Esp cable insulation repair method for uniform insulation thickness

Abstract

Aspects of the present disclosure provide a method for insulating a cable. The method including applying a plurality of layers of an insulating material around a portion of a conductor of a cable, at least one layer of the plurality of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator, curing the plurality of layers to form an insulation layer having an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, and determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

Description

ESP CABLE INSULATION REPAIR METHOD FOR UNIFORM INSULATIONTHICKNESSCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 554519. filed February 16, 2024, which is incorporated by reference herein in its entirety.BACKGROUND

[0002] The present disclosure generally relates to the field of cables for use in the Oil & Gas industry'. Cables can be used to transmit power and / or information to and from equipment. For instance, cables can be used to transmit power and / or information to Electrical Submersible Pumps (ESPs). ESP cables include individually insulated conductors. Occasionally, during the manufacturing process the individually insulated conductors need to be insulated or re-insulated. In some instances, the insulated conductors need to be spliced together and the spliced portion needs to be re-insulated. In some instances, the insulated conductors are damaged and need to be re-insulated during repair. Reinsulating the conductors requires stripping and seamlessly reapplying insulation. When applying insulation, it is important that the insulation is applied seamlessly and uniformly. Thus, there is a need in the art for improvements in applying insulation to cables.SUMMARY

[0003] Aspects of the present disclosure provide, a method for insulating a cable. The method including applying a plurality of layers of an insulating material around a portion of a conductor of a cable, at least one layer of the plurality7of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator, curing the plurality of layers to form an insulation layer having an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, and determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

[0004] Aspects of the present disclosure provide a method for insulating a conductor of a cable. The method including applying a first layer of an insulating material including a first visual indicator around a portion of a conductor of a cable, wherein the applied first layer has a first layer thickness and a first layer outer diameter, applying a second layer of the insulating material including a second visual indicator about the first layer, curing the first layer and the second layer to form an insulation layer, the insulation layer including an outer diameter and an insulation layer thickness, reducing the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, wherein the first layer outer diameter is the desired diameter and the first layer thickness is the desired insulation layer thickness, and determining the outer diameter of the insulation layer has reached the desired diameter and the insulation layer thickness has reached the desired insulation layer thickness based on an appearance of the first visual indicator.

[0005] Aspects of the present disclosure provide A method for insulating a conductor of a cable. The method including removing a portion of insulation from a cable to expose a portion of a conductor of a cable, preparing the exposed portion of the conductor, applying a plurality of layers of an insulating material around the exposed portion of the conductor, at least one layer of the plurality7of layers including a first visual indicator, at least another layer of the plurality7of layers including a second visual indicator, curing the plurality of layers to form an insulation layer having an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.BRIEF DESCRIPTION OF DRAWINGS

[0006] So that the manner in which the above-recited features of the disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this disclosure and are therefore not to be considered limiting of its scope, for the disclosure may admit to other equally effective embodiments. Similarly, it is to be noted that the appended drawings may not be to scale.

[0007] Figure 1 illustrates an exemplary artificial lift system including an Electrical Submersible Pump (ESP) coupled to equipment via a cable, according to one or more embodiments.

[0008] Figure 2 illustrates a front cross-sectional view of an exemplary insulated conductor, according to one or more embodiments.

[0009] Figure 3 illustrates a method for insulating the conductor resulting in uniform insulation thickness, according to one or more embodiments.

[0010] Figures 4A-4C illustrate side-cross sectional views of the cable of Figure 2 taken at line 4-4 of the conductor during the method of Figure 3, according to one or more embodiments.

[0011] Figure 5 A illustrates a front cross-sectional view of an exemplary conductor including plurality of layers of insulating material, according to one or more embodiments.

[0012] Figure 5B illustrates a front cross-sectional view of another exemplary conductor including plurality of layers of insulating material, according to one or more embodiments.

[0013] Figure 5C illustrates a front cross-sectional view of another exemplary' conductor including a plurality of layers of insulating material, according to one or more embodiments.

[0014] To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures, ft is contemplated that elements disclosed in one embodiment may be beneficially utilized on other embodiments without specific recitation.DETAILED DESCRIPTION

[0015] The disclosure contemplates that terms such as "‘couples,” “coupling,” “couple,” and “coupled” may include but are not limited to welding, interference fitting, and / or fastening such as by using bolts, threaded connections, pins, clips, and / or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling.” “couple,” and “coupled” mayinclude but are not limited to direct coupling and / or indirect coupling, such as indirect coupling through components such as links.

[0016] For the sake of brevity, all similar components have been given similar reference numbers with the same last two digits and a full description of such similar components may not be repeated herein. Similarly, for the sake of brevity, all like components or layers have been given the same reference numbers, and a full description of such components may not be repeated herein.

