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After removing the XLPE cushion layer, the lead (Pb) layer was in acceptable situation, with an acceptable form, relatively clean floor and without substantial dents or cuts (e.g., from thermal growth). Both samples have considerably the same storage modulus within the temperature vary from approximately −70 levels C. up to roughly 115 degrees C. The value of storage modulus of the totally cured sample tends to be about one order of magnitude larger than that of uncured pattern in the high temperature range, larger than the melting point of XLPE. As an example, consider a rapid manufacturing process that features extrusion the place the excessive velocity of the melt extrusion of an XLPE layer can accelerate crosslinking by permitting for rapid quenching of the melt extruded XLPE layer in scorching water, which, consequently, can achieve a high crosslink reaction fee. As a way to introduce sufficient heat to fully activate the peroxide curative, after extrusion an meeting can be despatched by means of a excessive strain steam or scorching nitrogen containing tube. The SPEEDSTAR™ MVD control circuitry can embrace a plug-and-play sine wave output filter, a multilevel PWM inverter output, a 0.95 power factor, programmable load reduction (e.g., gentle-stall function), velocity management circuitry to take care of fixed load or stress, rocking begin (e.g., for caught pumps ensuing from scale, sand, and many others.), a utility power receptacle, an acquisition system for the PHOENIX™ monitoring system, a site communication box to support surveillance and management service, a speed control potentiometer.

The SPEEDSTAR™ MVD management circuitry is suitable for indoor or outdoor use and comes customary with a seen fused disconnect switch, precharge circuitry, and sine wave output filter (e.g., integral sine wave filter, ISWF) tailor-made for control and safety of excessive-horsepower ESPs. In the example of FIG. 2, the VSD unit 270 is shown together with a plot of a sine wave (e.g., achieved via a sine wave filter that features a capacitor and a reactor), responsiveness to vibration, responsiveness to temperature and as being managed to cut back imply time between failures (MTBFs). In the example of FIG. 10, the top assemblies type somewhat "D" shapes (e.g., one being a backward "D") while the middle or intermediate meeting varieties a considerably elongated "0" shape. In the example of FIG. 5, the MLE 500 (or "lead extension") a conductor 510, a conductor shield 520, insulation 530, an insulation shield 540 and/or a metallic shield 550, a number of other barrier layers 560, a braid layer 570 and armor 580. While the example of FIG. 5 mentions MLE or "lead extension", it could also be carried out as a single conductor assembly cable for a number of of a wide range of downhole uses. As proven, the MLEs 500 connect to a motor block 315, which may be a motor (or motors) of a pump (e.g., an ESP, and so forth.) and be controllable through the VSD/step-up transformer block 370. In the instance of FIG. 3, the conductors of the MLEs 500 electrically connect at a WYE level 325. The circuitry block 350 may derive energy through the WYE level 325 and will optionally transmit, obtain or transmit and receive data by way of the WYE point 325. As proven, the circuitry block 350 may be grounded.

FIG. 5 reveals an example of one of the MLEs 500 suitable for use in the system 300 of FIG. 3 or optionally one or more different techniques (e.g., SAGD, and so forth.). While the instance of FIG. 2 exhibits an ESP which will embrace centrifugal pump levels, one other kind of ESP could also be controlled. As proven in the plot 2200, the plateau modulus of fully cured XLPE and XLPE/PP/Talc 90/6/four wt % composite are usually considerably the identical; whereas the plateau modulus of XLPE/PP/Talc 80/15/5 and 70/25/5 wt % composites are a lot increased than that of totally cured XLPE. As an example, adding polypropylene (PP) or PP with talc can enhance the mechanical and thermal stability of an extruded XLPE material. By sustaining the concentration of talc at roughly 5 wt %, the XLPE/PP/Talc composite viscosity systematically decreases with growing the concentration of PP indicating that the XLPE/PP/Talc composites can be processed extra easily than the pure XLPE beneath the identical processing situation. As shown in Table 1, acceptable mechanical properties of fully cured XLPE modified simply barely by including PP and talc. For example, the cushion layer 760 can embrace one or more further materials reminiscent of, for example, talc and/or polypropylene.

The cushion layer 760 will be made from a number of extruded materials that may persist in a downhole environment of a hydrocarbon nicely over a longer term than nylon or polyethylene terephthalate string, which can assist to take care of lead (Pb) layer safety. For example, a test could also be carried out in a pressure vessel that includes brine where at the least a portion of a cable and/or a number of cable supplies may be submersed in the brine. In some embodiments, a number of jacket layer compounds could also be oil and/or water and/or brine and/or thermal and/or decompression resistant. For instance, a polymeric insulation layer may embrace a single layer or multiple layers of dielectric tape which may be helically wrapped round an electrical conductor and that may be bonded to the electrical conductor (e.g., and to itself) by means of use of an adhesive. As shown in FIG. 10, the cable 1000 includes a conductor 1010, insulation 1030, a lead (Pb) barrier layer 1050 and armor 1080. Arrows in FIG. 10 characterize pressure as may be applied during an armoring process. In some embodiments, a barrier layer may be formed from one or more fluoropolymers, lead, or one other material resistant to downhole gases and fluids.

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