousand
feet (mho-kft).
Alternatively, the conductance can be expresses in units of
microamps per volt per thousand feet (A/kv/kft). Observe that
the leakage conductance is directly related to the reciprocal
of the insulation resistance.
Traditionally, the industry has strived to determine one
megohmmeter number that can be used to judge the quality of
any cable. Basic analysis reveals it is futile to try to
define performance of all cables by using single number read
from meter. Length, wire diameter, insulation type,
construction geometry, and voltage must be considered.
The example below illustrates the the effect of length and
voltage on the meter r99 eading. These based on a leakage
conductance of 0.2 a/kv/kft.
Effect of length and voltage on insulation resistance

Length
Kft
Voltage
kv
Current
a
Conductance
A/kv
Resistance
megohm
1 1 0.2 0.2 5000
1 5 1 0.2 5000
1 15 3 0.2 5000
2 15 6 0.4 2500
5 1 1 1.0 1000
5 15 15 1.0 1000
10 15 30 2.0 500

I = V/R = 1/5000*10
3
= 0.2*10
-6
amps = 0.2 a/kv/kft
I = V/R = 5/5000*10
3
= 1.0*10
-6
amps = 1.0 a/kv/kft
I = V/R = 15/5000*10
3
= 3.0*10
-6
amps = 3.0 a/kv/kft
I = V/R = 15*2/5000*10
3
= 6.0*10
-6
amps = 6.0 a/kv/kft
I = V/R = 15/5000*10
3
= 3.0*10
-6
amps = 1.0 a/kv/kft
I = V/R = 1*5/5000*10
3
= 1.0*10
-6
amps = 1.0 a/kv/kft
I = V/R = 15*10/5000*10
3
= 30.0*10
-6
amps = 30 a/kv/kft
R = V/I = 1/0.2*10
-6
= 5*10
6
ohm = 5000 M
R = V/I = 5/0.2*10
-6
= 5*10
6
ohm = 5000 M
R = V/I = 15/3.0*10
-6
= 5*10
6
ohm = 5000 M
R = V/I = 15/6.0*10
-6
= 2.5*10
6
ohm = 2500 M
R = V/I = 1/1.0*10
-6
= 1*10
6
ohm = 1000 M
R = V/I = 15/30*10
-6
= 0.5*10
6
ohm = 500 M
Chapter 6

32
The measured megohm value is not a single number, but varies
with length. This corresponds to the parallel resistance model
previously discussed.
6.9.4. Resistance vs wire size
Insulation resistance is related to dimensions of by
resistivity ().
A
L
R

=
Characteristic material properties are included in the
resistivity. The length (L) and surface across sectional area
(A) define the volume occupied by the insulation. Previous
discussion identified the effect of length on the resistance.
The ara is calculated from circumference around the conductor
(d) and thickness (t) of the insulation.
A = d*t
Because cable insulation is essentially a tube around a wire,
an alternate from this relationship is used. It takes into
consideration the overall diameter (D), the wire diameter (d)
and the bulk resistivity constant (K) which is a constant for
each material.

d
D
K R log =
Typical resistance constants for high quality electrical
insulations have been determined by the power cable industry.
These are based on years of experience at high voltage levels.
For example, the bulk constant of ethylene propylene diene
monomers (EPDM) insulation for use at service level up to
138,000 volt ac is 20,000 megohm-thousand feet for new
insulation. The polyethylene value is 50,000 Mohm-kft.
Insulation that has been environmentally exposed will have
values that are significantly lower than these new resistance
constants. Because new insulation is such high quality, lower
values on used cable may still represent excellent insulation
for this application.
Stranded wire will be having more insulation in contact with
the wire than solid conductor. This greater surface causes a
proportional increase in the area. In addition, a large size
will have a greater area.
An increase in area causes a decrease in the resistance of the
insulation. Because of the very small dimensions involved in a
wire configuration, any increase in area can have a dramatic
effect.
The table below shows the impact of the wire configuration.
The EPDM constant for new cable is used to determine the
minimum insulation resistance and corresponding leakage
conductance for cables with nominal 75 and 90 mil insulation
Chapter 6

