WO2016186976A1

WO2016186976A1 - Injection molded insulated cable repair

Info

Publication number: WO2016186976A1
Application number: PCT/US2016/032239
Authority: WO
Inventors: William Goertzen; Jason Holzmueller; Mark A. Metzger
Original assignee: Schlumberger Technology Corporation; Schlumberger Canada Limited; Services Petroliers Schlumberger; Schlumberger Technology B.V.
Priority date: 2015-05-15
Filing date: 2016-05-13
Publication date: 2016-11-24

Abstract

A cable can include a conductor that includes a first length, a second length and an intermediate length between the first length and the second length; a first length of extruded insulation disposed about the first length of the conductor; a second length of extruded insulation disposed about the second length of the conductor; and injection molded material disposed about the intermediate length of the conductor.

Description

I NJECTION MOLDED INSULATED CABLE REPAIR

RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of a U.S. Provisional Application having Serial No. 62/162,267, filed 15 May 2015, which is incorporated by reference herein.

BACKGROUND

[0002] Fluid may be injected into and/or produced from a subterranean environment. For example, consider injection and/or production of water, gas, oil, etc. As an example, one or more types of equipment may be utilized for purposes of injection and/or production. For example, equipment can include electrically operated equipment where power may be provided via a power cable.

[0003] As an example, a power cable may be of a considerable length, which may depend on where equipment is positioned. For example, an electric

submersible pump (ESP) may be positioned in a bore in a subterranean environment and powered via a power cable that is of a length of 100 meters or more. As an example, such a power cable may be of a length of 1 ,000 meters or more.

[0004] While a power cable is mentioned, as an example, a cable may be utilized for transmission of power and/or transmission of information. As an example, a power cable may be utilized to provide electrical power and to provide for transmission of digital and/or analog signals.

[0005] As an example, a cable can include one or more polymeric materials. Polymeric materials can include one or more polymers. A polymer may be considered to be a relatively large molecule or macromolecule composed of subunits. Polymers are created via polymerization of smaller molecules that can include molecules known as monomers. Polymers may be characterized by physical properties such as, for example, toughness, viscoelasticity, tendency to form glasses and semicrystalline structures, melting temperature, etc. As an example, a cable can include electrical insulation that may be or include one or more polymers (e.g., one or more polymeric materials). SUMMARY

[0006] A cable can include a conductor that includes a first length, a second length and an intermediate length between the first length and the second length; a first length of extruded insulation disposed about the first length of the conductor; a second length of extruded insulation disposed about the second length of the conductor; and injection molded material disposed about the intermediate length of the conductor. A method can include providing an intermediate portion of a cable conductor in an injection mold; injecting material into the injection mold; and forming a layer of the material about the cable conductor. A multiphase cable for an electric submersible pump motor can include conductors where at least one of the conductors includes a first length, a second length and an intermediate length between the first length and the second length; a first length of extruded insulation disposed about the first length of the conductor; a second length of extruded insulation disposed about the second length of the conductor; and injection molded material disposed about the intermediate length of the conductor. Various other apparatuses, systems, methods, etc., are also disclosed.

[0007] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Features and advantages of the described implementations can be more readily understood by reference to the following description taken in conjunction with the accompanying drawings.

[0009] Fig. 1 llustrates

[0010] Fig. 2 llustrates

[0011] Fig. 3 llustrates

[0012] Fig. 4 llustrates

[0013] Fig. 5 llustrates

[0014] Fig. 6 llustrates

[0015] Fig. 7 llustrates

[0016] Fig. 8 llustrates

[0017] Fig. 9 llustrates [0018] Fig. 10 illustrates an example of a method;

[0019] Fig. 1 1 illustrates example of intermediate portions of cables;

[0020] Fig. 12 illustrates an example of an injection mold, an example of an intermediate portion of a cable with injection molded material;

[0021] Fig. 13 shows an example of a photograph of a portion of a cable;

[0022] Fig. 14 shows examples of systems; and

[0023] Fig. 15 illustrates example components of a system and a networked system.

DETAI LED DESCRIPTION

[0024] The following description includes the best mode presently

contemplated for practicing the described implementations. This description is not to be taken in a limiting sense, but rather is made merely for the purpose of describing the general principles of the implementations. The scope of the described

implementations should be ascertained with reference to the issued claims.

[0025] Fig. 1 shows examples of geologic environments 120 and 140. In Fig. 1 , the geologic environment 120 may be a sedimentary basin that includes layers (e.g., stratification) that include a reservoir 121 and that may be, for example, intersected by a fault 123 (e.g., or faults). As an example, the geologic environment 120 may be outfitted with one or more of a variety of sensors, detectors, actuators, etc. For example, equipment 122 may include communication circuitry to receive and to transmit information with respect to one or more networks 125. Such information may include information associated with downhole equipment 124, which may be equipment to acquire information, to assist with resource recovery, etc.

Other equipment 126 may be located remote from a well site and include sensing, detecting, emitting or other circuitry. Such equipment may include storage and communication circuitry to store and to communicate data, instructions, etc. As an example, one or more satellites may be provided for purposes of communications, data acquisition, etc. For example, Fig. 1 shows a satellite in communication with the network 125 that may be configured for communications, noting that the satellite may additionally or alternatively include circuitry for imagery (e.g., spatial, spectral, temporal, radiometric, etc.).

[0026] Fig. 1 also shows the geologic environment 120 as optionally including equipment 127 and 128 associated with a well that includes a substantially horizontal portion that may intersect with one or more fractures 129. For example, consider a well in a shale formation that may include natural fractures, artificial fractures (e.g. , hydraulic fractures) or a combination of natural and artificial fractures. As an example, a well may be drilled for a reservoir that is laterally extensive. In such an example, lateral variations in properties, stresses, etc. may exist where an assessment of such variations may assist with planning, operations, etc. to develop the reservoir (e.g., via fracturing, injecting, extracting, etc.). As an example, the equipment 127 and/or 128 may include components, a system, systems, etc. for fracturing, seismic sensing, analysis of seismic data, assessment of one or more fractures, etc.

[0027] As to the geologic environment 140, as shown in Fig. 1 , it includes two wells 141 and 143 (e.g., bores), which may be, for example, disposed at least partially in a layer such as a sand layer disposed between caprock and shale. As an example, the geologic environment 140 may be outfitted with equipment 145, which may be, for example, steam assisted gravity drainage (SAGD) equipment for injecting steam for enhancing extraction of a resource from a reservoir. SAGD is a technique that involves subterranean delivery of steam to enhance flow of heavy oil, bitumen, etc. SAGD can be applied for Enhanced Oil Recovery (EOR), which is also known as tertiary recovery because it changes properties of oil in situ.

[0028] As an example, a SAGD operation in the geologic environment 140 may use the well 141 for steam-injection and the well 143 for resource production. In such an example, the equipment 145 may be a downhole steam generator and the equipment 147 may be an electric submersible pump (e.g. , an ESP).

[0029] As illustrated in a cross-sectional view of Fig. 1 , steam injected via the well 141 may rise in a subterranean portion of the geologic environment and transfer heat to a desirable resource such as heavy oil. In turn, as the resource is heated, its viscosity decreases, allowing it to flow more readily to the well 143 (e.g., a resource production well). In such an example, equipment 147 (e.g. , an ESP) may then assist with lifting the resource in the well 143 to, for example, a surface facility (e.g. , via a wellhead, etc.). As an example, where a production well includes artificial lift equipment such as an ESP, operation of such equipment may be impacted by the presence of condensed steam (e.g., water in addition to a desired resource). In such an example, an ESP may experience conditions that may depend in part on operation of other equipment (e.g. , steam injection, operation of another ESP, etc.). [0030] Conditions in a geologic environment may be transient and/or persistent. Where equipment is placed within a geologic environment, longevity of the equipment can depend on characteristics of the environment and, for example, duration of use of the equipment as well as function of the equipment. Where equipment is to endure in an environment over an extended period of time, uncertainty may arise in one or more factors that could impact integrity or expected lifetime of the equipment. As an example, where a period of time may be of the order of decades, equipment that is intended to last for such a period of time may be constructed to endure conditions imposed thereon, whether imposed by an environment or environments and/or one or more functions of the equipment itself.

[0031] As an example, an environment may be a harsh environment, for example, an environment that may be classified as being a high-pressure and high- temperature environment (HPHT). A so-called HPHT environment may include pressures up to about 138 MPa (e.g., about 20,000 psi) and temperatures up to about 205 degrees C (e.g., about 400 degrees F and about 480 K), a so-called ultra- HPHT environment may include pressures up to about 241 MPa (e.g., about 35,000 psi) and temperatures up to about 260 degrees C (e.g. , about 500 degrees F and about 530 K) and a so-called HPHT-hc environment may include pressures greater than about 241 MPa (e.g., about 35,000 psi) and temperatures greater than about 260 degrees C (e.g., about 500 degrees F and about 530 K). As an example, an environment may be classified based in one of the aforementioned classes based on pressure or temperature alone. As an example, an environment may have its pressure and/or temperature elevated, for example, through use of equipment, techniques, etc. For example, a SAGD operation may elevate temperature of an environment (e.g., by 100 degrees C or more; about 370 K or more).

[0032] Fig. 2 shows an example of an ESP system 200 that includes an ESP 210 as an example of equipment that may be placed in a geologic environment. As an example, an ESP may be expected to function in an environment over an extended period of time (e.g. , optionally of the order of years).

[0033] In the example of Fig. 2, the ESP system 200 includes a network 201 , a well 203 disposed in a geologic environment (e.g. , with surface equipment, etc.), a power supply 205, the ESP 210, a controller 230, a motor controller 250 and a VSD unit 270. The power supply 205 may receive power from a power grid, an onsite generator (e.g. , natural gas driven turbine), or other source. The power supply 205 may supply a voltage, for example, of about 4.16 kV.

[0034] As shown, the well 203 includes a wellhead that can include a choke (e.g., a choke valve). For example, the well 203 can include a choke valve to control various operations such as to reduce pressure of a fluid from high pressure in a closed wellbore to atmospheric pressure. A wellhead may include one or more sensors such as a temperature sensor, a pressure sensor, a solids sensor, etc.

