阅读说明：本技术 用于增强型电磁线绝缘材料的系统和方法 (System and method for reinforced magnet wire insulation ) 是由 L·帕尔美特 B·利米 D·伦克 K·约翰逊 于 2018-07-16 设计创作，主要内容包括：描述了一种制造适用于电动潜油马达应用的增强型电磁线绝缘材料的方法。所述方法包括将铜电磁线拉伸至一定尺寸并清洁所述铜电磁线。所述方法包括将所述铜电磁线拉动通过聚酰亚胺缠绕机以产生缠绕的铜电磁线,以及将所述缠绕的铜电磁线围绕线轴放置。所述方法包括通过使所述缠绕的电磁线穿过包括感应线圈的管解绕来加热所述缠绕的铜电磁线,以及通过在所述管的内部产生至少部分真空从所述加热的缠绕铜电磁线中去除湿气。所述方法包括在去除湿气之后重新拉伸所述缠绕的铜电磁线通过挤压模具。所述方法包括将熔融的PEEK施加到所述缠绕的铜电磁线上以产生增强型电磁线,以及将所述增强型电磁线卷绕到感应马达中。(A method of making an enhanced magnet wire insulation material suitable for use in electrical submersible motor applications is described. The method includes drawing a copper magnet wire to a size and cleaning the copper magnet wire. The method includes drawing the copper magnet wire through a polyimide winder to produce a wound copper magnet wire, and placing the wound copper magnet wire around a spool. The method includes heating the wound copper magnet wire by unwinding the wound magnet wire through a tube including an induction coil, and removing moisture from the heated wound copper magnet wire by creating at least a partial vacuum inside the tube. The method includes redrawing the wound copper magnet wire through an extrusion die after removing moisture. The method includes applying molten PEEK onto the wound copper magnet wire to create a reinforced magnet wire, and winding the reinforced magnet wire into an induction motor.)

1. A method of making an enhanced magnet wire insulation material suitable for use in electrical submersible motor applications, the method comprising:

drawing the copper magnet wire to a certain size;

cleaning the copper magnet wire;

drawing the copper electromagnetic wire through a polyimide winder to produce a wound copper electromagnetic wire, and placing the wound copper electromagnetic wire around a spool;

heating the wound copper magnet wire by unwinding the wound magnet wire through a tube comprising an induction coil;

removing moisture from the heated wound copper magnet wire by creating at least a partial vacuum inside the tube;

redrawing the wound copper magnet wire through an extrusion die after moisture removal,

applying molten PEEK to the wound copper magnet wire to create a reinforced magnet wire; and

winding the enhanced magnet wire into an induction motor for operating an electric submersible pump.

2. The method of claim 1, wherein heating the wound magnet wire comprises heating the wound magnet wire to a temperature of 300 ° f.

3. The method of claim 1, wherein heating the wound magnet wire comprises sliding the wound magnet wire through an interior of the induction coil.

4. The method of claim 1, wherein the at least partial vacuum is generated inside the tube by a vacuum pump coupled to the inside of the tube.

5. The method of claim 4, wherein the at least partial vacuum is in a space between the wound magnet wire and an inner diameter of the tube.

6. The method of claim 1, further comprising closing an end of the tube with a rubber stopper to at least partially prevent air from entering the tube.

7. The method of claim 1, wherein winding the enhanced magnet wire into the induction motor further comprises winding the enhanced magnet wire through an open slot of a stator of the induction motor, wherein the open slot has an empty space around the enhanced magnet wire.

8. The method of claim 7, further comprising cooling the induction motor by convection by flowing motor oil through the empty spaces in the open slots around the enhanced magnet wires.

9. The method of claim 1, wherein the wound enhanced magnet wire is suitable for temperatures of about 550 ° f when the induction motor is used to operate the electric submersible pump.

10. A system for manufacturing an enhanced magnet wire insulation material suitable for use in electrical submersible motor applications, the system comprising:

a PEEK wire extruder;

a tube extending between the PEEK wire extruder and a spool comprising polyimide wound copper electromagnetic wire;

the tube includes:

an induction coil inside the tube;

a vacuum pump operably coupled to the interior of the tube;

a spool side of the tube comprising a plug having a bore extending through the plug;

wherein the polyimide wrapped copper magnet wire extends from the spool, through the hole in the plug, through the tube, and into the PEEK wire extruder.