33
thickness. The minimum thickness (t) for nominal 75 mil
insulation is 68 mils. The overall diameter (D) is calculated.
D = d + 2t
As an example, the overall diameter for AWG #1 is 439 mils
(289+75+75).
Size effect on insulation resistance, EPDM (K=20,000 M-kft)
Wire Size
AWG
Wire
Diameter
(d) mil
R M-kft
for 75
mil wall
G
a/kv/kf
t
R M-kft
for 90
mil wall
G
a/kv/kft
6 162 5290 0.19 6020 0.17
4 205 4430 0.19 5070 0.20
4S 232 4110 0.24 4710 0.21
2 258 3680 0.27 4240 0.24
2S 292 3390 0.30 3910 0.26
1 289 3350 0.30 3860 0.26
1S 328 3080 0.33 3560 0.28

It is apparent that the measured insulation resistance changes
significantly with a change in wire dimensions. The resistance
will also change depending on the insulation material. The
same table recalculated for polypropylene.
Size effect on insulation resistance, Poly (K=50,000 M-kft)
Wire Size
AWG
Wire
Diameter
(d) mil
R M-kft
for 75
mil wall
G
a/kv/kf
t
R M-kft
for 90
mil wall
G
a/kv/kft
6 162 13240 0.076 15050 0.066
4 205 11080 0.090 12680 0.079
4S 232 10275 0.096 11775 0.084
2 258 9210 0.109 10600 0.094
2S 292 8470 0.118 9780 0.102
1 289 8370 0.120 9660 0.104
1S 328 7690 0.130 8900 0.112
When insulation resistance decreases, the leakage conductance
increases. The relationships demonstrate some of the reasons
why it is very difficult to have a single value of leakage
conductance or insulation resistance for every submersible
cable. These changes are for new cable. The effect is even
more pronounced for used cable.
Example:
In AWG #1, 75 mils nominal insulation, EPDM thickness is 75
mils, and wire diameter is 289 mils.
So, d = 75 mils, D = 289 + 2 * 75 = 439 mils = 0.239 inch
d
D
K R log =
289 . 0
439 . 0
log * 000 , 20 = = 3,631 M-kft
In AWG #4, stranded, 75 mils nominal insulation, EPDM
thickness is 75 mils, and wire diameter is 205 mils.
Chapter 6

34
d
D
K R log =
205 . 0
355 . 0
log * 000 , 20 = = 4,769 M-kft
In AWG #1 stranded, 75 mils nominal insulation, polyethylene
thickness is 75 mils, and wire diameter is 289 mils.
d
D
K R log =
289 . 0
439 . 0
log * 000 , 50 = = 9,078 M-kft
6.9.5. Resistance vs. shielding
During a test or use, a voltage gradient is set up
between the conductor and the ground plan as illustrated I the
following figure. This potential difference is distributed
across all the insulating materials in the electric field.
Therefore, the total measured resistance depends on the
insulating properties of all materials between energized
conductors and ground plane.

Voltage gradient between conductor and ground
If shielding is placed directly over the individual insulated
wire, the ground plane is moved closer conductor. This reduces
the resistance, so it increases the leakage conductance and
leakage current. For example, a lead covered cable provides a
very effective shield. Hence the leakage current values will
be greater for leaded cable than for other designs.
Most three phase cables have three conductors twisted a
triplex configuration. This spacing tends to fog the
dimensions between the conductor and ground plane. Hence, this
insulation resistance tends to be greater than most other
configurations.
Ground
Armor
Insulation
Conductor
energized
Jacket
Chapter 6

35
6.9.6. Industry methods
There are many diverse methods used in an effort to
determine if a particular cable is suitable for reuse in a
well. For example, many users merely require that the cable be
visually inspected and that it pass a five minutes hi-pot dc
withstand test at specified voltage level. Even this rather
straightforward evaluation method is complicated by the lack
of consensus on the appropriate voltage test level for various
types of cable.
For a used 75 mil, EPDM insulated cable, the dc voltage used
in the industry is usually 11,000 volts. At the other extreme,
some users reportedly test the same cable at level up to
25,000 volts. This extreme difference indicates a series lack
of understanding about the basic testing criteria of cable.
Furthermore, certain users attempt to establish a specified
maximum leakage current. Others specify a leakage conductance
which is leakage current per thousand volts per thousand feet.
Still others may require that the leakage current or
insulation resistance be balanced within a maximum ratio of 3
to 1.
6.9.7. Recommended practice
There are several organizations responsible for
recommended practices addressing this high performance cable.
An overview of the development of these guidelines has been
represented by Institute of Electric and Electronic Engineers
(IEEE).
IEEE has three documents that address the performance of new
cable; these provide conservative criteria for evaluation of
newly manufactured cable and acceptance of the shipped cables.
The guidelines are supported by broad experience outside the
submersible industry. They were developed and accepted by
submersible cable manufacturers and producers based ob
industry knowledge at the time of development.

