Pushing the Limits of Traditional Cable Reuse Criteria: Innovations in Testing and Major Repairs of Power Cables for Electric Submersible Pumps in Orinoquia Oil Fields

To optimize traditional inspection, repair, and reuse methodologies for power cables with integrated capillary tubes in electric submersible pump (ESP) systems, a novel approach was developed to assess the condition of these cables within the challenging environments of Colombia's Orinoquia oil fields. This methodology facilitates cable recovery through extensive repairs that support circular economy models, capturing efficiencies that lower the organization's carbon footprint while preserving the reliability of ESP systems that are run with used cable. The approach includes an in-depth review of traditional cable testing methods, such as electrical insulation resistance testing, visual armor inspections, and capillary tube integrity assessments. An advanced workshop-based electrical testing protocol was introduced alongside a new cable repair procedure. This enhanced repair process applies when issues such as significant armor damage, electrical test failures, blockages or leaks in the capillary tube, or uncertain run life are identified. In these cases, the new methodology enables reuse by removing the cable's entire armor, exposing the electrical phases and capillary tube for detailed inspection. The process then involves cleaning, conditioning, and repairing each electrical phase, assessing and restoring the lead sheath, verifying insulation integrity, and securing necessary repairs. The capillary tube is installed or reinstalled, and the cable armor is reinstalled, leaving the power cable ready for field use. This paper presents the implementation of extended insulation testing, which has significantly enhanced the detection of internal cable damage. In Ecopetrol´s Orinoquía oil fields standard methodologies have previously missed such damages, underscoring the need for more rigorous inspection protocols. By identifying potential anomalies prior to reuse, the approach lessens operational risks and reduces premature failures. Through this methodology, over 150,000 ft of cable have been recovered, with 20 wells installed as of end of December 2024 without the need for new cable purchases—achieving a 60% cost reduction compared to new cables while maintaining operational reliability and reducing CO₂ emissions by 310 tons. An evaluation of electrical testing techniques and insulation material inspection after armor removal, along with real-world applications, provides new insights for enhancing cable inspection, repair, and reuse practices. Integrating the IEEE (Institute of Electrical and Electronics Engineers) and other standards with comprehensive repair protocols delivers an innovative approach that improves the integrity and longevity of reused cables. This advancement supports the ESP Operator by reducing costs, increasing reliability, and reducing early-stage failures, thereby enhancing field profitability. Additionally, this methodology enables reuse of cables with previously unusable capillary tubes, optimizing resource use and adding value through contributions to a circular economy.