[0035] As to the ESP 210, it is shown as including cables 21 1 (e.g., or a cable), a pump 212, gas handling features 213, a pump intake 214, a motor 215, one or more sensors 216 (e.g., temperature, pressure, strain, current leakage, vibration, etc.) and a protector 217.

[0036] As an example, an ESP may include a REDA™ HOTLI NE™ high- temperature ESP motor. Such a motor may be suitable for implementation in a thermal recovery heavy oil production system, such as, for example, SAGD system or other steam-flooding system.

[0037] As an example, an ESP motor can include a three-phase squirrel cage with two-pole induction. As an example, an ESP motor may include steel stator laminations that can help focus magnetic forces on rotors, for example, to help reduce energy loss. As an example, stator windings can include copper and insulation.

[0038] As an example, the one or more sensors 216 of the ESP 210 may be part of a digital downhole monitoring system. For example, consider the

commercially available PHOENIX™ MULTISENSOR XT150 system marketed by Schlumberger Limited (Houston, Texas). A monitoring system may include a base unit that operatively couples to an ESP motor (see, e.g., the motor 215), for example, directly, via a motor-base crossover, etc. As an example, such a base unit (e.g. , base gauge) may measure intake pressure, intake temperature, motor oil

temperature, motor winding temperature, vibration, currently leakage, etc. As explained with respect to Fig. 4, a base unit may transmit information via a power cable that provides power to an ESP motor and may receive power via such a cable as well.

[0039] As an example, a remote unit may be provided that may be located at a pump discharge (e.g. , located at an end opposite the pump intake 214). As an example, a base unit and a remote unit may, in combination, measure intake and discharge pressures across a pump (see, e.g. , the pump 212), for example, for analysis of a pump curve. As an example, alarms may be set for one or more parameters (e.g. , measurements, parameters based on measurements, etc.).

[0040] Where a system includes a base unit and a remote unit, such as those of the PHOENIX™ MULTISENSOR XT150 system, the units may be linked via wires. Such an arrangement provide power from the base unit to the remote unit and allows for communication between the base unit and the remote unit (e.g. , at least transmission of information from the remote unit to the base unit). As an example, a remote unit is powered via a wired interface to a base unit such that one or more sensors of the remote unit can sense physical phenomena. In such an example, the remote unit can then transmit sensed information to the base unit, which, in turn, may transmit such information to a surface unit via a power cable configured to provide power to an ESP motor.

[0041] In the example of Fig. 2, the well 203 may include one or more well sensors 220, for example, such as the commercially available OPTICLINE™ sensors or WELLWATCHER BRITEBLUE™ sensors marketed by Schlumberger Limited (Houston, Texas). Such sensors are fiber-optic based and can provide for real time sensing of temperature, for example, in SAGD or other operations. As shown in the example of Fig. 1 , a well can include a relatively horizontal portion. Such a portion may collect heated heavy oil responsive to steam injection. Measurements of temperature along the length of the well can provide for feedback, for example, to understand conditions downhole of an ESP. Well sensors may extend a

considerable distance into a well and possibly beyond a position of an ESP.

[0042] In the example of Fig. 2, the controller 230 can include one or more interfaces, for example, for receipt, transmission or receipt and transmission of information with the motor controller 250, a VSD unit 270, the power supply 205 (e.g., a gas fueled turbine generator, a power company, etc.), the network 201 , equipment in the well 203, equipment in another well, etc.

[0043] As shown in Fig. 2, the controller 230 may include or provide access to one or more modules or frameworks. Further, the controller 230 may include features of an ESP motor controller and optionally supplant the ESP motor controller 250. For example, the controller 230 may include the UNICONN™ motor controller 282 marketed by Schlumberger Limited (Houston, Texas). In the example of Fig. 2, the controller 230 may access one or more of the PIPESIM™ framework 284, the ECLIPSE™ framework 286 marketed by Schlumberger Limited (Houston, Texas) and the PETREL™ framework 288 marketed by Schlumberger Limited (Houston, Texas) (e.g. , and optionally the OCEAN™ framework marketed by Schlumberger Limited (Houston, Texas)).

[0044] In the example of Fig. 2, the motor controller 250 may be a

commercially available motor controller such as the UNICONN™ motor controller. The UNICONN™ motor controller can connect to a SCADA system, the

ESPWATCHER™ surveillance system, etc. The UNICONN™ motor controller can perform some control and data acquisition tasks for ESPs, surface pumps or other monitored wells. As an example, the UNICONN™ motor controller can interface with the aforementioned PHOENIX™ monitoring system, for example, to access pressure, temperature and vibration data and various protection parameters as well as to provide direct current power to downhole sensors. The UNICONN™ motor controller can interface with fixed speed drive (FSD) controllers or a VSD unit, for example, such as the VSD unit 270.

[0045] For FSD controllers, the UNICONN™ motor controller can monitor ESP system three-phase currents, three-phase surface voltage, supply voltage and frequency, ESP spinning frequency and leg ground, power factor and motor load.

[0046] For VSD units, the UNICONN™ motor controller can monitor VSD output current, ESP running current, VSD output voltage, supply voltage, VSD input and VSD output power, VSD output frequency, drive loading, motor load, three- phase ESP running current, three-phase VSD input or output voltage, ESP spinning frequency, and leg-ground.

[0047] In the example of Fig. 2, the ESP motor controller 250 includes various modules to handle, for example, backspin of an ESP, sanding of an ESP, flux of an ESP and gas lock of an ESP. The motor controller 250 may include one or more of a variety of features, additionally, alternatively, etc.

[0048] In the example of Fig. 2, the VSD unit 270 may be a low voltage drive (LVD) unit, a medium voltage drive (MVD) unit or other type of unit (e.g. , a high voltage drive, which may provide a voltage in excess of about 4.16 kV). As an example, the VSD unit 270 may receive power with a voltage of about 4.16 kV and control a motor as a load with a voltage from about 0 V to about 4.16 kV. The VSD unit 270 may include commercially available control circuitry such as the SPEEDSTAR™ MVD control circuitry marketed by Schlumberger Limited (Houston, Texas).

[0049] Fig. 3 shows cut-away views of examples of equipment such as, for example, a portion of a pump 320, a protector 370 and a motor 350 of an ESP. The pump 320, the protector 370 and the motor 350 are shown with respect to cylindrical coordinate systems (e.g., r, z, Θ). Various features of equipment may be described, defined, etc. with respect to a cylindrical coordinate system. As an example, a lower end of the pump 320 may be coupled to an upper end of the protector 370 and a lower end of the protector 370 may be coupled to an upper end of the motor 350. As shown in Fig. 3, a shaft segment of the pump 320 may be coupled via a connector to a shaft segment of the protector 370 and the shaft segment of the protector 370 may be coupled via a connector to a shaft segment of the motor 350. As an example, an ESP may be oriented in a desired direction, which may be vertical, horizontal or other angle. As shown in Fig. 3, the motor 350 is an electric motor that includes a connector 352, for example, to operatively couple the electric motor to a power cable, for example, optionally via one or more motor lead extensions (see, e.g., Fig. 4).

[0050] Fig. 4 shows a block diagram of an example of a system 400 that includes a power source 401 as well as data 402 (e.g., information). The power source 401 provides power to a VSD block 470 while the data 402 may be provided to a communication block 430. The data 402 may include instructions, for example, to instruct circuitry of the circuitry block 450, one or more sensors of the sensor block 460, etc. The data 402 may be or include data communicated, for example, from the circuitry block 450, the sensor block 460, etc. In the example of Fig. 4, a choke block 440 can provide for transmission of data signals via a power cable 41 1 (e.g., including motor lead extensions "MLEs"). A power cable may be provided in a format such as a round format or a flat format with multiple conductors. MLEs may be spliced onto a power cable to allow each of the conductors to physically connect to an appropriate corresponding connector of an electric motor (see, e.g. , the connector 352 of Fig. 3). As an example, MLEs may be bundled within an outer casing (e.g. , a layer of armor, etc.).

[0051] As shown, the power cable 41 1 connects to a motor block 415, which may be a motor (or motors) of an ESP and be controllable via the VSD block 470. In the example of Fig. 4, the conductors of the power cable 41 1 electrically connect at a wye point 425. The circuitry block 450 may derive power via the wye point 425 and may optionally transmit, receive or transmit and receive data via the wye point 425. As shown, the circuitry block 450 may be grounded.

[0052] As an example, power cables and MLEs that can resist damaging forces, whether mechanical, electrical or chemical, may help ensure proper operation of a motor, circuitry, sensors, etc.; noting that a faulty power cable (or MLE) can potentially damage a motor, circuitry, sensors, etc. Further, as mentioned, an ESP may be located several kilometers into a wellbore. Accordingly, time and cost to replace a faulty ESP, power cable, MLE, etc., can be substantial (e.g. , time to withdraw, downtime for fluid pumping, time to insert, etc.).

[0053] As an example, a cable may allow for extended run life, low cost, and improved manufacturability. For example, a downhole power cable for electric submersible pumps (ESP) may include various features, materials of construction, etc. that may improve reliability and reduce environmental impact (e.g., during use, after use, etc.).

[0054] As an example, a cable may be rated. For example, ESP cables may be rated by voltage such as about 3 kV, about 4 kV or about 5 kV. As to form, a round cable may be implemented in boreholes where sufficient room exists and a so- called "flat" cable may be implemented where less room may be available (e.g. , to provide clearance, etc.).

[0055] As an example, a round ESP cable rated to about 5 kV may include a copper conductor(s), oil and heat resistant ethylene propylene diene monomer (M- class) rubber insulation (EPDM insulation), a barrier layer (e.g. , lead and/or fluoropolymer or without a barrier layer), a jacket layer (e.g., oil resistant EPDM or nitrile rubber), and armor (e.g. , galvanized or stainless steel or alloys that include nickel and copper such as MONEL™ alloys, Huntington Alloys Corporation,

Huntington, West Virginia).