IEEE test values
Thickness
Mils
Factory
kv
Acceptance
kv
Maintenance
kv
75 27 22 11
90 35 28 14
These provide a starting point for evaluating used cable.
Maintenance test are performed on cables that remain installed
but can be tested. Used submersible cable is usually tested
after removal from the well where considerably higher test
voltages can be applied. Therefore, the maintenance values are
often regarded by some evaluators as too low for used cable.
Despite the lack of hard data to support their
recommendations, an API task Group is pressing forward in an
attempt to provide guidance for reuse testing. At this time,
Chapter 6

36
the tentative draft guideline for testing used EPDM and
polypropylene (poly) cable is based solely on new cable
criteria. More work needs to be done.
6.9.8. Megohm correlation
There is considerable controversy about the minimum
required megohm reading on a used cable. The test method is
widely used, but how it works on this specialty cable is not
well under stood. Perhaps it will be useful to review what
this test actually measures. How test results are related to
cable length and other variables are then considered.
An insulation resistance (megohmmeter) test is usually
performed by 1000 volts dc to one conductor. The other two
conductors and the armor are grounded.
The following figure illustrates the relationship between
insulation resistance and cable length. Two assumptions are
used, first, resistance is uniformly distributed along the
length of the cable, second, the end effects are ignored.
Insulation resistance vs Length
0
200
400
600
800
1000
1200
1400
1600
1800
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Thousand feet
M
e
g
o
h
m

The curve is based on a 200 megohm resistance for an 8000 foot
cable. This a value some have used as a threshold for
acceptance used cable. However, we will develop more effective
relationship later.
The graph dramatically illustrates that as cable get shorter,
the insulation resistance (IR) reading increases very rapidly.
As a result, it is very difficult for those unaware of this
relationship to properly interpret megohm readings as a
function of length. The relationship is definitely not liner.
In addition, it should be observed that as the cable gets
shorter, it becomes more and more difficult to get meaningful
results. The meter has limited resolution for values greater
Chapter 6

37
than 5000 megohms.

Furthermore, for short length, the end effect resistance
begins to dominate more than the actual insulation resistance.
The end effect resistance is lowered by increasing humidity,
lack of cleanliness, and preparation of the ends.
One other observation from the simple parallel resistance
model is worthy of further comment. The megohmmeter will
always indicate a value lower than the lowest resistance along
the complete length of the cable. The lower value arises
because of the parallel nature of the resistors. This effect
depicts how the entire length of an otherwise perfectly good
cable can be condemned because a small section has been
damaged locally.
In other words, one can not determine the overall quality of a
cable from the megohm reading. The value may reflect the
insulation resistance and presumably the condition of all the
insulation along the cable or it may reflect just the
resistance of a local spot along the cable.
Because of these inherent test limitations, it is clear that
megom readings alone do not provide sufficient information to
be used as the sole criteria for evaluating the condition of a
cable.
6.9.9. DC Hi-pot voltage
The preferred method of evaluating cable at this time is
the high potential dc tester. Even this respected method
always many interpretations. As a result, there is no
consensus of appropriate voltage or current levels for
evaluating used cable.
The IEEE recommended practice gas generally accepted voltage
values for factory test of newly manufactured and acceptance
test of newly delivered cable. These were given in the
previous table.
With the present improved quality of cable and the experience
of the industry, the values given for maintenance test are
often considered too low for cable removed from service. Many
service centers and users specify much higher dc voltage for
evaluating used cable.
One part of the argument is that higher voltage will find more
weak spots before installation of the cable in the well. The
counter point f argument is that excessive test voltage will
unnecessarily damage of insulation of otherwise perfectly good
cable. In addition, there is concern in some circles that
repeated testing of cable may cause deterioration of the
insulation. An underlying problem is the lack of experimental
data or information to validate either of these arguments.
6.9.10. DC Hi-pot leakage current
Another difficulty arises when trying to interpret the
Chapter 6