[0017] Aspects of the present disclosure provide a method for insulating a conductor of a cable. In one or more embodiments, insulating the conductor of the cable includes applying a plurality of layers of an insulating material around a portion of the conductor of the cable, curing the plurality of layers to form an insulation layer with an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter for the insulation layer to a desired diameter while maintaining a desired insulation thickness, and determining the desired diameter has been reached and the desired insulation thickness has been maintained. At least one layer of the plurality of layers including a first visual indicator and at least another layer of the plurality of layers including a second visual indicator. Determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

[0018] Figure 1 illustrates an exemplary artificial lift system 100 including equipment 101 disposed on a surface 102. The equipment 101 is used to manipulate (e.g, lower and control) a pump system 103, such as an Electrical Submersible Pump (ESP) system 103, disposed in a wellbore 104. The ESP system 103 may be used for a variety7of pumping purposes, such as pumping fluid from the wellbore 104 to the surface 102.

[0019] A cable 105 electrically couples the ESP system 103 and the equipment 101. In one or more embodiments, the cable 105 electrically couples a motor of the ESP system 103 with the equipment 101 and the motor powers a pump of the ESP system 103. The cable 105 may transmit power and / or information between the ESP system 103 and the equipment 101. In one or more embodiments, the cable 105 may power, operate, manipulate, or transmit information to and / or from the ESP system 103 and / or one or more components of the ESP system 103.

[0020] Although the illustrated embodiment illustrates an ESP system 103 disposed in a wellbore 104 for pumping fluid from the wellbore 104 to the surface 102, it is contemplated, that the cable 105 of the present disclosure may electrically couple and transmit power and / or information between any equipment. Similarly, although the illustrated embodiment illustrates the cable 105 running through the wellbore 104. the cable 105 may be run next to production tubing in the wellbore 104.

[0021] The cable 105 is made of one or more insulated conductors (such as insulated conductor 205 of Figure 2). In one or more embodiments, the cable 105 includes three insulated conductors. The one or more insulated layers may include lead around the outer diameter of the insulation. The one or more insulated conductors are then surrounded with an external layer (e.g., an armor layer). In one or more embodiments, the insulated conductors are laid flat next to one another and the armor layer surrounds the insulated conductors. In one or more embodiments, the insulated conductors are wound around one another with an extruded polymer jacket, and then surrounded with the armor layer.

[0022] Figure 2 illustrates a front cross-sectional view of an exemplary insulated conductor 205 of an ESP cable (such as cable 105 of Figure 1). The insulated conductor 205 includes a conductor 206 and insulation 207. The conductor 206 is disposed inside the insulation 207. The conductor 206 conducts power and / or information along the insulated conductor 205. Accordingly, the conductor 206 is made of a conductive material. In one or more embodiments, the conductor 206 is made of copper. In one or more embodiments, the conductor 206 may be of a solid, stranded, or compact stranded type.

[0023] The insulation 207 insulates the conductor 206 such that the insulation 207 prevents exposure of the conductor 206 to the environment surrounding the insulated conductor 205. For example, the insulation 207 may seamlessly encapsulate the conductor 206. In one or more embodiments, the insulation 207 electrically insulates the conductor 206 from the environment such that the insulated conductor 205 efficiently conducts power and / or information. In one or more embodiments, the insulation 207 protects the conductor from external loading including, but not limited to, bending loading, compressive loading, tension loading, and side loading. In one or more embodiments, the insulation 207 protects the conductor 206 from environmental factors including, but not limited to, fluid, high and / or low temperatures, and high and / or lowpressures. In one or more embodiments, the insulation 207 is made of a cured material, such as ethylene propylene diene monomer rubber (EPDM) 290. In one or more embodiments, uncured insulation, such as EPDM 290, is extruded onto the conductor 206 and is then heat treated to cure the EPDM 290 to form the insulation 207. EPDM 290.

[0024] In one or more embodiments, the insulated conductor 205 further includes an adhesive layer 208. The adhesive layer 208 is disposed between the conductor 206 and the insulation 207. The adhesive layer 208 is used to facilitate the bond between the conductor 206 and the insulation 207. In one or more embodiments, the adhesive layer 208 is an elastomer and is extruded with the insulation 207. In one or more embodiments, the adhesive layer is a solvent based adhesive (e.g., chemlock 250), that may be applied to the conductor directly. In such embodiments, the adhesive layer 208 may be dried before extruding the insulation layer 207.

[0025] Figure 3 illustrates a method 300 for insulating an insulated conductor of a cable (such as insulated conductor 205 of Figure 2) resulting in a uniform insulation thickness.

