Abstract: An embodiment of a method for manufacturing a cable, comprises providing a cable core comprising at least one conductor therein, extruding a stopping layer about at least the cable core, extruding a jacketing layer about the stopping layer, and cabling at least one armor wire layer about the jacketing layer to form the cable, wherein the stopping layer comprises a polymer layer configured to mechanically and thermally protect the cable core.

Abstract: An electric submersible pump (ESP) cable encapsulated in coiled tubing is provided. In an example process, ESP cable is drawn through coiled tubing. Liquid filler that cures into a supportive solid matrix is pumped into the coiled tubing. The solid matrix may be a rubberized filler or a closed-cell foam. Additives in the liquid filler can compensate for thermal expansion during operation of the ESP, or decrease overall weight of the solid matrix, or swell in the presence of oil, water, salt, or gas to seal a hole in the coiled tubing. The coiled tubing may be formed and seam-welded around the ESP cable from flat steel strip. A long coiled tubing resistant to stretch for deep wells may be produced by providing extra ESP cable for slack before the liquid filler cures into solid matrix. The coiled tubing may be clad with corrosion-resistant alloy for corrosive wells.

Abstract: A method for manufacturing a component includes a step of providing at least one metallic element. A surface of the at least one metallic element is modified to facilitate a bonding of the at least one metallic element to a polymeric layer. The polymeric layer is then bonded to the at least one metallic element to form the component.

Abstract: An embodiment of a method for manufacturing a cable, comprises providing a cable core comprising at least one conductor therein, extruding a stopping layer about at least the cable core, extruding a jacketing layer about the stopping layer, and cabling at least one armor wire layer about the jacketing layer to form the cable, wherein the stopping layer comprises a polymer layer configured to mechanically and thermally protect the cable core.