Systems and Methods for Splicing Electrical Conductors in an ESP Motor

Systems and methods for providing moisture-proof seals around the splices in an ESP motor. Two-layer encapsulation around each splice includes an outer layer of heat-shrink material that shrinks at a first temperature, and an inner layer of insulating material that melts at a temperature below the first temperature. The encapsulation materials are positioned around the electrical junction of the splice and heated. As the temperature reaches the melting temperature of the inner material, this material melts. As the temperature reaches the temperature at which the outer layer begins to shrink, the outer layer presses softened material of the inner layer against the conductors and the wire insulation near the splice, thereby conforming the material of the inner layer to the magnet wires at the splice and forming a moisture-proof barrier. Similarly constructed splices can connect motor lead extensions to the stator windings and form a Y-point of the motor.