[0056] As an example, a flat ESP cable rated to about 5 kV may include a copper conductor(s), oil and heat resistant EPDM rubber insulation, a barrier layer (e.g., lead and/or fluoropolymer or without a barrier layer), a jacket layer (e.g., oil resistant EPDM or nitrile rubber or without a jacket layer), and armor (e.g. , galvanized or stainless steel or alloys that include nickel and copper such as

MONEL™ alloys). [0057] In the foregoing examples, armor on the outside of a cable acts to protect the cable from damage, for example, from handling during transport, equipment installation, and equipment removal from the wellbore. Additionally, armor can help to prevent an underlying jacket, barrier, and insulation layers from swelling and abrasion during operation. In such examples, as armor is formed out of metallic strips and wrapped around the cable, voids exist between the overlapping armor layers which can collect well fluid after the cable has been installed in a wellbore. In such scenarios, when the cable is removed from the wellbore the well fluid tends to remain trapped in voids and therefore can cause environmental damage as it drips off of the cable during transport and recycling. Further, as an example, if armor is not present, well fluid can become trapped inside a jacket layer and, for example, lead to environmental challenging situations when the cable is removed from a wellbore.

[0058] As an example, a cable can reduce environmental impact via a reduction of features that may pose potential risks for well fluid (e.g., oil, etc.) to be trapped inside the cable. For example, such a cable can include a durable polymeric coating over an armor layer (e.g. , or a jacket layer) to help prevent well fluid from becoming trapped between overlapping armor layers (e.g. , or inside the jacket if the cable does not have armor). In such an example, the polymeric coating may be an outermost layer that is smooth (e.g., without ridges, etc. as may be formed by overlying metal strips of armor).

[0059] As an example, a layer disposed over an armor layer (e.g. , over an outer surface of an armor layer) may be of sufficient robustness to reduce risk of damage, for example, during installation. In such an example, the layer may be resistant to abrasion from well fluid.

[0060] Fig. 5 shows an example of a cable 500 that includes various components. For example, the cable 500 can include conductors 510, conductor shields (e.g., which may be optional), insulation 520, insulation shields (optional), conductive layers (e.g. , which may be optional), barrier layers 530 (e.g. , which may be optional), a cable jacket 540, cable armor 550 (e.g. , which may be optional) and an outer coating 560 (e.g. , an outermost coating or layer).

[0061] As an example, insulation may be a thermoplastic material. For example, consider a poly-aryl ether ketone (e.g., PEK, PEEK, PEKEKK, etc.), a melt extrudable fluoropolymer (e.g. , ethylene tetrafluoroethylene (ETFE), polyvinylidene fluoride (PVDF), fluorinated ethylene propylene (FEP), perfluoroalkoxy (PFA), epitaxial co-crystaline alloy (ECA) fluoroplastic, etc.), or other suitable material. As an example, polyether ether ketone (PEEK) may be utilized as insulation.

[0062] As an example, a mixture (e.g. , a composition) may include a melt- fabricable tetrafluoroethylene/perfluoro(alkyl vinyl ether) copolymer (e.g. , where the perfluoroalkyl contains 1 to 5 carbon atoms) and melt flowable

polytetrafluoroethylene (PTFE). As an example, such a mixture may be suitable for extrusion about a conductor to form an insulating layer. For example, the insulation 520 may be formed in such a manner.

[0063] As an example, a composition may be or include a commercially available DuPont™ ECCtreme® ECA 3000 fluoroplastic resin (DuPont Chemicals and Fluoroproducts, Wilmington Delaware). As an example, such a resin may be a perfluoropolymer mixture (PFP) that may be heat aged to become an ECC PFP, which may be utilized as insulation (see, e.g. , the insulation 520 about the conductor 510). As an example, a polymeric material can include epitaxial co-crystals of perfluoroalkoxy (PFA) and polytetrafluoroethylene (PTFE). As an example, perfluoroalkoxy (PFA) can be a polymer of tetrafluoroethylene and

perfluorovinylether.

[0064] As an example, insulation may be classified based on temperature. For example, a low-temperature insulation class may include materials such as polypropylene (PP), co-polymers of PP and polyethylene (PE), ETFE, PVDF, etc.; and, for example, a mid-temperature insulation class may include materials such as FEP, PFA, etc. As an example, a high-temperature insulation class may include materials that can withstand temperatures greater than approximately 260 degrees C (e.g., approximately 500 degrees F). As an example, PEEK and ECA may function as insulators at temperatures in excess of approximately 260 degrees C (e.g., approximately 500 degrees F).

[0065] As an example, insulation may be or include ethylene propylene diene monomer (M-class) rubber (EPDM). As an example, EPDM may be suitable for applications at moderate temperatures (e.g., up to about 232 degrees C) and/or at higher temperatures (e.g., up to about 260 degrees C).

[0066] As an example, a cable can include a hydrogenated nitrile butadiene rubber (HNBR) insulation shield with EPDM insulation where the HNBR insulation shield can be adhered (e.g., bonded) to the EPDM insulation. In such an example, HNBR and EPDM elastomers may use compatibilizers to provide for co-crosslinking at an HNBR-EPDM interface. As an example, layers may be co-extruded, for example, via pressure extrusion and, for example, cured using compatible cure systems (e.g., with appropriate cure rates).

[0067] As an example, a cable can include a corrosion resistant nanomaterial coating that can help protect against corrosive gases where such a coating may interact with EPDM-based insulation. As an example, consider one or more polymeric materials (e.g. , EPDM, PEEK, PFA, ECA, etc.) as forming a primary dielectric layer, which may be applied, for example, via an extrusion process over a graphene oxide-coated conductor. In such an example, the graphene oxide coating may promote adhesion of the extruded one or more polymeric material through one or more chemical interactions (e.g., hydrogen bonding, etc.). As an example, a surface modifier that modifies a polymeric material may be or include maleic anhydride (e.g., consider a maleic anhydride modified EPDM layer, etc.).

[0068] As an example, a HNBR-based insulation shield compound may be utilized, for example, with one or more filler materials. As an example, consider graphene filler such as, for example, high aspect ratio graphene nanoplatelets.

[0069] As an example, an insulation layer may adhere to or be bonded to a conductor shield, for example, where a conductor shield is present. As an example, an insulation layer may be continuous with an insulation shield, for example, with complete bonding or without complete bonding thereto. As an example, where PEEK is selected as a material for an insulation layer, mechanical properties thereof may allow for improved damage resistance, for example, to resist damage to a cable during cable install, cable operation, cable repositioning, cable removal, etc. In such an example, PEEK can offer relatively high stiffness, which may allow for greater ease in sealing over a cable (e.g., cable members such as members that each include a conductor), for example, at a cable termination point or points (e.g., motor pothead, well connectors, feed-throughs, etc.). As an example, such an approach may improve cable and system reliability.

[0070] As an example, a cable may include a barrier layer to help protect the cable from corrosive downhole gases and fluids. As an example, one or more additional barrier layers may be used, for example, depending on intended use, environmental conditions, etc. As an example, a barrier may be formed of extruded material, tape, etc. As an example, a barrier layer may include a fluoropolymer or fluoropolymers, lead, and/or other material (e.g., to help protect against well fluids, etc.). As an example, a combination of extruded and taped layers may be used.

[0071] In the example of Fig. 5, the cable 500 is shown as including a contiguous cable jacket 540 that jackets the first, second and third conductors 510 (e.g., including layers of the first, second and third conductors 510).

[0072] As an example, for a flat cable configuration (e.g., and for a round cable configuration where conductors may be twisted together), a fluid, gas and temperature resistant jacket may be used. Such a jacket may help protect a cable from damage, for example, in challenging downhole environments.

[0073] As an example, a cable jacket may include one or more layers of EPDM, nitrile, hydrogenated nitrile butadiene rubber (HNBR), fluoropolymer, chloroprene, and/or other material resistant to constituents, conditions, etc. in a downhole environment.

[0074] As an example, a jacket may be made of a fluid resistant nitrile elastomer, for example, with low swell ratings in water and in hydrocarbon oil and, for example, with appropriate resistance to wellbore gases.

[0075] As an example, low swell property of the jacket may act to reduce (e.g., minimize) an amount of well fluid that may possibly be absorbed into the cable. As an example, an elastomer jacket may help to prevent fluid migration into a cable and help to provide mechanical protection of insulated conductors set within the elastomer jacket (e.g., jacketed by the elastomer jacket).

[0076] As an example, cable armor, which may be optional, may include galvanized steel, stainless steel, alloys that include nickel and copper such as MONEL™ alloys, or other metal, metal alloy, or non-metal resistant to downhole conditions.

[0077] As shown in the example of Fig. 5, the cable 500 includes a cable outer coating 560. Such a coating may optionally be provided over cable armor, if present. As mentioned, a cable outer coating may help to reduce environmental impact, for example, by reducing presence of features that may pose potential risks for well fluid (e.g., oil, etc.) to be trapped inside the cable. For example, a cable outer coating may be a durable polymeric coating over an armor layer (e.g., or other layer such as a jacket layer) to help prevent well fluid from becoming trapped between overlapping armor layers (e.g., or inside the jacket if the cable does not have armor). In such an example, an outermost layer of a cable may be formed in a manner that has reduced surface roughness, reduced undulations, reduced corrugations, etc., for example, which may act to carry and/or entrap fluid, debris, etc. As an example, a cable outer coating may be relatively smooth and be resistant to swell (e.g., via gasses, liquids, etc.).

[0078] As an example, a cable outer coating may be made of polyvinylidene fluoride (PVDF, KYNAR™ polymer (Arkema, Inc. , King of Prussia, Pennsylvania), TEDLAR™ polymer (E. I. du Pont de Nemours & Co., Wilmington, Delaware), etc.). As an example, a cable outer coating may be made of PVDF modified with about 0.1 percent to about 10 percent by weight adducted maleic anhydride, for example, to facilitate bonding to a metallic armor or elastomer jacket (e.g. where armor is not employed).

