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Product

power connection cable seriesIEEE 1018 / 1019 Flat ESP3 kV · 4 kV · 5 kV DownholeGalvanized / Monel Armour

Flat Electrical Submersible Pump CableIEEE 1018 / 1019 3–5 kV low-profile flat 3-conductor armoured downhole ESP cable

Flat Electrical Submersible Pump (ESP) Cable (3 kV, 4 kV & 5 kV) engineered per IEEE Std 1018, IEEE Std 1019 and API RP 11S5/11S6 with three parallel solid/compacted copper conductors (#6 AWG to #1/0 AWG), polypropylene or high-temp.

Crude Oil & H₂S Gas Barrier
+204 °C / 35 MPa Downhole
Lead or EPDM Barrier
IEEE 1018 / API 11S5
Order designation
ESP-FLAT 4kV #4 EPDM
Flat height
12.7 mm
Flat width
33.0 mm
Weight ≈
1,540 kg/km
Nominal current
100 A
All sizes (6)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Standards
IEEE 1018 / 1019
& API RP 11S5 / 11S6
Voltage classes
3 kV / 4 kV / 5
3-phase downhole VSD power
Conductor range
#6 to #1/0 AWG
Solid or compacted Cu (tinned)
Temp. ratings
+96 to +204 °C
PP (+96°C) · EPDM/Lead (+204°C)
Flat thickness
10.9 to 16.5 mm
Fits tight annulus clearance
Armour strip
Galv. / 316L / M
0.51–0.86 mm interlocked strip

Typical values for this cable type, based on IEEE Std 1018 / IEEE Std 1019 / API RP 11S5 / 11S6 — confirmed in the datasheet and quotation for your order.

Application fit

Is Flat Electrical Submersible Pump Cable right for your machine?

Banded externally along production tubing in deviated wells, slim-hole completions and past larger-diameter ESP pump housings where radial clearance between the tubing coupling and well casing is too tight for round cable.

Drilling jumbo & rotary mast feed

Suitable

Low-profile parallel 3-core geometry cuts radial height by ~45 % compared to round ESP cable of equal AWG.

Immersion & wet locations

Suitable

Individual Nitrile/EPDM jackets or extruded Lead sheaths prevent rapid gas decompression (CO₂/CH₄/H₂S) blowout.

VFD inverter to AC motor screened feeder

Suitable

Rated 3 kV, 4 kV and 5 kV phase-to-phase to handle surface step-up transformer + VSD harmonic peaks over 3,000+ m.

Energy chain / drag chain

Not suitable

Heavy interlocked-metal-strip downhole oil-well pump cable; not for machinery drag chains.

Use PUR-HF Drag-Chain Cable
Typical machinesTight-Clearance Oil & Gas ESP CompletionsHigh-GOR & Sour-Gas (H₂S / CO₂) Production WellsSAGD Thermal Heavy-Oil & Geothermal Wells (+204 °C)Offshore Platform & Subsea ESP BoostingDeep Water-Injection & Coalbed Methane Dewatering

Construction

Layer by layer

Flat Electrical Submersible Pump Cable showing 3 parallel solid/compacted tinned copper conductors, polyimide/FEP tape + EPDM (or PP) primary insulation, individual Nitrile/EPDM or Lead gas-barrier jackets, woven reinforcement braid (optional), and overall interlocked galvanized steel / stainless / Monel 400 strip armour.

