Electric submersible pump (ESP) power cable splice containment filler

A method of building an electric submersible pump (ESP) power cable, comprising:

• removing a first portion of a first protective armor from an end of a first portion of flat ESP power cable comprising a first plurality of electric conductors;
• removing insulation in part from ends of the first plurality of electric conductors;
• removing a second portion of a second protective armor from an end of a second portion of flat ESP power cable comprising a second plurality of electric conductors;
• removing insulation in part from ends of the second plurality of electric conductors;
• splicing each one of the first plurality of electric conductors to a corresponding one of the second plurality of electric conductors by a single crimped splice sleeve;
• securing a first filler from 3 inches to 5 inches long along the first plurality of electric conductors and extending between 0.1 inches and 1 inch under an edge of the first protective armor;
• securing a second filler from 3 inches to 5 inches long along the second plurality of electric conductors and extending between 0.1 inches and 1 inch under an edge of the second protective armor;
• and
• installing a third portion of a third protective armor over the first filler and the second filler and over the splicing of the first plurality of electric conductors to the corresponding second plurality of electric conductors.

A method of recovering hydrocarbons from a subterranean formation, comprising:

• connecting an electric submersible pump (ESP) power cable to an electric motor of an ESP located at a surface location proximate to a wellbore, wherein the power cable comprises a first plurality of electric conductors encased in a first protective armor and positioned in a flat cable configuration such that a first void area is defined between the first plurality of electric conductors, comprises a second plurality of electric conductors encased in a second protective armor and positioned in a flat cable configuration such that a second void area is defined between the second plurality of electric conductors, wherein each one of the second plurality of electric conductors is spliced to a corresponding one of the first plurality of electric conductors by a single crimped splice sleeve, and comprises a first filler from 3 inches to 5 inches long positioned at least partially in the first void area and extending between 0.1 inches and 1 inch under an edge of the first protective armor and a second filler from 3 inches to 5 inches long positioned at least partially in the second void area and extending between 0.1 inches and 1 inch under an edge of the second protective armor;
• coupling the ESP to a production tubing;
• running the ESP and production tubing into the wellbore;
• supplying electric power to the ESP via the ESP power cable from an electric power source located at a surface location proximate to the wellbore;
• and
• producing hydrocarbons to the surface from the wellbore by the ESP.