38
microamp current values observed during hi-pot test. The
microamp dc current is made of three components. There are
capacitance charging current, absorption current, and
conduction current.
The charging current energizes the capacitor formed by the
dielectric that exists between the conductors and ground. This
current component starts extremely high and decreases
exponentially. If the applied voltage remains stable, the
value drops to zero within a few seconds after the test
begins.
Absorption current results from the charge absorption in the
dielectric as a result of polarization of the insulation. This
current component starts high but decreases somewhat more
slowly. The current typically stabilized after 5 minutes,
although reasonably acceptable data is available after 2
minutes.
Conduction current is steady state leakage current value. This
is the current that flows over, under, around and through the
insulation.
A low value of steady state conduction current is commonly
accepted as indicating a good cable. However, a much more
through evaluation can be made by measuring the leakage
current at various voltages and plotting leakage current vs
applied voltages. If the resistance is ideal, it will not be
affected by voltage level and the relationship will be linear.
Increasing leakage current with voltage indicates that the
insulation has been weakened. As the cable ages, deteriorates,
or becomes wet, the leakage current increases dramatically for
the same applied voltage.
Leakage current values are primarily influenced by materials
and environmental conditions.
Some users are not concerned with the current level but simply
use a dc withstand test. The approach is to apply a dc voltage
level to the cable for five minutes. If the cable does not
fail, then it is accepted. This approach provides no true
information about comparative quality or stability for reuse
in the particular environment.
Other users try to look at the level of microamp leakage.
However, there are no consistent guidelines for evaluating
these current levels.
6.9.11. Time before test
The leakage current is influenced by many factors
including the physical condition of the cable, the ac strength
of the insulation, the physical and chemical condition of the
insulation material, and the amount of gas still absorbed in
the insulation system. External influences are leakage at the
ends because of improper termination, inadequate cleaning,
moisture in the air, wind velocity, and insulation
temperature. All these factors tend to increase the leakage
Chapter 6

39
current.
It is imperative that cable be stabilized at ambient
conditions before comparing results. This ensures the
temperature will be consistent, while gas and moisture will be
allowed to migrate from the insulation system.
We have evaluated cable tested within two hours after removal
from a well. When the same type cable was exposed to the same
test well conditions during simultaneous tests, but was
allowed to set for 5 days after removal, the test results
indicated much better quality.
The cables evaluated in this test had 75 mil EPDM insulation,
a barrier, 60 mil EPDM jacket, and galvanized steel armor.
Subsequent investigations were made using different materials
for barrier.
Representative migohmmeter results taken two hours after
removal from the well are as below.
Megohmmter values
Phase
Mohms @
1000 v
Mohms @
5000 v
A-B 20,000 15,000
B-C 20,000 16,000
C-A 20,000 14,000
C-G 20,000 9,000
B-G 20,000 10,000
A-G 20,000 11,000
The magohmmeter values indicate the wet cable would be
expected to be good even though the 5000 v megohmmeter values
indicate some deterioration of the cable insulation system.
The cables were then subjected to a high potential as test at
two hours and five days after removal. The test was halted
when the insulation failed for the voltage exceeded the
termination rating.
Leakage Current and ac breakdown strength after delays
Material
Two hours Five days
kV ma kV ma
Alpha 34 21 39 10
Alpha 34 20 42 16
Alpha 44 28 52 16
Beta 30 24 100 24
Gamma 32 23 48 19
Gamma 28 32 48 16
Although the magnitude of the results was different for the
various materials, the effect was identical. All the cables
failed at low levels when energized immediately after pulling.
When the cable was allowed to dry, the results were very
different. The five day results show values as good as any
used cable has been evaluated.
Chapter 6

40
6.10. Cable Nomenclature
Insulation
o Reda
PPE or P = Polypropylene /ethylene
E = EPDM (ethylene propylene dienemethylene)
K = Polyimide (Kapton)
T = Semi-conductive tape(RedaSurface)
o Centrilift
P = Polypropylene
E = EPDM (ethylene propylene dienemethylene)
T = Thermolpastic
Barrier
o Reda
S = Extruded polyvinylidene fluoride
(PVDF or Solef)
TB-300 = Tape & braid polyvinyl fluoride
(PVF or Tedlar)
F = Extruded fluoropolymer (FEP)
TB-400 = Proprietary high temperature tape/braid
L = Lead
o Centrilift
L = Lead
Jacket
o Reda
PE = High density polyethylene (HDPE)
N = Nitrile (Oil resistant nitrile rubber compound)
E = EPDM (EPDM rubber compound)
o Centrilift
E = EPDM (EPDM rubber compound)
N = Nitrile (Oil resistant nitrile rubber compound)
T = Thermoplastic
Armor (General)
G = Galvanized steel
HG = Heavy galvanized steel
GG = Double galvanized (two layers)
SS = Stainless steel
M = Monel
= Standard interlocking profile
FP = Flat profile armor
Voltage rating and cable geometry (General)
3, 4, 5, 8 = Voltage rating (kV)
F = Flat cable configuration
R = Round cable configuration
Chapter 6

