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Where a lead (Pb) barrier layer thickness will be diminished for a number of assemblies (e.g., conductor assemblies), a discount in mass of a cable may be achieved in comparison to a braided layer approach. Talc or talcum is a clay mineral composed of hydrated magnesium silicate, for example, consider one or more of the chemical system H2Mg3(SiO3)4 or Mg3Si4O10(OH)2. As an example, an XLPE material can embody talc to offer extra thermal and chemical stability to uncured XLPE at high temperatures. Such a polymeric material could also be blended with a number of other materials akin to, for instance, polypropylene (PP) and/or talc. Talc is just not soluble in water, but is slightly soluble in dilute mineral acids. Mohs scale of mineral hardness, based on scratch hardness comparability, defines value 1 because the hardness of talc. The worth of the storage modulus above the melting level is a operate of the crosslink density of the material. Both samples have substantially the same storage modulus within the temperature range from approximately −70 levels C. as much as approximately 115 degrees C. The value of storage modulus of the fully cured pattern tends to be about one order of magnitude greater than that of uncured sample in the high temperature range, larger than the melting point of XLPE.

In the instance of FIG. 13, the XLPE is PolyOne SYNCURE™ S1054A (PolyOne Corporation) ("S1054A material"). As to a silane cure system, in this instance a polyethylene grasp batch will be grafted with silane teams that are mixed with a catalyst in an extruder. In the example of FIG. 23, the a number of conductors 2310 could also be formed from a uncooked conductor materials (e.g., copper) that has been drawn to a standard wire size, annealed, and plated in both a stranded or solid configuration. In such an instance, the one or more cushion layers will be made by extrusion of XLPE (e.g., XPLE thermoset materials). The information of the plot 1400 confirms that immersing the extruded XLPE movie in water for approximately 12 hours at approximately eighty levels C. is efficient for a fully curing process. A crosslinking process could be comparatively slow, for example, consider circumstances of at the very least eight hours in hot water or steam at 80 levels C. or up to 5 weeks at room temperature.

Given the foregoing information, XLPE annealing at ambient conditions is achieved in about one month and is achieved in hot water or steam for 12 hours at roughly 80 degrees C. (e.g., to complete the curing process). A way can embody controlling a manufacturing process as to one or more of such parameters to achieve a desired quantity of crosslinking (e.g., crosslink density of XLPE), for instance, at a sure time during manufacturing of a power cable, which can have a constructive affect on one or more subsequent processes of the manufacturing process for the facility cable (e.g., consider lessening threat of deformation throughout armoring of the power cable). For instance, a number of cushion layers can reduce threat of lead (Pb) deformation during an armoring process. An electric submersible pumping system can embrace an electric submersible pump that receives electricity from an electric energy source by way of a power cable related there between, the ability cable together with a protecting layer that includes XLPE over a lead (Pb) barrier layer. For instance, a energy cable to be used with an electric submersible pumping system can embrace a conductor, an insulation layer over the conductor, a barrier layer atop the insulation layer, and a protective layer that includes XLPE over the barrier layer.

As an example, a power cable such as the cable seven-hundred of FIG. 7 might be utilized with an electric submersible pumping system. A flat energy cable may be used as a energy cable in an electric submersible pumping system. A system (e.g., a mixture) can embrace about ninety five phr S1054A and about 5 phr S1000B (e.g., a catalyst batch part). Such a silane cure system may be employed without an extra crosslinking course of. As to crosslinking, consider the next three approaches as a number of examples: silane cure system, steady vulcanization and electron beam crosslinking. Made by following the SIOPLAS E two-step know-how, SYNCURE™ XLPE affords an alternate to organic peroxide, radiation and reactor copolymer crosslinking processes. XLPE is a crosslinked polyethylene with acceptable mechanical, thermal, and dielectric properties. In some embodiments, a flat energy cable could include one or more conductors, an insulation layer disposed over every conductor, a lead (Pb) barrier layer disposed over every insulation layer, a cushion layer of crosslinked polyethylene (XPLE) that may include one or more additives that may be included in an extrudate that includes polyethylene, and an armor layer. As to high temperature efficiency, the cable 700 of FIG. 12 can exhibit improved excessive temperature efficiency when compared to the cable 1200 of FIG. 12. For instance, because the extruded cushion layer 760 can be thicker than the braided layer 1260, the extruded cushion layer 760 can enable for more room for thermal enlargement, which might help to stop lead (Pb) from deforming at excessive temperatures.

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