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Where a lead (Pb) barrier layer thickness could be reduced for one or more assemblies (e.g., conductor assemblies), a reduction in mass of a cable may be achieved in comparison to a braided layer strategy. Talc or talcum is a clay mineral composed of hydrated magnesium silicate, for instance, consider one or more of the chemical method H2Mg3(SiO3)four or Mg3Si4O10(OH)2. For instance, an XLPE material can embrace talc to offer more thermal and chemical stability to uncured XLPE at high temperatures. Such a polymeric material could also be blended with one or more other supplies resembling, for instance, polypropylene (PP) and/or talc. Talc shouldn't be soluble in water, however is barely soluble in dilute mineral acids. Mohs scale of mineral hardness, primarily based on scratch hardness comparability, defines worth 1 because the hardness of talc. The value of the storage modulus above the melting point is a operate of the crosslink density of the material. Both samples have considerably the same storage modulus in the temperature vary from approximately −70 degrees C. as much as roughly one hundred fifteen degrees C. The worth of storage modulus of the fully cured pattern tends to be about one order of magnitude greater than that of uncured pattern within the high temperature range, higher than the melting level of XLPE.

In the example of FIG. 13, the XLPE is PolyOne SYNCURE™ S1054A (PolyOne Corporation) ("S1054A material"). As to a silane cure system, in this instance a polyethylene master batch can be grafted with silane teams that are combined with a catalyst in an extruder. In the instance of FIG. 23, the a number of conductors 2310 may be formed from a uncooked conductor materials (e.g., copper) that has been drawn to a normal wire dimension, annealed, and plated in both a stranded or stable configuration. In such an example, the one or more cushion layers could be made by extrusion of XLPE (e.g., XPLE thermoset material). The info of the plot 1400 confirms that immersing the extruded XLPE film in water for roughly 12 hours at approximately eighty degrees C. is efficient for a totally curing process. A crosslinking process can be relatively sluggish, for example, consider situations of a minimum of eight hours in sizzling water or steam at 80 degrees C. or up to 5 weeks at room temperature.

Given the foregoing knowledge, XLPE annealing at ambient conditions is achieved in about one month and is achieved in sizzling water or steam for 12 hours at approximately 80 levels C. (e.g., to complete the curing process). A technique can include controlling a manufacturing process as to a number of of such parameters to achieve a desired quantity of crosslinking (e.g., crosslink density of XLPE), for instance, at a sure time during manufacturing of a energy cable, which may have a optimistic affect on a number of subsequent processes of the production course of for the facility cable (e.g., consider lessening danger of deformation during armoring of the ability cable). As an example, a number of cushion layers can scale back risk of lead (Pb) deformation during an armoring course of. An electric submersible pumping system can embrace an electric submersible pump that receives electricity from an electric energy supply by means of a power cable connected there between, the ability cable together with a protective layer that includes XLPE over a lead (Pb) barrier layer. For instance, a energy cable to be used with an electric submersible pumping system can include a conductor, an insulation layer over the conductor, a barrier layer atop the insulation layer, and a protective layer that includes XLPE over the barrier layer.

As an example, a power cable such as the cable seven-hundred of FIG. 7 can be utilized with an electric submersible pumping system. A flat energy cable may be used as a energy cable in an electric submersible pumping system. A system (e.g., a mixture) can embody about 95 phr S1054A and about 5 phr S1000B (e.g., a catalyst batch element). Such a silane cure system may be employed without a further crosslinking process. As to crosslinking, consider the next three approaches as a number of examples: silane cure system, steady vulcanization and electron beam crosslinking. Made by following the SIOPLAS E two-step expertise, SYNCURE™ XLPE affords an alternative to natural peroxide, radiation and reactor copolymer crosslinking processes. XLPE is a crosslinked polyethylene with acceptable mechanical, thermal, and dielectric properties. In some embodiments, a flat power cable could embrace one or more conductors, an insulation layer disposed over each conductor, a lead (Pb) barrier layer disposed over every insulation layer, a cushion layer of crosslinked polyethylene (XPLE) that can embody one or more additives that could be included in an extrudate that includes polyethylene, and an armor layer. As to excessive temperature efficiency, the cable seven-hundred of FIG. 12 can exhibit improved excessive temperature performance when compared to the cable 1200 of FIG. 12. For example, because the extruded cushion layer 760 can be thicker than the braided layer 1260, the extruded cushion layer 760 can permit for more room for thermal enlargement, which can help to forestall lead (Pb) from deforming at high temperatures.

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