11. The system of claim 10, wherein the tube has an at least partial vacuum inside the tube between the polyimide wrapped copper magnet wire and an inner diameter of the tube.

12. The system of claim 10, wherein the polyimide wrapped copper magnet wire extends through an interior of the induction coil when the polyimide wrapped copper magnet wire extends through the tube.

13. A method, comprising:

drawing the magnet wire through a polyimide winder to produce a wound magnet wire;

heating the wound magnet wire in a tube comprising an induction coil;

removing moisture from the heated wound magnet wire by creating at least a partial vacuum inside the tube;

redrawing the wound magnet wire through an extrusion die after moisture removal;

applying an organic polymer thermoplastic material to the wound copper magnet wire to create an enhanced magnet wire; and

winding the enhanced magnet wire into an induction motor for operating an electric submersible pump.

14. The method of claim 13, wherein heating the wound magnet wire comprises sliding the wound magnet wire through an interior of the induction coil.

15. The method of claim 13, wherein the at least partial vacuum is generated inside the tube by a vacuum pump coupled to the inside of the tube.

16. The method of claim 15, wherein the at least partial vacuum is in a space between the wound magnet wire and an inner diameter of the tube.

17. The method of claim 13, further comprising closing an end of the tube with a rubber stopper to at least partially prevent air from entering the tube.

18. The method of claim 13, wherein winding the enhanced magnet wire into the induction motor further comprises winding the enhanced magnet wire through an open slot of a stator of the induction motor, wherein the open slot has an empty space around the enhanced magnet wire.

19. The method of claim 18, further comprising cooling the induction motor by convection by flowing motor oil through the empty spaces in the open slots around the enhanced magnet wires.

20. The method of claim 13, further comprising:

prior to the pulling of the magnet wire,

drawing the magnet wire to a dimension; and

and cleaning the copper magnet wire.

Technical Field

The present disclosure relates generally to the field of magnet wires, and more particularly to enhanced magnet wire insulation for electric submersible pump applications.

Background

Currently available magnet wires are not suitable for certain motor applications. In particular, magnet wires in motors for oil or gas pumping applications should be particularly reliable. When the motor is used in an oil or gas well, the failure or short circuit of the electrical line is particularly costly because the motor is located deep underground. If cracks form in the insulation material of the magnet wires in the motor, these cracks can lead to premature motor failure.

In the case of an Electric Submersible Pump (ESP), the failure of the motor can be catastrophic, as it means that the device must be removed from the well for servicing. ESP assemblies specifically require the use of magnet wires capable of withstanding high temperatures deep in the subsurface. Additionally, the ESP pump may sometimes leak, thereby allowing some water to enter the motor. In all types of pumping applications, a magnet wire with suitable water resistance to prevent short circuits when exposed to such leaks would be advantageous. Finally, magnet wires are often damaged during transport, resulting in breaks, scratches or pinholes. Such damage can reduce the life expectancy of the wire. Magnet wires with enhanced durability during transport are advantageous in all types of magnet wire applications.

Currently available electromagnetic wires are sometimes insulated with polyimide films, for example

(trademark of DuPont (E.I. Du Pont De Nemours and Company) tape). Polyimide films are a class of high temperature, abrasion and corrosion resistant synthetic polymer resins that are used primarily as coatings or films on substrate materials. Although, for the sake of brevity, this description uses

As an example of a polyimide film, but the various embodiments are not limited herein to the use of a particular polyimide film, such as

A belt. Although it is used for

The highest dielectric strength is found in any wire insulation material currently available, but it also has inherent weaknesses.

Readily absorb water (hygroscopic) and degrade rapidly. For use in

The adhesive with the tape attached to the wire may also delaminate at the extremely high temperatures of deep wells. Magnet wires wound with Kapton tape are also susceptible to damage during shipping.

Another insulation material currently available for magnet wires is an organic polymer thermoplastic insulation material such as PEEK (polyetheretherketone). Although PEEK has sufficient dielectric strength at room temperature, the dielectric strength drops rapidly when used above 500 ° f. The motor temperature in a high temperature well may exceed 550 ° f. Therefore, PEEK is also not an ideal wire insulation material for ESP motors.

Accordingly, there is a need for a system and method of producing reinforced magnet wire insulation that is more water resistant, more durable during transportation, and reliable for ESP applications at high temperatures.

Drawings

Embodiments of the disclosure may be better understood by reference to the following drawings.

