ESP Power Cable

Design and Application

m.Dewidar
 General Concept
 Power is supplied to the electric motor by
electric cable.
 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 Cable Flat Cable

Round Cable injection tube Flat Cable injection tube

 Cable Construction
Cable construction mainly consists of:
 Three copper conductors.
 Insulation
 Barrier
 Jacket
 Armor
 Injection
Tube (Option)
 Cable Construction
 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.
Conductor configurations
Conductor is configured in three types,
 SOLID

 Stranded

 Compacted


Cable Construction

Solid Stranded Compacted

 Cable Construction
 Insulation
The purpose of the insulation is to meet kv
rating required (phase to phase) in
addition, to provide protection to the
current carrying conductors from attack from
well fluids which will result in a short
down-hole circuit.


 Cable Construction
 Insulation Types
 Polypropylene Copolymer (Thermoplastic)
(used in cables for lower temperature applications)
 Advantages

 Excellent resistance to well fluids

 Excellent electrical properties

 Low cost

 Disadvantages

 Upper temperature range, softens at 205°F (96°C)

 Subject to crazing in certain environments


 Cable Construction
Insulation Types
 EPDM (Ethylene Propylene Diene Methylene)
used in cables for higher temperature applications
 Advantages

 Excellent high-temperature stability has been used at

up to 550°F (288°C) 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.


 Cable Construction
 Barrier (tape and Braid)
The 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.

 Cable Construction
 Barrier Selection
Factors to be considered are:
 Temperature

 Chemical environment

 Gas

 Handling

 Barrier Types
 Polyvinyl dine Fluoride Extrusion - 300°F (150°C)

 TEDLAR™ tape - 300°F (150°C)

 TEFLON™ FEP Extrusion - 350°F (175°C)

 High Temperature tape - 400°F (205°C)

 Lead - 550°F (288°C)

 Cable Construction
 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.

 Cable Construction
 Jacket Types
 Polyvinyl 185°F (85°C), High Density Polyethylene (HDPE)

 275°F (135°C), NITRILE*

 >350°F (176°C), EPDM

* Some manufacturer produce another types of Nitriles worked at

250 °F and 350 °F.

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* Greater than
275°F/135°C 350°F/176°C
 Cable Construction
 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 Types
 Standard galvanized armor(GSA, 0.020"/0.51mm and
0.025"/ 0.64 mm thick)
 Heavy galvanize steel (0.034"/0.86mm thick)

 Stainless steel

 Monel
 Cable Construction
 Armor Configurations
 Standard crown profile interlocked

 Flat profile interlock

 Flat profile
 Cable Construction
 Factors to be considered in armor selection
 Damage resistance

 Decompression containment

 Corrosion resistance

 Casing and tubing coupling sizes

 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

 Conductor AWG
 American Wire Gauge (AWG)
 AWG # 1

 Solid

Conductor size 1
Area 42.408 mm^2 (square-mm)
Diameter 289.3 mil
Diameter 7.348 mm
DC-resistance 0.000407 Ohm/m
Tensile strength 1272.23 kgf (2)
Weight 377.004 kg/km (Cu)
Conductor AWG
Number of wires in Stranded
Conductor
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 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
 Voltage Drop
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.
 Voltage Drop
Each manufacturer issues the voltage drop
curves for their cables conductor at
certain temperature, the following curves
represent an example (Reda),
 Voltage Drop
Voltage Drop for Reda Cables @ 77 OF

60

50
Voltage Drop volts/kft

40

30 AWG 6 AWG 4 AWG 2 AWG 1

20

10

0
0 20 40 60 80 100 120 140

Motor Amps

AWG #6 AWG #4 AWG #2 AWG #1

 Voltage Drop
For example,
if the motor amperage (name plate) is 100 amp so,
The voltage drop of conductor size AWG# 1 is 17.75
volts.
The voltage drop of conductor size AWG# 2 is 28.59
volts.
The voltage drop of conductor size AWG# 4 is 42.29
volts.
The voltage drop of conductor size AWG# 6 is 69.33
volts.
 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.
Correction of Voltage Drop
for Temperature
The issued voltage drop curves (by
manufacturers) are at certain
temperature (20 OC [68 OF] or 25 OC
[77 OF), so the voltage drop must be
corrected to the conductor
temperature.
Correction of Voltage Drop
for Temperature
The following steps are used for the corrections:
 Calculate the conductor temperature using the motor
amperage and the maximum well temperature,

 a * I  T well
2
T C OF
TC = Conductor temperature
I = Motor amperage
a = Factor for each cable size (issued by
manufacturer)
Twell = Maximum well temperature
Maximum Carrying Capacity of the
Cable Imax
Conductor Size (AWG)
Cable Type
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 0.0050 0.0039

Redalead Round () 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 0.0050 0.0039