[0026] Occasionally, a portion of the insulated conductor needs to be seamlessly reinsulated. In some instances, a portion of the insulation (such as insulation 207 of Figure 2) of the insulated conductor may get damaged and the insulated conductor needs to be re-insulated. In one or more embodiments, the insulated conductor may get damaged during manufacturing. In one or more embodiments, an insulated conductor needs to be spliced such that the conductor (such as conductor 206) of one insulated conductor is electrically coupled to the conductor of another insulated conductor to create a continuous insulated conductor (such as by cold-welding). After splicing the insulated conductor, the spliced portion needs to be re-insulated.

[0027] Properly insulating and / or reinsulating insulated conductors requires that the insulation be applied uniformly and requires that the diameter of the insulated conductor be within a specification (e.g., a nominal diameter plus or minus a tolerance). In one or more embodiments, uniform application of insulation includes ensuring the insulation is of a uniform thickness around the conductor. During application or re-application of insulation, the insulation is cured and then a portion of the outer diameter is removed (e.g.. sanded or ground down) to meet the specified requirement. However, if theconductor is out of center within the cured insulation, removing the portion of the outer diameter of the insulation to achieve the specified diameter results in non-uniform insulation thickness. Non-uniform insulation thickness can lead to high voltage stress and electrical weak spots in the insulated conductor.

[0028] The present disclosure provides for a method 300 for insulating an insulated conductor (such as insulated conductor 205 of Figure 2) resulting in a uniform insulation thickness. Figures 4A-4C visually depict the method 300 of Figure 3. Figure 4A illustrates a side cross-sectional view of the insulated conductor 205 taken along line 4-4 of Figure 2 visually depicting operation 301. Figure 4B illustrates a side cross-sectional view of the insulated conductor 205 taken along line 4-4 of Figure 2 visually depicting operations 302-304. Figure 4C illustrates a side cross-sectional view of the insulated conductor 205 taken along line 4-4 of Figure 2 visually depicting operations 305-306.

[0029] At operation 301 , the insulation 207 is removed to expose a portion 409 of the conductor 206. In embodiments including the adhesive layer 208, the adhesive layer 208 is also removed to expose the portion 409 of the conductor 206. In one or more embodiments, the insulation 207 and adhesive layer 208 are tapered down to the conductor 206, as illustrated. In one or more embodiments, the taper may be any length such that sufficient room is left in the tapered section so that the exposed tie layer 208 extends just past the exposed conductor 206 and the exposed insulation layer 207 would extend further beyond the exposed adhesive layer 208 on either side. In such embodiments, including such taper “steps,” ensures each repaired section will have a roughly uniform diameter and will stay parallel, or substantially parallel, to the conductor 206. In one or more embodiments, removing the insulation 207 and adhesive layer 208 includes cutting the insulation 207 and adhesive layer 208. such as by cutting with a knife. In one or more embodiments, method 300 is utilized for constructing an insulated conductor 205 and removing the insulation 207 may be unnecessary.

[0030] At operation 302, the exposed portion 409 of the conductor is prepared for insulation. In one or more embodiments, method 300 for insulating an insulated conductor is used to insulate an insulated conductor after splicing the insulated conductor. In such embodiments, a first conductor portion 410 and a second conductor portion 411 are spliced together. In one or more embodiments, the first conductor portion 410 and second conductor portion 411 are spliced together by cold- welding.

[0031] In one or more embodiments, preparing the exposed portion 409 of the conductor 206 includes smoothing at least a portion of the insulation 207 and the adhesive layer 208. In some embodiments, the smoothing is accomplished using sand paper. For instance, the insulation 207 and the adhesive layer 208 may be smoothed adjacent to the exposed portion 409 of the conductor 206. In one or more embodiments, preparing the exposed portion 409 of the conductor 206 includes cleaning the exposed portion 409 of the conductor 206. In one or more embodiments, the exposed portion 409 of the conductor 206 is cleaned with a chemical, such as acetone.

[0032] In one or more embodiments, preparing the exposed portion 409 of the conductor 206 includes applying a layer of adhesive 412 to the outer surface 413 of the conductor 206 at the exposed portion 409. In one or more embodiments, the adhesive 412 may be applied past the exposed portion 409 of the conductor 206 such that the adhesive 412 extends onto the insulation 207 and adhesive layer 208 (as shown in Figure 4B). For example, in one or more embodiments, the adhesive 412 may be applied about 0 inches to about 2 inches onto the insulation 207 and adhesive layer 208. In one or more embodiments, the adhesive is applied such that each wrap of adhesive is parallel to the previous wrap of adhesive and overlaps the adjacent strip of adhesive by 50% (e.g., at a “50% overlap”). In one or more embodiments, the adhesive 412 may be an elastomer, such as a high temperature elastomer adhesive. In one or more embodiments, the adhesive 412 may be an uncured elastomer. In one or more embodiments, the uncured elastomer may be an uncured version of the adhesive layer 208.

