In FIG. 7, the cushion layer 760 is exterior to the metallic shield 750 such that it may possibly mechanically cushion the metallic shield 750. For example, the cushion layer 760 can mechanically cushion the metallic shield 750 from force that can be applied by and/or performed by the armor of the armor layer 780, which could also be, for instance, a galvanized metallic armor. In FIG. 7, the power cable seven hundred consists of three conductor assemblies the place every assembly includes a conductor 710, insulation 730, a metallic shield 750, a cushion layer 760 and an armor layer 780. In FIG. 7, the power cable seven-hundred is configured with a flat geometry; whereas, the facility cables 701 and 702 are configured with a spherical geometry where conductors are considerably pie shaped in their cross-section. As defined, conductor and/or meeting geometries may be grouped the place geometry of one or more cushion layers could also be appropriately shaped to help preserve integrity of a number of metallic shields, which may function as fuel obstacles that can help to hinder permeation of fuel (e.g., H2S, etc.) towards a conductor of a energy cable. In some embodiments, a number of compatibilizers may be used to help ensure that cross-linking happens at an interface between an insulation layer (e.g., constructed from EPDM, etc.) and an insulation shield layer.

As an example, a cushion layer can embody a colorant (e.g., for coloration coding phases of a multiphase power cable). For ESP cables operated in a number of of corrosive, gassy or scorching environments, the performance of a lead (Pb) barrier layer helps to guarantee long run occasions. Lead (Pb) exhibits good impermeability to moisture, corrosion resistance, and processability as a protective barrier layer. For instance, a metallic shield layer may be formed from numerous metallic materials together with, but not restricted to: copper, aluminum, lead, and alloys thereof. As one instance, the cushion layer 760 will be formed of a cloth with a form and measurement that helps to take care of the shape and dimension of the metallic shield 750. In such an example, the shapes could also be substantially circular. As mentioned, a cushion layer may be of a non-circular shape equivalent to considerably pie form. As talked about, a cable can embody lead (Pb), which might be within the type of a lead (Pb) layer (e.g., a barrier layer). For instance, a lead (Pb) based barrier layer generally is a metallic shield layer that may serve as a ground plane. For example, in embodiments that embrace an HNBR insulation shield layer extruded over an EPDM insulation layer, the insulation shield layer may impart enhanced injury resistance in addition to improved resistance to effectively fluids and gases to the cable.

Such a discount in the lead (Pb) wall is feasible through improved harm protection offered by an extruded cushion material that's exterior to the lead (Pb) wall. In the foregoing EPDM insulation method and the foregoing polypropylene insulation method, the stiffness of the insulation can affect armoring with respect to distortion of the lead (Pb) layer. For instance, the ability cable 701 can embody armor the place the cushion layer 760 helps to protect one or more metallic shields from deformation because of power imparted during an armoring course of and the facility cable 702 can embody armor the place the cushion layers 760 and/or the cushion layer 762 assist to guard a number of metallic shields from deformation due to pressure imparted during an armoring course of. The armor wrapping course of applies drive. In FIG. 7, the conductor 710 generally is a strong copper conductor, the insulation 730 could be an EPDM-based mostly insulation, the metallic shield 750 can be a metallic lead (Pb) shield (e.g., a lead (Pb) layer), the cushion layer 760 may be an extruded polyethylene layer that has achieved a desired amount crosslinked (e.g., crosslinked polyethylene "XLPE") and the armor layer 780 could be a metallic armor.

Where a cable contains EPDM insulation adjacent to a copper conductor, a lead (Pb) layer could also be positioned over the EPDM insulation and a fabric tape or a braid (e.g., a braided fiber) could also be placed over the lead (Pb) layer as a producing aid to attenuate distortion of the lead (Pb) layer during armoring. For example, a barrier layer generally is a layer exterior to a shield (e.g., an insulation shield layer) that will purpose to provide additional protection from corrosive downhole gases and fluids. Further, when utilized as a wrapped strip, the armor can gouge or lower into a layer resembling a lead (Pb) layer. For instance, a power cable can include an insulation layer that features EPDM, a lead (Pb) barrier layer and a protective layer that features a crosslinked polyethylene the place the protecting layer might additional embrace polypropylene and/or talc. Lead (Pb) could also be included in a cable as an extruded protective layer, which may be referred to as a lead (Pb) barrier or lead (Pb) barrier layer.

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