Improved High-Temperature ESP Motor Lead Extension Cables for Reliable Geothermal Power Production

The U.S. Department of Energy is developing geothermal power production as an environmentally-clean, renewable energy source. For this technology to be commercially viable, several technologies are needed to enable long-term, reliable operation of the well pumps in the downhole environment. This project will demonstrate the performance of cable extensions based on novel inorganic insulation materials that are capable of long-term, high-voltage, high-temperature operation. In Phase I, the electrical and mechanical properties of the cable insulation materials will be characterized, and the cables will be designed based on the results of these tests. Next, prototype cable systems will be fabricated. Finally, electrical, mechanical, and environmental characterizations of the power cables will be performed to demonstrate their applicability to geothermal power generation. Commercial Applications and other Benefits as described by the awardee: In addition to the application for geothermal energy production, the technology should be applicable to Steam Assisted Gravity Drainage for the production of heavy oil and to deepwater, offshore, high-temperature high-pressure wells for the production of conventional oil and gas. Other potential applications include use in motor windings, downhole heaters for oil recovery, and micro-hole drilling operations.