41
Cable Size (General)
#1 = AWG # 1 (American Wire Gauge # 1)
6.11. Cable families and designation examples
Reda
- Redalene
Description
All cable designs in the Redalene family utilize
polypropylene insulation (designated P or PPE) and an oil-
resistant nitrile jacket (designated O).
Features
o Temperature
The maximum conductor temperature is 205F [96C].
o Conductor
The conductors are made of alloy-coated copper. The alloy
coating provides corrosion protection for the copper and
improves long-term electrical properties of the
insulation.
o Insulation
Polypropylene
o Barrier
Tape and braid. Barrier prevents failure from chemical
attack and gas decompression, ensuring superior
performance in wells with hostile environments or wells
with high gas/oil ratios.
o Jacket
Nitrile rubber compound with exceptional physical
properties and oil resistance is used.
o Armor
Cable armor made from steel strips featuring a galvanized
coating on all sides is the standard. The use of one of
many armor options can improve resistance to corrosion and
mechanical damage.

POTB POTB
PPEO PPEO

Chapter 6

42
Redalene: 205F (96C)
- Redahot
Description
All cable designs in the Redahot family utilize a
proprietary EPDM insulation (designated E) and an oil-
resistant nitrile jacket (designated O).
Features
o Temperature
The maximum conductor temperature is 220 to 350F [121
to 177C]. The temperature rating is based on the options
selected.
o Conductor
The conductors are made of alloy-coated copper. The alloy
coating provides corrosion protection for the copper and
prevents degradation of the adhesive bond between the
conductor and the EPDM (ethylene propylene diene
methylene) insulation.
o Insulation
EPDM insulation compounds provide the optimum combination
of electrical, physical and chemical properties.

o Barrier
Tape and braid. Barrier prevents failure from attack and
gas decompression, ensuring superior performance in wells
with hostile environments and wells with high gas/oil
ratios.
o Jacket
Nitrile rubber compounds with exceptional physical
properties and oil resistance.
o Armor
Cable armor made from steel strips featuring a galvanized
coating on all sides is the standard. The use of one of
many armor options can improve resistance to corrosion and
mechanical damage.
ETBO

Redahot: 250-350F (121-177C)
Chapter 6

43
- Redablack
Description
All cable designs in the Redablack family utilize a
patented EPDM insulation formulation (designated E) and a
patented EPDM jacket (designated E).
Features
o Temperature
The conductor temperature range is 300F to 400F [149F
to 204FC]. The temperature rating is based on the
options selected.
o Conductor
alloy coating provides corrosion protection for the
copper and prevents degradation of the adhesive bond
between the conductor and the EPDM (ethylene propylene
diene methylene) insulation.
o Insulation
EPDM insulation compounds provide the optimum
combination of electrical, physical and chemical
properties.
o Barrier
Tape and braid. Barrier prevents failures from chemical
attack and gas decompression, ensuring superior
performance in high-temperature wells with hostile
environments or wells with high gas/oil ratios.
o Jacket
The patented EPDM rubber jacket compounds provide
exceptional physical properties and temperature
capabilities.
o Armor
galvanized coating on all sides is the standard. The use
of one of many armor options can improve resistance to
gas, corrosion and mechanical damage.
EER EER
ETBEF ETBEF

REDABLACK: 300-400F (149-204C)
- Redablead
Chapter 6

44
Description
All cable designs in the Redalead family utilize a
patented EPDM insulation formulation (designated E) and
an impervious lead barrier (designated L).
Features
o Temperature range
The conductor temperature range is 400 to 450F [203
to 232C].
o Conductor
alloy coating provides corrosion protection for the
copper and prevents degradation of the adhesive bond
between the conductor and the EPDM (ethylene propylene
diene methylene) insulation.
o Insulation
EPDM provide the optimum combination of electrical,
physical and chemical properties.
o Barrier
The fatigue and corrosion-resistant lead has an
impervious lead barrier that prevents failure from
chemical attack and gas decompression, ensuring
superior performance in high-temperature wells with
hostile environments or wells with high gas/oil ratios.
o Jacket
Additional barriers and various jacket types are
available to prevent mechanical damage and to maximize
cable run life
o Armor
galvanized coating on all sides is the standard. The
use of one of many armor options can improve resistance
to gas, corrosion and mechanical damag
ELBE ELB