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
13 × Solid or compacted tinned/bare copper conductorsSolid (#6, #4, #2, #1 AWG) or 7/19-wire compacted/seal-stranded copper with lead-tin alloy coatingPrevents axial well-gas migration inside conductor strands
2PP (IEEE 1019) or High-Modulus EPDM (IEEE 1018) dielectricCopolymer Polypropylene (to +96 °C) or high-modulus oil-resistant EPDM rubber (to +204 °C / +400 °F) with optional Polyimide/FEP barrier tape75 mil (3 kV) to 90–115 mil (4–5 kV) radial wall
3Individual Nitrile / EPDM or Seamless Lead gas barrierIndividual Oil-Resistant Nitrile (+121 °C), High-Temp EPDM + woven nylon braid (+177 °C), or extruded Lead Alloy sheath (+204 °C H₂S proof)Contains internal insulation swelling and blocks H₂S attack
4Flat profiled interlocked metal strip armour20 mil (0.51 mm), 25 mil (0.64 mm) or 34 mil (0.86 mm) Galvanized Steel, AISI 304/316L Stainless or Monel 400 interlocked stripProtects against casing scrape during RIH (running in hole) & decompression hoop stress

ESP-FLAT-EPDM-177 (3–5 kV · +177 °C EPDM/Braid)

3-core flat EPDM-insulated, EPDM-jacketed, braid-reinforced galvanized steel armoured ESP cable

ESP-FLAT-LEAD-204 (4–5 kV · +204 °C Lead Barrier)

3-core flat EPDM + extruded Lead sheath + galvanized/Monel armour for sour H₂S & high-temp SAGD wells

ESP-FLAT-PP-96 (3–4 kV · +96 °C PP/Nitrile)

IEEE 1019 polypropylene-insulated, nitrile-jacketed flat ESP cable for low/medium-temperature oil wells

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEEE Std 1018 / IEEE Std 1019 / API RP 11S5 / 11S6. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated voltage classes
3 kV · 4 kV · 5 kV AC phase-to-phase (50–400 Hz VSD)
DC hi-pot routine test
22 kV DC (3 kV) · 27 kV DC (4 kV) · 33–35 kV DC (5 kV) for 5 min
Max. DC resistance @ 20 °C
1.37 Ω/km (#6) · 0.863 Ω/km (#4) · 0.541 Ω/km (#2) · 0.430 Ω/km (#1)
Insulation resistance
≥ 1,500 MΩ·km (EPDM) · ≥ 5,000 MΩ·km (PP) @ 20 °C

Thermal

PP / Nitrile rating (IEEE 1019)
-40 °C to +96 °C (+205 °F) bottomhole temperature
EPDM / EPDM-Braid (IEEE 1018)
-40 °C to +140 °C / +177 °C (+350 °F) bottomhole temp
EPDM / Lead Sheath (IEEE 1018)
-40 °C to +204 °C (+400 °F) / +232 °C peak

Mechanical

Flat height × width
11.4 × 29.2 mm (#6 AWG) to 15.8 × 41.5 mm (#1 AWG)
Min. sheave / reel diameter
1,100 mm to 1,400 mm (44" to 54" wellhead hay-pulley)
Armour strip thickness
0.51 mm (20 mil), 0.64 mm (25 mil) or 0.86 mm (34 mil)

Resistance

Rapid gas decompression
Constrained by individual braid/lead + interlocked armour against CO₂/CH₄
Sour gas H₂S immunity
Lead-sheathed + Monel 400 armour is 100 % impervious to H₂S
Hydrostatic well pressure
Up to 35 MPa (5,000 psi) standard · 55 MPa (8,000 psi) Lead/Monel

Reference standards

ESP cable standards
IEEE Std 1018 (EPDM) & IEEE Std 1019 (Polypropylene)
Application & field test
API RP 11S5 & API RP 11S6
RoHS & REACH
Industrial oilfield downhole compliant

Identification

Phase identification
Core 1, 2, 3 colour ridges or printed phase numbers under armour
Customs tariff (HS)
8544.6010
Shipping reels
Heavy-duty steel oilfield ESP reels (1,500 m to 3,600 m continuous)

Sizes

6 standard 4 kV / 5 kV Flat ESP Cable (#6 AWG to #1 AWG) configurations

Conductor AWG, barrier type, flat height × width dimensions, weight and typical ampacity.

