Seam-Welded ESP Cable Structure Without Interlocking Tape
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Solution Overview
Problem
The manufacturing of electric submersible pump cables faces challenges such as the burning of polymeric jacket, filler material, and insulation during seam welding of the outer metal layer, which reduces cable fatigue life and increases diameter and weight without providing additional strength.
Innovation Solution
The cable design includes three insulated electrical conductors and metallic elements cabled together, with metallic elements partially filling the interstitial space between the conductors and a metallic layer, which is then seam welded, and the metallic layer is drawn down to form the cable, providing a robust and efficient structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an interlocking tape is disposed around the polymeric jacket to protect it during seam welding, then the polymeric jacket is protected from burning, but the cable's fatigue life is reduced due to radial stresses imposed on the jacketed core and metal cladding when the cable is bent
Solution Approach 1:
The patent removes the interlocking tape from the cable structure entirely. Instead of adding a protective tape around the polymeric jacket, the invention uses a different approach: the metal cladding is directly applied over the polymeric jacket without an intermediate tape layer, and the polymeric insulation is formulated to resist burning during the welding process.
Solution Approach 2:
The patent modifies the properties of the polymeric insulation material to increase its resistance to burning during seam welding. This involves changing the chemical composition or adding flame-retardant additives to the polymeric insulation, allowing it to withstand the thermal exposure of welding without requiring protective tape.
2Object-affected harmful factors
If an interlocking tape is disposed around the polymeric jacket to protect it during seam welding, then the polymeric jacket is protected from burning, but the cable's diameter and weight increase without providing additional strength
Solution Approach 1:
The patent eliminates the interlocking tape component entirely, thereby reducing the cable's weight and diameter. The protective function previously provided by the tape is achieved through alternative means: direct application of metal cladding and use of flame-resistant polymeric insulation material.
Solution Approach 2:
The polymeric insulation material is given multiple functions: it provides electrical insulation and simultaneously serves as a flame-resistant protective layer during welding. The metal cladding also serves dual purposes: providing mechanical strength and acting as a heat sink during the welding process.
3Object-affected harmful factors
If the polymeric jacket, filler material, and polymeric insulation are protected during seam welding, then burning is prevented, but the manufacturing complexity increases
Solution Approach 1:
The patent simplifies the cable structure by removing the interlocking tape layer and any associated filler materials that would complicate the manufacturing process. The simplified structure consists of the core, polymeric insulation, polymeric jacket, and metal cladding, which are easier to manufacture and assemble.
Solution Approach 2:
The patent changes the properties of the polymeric materials to make them inherently resistant to burning during welding, eliminating the need for additional protective layers or complex manufacturing procedures. This parameter change simplifies the overall manufacturing process while maintaining protection against burning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the cable's strength and durability by reducing manufacturing issues, such as burning during welding, while maintaining flexibility and reducing weight, thereby improving its overall performance and reliability.
Implementation Method 1
seam welding a metallic layer about the three insulated electrical conductors and the metallic elements
Implementation Method 2
drawing down the metallic layer about the three insulated electrical conductors and the metallic elements to produce an electrical cable
Data Source
AI summary
Electrical cables and processes for making and using same. In some examples, the electrical cable can include one or more insulated electrical conductors and one or more metallic elements cabled together and a metallic layer disposed about the one or more insulated electrical conductors and the one or more metallic elements. The one or more metallic elements can partially fill a space located between the one or more insulated electrical conductors and the metallic layer. The one or more insulated electrical conductors can each include an electrically conductive core, a layer of electrically insulating material disposed about the electrically conductive core, and a layer of metallic strands disposed about the layer of electrically insulating material.