Redalead: 400-450F (203-232C)
Chapter 6

45

Motorleads: 250-450F(121-232C)

Centrilift
- Centriline CTT Cable (Centriline Thermoplastic
Thermoplastic)
Centriline CTT cable is designed for a maximum
operating temperature of 190F (88C) and can
be safely installed at temperatures as low as -
40F (-40C). This product is one of the most
cost effective cables in the Centriline cable
family.
The high dielectric electrical grade
thermoplastic insulation is formulated for
down-hole applications. Another layer of
electrical grade thermoplastic is applied over
the insulation as a jacket that adds physical
protection.
This cable can be used in shallow wells,
marginal oil wells and water well applications
where large quantities of CO
2
, and/or light
ends are not an issue. The CTT design is
available in a flat configuration for wells
with marginal clearance.
Galvanized steel armor provides an overall protection to
the cables. It is recommended that cable protectors be
used in highly deviated wells or wells with minimal
clearance.
CTT FLAT CABLE
1- Armor: Galvanized Steel
2- Jacket: Electrical Grade Thermoplastic
3- Insulation: High Dielectric Thermoplastic
4- Conductor: Soft Drawn Tin Coated Copper (SDTC)
- Centriline CPN Cable (Centriline Polypropylene Nitrile)
Centriline CPN cable is designed for maximum operating
temperatures of 205F (96C) and can be safely
installed at temperatures as low as -30F (-34C). This
Chapter 6

46
product is one of the most cost effective cables in the
Centriline cable family.
CPN Flat Cable
1 - Armor: Galvanized Steel
2 - Jacket: Oil Resistant, Patented Flexible Nitrile
3 - Insulation: High Dielectric Polypropylene
4 - Conductor: Solid Tinned Copper
Features and Benefits
CPN Round Cable
2 - Jacket: Oil Resistant, Patented Flexible Nitrile
3 - Insulation: High Dielectric Polypropylene
4 - Conductor: Solid Tinned Copper
A specially formulated nitrile rubber jacket provides
added physical protection and reduces the possibility of
damage due to gas, heat or pressure

- Centriline CEN Round Cable (Centriline EPDM Nitrile)
Centriline CEN Round cable is designed to operate over a
temperature range from -30F (-34C) to 280F (138C).
The insulation is a specially compounded, oil resistant
EPDM rubber with proven electrical properties. An oil
resistant nitrile jacket is used to protect the
insulation. This is the most cost effective construction
for wells operating below 280F (138C) with low to
moderate gassy conditions
Round constructions have a high temperature tape over the
insulation to allow the jacket to be removed without
damage to the insulation. Galvanized steel armor provides
an overall protection to the cables.
CEN Round Cable
2 - Jacket: High Modulus, Breathable Nitrile Rubber
3 - Tape: High Temperature Tape with Phase Identification
4 - Insulation: High Dielectric, Low Swell EPDM
5 - Conductor: Solid Bare Copper
- Centriline CEE Cable (Centriline EPDM EPDM)
Centriline CEE cable is ideal for moderately gassy wells.
CEE cable features insulation compounded with oil
resistant EPDM rubber with proven electrical properties.
A patented, high module EPDM rubber jacket adds hoop
strength and allows breath-ability during decompression.
This cable is designed to operate over a broad range of
Chapter 6