FIG. 1 is a flow chart illustrating an exemplary method for manufacturing enhanced magnet wire insulation for use in an Electric Submersible Pump (ESP) system.

Fig. 2A shows a cross-sectional view of the ESP motor of fig. 3 taken along line 2A-2A, which contains a plurality of slots including exemplary enhanced magnet wires employing one or more illustrative embodiments of insulating material.

Fig. 2B shows a detail of the single wire way of fig. 2A, which includes an exemplary reinforced magnet wire employing the insulation material of the illustrative embodiments.

FIG. 2C illustrates a cross-sectional view taken along line 2C-2C of FIG. 2B, showing the combination of the insulating layers of an exemplary magnet wire.

Fig. 3 shows an exemplary ESP three-phase induction motor for use in one or more illustrative embodiments.

FIG. 4 illustrates an exemplary ESP assembly deployed underground that includes one or more embodiments of the enhanced magnet wire of the illustrative embodiments.

Fig. 5 is a schematic diagram of an induction coil heating system of an illustrative embodiment.

Detailed Description

Systems and methods for reinforced magnet wire insulation will now be described. In the following exemplary description, numerous specific details are set forth in order to provide a more thorough understanding of various embodiments. It will be apparent, however, to one skilled in the art that the present invention may be practiced without all aspects of the specific details set forth herein. In other instances, specific features, quantities, or measurements that are well known to those of ordinary skill in the art have not been described in detail so as not to obscure the various embodiments.

As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a wire includes one or more wires.

"coupled" refers to a direct connection or an indirect connection (e.g., at least one intermediate connection) between one or more objects or components. The phrase "directly attached" refers to a direct connection between objects or components.

Various embodiments provide a system and method for enhanced magnet wire insulation for use in Electric Submersible Pump (ESP) applications. While various embodiments are described in terms of oil or gas pumping operations, there is no intent to limit various embodiments to such operations herein.

The system of various embodiments includes an ESP system. The ESP system of the illustrative embodiment includes magnet wires 250 (shown in fig. 2C), reinforced insulation 230, 240 for the magnet wires (shown in fig. 2C), a pump 420 (shown in fig. 3), and an electric submersible motor 300 (shown in fig. 3). FIG. 1 illustrates one or more methods of manufacturing enhanced magnet wire insulation material for use in an ESP system. At step 100, copper magnet wire 250 may be drawn to a size and cleaned using methods known in the art. At step 110, the copper magnet wire 250 may be pulled through a polyimide film (tape) winder to wind the copper magnet wire 250. The polyimide tape 230 may include an adhesive on a surface thereof, or the adhesive may be separately applied. The adhesive is in contact with magnet wire 250 and may be heat activated to provide bonding to magnet wire 250. One type of polyimide tape 230 that can be used is poly (4,4 '-oxydiphenylene-pyromellitimide), also known as poly (4, 4' -oxydiphenylene-pyromellitimide)

Various types of polyImide bands 230 may be suitable, such as bands of the type FN, HN and HPP-STOther polyimide tapes of similar chemistry may also be used.

While polyimide tape 230 has the highest dielectric strength of any wire insulation material currently available alone, it has significant mechanical disadvantages when used in ESP applications. First, the polyimide tape 230 is hygroscopic (it readily absorbs water) and degrades in the presence of water. In deep wells such as oil or gas wells, a small amount of water may enter the motor, making the polyimide tape insulation 230 susceptible to short circuits, which is a serious system failure. Such failures are catastrophic since the ESP motor is located deep in the well. Another known problem with the polyimide tape insulation 230 is that it may delaminate at extremely high temperatures, such as above 300 ° f. In addition, transporting magnet wires 250 with polyimide insulation 230 may cause scratches or pinholes in polyimide insulation 230, thereby reducing its lifetime and effectiveness. In addition, excessive vibration may also weaken the adhesive of the polyimide tape 230. This mechanical disadvantage of polyimide may cause the belt to loosen and cause direct shorting of the motor 300. Finally, if the wire 250 is not very clean when applying the polyimide tape 230, the adhesive will not adhere properly and the polyimide 230 may be easily damaged during winding, which may also cause the windings to short.

To overcome these and other disadvantages of the polyimide tape 230, for example, at step 120, the polyimide wrapped magnet wire 250 is then redrawn through an extrusion die (die) to apply an organic polymer thermoplastic material 240, such as molten PEEK (polyetheretherketone), onto the wrapped wire, resulting in a twice insulated wire 220. Other organic polymer thermoplastics having similar chemistry to PEEK may also be employed.