[0079] Fig. 6 shows an example of a geometric arrangement of components of a round cable 610 and an example of a geometric arrangement of components of an oblong cable 630. As shown the cable 610 includes three conductors 612, a polymeric layer 614 and an outer layer 616 and the oblong cable 630 includes three conductors 632, a polymeric layer 634 (e.g., optionally a composite material with desirable heat transfer properties) and an optional outer polymeric layer 636 (e.g., outer polymeric coat, which may be a composite material). In the examples of Fig. 6, a conductor may be surrounded by one or more optional layers, as generally illustrated via dashed lines. For example, as to the cable 630, consider three 1 gauge conductors (e.g. , a diameter of about 7.35 mm), each with a 2 mm layer and a 1 mm layer. In such an example, the polymeric layer 634 may encapsulate the three 1 gauge conductors and their respective layers where, at ends, the polymeric layer 634 may be about 1 mm thick. In such an example, an optional armor layer may be of a thickness of about 0.5 mm. In such an example, the optional outer polymeric layer 636 (e.g., as covering armor) may be of a thickness of about 1 mm (e.g., a 1 mm layer).

[0080] As shown in Fig. 6, the cable 610 includes a circular cross-sectional shape while the cable 630 includes an oblong cross-sectional shape. In the example of Fig. 6, the cable 610 with the circular cross-sectional shape has an area of unity and the cable 630 with the oblong cross-sectional shape has area of about 0.82. As to perimeter, where the cable 610 has a perimeter of unity, the cable 630 has a perimeter of about 1.05. Thus, the cable 630 has a smaller volume and a larger surface area when compared to the cable 610. A smaller volume can provide for a smaller mass and, for example, less tensile stress on a cable that may be deployed a distance in a downhole environment (e.g., due to mass of the cable itself).

[0081] In the cable 630, the conductors 632 may be about 7.35 mm (e.g., about 1 AWG) in diameter with insulation of about 2 mm thickness, lead (Pb) of about 1 mm thickness, a jacket layer (e.g., the layer 634) over the lead (Pb) of about 1 mm thickness at ends of the cable 630, optional armor of about 0.5 mm thickness and an optional polymeric layer of about 1 mm thickness (e.g., the layer 636 as an outer polymeric coat). As an example, the cable 630 may be of a width of about 20 mm (e.g., about 0.8 inches) and a length of about 50 mm (e.g. , about 2 inches), for example, about a 2.5 to 1 width to length ratio).

[0082] As an example, a cable may be formed with phases split out from each other where each phase is encased in solid metallic tubing.

[0083] As an example, a cable can include multiple conductors where each conductor can carry current of a phase of a multiphase power supply for a multiphase electric motor. In such an example, a conductor may be in a range from about 8 AWG (about 3.7 mm) to about 00 AWG (about 9.3 mm).

[0084] Table 1 . Examples of Components.

[0085] In Table 1 , where a cable has an oblong cross-sectional shape, the jacket over lead (Pb) layer may be, for example, of a thickness of about 20 mils to about 85 mils (e.g. , about 0.5 mm to about 2.2 mm) at ends of the oblong cross- sectional shape and, for example, at various points along opposing sides of the oblong cross-sectional shape. For example, material forming the jacket over lead (Pb) layer may be thicker in regions between conductors (e.g., consider

approximately triangular shaped regions). [0086] As an example, a cable may include conductors for delivery of power to a multiphase electric motor with a voltage range of about 3 kV to about 8 kV. As an example, a cable may carry power, at times, for example, with amperage of up to about 200 A or more.

[0087] As to operational conditions, where an electric motor operates a pump, locking of the pump can cause current to increase and, where fluid flow past a cable may decrease, heat may build rapidly within the cable. As an example, locking may occur due to gas in one or more pump stages, bearing issues, particulate matter, etc.

[0088] As an example, a cable may carry current to power a multiphase electric motor or other piece of equipment (e.g. , downhole equipment powerable by a cable).

[0089] Fig. 7 shows various examples of motor equipment. A pothead unit 701 includes opposing ends 702 and 704 and a through bore, for example, defined by a bore wall 705. As shown, the ends 702 and 704 may include flanges configured for connection to other units (e.g., a protector unit at the end 702 and a motor unit at the end 704). The pothead unit 701 includes cable passages 707-1 , 707-2 and 707- 3 (e.g. , cable connector sockets) configured for receipt of cable connectors 716-1 , 716-2 and 716-3 of respective cables 714-1 , 714-2 and 714-3. As an example, the cables 714-1 , 714-2 and 714-3 and/or the cable connectors 716-1 , 716-2 and 716-3 may include one or more polymeric materials. For example, a cable may include polymeric insulation while a cable connector may include polymeric insulation, a polymeric component (e.g., a bushing), etc. As an example, the cables 714-1 , 714-2 and 714-3 may be coupled to a single larger cable. The single larger cable may extend to a connector end for connection to a power source or, for example, equipment intermediate the cable and a power source (e.g. , an electrical filter unit, etc.). As an example, a power source may be a VSD unit that provides three-phase power for operation of a motor.

[0090] Fig. 7 also shows a pothead unit 720 that includes a socket 721 . As an example, a cable 722 may include a plug 724 that can couple to the socket 721 of the pothead unit 720. In such an example, the cable 722 may include one or more conductors 726. As an example, a cable may include at least one fiber optic cable or one or more other types of cables.

[0091] As explained above, equipment may be placed in a geologic

environment where such equipment may be subject to conditions associated with function or functions of the equipment and/or be subject to conditions associated with the geologic environment. Equipment may experience conditions that are persistent (e.g. , relatively constant), transient or a combination of both. As an example, to enhance equipment integrity (e.g. , reduction in failures, increased performance, longevity, etc.), equipment may include at least one polymeric material.

[0092] Fig. 8 shows a perspective cut-away view of an example of a motor assembly 800 that includes a power cable 844 (e.g., MLEs, etc.) to supply energy, a shaft 850, a housing 860 that may be made of multiple components (e.g. , multiple units joined to form the housing 860), stacked laminations 880, stator windings 870 of wire (e.g., magnet wire) and rotor laminations 890 and rotor windings 895 coupled to the shaft 850 (e.g., rotatably driven by energizing the stator windings 870).

[0093] As shown in Fig. 8, the housing 860 includes an inner surface 861 and an outer surface 865. As an example, the housing 860 can define one or more cavities via its inner surface 861 where one or more of the cavities may be

hermetically sealed. As an example, such a cavity may be filled at least partially with dielectric oil. As an example, dielectric oil may be formulated to have a desired viscosity and/or viscoelastic properties, etc.

[0094] As shown, the shaft 850 may be fitted with a coupling 852 to couple the shaft to another shaft. A coupling may include, for example, splines that engage splines of one or more shafts. The shaft 850 may be supported by bearings 854-1 , 854-2, 854-3, etc. disposed in the housing 860.

[0095] As shown, the housing 860 includes opposing axial ends 862 and 864 with the substantially cylindrical outer surface 865 extending therebetween. The outer surface 865 can include one or more sealable openings for passage of oil (e.g., dielectric oil), for example, to lubricate the bearings and to protect various

components of the motor assembly 800. As an example, the motor assembly 800 may include one or more sealable cavities. For example, a passage 866 allows for passage of one or more conductors of the cable 844 (e.g. , or cables) to a motor cavity 867 of the motor assembly 800 where the motor cavity 867 may be a sealable cavity. As shown, the motor cavity 867 houses the stator windings 870 and the stator laminations 880. As an example, an individual winding may include a plurality of conductors (e.g., magnet wires). For example, a cross-section 872 of an individual winding may reveal a plurality of conductors that are disposed in a matrix (e.g., of material or materials) or otherwise bound together (e.g., by a material or materials). In the example of Fig. 8, the motor housing 860 includes an oil reservoir 868, for example, that may include one or more passages (e.g., a sealable external passage and a passage to the motor cavity 867) for passage of oil.

[0096] As an example, a shaft may be reciprocating, for example, where a shaft includes one or more magnets (e.g., permanent magnets) that respond to current that passes through stator windings.

[0097] As mentioned, a cable can include conductors and insulation where the insulation includes a polymeric material such as, for example, a thermoplastic. As a submersible electric motor may be disposed in an environment where temperatures may be more than 100 degrees C, insulation may be selected and utilized that can withstand such temperatures.

[0098] Fig. 9 shows an example of an extrusion system 905 that can be utilized for extruding insulation 912 about a conductor 91 1 , which may be a solid conductor, stranded conductor, etc.

[0099] In the example of Fig. 9, the extrusion system 905 can include a reel 910 that can dispense the conductor 91 1 , which may enter an extruder 920 that can receive insulation material that can be extruded about the conductor 91 1 to form the insulation 912.

[00100] Fig. 9 shows a schematic cross-sectional view of an example of a portion of a conductor cable that includes the conductor 91 1 and the insulation 912 where the insulation 912 includes a defect 913. In the example of Fig. 9, the defect 913 may be an extrusion defect.

[00101 ] Fig. 9 also shows a perspective view of a portion of a cable that includes the conductor 91 1 , the insulation 912, a lead (Pb) barrier 914 and a fluoropolymer barrier 916. Where a defect exists in the insulation 912 (see, e.g. , the defect 913), the conductor 91 1 may be at risk as well as one or more layers that are disposed about the insulation 912.

[00102] As an example, an extrusion defect may be associated with surging where thickness varies in a direction of extrusion. As an example, a screw motor speed may vary and result in an unsteady rotational speed of a screw or screws. As an example, feed may be uneven, for example, due to one or more of particle size, light weight, or bridging in a hopper and/or throat. As an example, where feed of particles is erratic, surging may manifest as a defect. [00103] As an example, an extrusion defect may be associated with gas such as, for example, air, which may be carried forward in an extruder and disturb flow of molten material. As an example, trapped-gas surface may include bubbles and/or pits.

[00104] As an example, an extrusion defect may be associated with resin and be considered to be a resin defect. For example, consider occlusions, char particles, voids, unsuitable filler/pigment distribution, improper mixing of resin and additives, foreign material contamination, overheating, etc.