[0033] At operation 303, a plurality of layers 414 of an insulating material are applied to (e.g., wrapped around) the exposed portion 409 of the conductor 206. At least one layer of the plurality of layers 414 includes a first visual indicator and at least another layer of the plurality of layers includes a second visual indicator.

[0034] In one or more embodiments, each layer of the plurality of layers 414 may have the equal thicknesses. In one or more embodiments, each layer of the plurality of layers 414 may have different thicknesses. In one or more embodiments, some of the layers of the plurality of layers 414 have the same thickness while others have different thicknesses.

[0035] In embodiments including the adhesive layer 412. the plurality of layers 414 are applied to the adhesive layer 412. In one or more embodiments, the plurality of layers414 are applied such that they overlap the insulation 207 and adhesive layer 208 similar to how the adhesive layer 412 can be applied. In one or more embodiments, the plurality of layers 414 are applied to have a larger diameter than the desired completed diameter of the insulated conductor 205 to account for settling and / or shrinkage of the plurality of layers 414 during curing.

[0036] According to one or more embodiments, a first layer 415 may be applied to the outer surface 413 of the conductor 206 or applied to the adhesive 412. The first layer415 is applied to the exposed portion 409 of the conductor 206 such that the first layer 415 includes a first layer outer diameter DI and includes a first layer thickness Tl. The first layer thickness Tl may be the distance between the outer surface 416 of the first layer 415 and the outer surface 413 of the conductor 206.

[0037] The first layer 415 includes the first visual indicator. The first visual indicator can be any indication that would alert an operator or device that the first layer 415 is the first layer 415. The first visual indicator can also be any indication that differentiates the first layer 415 from another layer. In one or more embodiments, the first visual indicator is a color. In one or more embodiments, the first visual indicator is a pattern. In one or more embodiments, the first visual indicator is some other marking (e.g, text).

[0038] According to one or more embodiments, a second layer 417 may be applied to the outer surface 416 of the first layer 415. The second layer 417 is applied to the first layer 415 such that the second layer 417 includes a second layer outer diameter D2 and includes a second layer thickness T2. The second layer thickness T2 may be the distance between the outer surface 416 of the first layer 415 and the outer surface 418 of the second layer 417.

[0039] The second layer 417 includes the second visual indicator. The second visual indicator can be any indication that would alert an operator or device that the second layer 417 is the second layer 417. The second visual indicator can also be any indication that differentiates the second layer 417 from another layer. In one or more embodiments, the second visual indicator is a color. In one or more embodiments, the second indicator is apattern. In one or more embodiments, the second visual indicator is some other marking (e.g., text).

[0040] In one or more embodiments, the insulating material is a polymer. In one or more embodiments, the insulating material is EPDM 290 (uncured EPDM 290). In one or more embodiments, plurality of layers 414 are each applied with a 50% overlap.

[0041] At operation 304, the plurality of layers 414 are cured to create an insulation layer 419. In one or more embodiments, the insulation layer 419 is made of EPDM 290. The insulation layer 419 may be a monolithic layer of the cured insulating material such that the insulation layer 419 is a homogenous layer of the same material. The insulation layer 419 includes an outer diameter. In one or more embodiments, the outer diameter of the insulation layer 419 is equal to the diameter of the outer-most layer of the plurality of layers 414. In one or more embodiments, the outer diameter of the insulation layer 419 is less or slightly less than the diameter of the outer-most layer of the plurality' of layers 414 due to settling or shrinkage of the plurality7of layers 414 during curing. The insulation layer 419 further includes an insulation layer thickness. In one or more embodiments, the insulation layer thickness may be equal to the total thicknesses of the plurality of layers 414. In one or more embodiments, the thickness of the insulation layer 419 is less or slightly less than the total thickness of the applied plurality7of layers 414 due to settling or shrinkage of the plurality7of layers 414 during curing.

[0042] In one or more embodiments, curing the plurality7of layers 414 includes treating the plurality7of layers 414, wrapping the plurality7of layers in baking tape, and heating the insulated conductor 205. In one or more embodiments, treating the plurality of layers includes treating the plurality of layers 414 with Translink 77. In one or more embodiments, treating the insulated conductor 205 includes heating the insulated conductor 205. In one or more embodiments, the insulated conductor 205 is heated in the oven for about 4 hours to about 6 hours, such as about 5.5 hours.

[0043] At operation 305, a portion of the insulation layer 419 is removed to reach a desired diameter and maintain a desired insulation thickness.

[0044] The desired diameter may be a nominal diameter or specified diameter for the insulated conductor 205. Removing a portion of the insulation layer 419 includesreducing the diameter. In one or more embodiments, removing a portion of the insulation layer 419 includes sanding or grinding down the insulation layer 419.