Care must be taken to prevent air and moisture from being trapped between the polyimide tape 230 and the layer of polymeric thermoplastic 240. The polyimide tape 230 contains a very low percentage of moisture due to its chemical nature. When the polyimide tape 230 is heated in the motor 300, there may occur a problem in that moisture contained in the polyimide tape 230 boils and may cause the polymeric thermoplastic material layer 240 to bubble or swell. The foaming and/or bulging may undesirably result in popping in the polymeric thermoplastic material 240. To address this problem, at heating step 115, magnet wire 250 wrapped with polyimide 230 may be heated to 300 ° f using induction coil 500 (shown in fig. 5) before magnet wire 250 enters polymeric thermoplastic 240 extrusion die (extruder) 505 (shown in fig. 5). Thus, all or substantially all of the moisture may boil out of the polyimide tape 230 before the polymeric thermoplastic material 240 (such as PEEK) is extruded over the polyimide tape 230 layer. Wound magnet wire 250 may be placed around spool 525 (as shown in fig. 5) to facilitate handling thousands of feet of wound magnet wire 250.

Fig. 5 shows an induction coil heating system of an illustrative embodiment. The induction coil 500 may be placed within a metal tube 535 bolted to the extruder 505. Tube 535 is about 4 feet in length and about 3 inches in diameter. The inductive coil 500 may be a resistive coil about one inch long that plugs into a 220V jack. The induction coil 500 may extend around the inner diameter of the tube 335, surrounding the magnet wire 250 as the magnet wire 250 is fed through the interior of the tube 535. The entrance of the tube 535 on the spool side of the tube 535 may include a rubber stopper 520 with a central bore just large enough for the wound magnet wire 250 to pass through the stopper 520 and into the tube 535. The rubber stopper 520 may prevent air from entering the tube 535. In the illustrative example, the diameter of the tube 535 may be about three inches for a wound magnet wire 250 having a diameter of about 0.09 to 0.125 inches. A tube 535 having a larger diameter than the wound magnet wire 250 may provide a space inside the tube 535 that may achieve a good vacuum without drawing in outside air. A mini vacuum pump 510 may be coupled to the tube 535 through a hose 575 to remove air and moisture from the interior of the tube 535 and to help enhance the removal of moisture from the polyimide tape 230. Only a partial vacuum may be required to achieve the desired moisture removal. The electromagnetic wire 250 wound with polyimide 230 may be fed from a spool 525 into a tube 535. Spool 525 can hold 25 ten thousand feet of wound magnet wire 250. Moisture may be removed from polyimide layer 230 as magnet wire 250 wrapped with polyimide 230 passes through induction coil 500 and/or the interior of tube 535. The moisture-removed spooled magnet wire 250 may then enter an extruder 505 to add the PEEK insulation layer 240.

Returning to FIG. 1, at step 130, the PEEK die forces the molten organic polymer thermoplastic material 240 around the polyimide tape layer 230, sealing in the polyimide tape 230, and creating a reinforced magnet wire 220. In an illustrative example, PEEK pellets may be placed in a pellet hopper 530 to extrude the polymeric thermoplastic material 240 onto the polyimide layer 230 in an extruder 505. At step 140, the enhanced magnet wire may now be wound onto the motor 300 in a conventional manner and used for ESP applications.

In the method of the illustrative embodiment, it should be noted that two sections of reinforced magnet wire 220 can be spliced together and still have a seamless, uniform insulating coating over the underlying polyimide tape 230. To this end, for example, a PEEK shrink tube may be slipped over one of the reinforced magnet wires 220 to be spliced. The ends of the two reinforced magnet wires 220 can then be crimped together with sufficient force using a suitable wire press and die such that the reinforced magnet wires 220 are cold welded together. The generated burrs may be filed smoothly and the polyimide tape 230 may be applied on the bare wire. The PEEK shrink tubing may then be slipped over the splice (and centered). Finally, a small "clamshell" heater or similar device may be placed around the splice. The heater may then be turned on until the temperature near the splice reaches 700 ° f. The heater should then be immediately turned off and removed. The temperature of 700 ° f is very important because at this temperature the PEEK shrink tubing (and other shrink tubing of similar chemistry) (and PEEK on the wire) will cure and fuse together to form a seamless splice.