[00105] As an example, where an extrusion defect or other type of defect is detected, one option is to dispose of a length of cable. For example, where an extruded layer is examined for defects and a defect or defects detected, a length of cable that includes the defect or defects may be discarded.

[00106] Where a cable may be of a length of the order of about 100 meters or less, discarding defective lengths of cable may be of lesser economic consequence when compared to a cable that may be of a length of the order of more than about 100 meters. For example, where a cable is to be about 1000 meters in length, cutting out a defect at 500 meters results in two cable lengths of about 500 meters each; neither of which meets the specified length of about 1000 meters. In such an example, 1000 meters of cable may be wasted due to the defect at 500 meters.

[00107] While splicing may exist as an option, for example, to cut out the defective portion and splice the remaining portions together, such an option can be labor intensive and may result in a sub-optimal conductor and/or sub-optimal insulation. Further, where splicing involves specialized tape, the cost of such tape may be substantial, for example, when compared to the cost of insulation as extruded.

[00108] Fig. 10 shows an example of a method 1000 that includes a provision block 1010 for providing an intermediate portion of a cable conductor in an injection mold, an injection block 1020 for injecting material into the mold, and a formation block 1030 for forming a layer about the cable conductor.

[00109] In the example of Fig. 10, the intermediate portion of the cable conductor can be intermediate a first length of the cable conductor that includes extruded insulation and a second length of the cable conductor that includes extruded insulation. [00110] As an example, the method 1000 can include detaching excess material from the layer of the material about the cable conductor, for example, where injection molding results in excess material being attached to a layer of the injection molded material.

[00111 ] As an example, a method can include forming another layer about a layer of injection molded material. For example, consider forming one or more barrier layers about injection molded material, which may be insulation.

[00112] As an example, a cable can include a conductor that includes a first length, a second length and an intermediate length between the first length and the second length; a first length of extruded insulation disposed about the first length of the conductor; a second length of extruded insulation disposed about the second length of the conductor; and injection molded material disposed about the intermediate length of the conductor. For example, the method 1000 of Fig. 10 may be utilized to form the injection molded material disposed about the intermediate length of the conductor. In the foregoing example, the cable can include a first end and a second end where the intermediate length is between the first end and the second end and, for example, at the first length from the first end and at the second length from the second end. As an example, injection molded material can include one or more constituents of the extruded insulation material (e.g., polymer, filler, etc.).

[00113] As an example, a conductor can include copper. As an example, extruded insulation can be or include PEEK. As an example, extruded insulation can be or include ECA. As an example, extruded insulation can be or include EPDM.

[00114] As an example, a method can include injection molding of EPDM to form injection molded material about a portion of a conductor or conductors. As an example, such a method can include in mold curing. For example, a dwell time may be utilized with associated temperature and/or pressure to achieve a desired level of cure (e.g., in mold curing). As an example, curing may occur to some extent in a mold and to some extent out of a mold. As an example, curing may occur in a mold.

[00115] As an example, for a thermoplastic material, after forming a layer of injection molded thermoplastic material about a cable conductor (see, e.g., the formation block 1030), such a section may be cooled, for example, in the mold before removal. As an example, such a section may optionally be removed while at an elevated temperature (e.g. , a mold temperature). As an example, a removal temperature may be selected based on one or more factors. As an example, removal temperature may be selected based on a finishing factor that may include removal of excess material, surface finishing, etc. As an example, a finishing factor may be a treatment.

[00116] As an example, a cable can include EPDM insulation. In such an example, the EPDM may be rated as high-temperature (e.g., to about 260 degrees C). As an example, such high-temperature EPDM may be injected molded about a portion of a conductor or conductors to effectuate a repair and/or to effectuate insulating spliced conductors. Such an approach may be applied where a pressure sensitive adhesive (PSA) tape may be of a lesser temperature rating (e.g., due to one or more constituents of the PSA tape). As an example, a method can include forming an EPDM injection molded insulated splice, for example, for an ESP cable (e.g., multiphase power cable, etc.). In such an example, reliability and/or consistency achieved via such a method may be greater than for a method that includes hand wrapping of tape (e.g., PSA tape).

[00117] As an example, injection molded material can be bonded to a portion of a first length of extruded insulation that is adjacent to an intermediate length of a conductor and injection molded material can be bonded to a portion of a second length of extruded insulation that is adjacent to the intermediate length of the conductor. For example, injection molding may cause material to bond to extruded insulation.

[00118] As an example, injection molded material can contact a conductor. For example, injection molded material can be insulation that is in contact with a conductor. As an example, injection molded material can be repair material.

[00119] As an example, a first length of a conductor may be a length of at least 10 meters and/or a second length of the conductor may be a length of at least 10 meters. As an example, an intermediate length of such a conductor can be a length of at least 1 centimeter. As an example, an intermediate length of a conductor can be a length that is less than approximately 50 centimeters and that is greater than approximately 1 centimeter.

[00120] As an example, a cable can include a layer disposed about an injection molded material. In such an example, the layer may include lead (Pb). As an example, a layer may include a fluoropolymer and be disposed about an injection molded material. [00121 ] As an example, a method of repairing a defect in insulation in a power cable in a wellbore can include providing a power cable that includes an electrical conductor or conductors encased in insulation and that may be arranged together in an array where one or more defects may exist in the insulation. In such an example, a defect may include but not be limited to bubbling of the insulation due to air or gas infiltration during curing of the insulation; holes in the insulation; failure of the insulation to properly bond to the conductive cable in the system; pits in the insulation; and/or one or more other types of defects.

[00122] As an example, a power cable's insulation may be repaired by removing the insulation containing a defect from the cable insulation. In such an example, a bare conductive cable which was formerly encased in the defective insulation may then be pared to a standard length as may be associated with an injection mold of an injection molding system . For example, an electrical conductor may be installed into a mold in, for example, a vertical injection molding press. Once the electrical conductor is installed in the mold, insulating repair material may then be injected into the injection molding press such that it covers the electrical conductor. The mold may then be heated and cooled to assure a bond between the injected insulating repair material and the non-defective insulation remaining on the cable to create a repaired section. Once this is accomplished, the repaired section may be removed from the mold and inspected, and excess repair material may be removed from the repaired section.

[00123] As an example, a repaired power cable can include an electrical conductor or conductors and insulation encasing the conductor(s), where the insulation encasing the conductor(s) has reinforced sections of defective insulation as well as additional sections of non-defective insulation. In such an example, a bond can be present between each of the reinforced sections of defective insulation and the non-defective insulation.

[00124] Fig. 1 1 shows an example of a portion of a cable 1 1 10 and an example of a portion of a cable 1 150. As shown in Fig. 1 1 , the cable 1 1 10 includes a first length 1 120 of a length L1 , a second length 1 130 of a length L2 and an intermediate length 1 140 of a length LI. As shown, the first and second lengths 1 120 and 1 130 are of a greater dimension due to an extruded layer of material such as insulation about a conductor of the cable 1 1 10; whereas, the intermediate length 1 140 is of a lesser dimension due to absence of the extruded layer of material such that the intermediate length 1 140 can be that of a conductor, which may be a bare conductor that includes copper (e.g., solid, stranded, etc.). As an example, the intermediate length 1 140 can be that of a treated conductor, which may be chemically treated, mechanically treated, thermally treated, etc. where such treatment or treatments may facilitate bonding of an injection molded material, which may be, for example, insulation (e.g. , insulation material). In the example cable 1 1 10, junctions 1 122 and 1 132 may be stepped. For example, insulation may be stripped from the cable 1 1 10 in a region where a defect or defects exist to form the junction 1 122 as a stepped junction at one end of the intermediate length 1 140 and to form the junction 1 132 as a stepped junction at another end of the intermediate length 1 140.

[00125] As shown in Fig. 1 1 , the cable 1 150 includes a first length 1 160 of a length L1 , a second length 1 170 of a length L2 and an intermediate length 1 180 of a length LI . As shown, the first and second lengths 1 160 and 1 170 are of a greater dimension due to an extruded layer of material such as insulation about a conductor of the cable 1 150; whereas, the intermediate length 1 180 is of a lesser dimension due to absence of the extruded layer of material such that the intermediate length 1 180 can be that of a conductor, which may be a bare conductor that includes copper (e.g. , solid, stranded, etc.). As an example, the intermediate length 1 180 can be that of a treated conductor, which may be chemically treated, mechanically treated, thermally treated, etc. where such treatment or treatments may facilitate bonding of an injection molded material, which may be, for example, insulation (e.g. , insulation material). In the example cable 1 150, junctions 1 162 and 1 172 may be tapered. For example, insulation may be stripped from the cable 1 150 in a region where a defect or defects exist to form the junction 1 162 as a tapered junction at one end of the intermediate length 1 180 and to form the junction 1 172 as a tapered junction at another end of the intermediate length 1 180.

[00126] As an example, a conductor as well as one or more tapered and/or terminated ends of insulation may be activated chemically, thermally, electrically, magnetically, electro-magnetically, etc. As an example, a portion of a cable may be treated with plasma to facilitate cleaning and/or to enhance adhesion of injection molded material.

[00127] Fig. 12 shows an example of a portion of a mold 1210 that can be utilized in an injection molding system to form an injection molded layer about a portion of a cable. As shown in the example of Fig. 12, the mold 1210 can include a longitudinal channel 1220 of a length LC, feed channels 1222 and 1224 that are in fluid communication with the longitudinal channel 1220, jigs 1232 and 1234 disposed at a distance LJ and, for example, an intermediate jig 1236 disposed between the jigs 1232 and 1234.

[00128] As shown in the example of Fig. 12, the mold 1210 can receive a portion of a cable 1250 that includes a first length 1260, a second length 1270 and an intermediate length 1280 where the first length 1260 may be located at least in part via the jig 1232, where the second length 1270 may be located at least in part via the jig 1234 and where the intermediate length 1280 may be located at least in part via the intermediate jig 1236.

[00129] As an example, the cable 1250 can include a continuous conductor (e.g., a joint free conductor) that spans at least the intermediate length 1280 and at least portions of the first length 1260 and the second length 1270. As an example, the cable 1250 may include a continuous copper conductor (e.g. , solid, stranded, etc.) that spans a length in excess of about 100 meters. In such an example, the span may be considered to be joint free with respect to the continuous copper conductor in that joints do not exist that join segments of copper conductors.