Flat profile dimensions & ratings
Order designationAWG, insulation & barrierHeight
mm		Width
mm		Weight ≈
kg/km		Nom. rating
A		Enquiry
4 kV +177 °C EPDM/EPDM-Braid Flat ESP
ESP-FLAT 4kV #6 EPDM3 × #6 AWG (13.3 mm²) · EPDM/Braid11.429.21,18075
ESP-FLAT 4kV #4 EPDM3 × #4 AWG (21.2 mm²) · EPDM/Braid12.733.01,540100
ESP-FLAT 4kV #2 EPDM3 × #2 AWG (33.6 mm²) · EPDM/Braid14.538.12,120135
ESP-FLAT 4kV #1 EPDM3 × #1 AWG (42.4 mm²) · EPDM/Braid15.841.52,540155
5 kV +204 °C EPDM/Lead-Barrier Flat ESP
ESP-FLAT 5kV #4 Lead3 × #4 AWG · EPDM + Lead + Galv/Monel13.535.62,690105
ESP-FLAT 5kV #2 Lead3 × #2 AWG · EPDM + Lead + Galv/Monel15.240.63,480140
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • At the bottom of the string, Flat or Round main ESP cable is spliced to an ultra-low-profile Motor Lead Extension (MLE) cable to pass alongside the pump and seal sections.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
100 % 22–35 kV DC water-immersion hi-pot, IR & TDR testZero breakdown for 5 min, balanced phase leakage current and IR ≥ 1,500 MΩ·kmEvery manufactured reel
Sample tests
EPDM hot-modulus & Lead sheath concentricity checkMeets IEEE 1018 high-modulus physical retentionPer production lot
Autoclave high-pressure gas decompression (CH₄/CO₂/N₂) + crude oil testNo dielectric blowout after 25 MPa gas saturation and rapid bleedType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

IEEE Std 1018 & IEEE Std 1019API RP 11S5 & API RP 11S6ISO 9001 Oilfield QA

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

Stamped armour & reel plate: TEBAOFLEX FLAT ESP CABLE IEEE 1018/1019
Delivery form
Fumigated wooden drums or steel export reels
Standard lengths
500 m · 1000 m (or custom cut lengths)
MOQ
100 m (standard) · 500 m (custom)
Lead time
2–4 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFFlat Electrical Submersible Pump Cable – technical datasheet6 sizes · construction, technical data, approvalsXLSXFlat Electrical Submersible Pump Cable spec data (Excel)All 6 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

When should completion engineers choose Flat ESP Cable versus Round ESP Cable?
Choose Round ESP Cable in vertical upper wellbores where casing-to-tubing clearance is generous, because round geometry provides symmetrical hoop containment against decompression and lower phase unbalance. Choose Flat ESP Cable whenever casing clearance is tight (e.g. 5-1/2" or 7" casing with large tubing couplings), through high-dogleg deviated intervals, or as a mid-well crossover down to the Motor Lead Extension (MLE).
Why is a Lead barrier sheath (ESP-FLAT-LEAD) required in sour H₂S and +200 °C steam-assisted (SAGD) wells?
Above ~5–10 % H₂S or +177 °C, hydrogen sulphide gas permeates polymeric jackets, sulfiding copper conductors and embrittling elastomers. A continuous, pinhole-free extruded Lead alloy sheath over each insulated phase provides a 100 % impermeable metallic barrier against H₂S, CO₂ and steam up to +204/+232 °C.
What is the purpose of the woven synthetic braid over each EPDM-jacketed phase?
When a well is shut in or pulled, dissolved high-pressure gas inside the rubber tries to expand. A high-tenacity woven nylon/polyester braid tightly constrains each individual core's jacket against radial swelling before the outer flat steel armour is applied.
Can we order Flat ESP Cable with integrated stainless-steel capillary injection tubes or optical fibres?
Yes. Flat ESP cables can be manufactured with 1 or 2 external/internal 1/4" or 3/8" 316L/Inconel chemical-injection or gauge tubes armoured inside the profile.

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