[0045] At operation 306. it is determined that the desired diameter is reached and the desired insulation thickness is maintained based on the appearance of one of the first visual indicator and the second visual indicator.

[0046] The desired diameter is equivalent to a known diameter of one layer of the plurality of layers 414 and the desired insulation thickness is equivalent to the thickness of that layer and the summation of all of the layers 414 below that layer. Said layer includes a specific visual indicator. Accordingly, the diameter of the insulation layer 419 can be reduced until said visual indicator appears around the entirety of the exposed portion 409 of the insulated conductor 205. Thus, when said visual indicator appears, a device or operator is alerted to the fact that the desired diameter and desired thickness has been reached and reduction of the diameter can be ceased. In one or more embodiments, the desired diameter may be, in fact, over a specification. Thus, the visual indicator appears when the diameter is over specification. In such instances, the visual indicator indicates to the device or operator to cease reduction of the diameter in one area and move onto reducing the diameter in another area, such as in an area 90 degrees or 180 degrees from the area where the visual indicator appeared.

[0047] As illustrated in Figure 4C, according to one example, the desired diameter may be the first layer diameter DI and the desired insulation thickness may be the first layer thickness Tl. Accordingly, the diameter can be reduced until the first visual indicator appears around the exposed portion 409 of the insulated conductor 205.

[0048] According to another example, the desired diameter may be the second layer diameter D2 and the desired insulation thickness may be the sum of the first layer thickness Tl and second layer thickness T2. Accordingly, the diameter can be reduced until the second visual indicator appears around the exposed portion 409 of the insulated conductor 205.

[0049] In one or more embodiments, multiple layers 414 include the same or similar visual indicators, the pattern of visual indicators can be monitored to track the insulation thickness and desired diameter. For instance, there may be three layers 414 and the first layer 415 and third layer include the first indicator which is different from the visualindicator of the second layer 417. In such instances, the desired diameter may correlate to the diameter of the first layer 415 and the desired insulation thickness may correlate to the thickness of the first layer 415. Accordingly, the diameter may be reduced until the first visual indicator appears a second time.

[0050] Although the above method has been described with reference to a first layer 415 including a first layer diameter DI, a first layer thickness Tl, and a first visual indicator and a second layer 417 including a second layer diameter D2, a second layer thickness T2. and a second visual indicator, it is contemplated that the above method is applicable with any number of layers 414 with any number of diameters, thicknesses, and visual indicators.

[0051] Although the above description describes, and Figures 4A-4C illustrate, only a first layer 415 and a second layer 417, it is understood that there may be any number of layers included in the plurality of layer 414 applied above and / or below the first layer 415, above and / or below the second layer 417, and in between the first layer 415 and the second layer 417.

[0052] Figures 5A-5C illustrate front cross-sectional views of exemplary insulated conductors 505a-505c taken at line 5-5 of Figure 4B. Insulated conductors 505a-505c including varying configurations of the plurality of layers 514 before the portion of the insulation layer 419 is reduced to a desired diameter while maintaining a desired insulation thickness.

[0053] Figure 5A illustrates an insulated conductor 505a similar to the one described above with respect to Figures 4A-4C. The insulated conductor 505a includes a first layer 415 with a first layer diameter DI , a first layer thickness Tl , and a first visual indicator. The insulated conductor 505a further includes a second layer 417 with a second layer diameter D2, a second layer thickness T2, and a second visual indicator different from the first visual indicator. In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505a show n in Figure 5 A may be removed to reduce the diameter of the insulated conductor 505a to be equal to the first layer diameter DI with an insulation thickness equal to the first layer insulation thickness Tl. A device or operator may determine the diameter of the insulated conductor 505a is the first layerdiameter DI and the insulation thickness is equal to the first layer insulation thickness T1 based on the appearance of the first visual indicator.

[0054] Figure 5B illustrates an insulated conductor 505b. The insulated conductor 505b includes a first layer 415 with a first layer diameter DI, a first layer thickness Tl. and a first visual indicator. The insulated conductor 505b further includes a second layer 417 with a second layer diameter D2, a second layer thickness T2, and a second visual indicator different from the first visual indicator. The insulated conductor 505b further includes a third layer 520, with a third layer diameter D3. a third layer thickness T3, and a third visual indicator different from the first visual indicator and different from the second visual indicator.

[0055] In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505b shown in Figure 5B may be removed to reduce the diameter of the insulated conductor 505b to be equal to the first layer diameter DI with an insulation layer thickness equal to the first layer thickness Tl. A device or operator may determine the diameter of the insulated conductor 505b is equal to the first layer diameter DI and the insulation thickness layer is equal to the first layer thickness Tl based on the appearance of the first visual indicator.