[00130] As shown in the example of Fig. 12, the longitudinal channel 1220 has a length LC that exceeds an intermediate length LI of the intermediate length 1280 of the cable 1250. In the example of Fig. 12, the cable 1250 can include one or more stepped and/or one or more tapered junctions. As shown, junctions can be spaced at a length that is less than the channel length LC of the channel 1220 of the mold 1210.

[00131 ] The portion of a mold 1210 can form a cavity with another portion of a mold, which can include at least one or more features of the mold 1210. For example, another portion of a mold can include a longitudinal channel akin to the longitudinal channel 1220. In such an example, the two longitudinal channels can form a substantially cylindrical cavity about an intermediate length of a cable. In such an example, one or more additional channels can be in fluid communication with the substantially cylindrical cavity to allow for flow of injection molding material to the substantially cylindrical cavity such that the injection molding material can surround the intermediate length of the cable.

[00132] As an example, injection molding can be performed by an injection molding system according to an injection molding cycle. For example, an injection molding cycle can commence once a portion of a cable is positioned with respect to a mold, which may be a multi-piece mold where various mold pieces form a cavity or cavities. Next, the injection molding system can inject material into the cavity or cavities. In such an example, appropriate temperature and pressure profiles may be applied. As an example, a cooling phase may decrease temperature to sufficiently cool the injection molded material. A mold may then be opened for removal of the cable that includes the cooled, injection molded material.

[00133] As an example, an injection molding cycle may optionally be adjustable as to charge, which may be an amount of material utilized in a cycle. As an example, an injection molding system can include a clamp that applies force to a mold, which may be a multi-piece mold. Such a clamp may be operatively coupled to equipment that can, for example, bring pieces together to form a cavity or cavities (e.g., closing a mold) and that can, for example, separate pieces to open a cavity or cavities. As an example, a cycle may be defined at least in part by a cycle time. As an example, an injection molding system can include pins that can be actuated to apply force to a cable for purposes of removal. As an example, an injection molding system can include a controller, for example, to control one or more process conditions (e.g., temperature, pressure, time, etc.). As an example, a mold may include heating and/or cooling channels that may be utilized to control temperature.

[00134] As an example, injection molded material and/or a mold may be defined in part by an aspect ratio that may, for example, correspond to a flow length to an average wall thickness.

[00135] As an example, an injection molding system may form a runner or runners, one or more sprues, one or more gates and/or flash as excess material formed with and attached to a desired portion of injection molded material. As an example, a final product may be formed by removal of excess material, which can include for example, removal of one or more of a runner, a gate, a sprue, flash or other type of excess material. As an example, a gate can be remnant material left over from cutting a product from a runner or a sprue where a gate may be cut flush with a surface of the product.

[00136] Fig. 12 shows an example of an injection molded portion of a cable 1251 , which may include a quality control adjusted cable of the cable 1250, where the portion of the cable 1251 is shown with excess material that can be removed. As an example, quality control can be implemented to adjust quality of a cable due to, for example, one or more insulation defects.

[00137] In the example of Fig. 12, a defect may have been detected at a position along the intermediate length 1280 of the cable 1250 and the intermediate length 1280 prepared for injection molding. In such an example, injection molded material 1285 can be formed as a layer about the intermediate length 1280 of the cable 1250. As shown in Fig. 12, excess material 1290 can be attached to the layer about the intermediate length 1280 where the excess material 1290 can include a runner, gates and a sprue. In such an example, the gates may be cut from the intermediate length 1280.

[00138] Fig. 12 shows examples of joints 1265 and 1275 where injection molded material "join" extruded material. As shown in an enlarged view, the joint 1265 may have predominantly injection molded material to one side and may have predominantly extruded material to another side. As an example, the portions adjacent to the joint 1265 may be defined by dimensions such as, for example, diameters D1 and Dl where the diameters may be approximately the same.

[00139] Fig. 13 shows an example of a photograph 1300 of a portion of a cable that includes a first length 1360, an intermediate length 1385 and a joint 1365. In such an example, extruded material about the first length 1360 may be bonded to injection molded material about the intermediate length 1385 at the joint 1365. In such an example, a conductor that extends across the intermediate length 1385 and the first length 1360 may be insulated by insulation formed via extrusion and insulation formed via injection molding where the insulations may optionally be made of substantially the same material or suitable materials that have appropriate electrical insulating properties for the conductor (e.g., solid, stranded, etc.).

[00140] Fig. 14 shows examples of systems 1400, 1401 and 1402. As an example, the system 1400 and/or the system 1402 may be implemented to perform a method such as, for example, the method 1000 of Fig. 10. As an example, the system 1400 and/or the system 1402 may include one or more features of the portion of the example mold 1210 of Fig. 12.

[00141 ] As shown in Fig. 14, the system 1400 can include a cable 1410 that can be translated with respect to an injection molding unit 1440, for example, via one or more reels 1422 and 1424. In such an example, a controller 1450 can be operatively coupled to one or more components of the system 1400. As an example, the controller 1450 can include one or more processors 1452, memory 1454 accessible by at least one of the one or more processors 1452, instructions 1456 stored in the memory 1454 and one or more network interfaces 1458. In such an example, the memory 1454 can be one or more computer-readable storage media that are non-transitory, not a carrier wave and not a signal. For example, the memory 1454 can be a physical component or physical components operatively coupled to one or more of the one or more processors 1452.

[00142] As an example, the system 1400 may be operatively coupled to one or more power supplies, which may supply power to one or more components of the system 1400. As an example, the system 1400 can include feedstock for the injection molding unit 1440, for example, to supply material or materials that can be injection molded via the injection molding unit 1440.

[00143] In the example of Fig. 14, the system 1400 can include one or more components 1472 and 1474, which may be or include, for example, one or more inspection components and/or one or more treatment components. As to inspection components, an optical inspection component may be utilized for purposes of quality control, for example, to identify one or more actual and/or possible defects in one or more portions of a cable. For example, an optical inspection component may identify a defect such as the defect 913 of the insulation 912 of Fig. 9. As an example, an optical inspection component may generate a photograph such as, for example, the photograph 1300 of Fig. 13, which may, for example, be processed as to one or more quality control aspects. As an example, an injection molded material can include one or more optically detectable constituents that may, for example, facilitate detection of quality (e.g., bonding, distribution at a joint, etc.). For example, consider a fluorescing constituent, a colored constituent, etc. As an example, an extruded material (e.g., an extruded insulation material) may include one or more optically detectable constituents that may, for example, facilitate detection of quality (e.g. , bonding, distribution at a joint, tapering, etc.).

[00144] As to treatment components, consider, for example, a stripper that can strip away material from the cable 1410 (e.g., physical stripper, chemical stripper, radiation stripper, heat stripper, etc.). As an example, a treatment component may provide for one or more of heat, chemical, plasma, UV, etc. types of treatment. As an example, a treatment component may apply one or more treatments before and/or after injection molded material is molded to a portion of the cable 1410 (e.g. , before and/or after a portion of the cable 1410 is repaired). As an example, a treatment component may provide for surface treatment as to, for example, one or more of a conductor, insulation, injection molded material, etc. As an example, consider a treatment component that acts to remove and/or diminish surface features that may result from an injection molding process (e.g. , gate finishing, flash finishing, etc.). As an example, a heating component may act to melt a portion of injection molded material in a manner that acts to smooth a surface of the injection molded material. As an example, a treatment component may emit heat and/or radiation that may act to initiate and/or further one or more reactions (e.g. , polymerization reactions, etc.).

[00145] As shown in the example of Fig. 14, the controller 1450 can include receiving and/or transmitting information to one or more of the components of the system 1400. For example, the controller 1450 may receive information from an inspection component and, in response, control one or more of the reels 1422 and 1424 to position a portion of the cable 1410 with respect to the injection molding unit 1440 (e.g., an injection molding system, etc.). As an example, inspection

components may be positioned to inspect prior to repair, during repair and/or after repair of a portion of a cable and/or prior to treatment, during treatment and/or after treatment of a portion of a cable. As an example, the controller 1450 can receive information and determine one or more control actions based at least in part on such information which can be actions such as to repair, not repair, treat, not treat, etc. one or more portions of a cable.

[00146] Fig. 14 shows the system 1401 as being a wellsite system where the system 1402 may be a mobile system that can be transported to and/or from the system 1401 . For example, the system 1402 can include the injection molding unit 1440 and the controller 1450 and optionally one or more of the other components of the system 1400. As an example, the system 1400 and/or the system 1402 may be utilized for purposes of repair in a continuous conductor of a portion of a cable and/or for purposes of splicing of conductors where, for example, after splicing, material can be injection molded about a spliced region. In such an example, the material can be or include insulation to, for example, electrically insulated a spliced region.

[00147] As an example, the system 1400 and/or the system 1402 may be utilized for repair and/or splices. As an example, the system 1402 may be

transportable to and/or from a field site or other site for repair and/or splices. As an example, the system 1400 and/or the system 1402 may help to reduce a number of manual tasks associated with repair and/or splicing, which can tend to depend on the individual performing such tasks. As an example, the system 1400 and/or the system 1402 may help to improve reliability of a cable, for example, as a splice can be possible point where failure may occur, particularly where the impact of conditions, skill, etc. of a manual splicing process may be mitigated via use of the system 1400 and/or the system 1402.

[00148] As an example, a power cable can include electrical conductors encased by insulation where the electrical conductors are arranged, for example, in a flat-pack array of three. The power cable may also include one or more other components, such as a metal barrier (e.g., lead (Pb) and/or other metal, alloy, etc.) and a barrier layer (e.g., polymeric, composite, etc.), and be encased by a cable jacket.

[00149] As an example, electrical conductors may be high purity copper and may be solid, stranded or compacted-stranded. Such conductors may also be coated with a corrosion- resistant coating to prevent degradation of the conductor. Examples of such corrosion-resistant coatings include tin, zinc, lead, nickel, silver, and other corrosion-resistant alloys and metals.