47
temperatures from 60F (-51C) to 400F (204C). CEE
cables can be manufactured in special designs for
specific well conditions. CEE cable is available in a
round as well as a flat construction for wells with
marginal clearance.
CEE Flat Cable
1. Armor: Galvanized Steel
2. Tape/Braid: High Temperature Barrier Tape and
hydrolytically Stable B-400 Braid
3. Jacket: High Modulus, Breathable EPDM Rubber
4. Insulation: High Dielectric, Low Swell EPDM Rubber
o Flat construction is provided with a barrier tape and a
high temperature braid over EPDM jacket, adding hoop
strength to the product for decompression resistance.
o CEE cables can be provided with capillary cables to control safety valves or inject
chemicals.
CEE Round Cable
2 - Jacket: High Modulus, Breathable EPDM Rubber
3 - Tape: High Temperature Barrier Tape
4 - Insulation: High Dielectric, Low Swell EPDM Rubber
o Round constructions have a high
temperature tape over the insulation to
allow the jacket to be removed without
damage to the insulation. Additional tape
and braid can be added to provide hoop
strength.
o Galvanized steel armor provides overall
protection for the cable. Cables can be
provided with special armors and
configurations to meet different well
requirements
- Centriline Duralead CPL (Centriline
Polypropylene Lead) Following extensive
testing at the Cable Development Center,
Centriline Duralead CPLF cable has been
rated to operate in a wide temperature
range* from -40F (-40C) to 257F (125C). The
insulation is a specially compounded polypropylene with
proven electrical properties. A fatigue and corrosion
resistant lead sheath is used over the insulation, which
is imperious to chemical or gas penetration. The lead
sheath prevents decompression and is ideal for wells that
are gassy and have high levels of CO
2
or H
2
S.
Using new technology, the galvanized steel armor is
Chapter 6

48
directly wrapped over the lead sheath. This armor has
been edge coated on all four sides, providing the best
corrosion protection. CPL is tested according to IEEE
1019 and API 11S6 and has 90 mil insulation tested to 5kV
standards. CPL has met rigorous repetitive bend testing
requirements. It is recommended that cable protectors be
used in highly deviated wells or wells with minimal
clearance. CPL cable is available with special armors as
required for different well conditions.
CPL FLAT CABLE
1- Armor: Galvanized steel
2- Lead Sheath: Lead sheath barrier, impervious to fluids
and gas
3- Insulation: High dielectric polypropylene
4- Conductor: Solid tinned copper
Example (cable selection)
In the example of chapter 2 (ESP motor), Motor is rated 120
hp, 60 HZ, 2270 v, 32.5 Amp
Pump Load is 104 hp
Motor operating current = (104/ 120) * 32.5 = 28.1 amp.
Choose a cable size with a volts drop < 30v/1000 ft

Choose #6 AWG cable
Voltage drop at 32.5 amps = 20 volts/1000 ft
Correct for Temp. [(160+100)/2]= 130 Deg F) = 20 * 1.12 = 22.4
volts/1000 ft
We have 5500 ft of cable allowing for 100 ft at surface
Chapter 6

49
Voltage drop = 5.6 * 22.4 = 126 volts
Surface Voltage required = 2270(motor) +126= 2396 v.

Calculate the conductor temperature using the motor amperage
and the maximum well temperature,

T I
a
T well C
+ =
2
*
O
F
Select Reda hot round cable (275
o
F), then check the conductor
temperature,
I = 32.5 A, T
well
= 160
O
F, cable is AWG# 6 Reda hot type
a = 0.02 (from Reda issued table)
T
c
= 0.02 x (32.5)
2
+ 160 = 181
O
F
Cable Type
Conductor Size (AWG)
6 4 2 1 1/0 2/0
Redablack Flat (EEF) 0.0275 0.0167 0.0086 0.0064 0.005 0.0039
Redablack Round (EER) 0.0199 0.0115 0.0058 0.0043 0.0032 0.0025
Redalead Flat (ELB) 0.0281 0.0169 0.0086 0.0064 0.005 0.0039
Redalead Round (ELBE) 0.0202 0.0116 0.0058 0.0042 0.0031 0.0025
Redablack Flat (ETBE-300F) 0.0275 0.0167 0.0086 0.0064 0.005 0.0039
Redahot Round (ETBO) 0.02 0.0117 0.0062 0.0046 0.0034 0.0027
Motorlead (KELB) 0.0281 0.0169 0.0086 0.0064 0.005 0.0039
Low Temperature Motorlead (KEOTB) 0.0275 0.0169 0.009 0.0068 0.0053 0.0042
Redalene Flat (POTB) 0.0281 0.0176 0.0097 0.007 0.0048 0.0038
Redalene Round (PPEO) 0.0199 0.0112 0.0062 0.0045 0.0031 0.0025
The maximum carrying capacity of a cable can be calculated
using the following equation:
a
BHT
T
I
C

=
max
max

Chapter 6

50
I
max
= [(275-160)/0.02]
0.5
= 75.8 Amps

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Electric Submersible Pumps Mohamed Dewidar 2013

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