[0056] In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505b shown in Figure 5B may be removed to reduce the diameter of the insulated conductor 505b to be equal to the second layer diameter D2 with an insulation layer thickness equal to the sum of the first layer thickness Tl and the second layer thickness T2. A device or operator may determine the diameter of the insulated conductor 505b is equal to the second layer diameter D2 and the insulation layer thickness is equal to the sum of the first layer thickness Tl and the second layer thickness T2 based on the appearance of the second visual indicator.

[0057] Figure 5C illustrates an insulated conductor 505c. The insulated conductor 505c includes a first layer 415 with a first layer diameter DI, a first layer thickness Tl, and a first visual indicator. The insulated conductor 505c further includes a second layer 417 with a second layer diameter D2, a second layer thickness T2, and a second visual indicator different from the first visual indicator. The insulated conductor 505c further includes a third layer 520, with a third layer diameter D3. a third layer thickness T3, anda third visual indicator which is the same as the first visual indicator. The insulated conductor 505c further includes a fourth layer 521, with a fourth layer diameter D4, a fourth layer thickness T4, and a fourth visual indicator which is the same as the second visual indicator.

[0058] In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505c shown in Figure 5C may be removed to reduce the diameter of the insulated conductor 505c to be equal to the first layer diameter DI with an insulation layer thickness equal to the first layer thickness Tl. A device or operator may determine the diameter of the insulated conductor 505c is equal to the first layer diameter DI and the insulation layer thickness is equal to the first layer thickness Tl based on the appearance of the first visual indicator (e.g.. the second time the device or operator sees the visual indicator indicating that the visual layer is the first layer 415 or the third layer 520).

[0059] In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505c shown in Figure 5C may be removed to reduce the diameter of the insulated conductor 505c to be equal to the second layer diameter D2 with an insulation layer thickness equal to the sum of the first layer thickness Tl and the second layer thickness T2. A device or operator may determine the diameter of the insulated conductor 505c is equal to the second layer diameter D2 and the insulation layer thickness is equal to the sum of the first layer thickness Tl and the second layer thickness T2 based on the appearance of the second visual indicator (e.g., the second time the device or operator sees the visual indicator indicating that the visual layer is the second layer 417 or the fourth layer 521).

[0060] In one or more embodiments, a portion of the insulation layer 419 of the insulated conductor 505c shown in Figure 5C may be removed to reduce the diameter of the insulated conductor 505c to be equal to the third layer diameter D3 with an insulation layer thickness equal to the sum of the first layer thickness Tl, the second layer thickness T2, and the third layer thickness T3. A device or operator may determine the diameter of the insulated conductor 505c is equal to the third layer diameter D2 and the insulation layer thickness is equal to the sum of the first layer thickness Tl, the second layer thickness T2, and the third layer thickness T3 based on the appearance of the third visualindicator (e.g, the first time the device or operator sees the visual indicator indicating that the visual layer is the first layer 415 or the third layer 520).Example Aspects

[0061] Aspect 1 : A method for insulating a cable including: applying a plurality of layers of an insulating material around a portion of a conductor of a cable, at least one layer of the plurality of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator, curing the plurality of layers to form an insulation layer having an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, and determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

[0062] Aspect 2: The method of aspect 1. wherein the first visual indicator is a first color and the second visual indicator is a second color.

[0063] Aspect 3: The method of Aspects 1 or 2. wherein plurality of layers include a first layer including the first visual indicator and a second layer including the second visual indicator. The first layer is applied to the conductor, the first layer includes a first layer thickness and a first layer diameter. The second layer is applied to the first layer, the second layer includes a second layer thickness and a second layer diameter.

[0064] Aspect 4: The method of Aspect 3, wherein the desired diameter is the first layer diameter and the desired insulation layer thickness is the first layer thickness, and wherein determining the desired diameter has been reached and the desired insulation layer thickness has been maintained is based on the appearance of the first visual indicator.

[0065] Aspect 5: The method of Aspect 3, wherein the plurality of layers further comprise a third layer.

[0066] Aspect 6: The method of Aspect 5, wherein the desired diameter is the second layer diameter and the desired insulation layer thickness is a summation of the first layer thickness and the second layer thickness, and wherein determining the desired diameter has been reached and the desired insulation layer thickness has been maintained is based on the appearance of the second visual indicator.

[0067] Aspect 7: The method of Aspects 5 or 6. wherein the third layer includes a third visual indicator, the third visual indicator being the same as the first visual indicator.

[0068] Aspect 8: The method of Aspects 5 or 6 wherein the third layer includes a third visual indicator, the third visual indicator being different from the first visual indicator.

[0069] Aspect 9: The method of any of Aspects 1-8 further comprising applying an adhesive to the portion of the conductor and applying the plurality of layers to the adhesive.