[00150] In an implementation, an example power cable may also have a conductor shield, which can be a semiconductive layer around respective individual conductors that can control electrical stress in the cable, for example, to minimize discharge. As an example, a conductor shield layer may be bonded to a conductor and insulation to help prevent gas migration or, for example, a conductor shield layer may be made strippable. As an example, a layer may be an elastomer or thermoplastic co-extruded with the insulation allowing for crosslinking of layers.

[00151 ] An elastomer compound, such as ethylene propylene diene monomer / terpolymer (e.g., EPDM), loaded with conductive fillers may be used for as a conductor shield layer. As an example, a polyether ether ketone (PEEK) compound containing conductive fillers may be used as a conductor shield layer. As an example, an insulation shield and insulation can differ as to their materials.

[00152] Material for an insulation layer (e.g., insulation) may be, for example, a meltable fluoroplastic such as EPDM, ECA, ETFE or TEFZEL™ (DuPont

Corporation, Wilmington, Delaware), FEP, PFA, MFA, or PVDF. In some

embodiments, where temperature and reliability may be concerns, a member of the family of polyaryletherketones such as PEEK, PEK, or PEKEKK may be used.

When EPDM is selected, compound formulations for oil and decompression- resistance may be used. In some embodiments, an insulation layer can adhere to or be completely bonded to a conductor shield, when present. As an example, an insulation layer may be continuous with an insulation shield, if present, and may be wholly bonded, partially bonded, etc.

[00153] As an example, an insulation deposition process such as an extrusion process may result in one or more defects in an insulation layer. For example, consider a scenario where an insulation material is extruded continuously at a speed which allows gas (e.g., air, etc.) to infiltrate an extruded insulation layer, which may cause bubbles, pits, etc., in the extruded insulation layer. As an example, one or more defects in an extruded insulation layer may result when moisture is present in insulation layer material prior to extrusion, which may at times result in voids and/or bubbles in the insulation layer due to expansion of moisture during the extrusion process. As an example, one or more defects may result during an extrusion or manufacturing process for an insulation layer due to extrusion which occurs at too fast or too slow a speed; contamination of the insulation layer material with other materials; and/or a number of one or more other factors.

[00154] As an example, an insulation shield may be applied over insulation, for example, as a semiconductive layer to minimize electrical stresses in a cable. As an example, an insulation shield may be bonded to insulation or may be strippable. As an example, material for an insulation shield may be a semiconductive tape and/or a semiconductive polymer. As an example, the same material may be used for an insulation shield as for a conductor shield. Conversely, a different material may also be used if the different material is more workable, desirable, etc.

[00155] As an example, a conductive layer may optionally be applied to serve as an electrical ground plane outside of an insulation shield. Such a conductive layer may help to isolate effects of different electrical phases of a multiphase cable from one another. As an example, copper, aluminum, lead (Pb), or another conductive material, tape, braid, paint, or extrusion may be applied over an insulation shield to provide a conductive layer. As an example, a conductive layer may serve as a barrier to gases and fluids, protecting the inner cable layers.

[00156] As an example, a barrier layer may help to protect a cable 100 from corrosive gases and fluids. As an example, one or more additional barrier layers may be applied, as desired. As an example, a barrier layer may be made up of extruded or taped layers of fluoropolymers, lead (Pb), or other material sufficient for protection against fluids. A combination of extruded and taped layers may also be used.

[00157] As an example, during manufacture, a nonmetallic jacket may be continually extruded in a manner that aims to minimize gaps, holes, and/or voids in the jacket layer that could, for example, allow for ingress of fluid.

[00158] As an example, a power cable may include a variety of features (e.g., conductors, layers, optic fibers, etc.). As an example, insulation may be thicker or thinner than that shown in examples of Fig. 5, Fig. 9, etc. As an example, a lead (Pb) barrier and/or a barrier layer may or may not be included. Likewise, while electrical conductors may be encased by insulation and arranged in a flat-pack array of three as in Fig. 5, one or more other orientations of one or more electrical conductors may be stacked on top of other wire, etc. As an example, there may be more or less than three electrical conductors in one or more orientations.

[00159] As an example, where insulation includes one or more defects, such one or more defects may impact insulation properties (e.g. , cable quality). As an example, a high-temperature and/or fluid/gas-resistant power cable may utilize PEEK and/or fluoropolymer insulations. Where one or more defects exist, repairing such one or more defects may demand that repairs be made in a manner that does not impact temperature and performance aspects of pressure-sensitive adhesive tapes that find use in, for example, repair of ESP cables.

[00160] As an example, a method may aim to produce a power cable without one or more splices. As an example, consider a power cable with a length in the range of about 500 meters to about 3,000 meters (e.g., or more) where one or more defects may be repaired via injection molding, which may help to avoid excessive scrap and associated costs.

[00161 ] As an example, a method of repairing a defect in a power cable can include providing a power cable that includes an electrical conductor encased in insulation. In such an example, a defect can be removed by removal of at least a portion of the insulation, for example, where a standard length may be specified as to the portion of the insulation to be removed. In such an example, removing the portion of the insulation can expose a portion of the electrical conductor (e.g., to the standard length). As an example, a standard length may be of a size to fit within an injection mold of an injection molding system. As an example, consider a standard length in a range of about 1 centimeter to about 60 centimeters (e.g. , or more). As an example, an injection mold may include an adjustable cavity where, for example, one or more ends of the cavity may be adjustable (e.g. , via an insert, a sliding component, etc.). As an example, insulation surrounding an electrical conductor can be prepared to an end condition, which may be, for example, a taper, a step, etc.

[00162] As an example, a portion of a power cable can be installed in a mold, for example, of a front-loading injection press of an injection molding system. In such an example, once insulating repair material is injected into the mold, to promote bonding of the repair material with the other, pre-existing insulation, the mold may be heated adjacent to the bond interface between the injected repair material and the pre-existing insulation and, for example, simultaneously cooled on the exterior portion of the mold to prevent overflow of molten injected repair material and/or preexisting insulation (e.g., which may to some extent melt). In some embodiments, the mold may be heated to within approximately 30 degrees C of a melting point of the injected repair material. In such embodiments, to help to avoid overflow of the melted injected repair material and/or pre-existing insulation material outside the mold, the exterior (e.g. , of about 1 centimeter to about 5 centimeters, etc.) of the mold on either side may be simultaneously cooled to a temperature that is more than 30 degrees C cooler than the melting point of the pre-existing insulation. As an example, insulating repair material may be or include one or more meltable fluoroplastic such as EPDM, ECA, ETFE or TEFZEL™ (DuPont Corporation, Wilmington, Delaware), FEP, PFA, MFA, or PVDF. In some embodiments, where temperature and reliability are concerns, a member or members of the family of polyaryletherketones such as PEEK, PEK, or PEKEKK may be used. When EPDM is selected, compound formulations for oil and decompression-resistance may be used.

[00163] For bonding of insulating repair material with pre-existing insulation, insulating repair material may be of the same class or classes of polymer or polymers as the pre-existing insulation. As an example, insulating repair material may be formulated (e.g. , via one or more additives and/or via structure, charge, etc.) to have a different melting point, for example, consider a melting point that is within a range of about 5 degrees C to about 10 degrees C of a melting point of pre-existing insulation. For example, in some embodiments, the melting point of the insulating repair material is in a range of about 5 degrees C to about 10 degrees C (e.g. , or higher) than the melting point of the pre-existing insulation, such that, when injected, the liquefied (e.g., molten, flowable) insulating repair material is sufficiently hot to melt and bond with the pre-existing insulation, which has a lower melting point.

[00164] As an example, a repaired power cable can include non-defective insulation that is bonded with a reinforced section of defective insulation. In such an example, excess repair material (e.g., runner, sprue, gate, flash, etc.) may be removed from repaired power cable as removed from a mold of an injection molding system. As an example, repair material can be adjacent to, or sandwiched by, non- defective insulation on both sides of a longitudinal portion of a cable (e.g., an insulated conductor, etc.). Referring again to the photograph 1300 of Fig. 13, the joint 1365 may be considered to be or include a bond interface between non- defective insulation and a reinforced section that was deemed to include defective insulation.

[00165] As an example, a method can include removing insulation around a defect area of an insulated copper conductor and preparing the copper conductor to expose bare copper, optionally to a standard length and end condition. For example, the insulation may be prepared to a blunt edge, a penciled edge, etc.

[00166] While various examples pertain to injection molding of insulation about a continuous conductor (e.g., solid, stranded, etc.), as an example, injection molding may be utilized to form a layer of insulation about two separate conductors that have been joined, for example, via a process such as cold welding, etc.

[00167] As an example, preparation may include one or more treatments that aim to enhance bonding between an injected material (e.g. , injection molded polymeric material) and terminated sections of a cable. For example, consider one or more of mechanical abrasion, plasma treatment, etching of terminated polymer insulation, etc.

[00168] As an example, a method can include installing a prepared cable into a vertical injection press, for example, with accommodation to handle one or more reels of cable (e.g. , on one side or both sides of an injection mold).

[00169] Referring again to the example photograph 1300 of Fig. 13, the cable includes polypropylene insulation disposed about a copper conductor where the polypropylene insulation includes injection molded polypropylene. [00170] As an example, a method can include injecting repair material (e.g. , consider a thermoplastic of a same type as pre-existing insulation of a cable) into a cavity that includes an uncovered copper conductor region of the cable where a cavity length may help to assure bonding (e.g. , optionally with mixing) between new material and pre-existing material. As an example, a cable may be prepared in part via coating with a coat of a material that may be surrounded by injection molded material. As an example, a method can include pre-heating and in-mold heating operations, for example, balanced by proper cooling and support of a middle and end portions of a cable (e.g., via jigs, etc.).

[00171 ] As an example, one or more heating methods can be used. As an example, one or more of induction heating and forced cooling can be used to obtain desired results.