FIG. 2A details one or more arrangements of copper wire windings insulated with the enhanced magnet wire insulation of the illustrative embodiments. Fig. 2A is a cross-section along line 2A-2A of fig. 3 and shows a cross-sectional view of the stator 320 surrounding the rotor assembly 330. An organic polymer thermoplastic material 240, such as PEEK, can be used to create wire insulation that is not affected by water and has no sticking problems. The organic polymer thermoplastic material 240, such as PEEK, has a low coefficient of friction, which is advantageous when winding the stator 320. PEEK can also be well resistant to shipping and winding because it has no seams or wraps and is not easily damaged during shipping or winding. However, PEEK alone is not conducive to magnet wire insulation for ESP applications because its dielectric strength rapidly decreases at temperatures above 500 ° f.

The enhanced magnet wire 220 of the illustrative embodiment combines the advantages of greatly improved insulation quality and reliability. The reinforced magnet wire 220 will have a hard and smooth surface so that varnish or epoxy filler may no longer be needed to fill the stator slots 200 because there may be no fear of scratching. In addition, this advantage saves production time and costs. The lower coefficient of friction of the organic polymer thermoplastic material 240 may improve the winding process, for example, by making the reinforced magnet wire 220 easier to insert into the stator slot 200, reducing the likelihood of damaging the wire during the winding process, and reducing the physical effort required by personnel during the winding process. Importantly, the resulting reinforced magnet wire 220 may be more water resistant than wires insulated using any of the previous insulating materials alone. When incorporated into a system having a three-phase induction, permanent magnet, or other motor 300 for ESP applications, the method results in an improved system for lifting oil or gas from a production well. As contemplated by those skilled in the art using these materials, the method and other embodiments thereof may produce enhanced magnet wire 220, which may then be wound onto motor 300 and used in ESP applications with increased reliability compared to previous solutions.

Fig. 2B shows a detail of the exemplary slot of fig. 2A. An exemplary enhanced magnet wire 220 is shown in slot 200 of fig. 2B. As shown in one or more illustrative embodiments, magnet wire 250 is shown protected by two layers of insulating material to form enhanced magnet wire 220. A combination of one or more embodiments of the enhanced magnet wire insulating material layers may be used to protect the enhanced magnet wire 220. An organic polymer thermoplastic material 240, such as PEEK, may provide improved wear resistance for magnet wire 220. Thus, slot 200 may be "open," with no varnish or epoxy filled space 225 in slot 200 not occupied by reinforced magnet wires 220. Accordingly, the sump 200 may include voids that allow motor oil to freely move through the space 225 in the sump 200. The motor oil moving through the open slot 200 may allow the motor 300 to cool by convection, such that the motor 300 operates cooler than when an insulator (such as varnish or epoxy) fills the slot 200.

FIG. 2C illustrates a cross-section of the enhanced magnet wire 220 taken along line 2C-2C of FIG. 2B. The copper magnet wires 250 are encased in a polyimide tape 230, which is itself encased in an organic polymer thermoplastic material 240, to produce one or more embodiments of the illustrative embodiment reinforced magnet wires 220. The illustrative embodiments of the enhanced magnet wire 220 may be suitable for temperatures of 550 degrees f and/or about 550 degrees f, such as when the motor 300 is used to operate an electric submersible pump 420 in a downhole oil and/or gas well. The advantages of the enhanced insulation and methods and systems described herein are not limited to a single layer of each type of insulation, and logical extensions thereof may be envisioned by one of ordinary skill in the art, all of which are embodiments.

Fig. 3 shows an exemplary ESP employing a three-phase induction motor 300 for use in the system of the illustrative embodiment. Although embodiments are not limited to use in a three-phase induction motor 300, such a motor may be used in systems of various embodiments to improve the advantages of enhanced magnet wire 220 insulation. The three-phase induction motor 300 of the system of various embodiments may be, for example, a three-phase "squirrel cage" induction motor as is known in the art. In some embodiments, the enhanced magnet wire 220 may be manually wound around the motor 300. The motor 300 of the system of various embodiments may operate at 15 to 1,000 horsepower, but the various embodiments are not limited to this example. Also shown are end coils 340 and main leads 350. The main conductor 350 is connected to a power cable 470 (shown in fig. 4) of the motor 300.

