Abstract: A submersible component can include a conductor; and a polymeric material disposed about at least a portion of the conductor where the polymeric material includes at least approximately 50 percent by weight polyether ether ketone (PEEK) and at least 5 percent by weight perfluoroalkoxy alkanes (PFA). A submersible electrical unit can include an electrically conductive winding; and a polymeric composite material disposed about at least a portion of the electrically conductive winding where the polymeric composite material includes polymeric material at at least approximately 40 percent by volume and one or more fillers at at least approximately 10 percent by volume.

Abstract: A submersible component can include a conductor; and a polymeric material disposed about at least a portion of the conductor where the polymeric material includes at least approximately 50 percent by weight polyether ether ketone (PEEK) and at least 5 percent by weight perfluoroalkoxy alkanes (PFA). A submersible electrical unit can include an electrically conductive winding; and a polymeric composite material disposed about at least a portion of the electrically conductive winding where the polymeric composite material includes polymeric material at at least approximately 40 percent by volume and one or more fillers at at least approximately 10 percent by volume.

Abstract: An elastomer alloy includes a base polymer including hydrogenated nitrile butadiene rubber (HNBR) and at least one secondary polymer, which is at least one of paraffin wax, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), and a plastomer. The base polymer and the at least one secondary polymer are blended into a polymer matrix. The elastomer alloy also includes a plurality of smart fillers dispersed within the polymer matrix, at least one chemical foaming agent, and a curing activator.

Abstract: A technique facilitates efficient well production in relatively low volume applications, e.g. applications after well pressure and volume taper off for a given well. According to an embodiment, use of an electric submersible progressive cavity pump is enabled in harsh, high temperature downhole environments. A pump stator facilitates long-term use in such harsh environments by providing a composite structure having an outer housing and a thermoset resin layer located within the outer housing and secured to the outer housing. The thermoset resin layer is constructed with an internal surface having an internal thread design. Additionally, an elastomeric layer is located within the thermoset resin layer and has a shape which follows the internal thread. In this manner, the elastomeric layer is able to provide an interior surface generally matching the shape of the internal thread of the thermoset resin layer and arranged for interaction with a corresponding pump rotor.

Abstract: Techniques for forming a helical rubber hose are provided. Such techniques include modified crosshead extrusion techniques in which an elastomer is melted, fed into a crosshead assembly, and extruded on a helical mandrel fed through the crosshead assembly to form a hose. In techniques described herein, relative axial and rotational motion of the mandrel and a die plate at or on the outlet or output of the crosshead assembly are kinematically matched such that the distance of relative axial movement of the mandrel per one revolution equals one pitch of the mandrel.

Abstract: A method can include extruding an electrically insulating elastomeric compound about a conductor where the electrically insulating elastomeric compound includes ethylene propylene diene monomer (M-class) rubber (EPDM) and an alkane-based peroxide that generates radicals that form decomposition products; cross-linking the EPDM via radical polymerization to form an electrically insulating layer about the conductor; heating the cross-linked EPDM to at least 55 degrees C. to reduce the concentration of the decomposition products in the electrically insulating layer; and disposing a gas barrier layer about the electrically insulating layer.

Abstract: A method can include extruding polyethylene about a lead (Pb) barrier layer disposed about a conductor to form an assembly; and armoring at least one of the assemblies with metallic armor to form a cable. A power cable can include a conductor; a lead (Pb) barrier layer disposed about the conductor; a cushion layer disposed about the lead (Pb) barrier layer where the cushion layer includes crosslinked polyethylene (XLPE); and metallic armor wrapped about the cushion layer.

Abstract: A method can include extruding an electrically insulating elastomeric compound about a conductor where the electrically insulating elastomeric compound includes ethylene propylene diene monomer (M-class) rubber (EPDM) and an alkane-based peroxide that generates radicals that form decomposition products; cross-linking the EPDM via radical polymerization to form an electrically insulating layer about the conductor; heating the cross-linked EPDM to at least 55 degrees C. to reduce the concentration of the decomposition products in the electrically insulating layer; and disposing a gas barrier layer about the electrically insulating layer.

Abstract: Various cables for cable deployed electric submersible pumping systems and methods of manufacturing such cables are provided. The cable includes a power cable core and coiled tubing formed around the power cable core. The power cable core includes one or more conductors, insulation surrounding each conductor, and an elastomeric jacket extruded around the insulated conductors. Various mechanisms, systems, and methods are described to anchor the power cable core in the coiled tubing and to transfer weight from the power cable core to the coiled tubing.

Abstract: An electric submersible pumping system cable is provided with a plurality of conductors. The electric submersible pumping system cable includes at least one central strength member which may be in the form of a central strength member bundle. The plurality of conductors may be in the form of a plurality of individually insulated conductors arranged about the central strength member. The electric submersible pumping system cable also may include a jacket layer disposed over the insulated conductors.