[00172] As an example, injected material can be of the same composition as pre-existing cable insulation, or alternatively, one or more thermoplastic insulations with slightly different melting points or compositions (e.g., optionally including one or more dielectric fillers) can be employed, for example, to accomplish a suitable repair. For example, using an injected polymer with a slightly higher melting point can be one method to force bonding at an interface between new material and old.

[00173] As an example, where injection molding generates excess material such excess material may be removed. For example, a sprue and a runner attached to a portion of a cable can be removed where, for example, a gate region or gate regions may optionally be sanded, etc., to smooth and/or shape the exterior surface of the injection molded material about a conductor.

[00174] As an example, where reels are disposed to respective sides of a mold, the reels may be rotated to move cable (e.g. , to translate cable), for example, for purposes of inspection, repair, etc. As an example, a method can include advancing cable from one reel to another reel where one or more repairs are made to the cable via an injection molding system. In such an example, where cable from one reel is advanced to the other reel, the method may be concluded and the reel with the cable utilized in one or more other processes. For example, consider a process that moves the repaired cable on to a process such as, for example, a barrier layer deposition process (e.g., consider extrusion of a metal barrier material to form a metal barrier layer about the insulation that includes injection molded insulation. [00175] Injection molded repair of one or more ESP cable components may be utilized for a variety of designs, which may employ, for example, one or more types of thermoplastic insulations.

[00176] As an example, a cable may be a steam-assisted gravity drainage (SAGD) equipment cable; cable-deployed subsea; a geothermal equipment cable, etc. As an example, a cable may be a power cable that may be rated according to a voltage level. For example, consider a medium voltage power cable that may be repaired via injection molding of insulation.

[00177] As an example, a method can include providing a power cable where the power cable includes one or more electrical conductors encased in insulation, and one or more defects in the insulation; removing at least a portion of the insulation containing a defect in the cable insulation system to expose the electrical conductor to a standard length; exposing the electrical conductor to a standard length; installing the electrical conductor into an injection press; injecting an insulating repair material into the injection press such that it covers the electrical conductor; heating and cooling the repair material to assure a bond between the injected insulating repair material and the insulation to create a repaired section. In such an example, the standard length may be a length in a range of about 0.5 inches, or approximately 1 .27 centimeters, and about 24 inches, or approximately 60.96 centimeters.

[00178] As an example, insulation can include a fluoropolymer. As an example, insulation can include one or more members of the family of

polyaryletherketones. As an example, insulation can include one or more meltable fluoroplastics.

[00179] As an example, an injected insulating repair material can include a polymer with a lower melting point than pre-existing insulation about a conductor (e.g., solid, stranded, etc.). As an example, injected insulating repair material can include a polymer with a higher melting point than pre-existing insulation about a conductor (e.g., solid, stranded, etc.).

[00180] As an example, a method of repairing a defect in a cable insulation system can include providing a power cable where the power cable includes one or more electrical conductors encased in insulation and one or more defects in the insulation; removing at least a portion of the insulation containing a defect in the cable insulation system to expose the electrical conductor to a standard length; preparing the insulation adjacent to the electrical conductor to an end condition; installing the electrical conductor in an injection press; injecting an insulating repair material into the injection press such that it covers the electrical conductor; and heating and cooling the repair material to assure a bond between the injected insulating repair material and the insulation to create a repaired section. In such an example, the standard length may be between about 0.5 inches, or approximately 1 .27 centimeters, and about 24 inches, or approximately 60.96 centimeters.

[00181 ] As an example, a method can include preparing pre-existing insulation to an end condition, which may include preparing the insulation to have a blunt edge (e.g., a stepped edge) or, for example, a tapered edge (e.g., a penciled edge).

[00182] As an example, a repaired power cable can include one or more electrical conductors; insulation encasing the conductive wire(s) where the insulation includes one or more reinforced sections of defective insulation and one or more sections of non-defective insulation; at least one bond between each of the reinforced sections of defective insulation and the non-defective insulation. In such an example, the reinforced section of defective insulation can include two parts of an extruded meltable fluoroplastic sandwiching one part of an injection-molded meltable fluoroplastic having a different melting point.

[00183] As an example, a reinforced section of defective insulation can include two parts of an extruded meltable fluoroplastic sandwiching one part of a polymer made up of one or more polyaryletherketones. As an example, a reinforced section of defective insulation can include one or more parts of an extruded meltable fluoroplastic and one or more parts of an injection-molded meltable fluoroplastic having a different melting point.

[00184] As an example, a method for repairing insulated cables and a repaired cable may be provided as to cables that can be used in one or more types of harsh environments (e.g. , subsea, geothermal, SAGD, etc.). As an example, polymer can be injection molded and bonded to a power cable to repair a polymeric insulation layer of the power cable where the power cable may be destined for long-term use in one or more harsh environments (e.g. , use of the order of a month or more, of the order of a year or more, etc.). As an example, a repair method can help to allow for manufacture of longer cables. As an example, a polymer may be or include one or more of a polyaryletherketone, an ethylene propylene diene monomer / terpolymer (e.g., EPDM), an epitaxial co-crystalline alloy (ECA), an ethylene tetrafluoroethylene (ETFE), a fluorinated ethylene propylene (FEP), a perfluoroalkoxy polymer resin (PFA), a methacrylated fatty acid (MFA), a polyvinylidene fluoride (PVDF), etc.

[00185] As an example, one or more methods described herein may include associated computer-readable storage media (CRM) blocks. Such blocks can include instructions suitable for execution by one or more processors (or cores) to instruct a computing device or system to perform one or more actions. As an example, a computer-readable storage medium can be non-transitory, not a carrier wave and not a signal.

[00186] According to an embodiment, one or more computer-readable media may include computer-executable instructions to instruct a computing system to perform one or more actions associated with injection molding. For example, an injection molding system can include a controller that includes a microcontroller and/or a processor (e.g., or processors) and memory accessible by the

microcontroller and/or the processor where instructions stored in the memory may be executed to cause the controller to control one or more operations of the injection molding system (e.g. , open/close of a mold, temperature, pressure, cooling, timing, etc.).

[00187] Fig. 15 shows components of an example of a computing system 1500 and an example of a networked system 1510. As an example, the computing system 1500 may be operatively coupled to an injection molding system and/or be part of an injection molding system.

[00188] As shown in Fig. 15, the system 1500 includes one or more processors 1502, memory and/or storage components 1504, one or more input and/or output devices 1506 and a bus 1508. According to an embodiment, instructions may be stored in one or more computer-readable media (e.g., memory/storage components 1504). Such instructions may be read by one or more processors (e.g. , the processor(s) 1502) via a communication bus (e.g., the bus 1508), which may be wired or wireless. The one or more processors may execute such instructions to implement (wholly or in part) one or more attributes (e.g. , as part of a method). A user may view output from and interact with a process via an I/O device (e.g., the device 1506). According to an embodiment, a computer-readable medium may be a storage component such as a physical memory storage device, for example, a chip, a chip on a package, a memory card, etc. [00189] According to an embodiment, components may be distributed, such as in the network system 1510. The network system 1510 includes components 1522- 1 , 1522-2, 1522-3, . . . , 1522-N. For example, the components 1522-1 may include the processor(s) 1502 while the component(s) 1522-3 may include memory accessible by the processor(s) 1502. Further, the component(s) 1522-2 may include an I/O device for display and optionally interaction with a method. The network may be or include the Internet, an intranet, a cellular network, a satellite network, etc.

[00190] Although only a few examples have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the examples. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, means- plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. It is the express intention of the applicant not to invoke 35 U.S. C. § 1 12, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the words "means for" together with an associated function.

Claims

CLAIMS What is claimed is:

1 . A cable comprising:

a conductor that comprises a first length, a second length and an intermediate length between the first length and the second length;

a first length of extruded insulation disposed about the first length of the conductor;

a second length of extruded insulation disposed about the second length of the conductor; and

injection molded material disposed about the intermediate length of the conductor.

2. The cable of claim 1 wherein the conductor comprises copper.

3. The cable of claim 1 wherein the extruded insulation comprises polyether ether ketone.

4. The cable of claim 1 wherein the extruded insulation comprises epitaxial co- crystaline alloy fluoroplastic.

5. The cable of claim 1 wherein the extruded insulation comprises ethylene propylene diene monomer (M-class) rubber.

6. The cable of claim 1 wherein the injection molded material bonds to a portion of the first length of extruded insulation that is adjacent to the intermediate length of the conductor and wherein the injection molded material bonds to a portion of the second length of extruded insulation that is adjacent to the intermediate length of the conductor.

7. The cable of claim 1 wherein the injection molded material contacts the conductor.

8. The cable of claim 1 wherein the first length of the conductor comprises a length of at least 10 meters.

9. The cable of claim 1 wherein the second length of the conductor comprises a length of at least 10 meters.

10. The cable of claim 1 wherein the intermediate length of the conductor comprises a length of at least 1 centimeter.

1 1 . The cable of claim 1 wherein the intermediate length of the conductor comprises a length that is less than approximately 50 centimeters and that is greater than approximately 1 centimeter.

12. The cable of claim 1 comprising a layer disposed about the injection molded material.

13. The cable of claim 12 wherein the layer comprises lead (Pb).

14. The cable of claim 12 wherein the layer comprises a fluoropolymer.

15. A method comprising:

providing an intermediate portion of a cable conductor in an injection mold; injecting material into the injection mold; and

forming a layer of the material about the cable conductor.

16. The method of claim 15 wherein the intermediate portion of the cable conductor is intermediate a first length of the cable conductor that comprises extruded insulation and a second length of the cable conductor that comprises extruded insulation.

17. The method of claim 15 comprising detaching excess material from the layer of the material about the cable conductor.

18. The method of claim 15 comprising forming another layer about the layer of the material.

19. A multiphase cable for an electric submersible pump motor, the multiphase cable comprising:

conductors wherein at least one of the conductors comprises a first length, a second length and an intermediate length between the first length and the second length; a first length of extruded insulation disposed about the first length of the conductor; a second length of extruded insulation disposed about the second length of the conductor; and injection molded material disposed about the intermediate length of the conductor.

20. The multiphase cable of claim 19 comprising three conductors.