Fig. 4 provides an illustration of an exemplary ESP system 400 arranged to pump natural gas and/or oil and insulated with the enhanced magnet wire 220 of the exemplary embodiment. As shown, the system also includes a power cable 470, production tubing 410, a multistage centrifugal pump 420, a gas separator (not shown), a suction port 430, one or more seals 440 (motor protector), downhole sensors 460, and a motor such as motor 300 utilizing enhanced magnet wire 220. The casing size of the illustrated ESP may be in the range of about 4.5 inches to 9 inches in outer diameter, although the exemplary embodiments are not limited to these examples.

The operational life of the ESP system 400 may be directly related to the quality and reliability of the power cable 470. The power cable 470 for the systems of various embodiments may be round or flat and configured to operate in a temperature range from about-60 ° f to about 450 ° f. The power cable of the system should provide extreme durability and reliability under a variety of conditions, including resistance to decompression and fatigue, and have a corrosion-resistant barrier against fluids and gases. In one or more illustrative embodiments, cables made in accordance with the ISO 9001 standard may be preferred.

The system of the illustrative embodiments may alternatively include a Permanent Magnet (PM) motor. PM motors use wound stators that may benefit from the enhanced insulated magnet wire described herein. Such motors are well known in the art. Other motors suitable for ESP applications may also be used as part of the system of the illustrative embodiments.

The system of the illustrative embodiments may alternatively include a Permanent Magnet (PM) motor. PM motors use wound stators that may benefit from reinforced insulated magnet wire.

One or more embodiments enable systems and methods to provide enhanced magnet wire insulation for ESP applications. Systems and methods for reinforced magnet wire insulation are described. An illustrative embodiment of a method of making an enhanced magnet wire insulation suitable for use in electrical submersible motor applications comprises: drawing the copper magnet wire to a certain size; cleaning the copper electromagnetic wire; drawing the copper electromagnetic wire through a polyimide winder to produce a wound copper electromagnetic wire, and placing the wound copper electromagnetic wire around a spool; heating the wound copper magnet wire by unwinding the wound magnet wire through a tube comprising an induction coil; removing moisture from the heated wound copper magnet wire by creating at least a partial vacuum inside the tube; redrawing the wound copper magnet wire through an extrusion die after moisture removal; applying molten PEEK to a wound copper magnet wire to produce an enhanced magnet wire; and winding the enhanced magnet wire into an induction motor for operating the electric submersible pump. In some embodiments, heating the wound magnet wire comprises heating the wound magnet wire to a temperature of 300 ° f. In certain embodiments, heating the wound magnet wire comprises sliding the wound magnet wire through an interior of the induction coil. In some embodiments, the at least partial vacuum is generated inside the tube by a vacuum pump coupled to the inside of the tube. In certain embodiments, the at least partial vacuum is in the space between the wound magnet wire and the inner diameter of the tube. In some embodiments, the method further comprises closing an end of the tube with a rubber stopper to at least partially prevent air from entering the tube. In certain embodiments, winding the enhanced magnet wire into the induction motor further comprises winding the enhanced magnet wire through an open slot of a stator of the induction motor, wherein the open slot has an empty space around the enhanced magnet wire. In some embodiments, the method further comprises cooling the induction motor by convection by flowing motor oil through empty spaces in the open slots around the enhanced magnet wires. In certain embodiments, the wound enhanced magnet wire is suitable for temperatures of about 550 ° f when the induction motor is used to operate an electric submersible pump.

An illustrative embodiment of a system for making an enhanced magnet wire insulation suitable for use in electrical submersible motor applications comprises: a PEEK wire extruder, a tube extending between the PEEK wire extruder and a spool comprising polyimide-wrapped copper electromagnetic wire, the tube comprising: an induction coil inside the tube; a vacuum pump operably coupled to the interior of the tube; a spool side of the tube including a plug having a bore extending therethrough; with polyimide wrapped copper magnet wire extending from a spool through a hole in the plug, through the tube and into a PEEK wire extruder. In some embodiments, the tube has at least a partial vacuum inside the tube between the polyimide wrapped copper magnet wire and the inner diameter of the tube. In certain embodiments, the polyimide wrapped copper magnet wire extends through the interior of the induction coil when the polyimide wrapped copper magnet wire extends through the tube.

The induction motor of the system of the illustrative embodiments may include various types of motors known in the art for use as electric submersible motors. For example, three-phase "squirrel cage" induction motors, as well as Permanent Magnet (PM) motors, are well known in the art. These and other motors suitable for use with ESP assemblies may all benefit from the enhanced magnet wire insulation of the systems and methods of various embodiments.

Exemplary embodiments include the following: