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There are two styles of Downhole Power Cables: flat and round. They come in a wide variety of configurations. Each manufacturer has a different configuration of materials, dimensions, and ratings to accommodate many different well conditions.
Both, flat and round have in common: material, construction, and ratings. They are constructed from inside out starting with: a conductor (solid or stranded), insulation, a jacket, on round cable it surrounds all three conductors, on flat cable it surrounds all three conductors individually with a conforming tape and braid around each jacket individually, an armor that is interlocking. Wells with high temperature, corrosive gases, and liquids require a lead sheath to protect the insulation and conductor. When lead is used it is normally found in flat cable over the insulation with a braid over the lead to help hold its shape. Wells with low temperature and bottom hole pressure are good candidates for an unarmored cable. It has the same basic construction and materials except the jacket are a polyethylene that also serves as the armor.
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