[0070] Aspect 10: The method of any of Aspects 1-9 further comprising exposing the portion of the conductor before applying the plurality of layers.

[0071] Aspect 11 : The method of any of Aspects 1-10 further comprising splicing a first conductor portion to a second conductor portion to create the conductor before applying the plurality of layers.

[0072] Aspect 13: A method for insulating a conductor of a cable, including: applying a first layer of an insulating material including a first visual indicator around a portion of a conductor of a cable, wherein the applied first layer has a first layer thickness and a first layer outer diameter, applying a second layer of the insulating material including a second visual indicator about the first layer, curing the first layer and the second layer to form an insulation layer, the insulation layer including an outer diameter and an insulation layer thickness, reducing the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, wherein the first layer outer diameter is the desired diameter and the first layer thickness is the desired insulation layer thickness, and determining the outer diameter of the insulation layer has reached the desired diameter and the insulation layer thickness has reached the desired insulation layer thickness based on an appearance of the first visual indicator.

[0073] Aspect 14: The method of Aspect 13 further comprising applying a third layer of the insulating material about the second layer, the third layer including a third visual indicator.

[0074] Aspect 15: The method of Aspect 14, wherein the third visual indicator is the same as the first visual indicator.

[0075] Aspect 16: The method of Aspect 14, wherein the third visual indicator is different from the first visual indicator.

[0076] Aspect 17: The method of any of Aspects 13-16. wherein the first visual indicator is a first color and the second visual indicator is a second color.

[0077] Aspect 18: A method for insulating a conductor of a cable, including: removing a portion of insulation from a cable to expose a portion of a conductor of a cable, preparing the exposed portion of the conductor, applying a plurality of layers of an insulating material around the exposed portion of the conductor, at least one layer of the plurality of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator, curing the plurality of layers to form an insulation layer having an outer diameter, removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, determining the desired diameter has been reached and the desired insulation thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

[0078] Aspect 19: The method of Aspect 18, wherein preparing the exposed portion of the conductor comprises applying an adhesive to the exposed portion of the conductor, the adhesive extending onto the insulation adjacent the exposed portion of the conductor.

[0079] Aspect 20: The method of Aspect 18 or 19, wherein the first visual indicator is a first color and the second visual indicator is a second color.

[0080] Any one or more components of insulated conductors 205, and 505a-c may be integrally formed together, directly coupled together, and / or indirectly coupled together and are not limited to the specific arrangement of components illustrated in Figures 1-2 and 4-5. Any one or more of the embodiments of the insulated conductors 205 and 505a- 505c may be combined in whole or part with any one or more of the embodiments of the insulated conductors 205 and 505a-505c.

[0081] The methods disclosed herein comprise one or more actions for achieving the methods. The method actions may be interchanged with one another without departing from the scope of the claims. In other words, unless a specific order of actions is specified, the order and / or use of specific actions may be modified without departing from the scope of the claims. Further, the various operations of methods described above maybe performed by any suitable means capable of performing the corresponding functions.

[0082] As used herein, the term ‘‘determining’" encompasses a wide variety of actions. For example, “determining” may include calculating, computing, processing, deriving.investigating, looking up (e.g.. looking up in a table, a database or another data structure), ascertaining and the like. Also, ’‘determining” may include receiving (e.g., receiving information), accessing (e.g., accessing data in a memory) and the like. Also, “determining” may include resolving, selecting, choosing, establishing and the like.

[0083] As used herein, a phrase referring to “at least one of’ a list of items refers to any combination of those items, including single members. As an example, “at least one of: a. b, or c” is intended to cover a. b, c. a-b, a-c. b-c, and a-b-c, as well as any combination with multiples of the same element (e.g., a-a, a-a-a, a-a-b, a-a-c, a-b-b, a-c-c, b-b, b-b-b, b-b-c, c-c, and c-c-c or any other ordering of a, b, and c).

[0084] While the present disclosure has been described with respect to a number of embodiments and examples, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope and spirit of the present disclosure.

[0085] The preceding description is provided to enable any person skilled in the art to practice the various aspects described herein. The examples discussed herein are not limiting of the scope, applicability, or aspects set forth in the claims. Various modifications to these aspects will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other aspects. For example, changes may be made in the function and arrangement of elements discussed without departing from the scope of the disclosure. Various examples may omit, substitute, or add various procedures or components as appropriate. For instance, the methods described may be performed in an order different from that described, and various actions may be added, omitted, or combined. Also, features described with respect to some examples may be combined in some other examples. For example, an apparatus may be implemented or a method may be practiced using any number of the aspects set forth herein. In addition, the scope of the disclosure is intended to cover such an apparatus or method that is practiced using other structure, functionality, or structure and functionality in addition to. or other than, the various aspects of the disclosure set forth herein. It should be understood that any aspect of the disclosure disclosed herein may be embodied by one or more elements of a claim.

[0086] The following claims are not intended to be limited to the aspects shown herein, but are to be accorded the full scope consistent with the language of the claims.Within a claim, reference to an element in the singular is not intended to mean “one and only one” unless specifically so stated, but rather “one or more.” Unless specifically stated otherwise, the term “some” refers to one or more. No claim element is to be construed under the provisions of 35 U.S.C. §112(f) unless the element is expressly recited using the phrase “means for”. All structural and functional equivalents to the elements of the various aspects described throughout this disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims.

Claims

WHAT IS CLAIMED IS:

1. A method for insulating a conductor of a cable comprising: applying a plurality of layers of an insulating material around a portion of a conductor of a cable, at least one layer of the plurality of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator; curing the plurality of layers to form an insulation layer having an outer diameter; removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness; and determining the desired diameter has been reached and the desired insulation layer thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

2. The method of claim 1, wherein the first visual indicator is a first color and the second visual indicator is a second color.

3. The method of claim 1, wherein the plurality of layers comprises: a first layer including the first visual indicator: and a second layer including the second visual indicator, wherein the first layer is applied to the conductor, the first layer includes a first layer thickness and a first layer diameter, and wherein the second layer is applied to the first layer, the second layer includes a second layer thickness and a second layer diameter.

4. The method of claim 3, wherein the desired diameter is the first layer diameter and the desired insulation layer thickness is the first layer thickness, and wherein determining the desired diameter has been reached and the desired insulation layer thickness has been maintained is based on the appearance of the first visual indicator.

5. The method of claim 3, wherein the plurality of layers further comprise a third layer.

6. The method of claim 5. wherein the desired diameter is the second layer diameter and the desired insulation layer thickness is a summation of the first layer thickness and the second layer thickness, and wherein determining the desired diameter has been reached and the desired insulation layer thickness has been maintained is based on the appearance of the second visual indicator.

7. The method of claim 5, wherein the third layer includes a third visual indicator, the third visual indicator being the same as the first visual indicator.

8. The method of claim 5, wherein the third layer includes a third visual indicator, the third visual indicator being different from the first visual indicator.

9. The method of claim 1. further comprising applying an adhesive to the portion of the conductor and applying the plurality of layers to the adhesive.

10. The method of claim 1, further comprising exposing the portion of the conductor before applying the plurality of layers.

11. The method of claim 1, further comprising splicing a first conductor portion to a second conductor portion to create the conductor before applying the plurality of layers.

12. The method of claim 11, wherein splicing comprises cold-welding.

13. A method for insulating a conductor of a cable, comprising: applying a first layer of an insulating material including a first visual indicator around a portion of a conductor of a cable, wherein the applied first layer has a first layer thickness and a first layer outer diameter; applying a second layer of the insulating material including a second visual indicator about the first layer; curing the first layer and the second layer to form an insulation layer, the insulation layer including an outer diameter and an insulation layer thickness; reducing the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness, wherein the first layer outer diameter isthe desired diameter and the first layer thickness is the desired insulation layer thickness; and determining the outer diameter of the insulation layer has reached the desired diameter and the insulation layer thickness has reached the desired insulation layer thickness based on an appearance of the first visual indicator.

14. The method of claim 13, further comprising applying athird layer of the insulating material about the second layer, the third layer including a third visual indicator.

15. The method of claim 14, wherein the third visual indicator is the same as the first visual indicator.

16. The method of claim 14. wherein the third visual indicator is different from the first visual indicator.

17. The method of claim 13, wherein the first visual indicator is a first color and the second visual indicator is a second color.

18. A method for insulating a conductor of a cable, comprising: removing a portion of insulation from a cable to expose a portion of a conductor of a cable; preparing the exposed portion of the conductor; applying a plurality of layers of an insulating material around the exposed portion of the conductor, at least one layer of the plurality of layers including a first visual indicator, at least another layer of the plurality of layers including a second visual indicator; curing the plurality of layers to form an insulation layer having an outer diameter; removing a portion of the outer diameter of the insulation layer to reduce the outer diameter of the insulation layer to a desired diameter while maintaining a desired insulation layer thickness; and determining the desired diameter has been reached and the desired insulation layer thickness has been maintained based on an appearance of one of the first visual indicator or the second visual indicator.

19. The method of claim 18, wherein preparing the exposed portion of the conductor comprises applying an adhesive to the exposed portion of the conductor, the adhesive extending onto the insulation adjacent the exposed portion of the conductor.

20. The method of claim 18, wherein the first visual indicator is a first color and the second visual indicator is a second color.

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