Redablack Round (ETBE-400) 0.0199 0.0115 0.0058 0.0043 0.0032 0.0025

Redahot Round (ETBO) 0.0200 0.0117 0.0062 0.0046 0.0034 0.0027

Motorlead (KELB) 0.0281 0.0169 0.0086 0.0064 0.0050 0.0039

Low Temperature Motorlead (KEOTB) 0.0275 0.0169 0.0090 0.0068 0.0053 0.0042

Redalene Flat (POTB) 0.0281 0.0176 0.0097 0.0070 0.0048 0.0038

Redalene Round (PPEO) 0.0199 0.0112 0.0062 0.0045 0.0031 0.0025

 Correction of Voltage Drop
for 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

V adj
 V a  (1  0.00214  (T C  77))
Vadj = Adjusted voltage drop
Va = Voltage drop from the curve
 Correction of Voltage Drop
for Temperature
Example:
I = 50 A, Twell = 200 OF, cable is AWG# 4 Reda hot
type
a = 0.0117 (from Reda issued table)
Tc = 0.0117 x (50)2 + 200 = 229 OF
Vadj = 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
instead of using the previous equation. For example, the
following table is issued by Centrilift for their cable:
Correction of Voltage Drop
for Temperature
Temp. OF Corr. factor Temp. OF 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
Maximum Carrying Capacity of the
Cable Imax
The maximum carrying capacity of a cable can be
calculated using the following equation:
T max  BHT
I max
 C
a

Tcmax= Maximum conductor temperature OF

BHT = Bottom hole temperature OF
a = Current temperature factor (an example here is
below Reda current temperature factor table for
their cables)
Maximum Carrying Capacity of the
Cable Imax
Conductor Size (AWG)
Cable Type
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 0.0050 0.0039

Redalead Round () 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 0.0050 0.0039

Redablack Round (ETBE-400) 0.0199 0.0115 0.0058 0.0043 0.0032 0.0025

Redahot Round (ETBO) 0.0200 0.0117 0.0062 0.0046 0.0034 0.0027

Motorlead (KELB) 0.0281 0.0169 0.0086 0.0064 0.0050 0.0039

Low Temperature Motorlead (KEOTB) 0.0275 0.0169 0.0090 0.0068 0.0053 0.0042

Redalene Flat (POTB) 0.0281 0.0176 0.0097 0.0070 0.0048 0.0038

Redalene Round (PPEO) 0.0199 0.0112 0.0062 0.0045 0.0031 0.0025

Maximum Carrying Capacity of the
Cable Imax
Cable type Max. OF 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 0.0100 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

Maximum Carrying Capacity of the
Cable Imax
Example:
The maximum current carrying capacity for Reda black
round 400 OF (ETBE) size AWG #2 at bottom hole
temperature 200 OF is :
T max  BHT 400  200
I max
 C
= = 185.7 Amps.
a 0.0058

400  200
for size AWG #4 = 131.9 Amps.
0.0115
Maximum Carrying Capacity of the
Cable Imax
The maximum carrying capacity of a cable can be
calculated using the following equation:
T max  BHT
I max
 C
a

Tcmax= Maximum conductor temperature OF

BHT = Bottom hole temperature OF
A = Current temperature factor (an example here is
below Reda current temperature factor table for
their cables)
 Maximum Carrying Capacity
Ampacity Chart Imax
Centrilift CEEF
350

300
Maximum Conductor Current (Ampere)

250

#2/0 AWG
200 #1/0 AWG
#1 AWG
#2 AWG

150 #4 AWG
#6 AWG

100

50

0
0 50 100 150 200 250 300 350 400 450
Maximum Well Temperature (°F)
 Maximum Carrying Capacity
Ampacity Chart Imax
Redablack Round (ETBE-400)
450

400

350
Maximum Conductor Current (Ampere)

300
#2/0 AWG

250 #1/0 AWG

#1 AWG
#2 AWG
200 #4 AWG
#6 AWG

150

100

50

0
0 50 100 150 200 250 300 350 400 450
Maximum Well Temperature (°F)
 Method of Selecting Wire Size
and Type
 The 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 VD’s are at 77 OF.
 Method of Selecting Wire Size
and Type
Voltage Drop for Reda Cables @ 77 OF

60

50
Voltage Drop volts/kft

40

30 AWG 6 AWG 4 AWG 2 AWG 1

20

10

0
0 20 40 60 80 100 120 140

Motor Amps

AWG #6 AWG #4 AWG #2 AWG #1

 Method of Selecting Wire Size
and Type
The Adjust VD for the selected cable to the down hole
well temperature, suppose that the average DHT is 200
OF, then,

V adj
 V a  (1  0.00214  (T C  77))
Vadj = 28.59 x (1+0.00214(200-77)) = 36.1 volt/1000’
Vadj > 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,
Vadj = 17.75 x (1+0.00214(200-77)) = 22.4 volt/1000’

Adjust conductor temperature based on the well DHT as follows,

 a * I  T well
2 OF
T C

=0.0058 x 1002 + 200 = 258 OF