Where a cable includes polypropylene insulation adjoining to a copper conductor, a lead (Pb) layer could also be positioned over the polypropylene insulation, which may improve its temperature rating (e.g., low voltage armored power cable from about 96 levels C. to about 125 degrees C.). Usually, as polypropylene insulation is stiffer than EPDM insulation, a fabric tape or braid could also be foregone when the insulation is polypropylene insulation. For example, the cushion layer 760 can embody a number of additional materials resembling, for instance, talc and/or polypropylene. FIG. 8 reveals an example of a technique 810 that features a formulation block 812 for formulating a material (e.g., a mixture of supplies), an extrusion block 816 for extruding the formulated material, a formation block 820 for forming a cable that can be an armored cable and a utilization block 824 for using the formed cable. A pelletized materials or pelletized supplies will be heated and deformed through extrusion (e.g., upon exposure to extrusion heat and stress). For example, the cushion layer 760 can be formed by extrusion of fabric concerning the exterior surface of the metallic shield 750, which is usually a lead (Pb) layer.

In FIG. 7, the instance cable seven-hundred can embody EPDM insulation as the insulation 730, which may have a wall thickness of roughly 1.6 mm (e.g., approximately 0.065 inch), can embody a lead (Pb) shield because the metallic shield 750, which can have a wall thickness of roughly 0.6 mm (e.g., approximately 0.025 inch), can embody crosslinked polyethylene because the cushion layer 760 and may embrace metallic armor (e.g., galvanized) as the armor layer 780, which can have a wall thickness of roughly 0.4 mm (e.g., roughly 0.015 inch). In FIG. 7, the conductor 710 can be a strong copper conductor, the insulation 730 might be an EPDM-based insulation, the metallic shield 750 can be a metallic lead (Pb) shield (e.g., a lead (Pb) layer), the cushion layer 760 could be an extruded polyethylene layer that has achieved a desired quantity crosslinked (e.g., crosslinked polyethylene "XLPE") and the armor layer 780 could be a metallic armor. As explained, conductor and/or meeting geometries can be grouped where geometry of a number of cushion layers could also be appropriately shaped to help preserve integrity of one or more metallic shields, which may perform as fuel boundaries that can help to hinder permeation of gas (e.g., H2S, and so forth.) toward a conductor of a energy cable.

FIG. 9 shows an instance of the cable seven-hundred throughout an armoring course of where a strip of armor 780 is being applied over an assembly that features three insulated and barrier layer protected conductors the place each includes a cushion layer 760-1, 760-2 and 760-3. In the example of FIG. 9, the cushion layers 760-1 and 760-three are surrounded to a greater extent by the armor 780 than the cushion layer 760-2, which is shown to be an intermediate element of the meeting whereas the cushion layers 760-1 and 760-three are shown to be finish or side elements of the assembly that is being armored. In FIG. 7, the cushion layer 760 is exterior to the metallic shield 750 such that it could actually mechanically cushion the metallic shield 750. For instance, the cushion layer 760 can mechanically cushion the metallic shield 750 from force that may be utilized by and/or carried out by the armor of the armor layer 780, which could also be, for instance, a galvanized metallic armor. For example, an extruded cushion layer can use a comfortable yet robust polymeric material such that force utilized to a protecting lead (Pb) layer will probably be absorbed because the cushion deforms, which may help to scale back indentation depth and dimension as to the protective lead (Pb) layer.

Even small residual creases in a lead (Pb) layer from an armoring process have been proven to trigger premature failure because of results comparable to crevice corrosion. As explained, braid will be of a very low hoop energy as a consequence of the character of the individual fibers and their orientations that make up the braid. Hydrocarbon wells tend to incorporate some quantity of moisture and cable working temperatures frequently exceed eighty levels C. Under such circumstances, the aforementioned braid materials can degrade and can even dissipate comparatively quickly after installation in a hydrocarbon well. An ESP cable that included the aforementioned PET braided materials was subject to brine in a strain vessel for a period of days (e.g., 7 days in a strain vessel at 240 levels C.). Where a cable is to be a kilometer in size, a limiting price of 6 meters per minute translates to roughly 167 minutes; whereas, a limiting rate of sixty one meters per minute interprets to roughly 16.3 minutes; noting that extrusion can be in excess of approximately 61 meters per minute. In such an example, the crosslink response price could be decided by thickness of the XLPE layer, velocity of extrusion of the XLPE layer and temperatures.

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