Abstract: A method can include extruding an electrically insulating elastomeric compound about a conductor where the electrically insulating elastomeric compound includes ethylene propylene diene monomer (M-class) rubber (EPDM) and an alkane-based peroxide that generates radicals that form decomposition products; cross-linking the EPDM via radical polymerization to form an electrically insulating layer about the conductor; heating the cross-linked EPDM to at least 55 degrees C. to reduce the concentration of the decomposition products in the electrically insulating layer; and disposing a gas barrier layer about the electrically insulating layer.

Abstract: A technique is provided to facilitate monitoring of contaminants which can potentially enter an electric submersible pumping system. A sensor system is used in conjunction with the electric submersible pumping system to detect the presence of specific contaminants which can affect future operation of the electric submersible pumping system. Depending on the embodiment, the sensor system may comprise a sensor or sensors disposed within the electric submersible pumping system and/or in or along components associated with the electric submersible pumping system. Each sensor is used to monitor for the contaminant and to provide data to a control system so as to facilitate decision-making regarding future operation of the electric submersible pumping system.

Abstract: A submersible component can include a conductor; and a polymeric material disposed about at least a portion of the conductor where the polymeric material includes at least approximately 50 percent by weight polyether ether ketone (PEEK) and at least 5 percent by weight perfluoroalkoxy alkanes (PFA). A submersible electrical unit can include an electrically conductive winding; and a polymeric composite material disposed about at least a portion of the electrically conductive winding where the polymeric composite material includes polymeric material at at least approximately 40 percent by volume and one or more fillers at at least approximately 10 percent by volume.

Abstract: A submersible component can include a conductor; and a polymeric material disposed about at least a portion of the conductor where the polymeric material includes at least approximately 50 percent by weight polyether ether ketone (PEEK) and at least 5 percent by weight perfluoroalkoxy alkanes (PFA). A submersible electrical unit can include an electrically conductive winding; and a polymeric composite material disposed about at least a portion of the electrically conductive winding where the polymeric composite material includes polymeric material at at least approximately 40 percent by volume and one or more fillers at at least approximately 10 percent by volume.

Abstract: A technique facilitates construction and operation of a power cable which may be used to supply power to an electric submersible pumping system downhole into a wellbore. The power cable comprises at least one electrical conductor. Each electrical conductor is insulated with an insulation layer and protected from deleterious fluids by a fluid barrier layer. Further protection is provided by a protective layer disposed around the fluid barrier layer. The protective layer is foamed to provide a cushion layer and to further protect components of the power cable. An armor layer may be disposed around the protective layer.

Abstract: An electric submersible pumping system cable is provided with a plurality of conductors. The electric submersible pumping system cable includes at least one central strength member which may be in the form of a central strength member bundle. The plurality of conductors may be in the form of a plurality of individually insulated conductors arranged about the central strength member. The electric submersible pumping system cable also may include a jacket layer disposed over the insulated conductors.

Abstract: A submersible component can include a conductor; and a polymeric material disposed about at least a portion of the conductor where the polymeric material includes at least approximately 50 percent by weight polyether ether ketone (PEEK) and at least 5 percent by weight perfluoroalkoxy alkanes (PFA). A submersible electrical unit can include an electrically conductive winding; and a polymeric composite material disposed about at least a portion of the electrically conductive winding where the polymeric composite material includes polymeric material at at least approximately 40 percent by volume and one or more fillers at at least approximately 10 percent by volume.

Abstract: A method can include extruding polyethylene about a lead (Pb) barrier layer disposed about a conductor to form an assembly; and armoring at least one of the assemblies with metallic armor to form a cable. A power cable can include a conductor; a lead (Pb) barrier layer disposed about the conductor; a cushion layer disposed about the lead (Pb) barrier layer where the cushion layer includes crosslinked polyethylene (XLPE); and metallic armor wrapped about the cushion layer.

Abstract: A technique facilitates construction and operation of a power cable which may be used to deploy an electric submersible pumping system downhole into a wellbore. The power cable is constructed to provide structural support of the electric submersible pumping system while also providing electric power to the electric submersible pumping system when located downhole in the wellbore. The power cable has at least one conductor and a plurality of layers selected and arranged to ensure long-term support and delivery of electrical power in the relatively harsh downhole environment.

Abstract: An electrical connector assembly for electric submersible pumps (ESPs) has a fluid impenetrable seal 3D-printed between the power cable and an internal housing component of the electrical connector assembly. Electrical insulation or dielectric for a conductor of the power cable may also be 3D-printed integrally with the fluid seal. The housing component, such as an internal electrical housing, may also be 3D-printed integrally with the printed seal. Likewise, in an implementation, the 3D-printed seal, the internal housing component, and an outer pothead case may all be 3D-printed as a unit onto the power cable. The 3D-printed seal and associated pothead components may be composed of a variety of chemical-resistant materials, such as printed polyarylether-ketones, printed fluorinated polymers, and metal alloys. The 3D-printed seal may also include barrier materials or reinforcement fillers to enhance strength and chemical resistance to well fluids and gases.