ESP Troubleshooting

®
Troubleshooting
ARTIFICIAL LIFT SYSTEMS

© Weatherford. All rights reserved.
Extended Performance
®
Extended performance of Electrical

Submersible Pumping systems requires
routine management of daily operations.
When evaluating controller AMP
readings, care should be taken to
properly diagnose operating conditions.

®
5.1 NORMAL OPERATION

The amperage on this chart
indicates a normal type of
operation. The unit is
running continuously with a
smooth line, and pulling
motor nameplate amps.
Due to the different types of
oil well conditions, an
ammeter chart could have a
different amp line
configuration and still be
Normal sample of diagnostic chart used considered normal
for interpretation.
operation for that particular
installation.
®
5.1 NORMAL OPERATION

(Continued)
As long as the amp chart
line is symmetric on a day-
to-day basis, the ammeter
chart can be considered
normal.
It is important to use the
ammeter chart to detect
and correct any deviations
from a well’s normal
operation before abnormal
Normal sample of diagnostic chart used
for interpretation. operations cause a
premature failure.

®
5.2 POWER
FLUCTUATIONS
This chart indicates a
normal operation, good
production rate, and a
smooth steady current
of 52 amperes.
The “blips” or “kicks”
shown at different
intervals are caused by
power fluctuations.
for interpretation.

®
5.2 POWER
FLUCTUATIONS
(Continued)
This could be caused by
the periodical starting of
some other heavy
electrical load on the
power system, such as
an injection pump.
This type of operation is
not detrimental as long
as the kicks are not too
for interpretation. severe or close
together.
®
5.3 GAS LOCKING

The amperage on this chart
indicates that after a
normal start, the
production rate slowly
declined (fluid level being
lowered) and the well’s
production became very
gassy at approximately
8:30 a.m.
The unit pumped off, or
gas locked, and went down
for interpretation. on underload.
Note: This unit timed out for the amount of time set on the
switchboard timer and restarted automatically.
®
5.3 GAS LOCKING

(Continued)
This condition might be
corrected by lowering the
pump. If the unit cannot be
lowered, then the
downtime should be
extended and the pump
operated on a cycle basis.
A re-sized unit should be
calculated for the next
pump change-out.
for interpretation.

®
5.4 PUMPOFF
From the well’s static level
(start-up) this well pumped
off in 8 hours and went down
on underload.
After a one hour downtime
(build-up) the pump
restarted automatically and
pumped off again in 2 hours.
The smooth amperage
indicates a relatively gas free
for interpretation. fluid.

®
5.4 PUMPOFF (Continued)

The pump installed in this well
is too large for the well’s
capacity. The downtime will
have to be extended and the
unit operated on cycles.
A smaller pump should be
designed for the next change-
out, unless a stimulation
method is performed on the
well up to its capacity or the
unit is lowered to a deeper
for interpretation.
depth. If the unit is lowered,
the installed pump must be
checked for proper rate and
total head available.
®
5.5 GASSY WELL

The amperage fluctuations
on this chart indicate large
amounts of gas going
through the pump.
The amperes change as the
pump handles heavy and
light (gas cut) density fluid
and the pressures in the
pump shift.

for interpretation.

®
5.5 GASSY WELL

This type of chart is
considered normal for
pumps handling large
quantities of gas.
Sometimes the amp line can
be smoothed out with a
combination of increased
casing and tubing pressures.
The amount of change is
dependent on the well
Normal sample of diagnostic chart used conditions that exist in each
for interpretation.
individual well.

®
5.5 GASSY WELL (Continued)

This chart may result from a
well that is very near pump
off (low submergence) and is
pulling in some air, causing
cavitation; however, this is
rare.
This type of operation could
also be caused by the
prevailing well conditions,
such as the volume being
for interpretation. produced by the type of
pump installed, the kind of
fluid being produced, etc.
®
5.6 EXCESSIVE CYCLES

This chart indicates that the
unit is starting normally but
the amperage immediately
begins to decline and the
unit goes down on
undercurrent in 15 minutes.
The unit times out and
restarts automatically and
repeats the cycle.

for interpretation.

®
5.6 EXCESSIVE CYCLES

(Continued)
There are several reasons
for this type of operation,
such as a highly oversized
pump, pumping against a
closed valve; a hole in the
tubing high up in the string,
etc.
Regardless, this type of
operation is detrimental to
good submersible pump
for interpretation. operations and should be
corrected as soon as
possible.
®
5.7 UNDERLOAD (UL)

This chart configuration
sometimes occurs a few days
after a new installation. It
shows the unit starting at 7:30
a.m. (heavy line pegs the
ammeter chart scale - this is
normal movement of the
ammeter marker at start-up).
The amperage drops to 47
Normal sample of diagnostic chart used amps, runs a few minutes and
for interpretation. goes down on underload.
NOTE: The unit is going down on UL because it is timing out

and restarting automatically.
®
5.7 UNDERLOAD (UL)

(Continued)
The chart indicates that the
pump is not handling fluid
of sufficient density and/or
volume to load the unit above
the present undercurrent
settings.
The horsepower requirements
is less than anticipated due
Normal sample of diagnostic chart used for interpretation. possibly to the pump handling
a lighter gradient fluid or a
smaller volume than
designed for.

®
5.7 UNDERLOAD (UL)

(Continued)
If the previous production
rates indicate sufficient fluid
is available, the UL setting
should be lowered.
The UL setting can be
lowered as long as
sufficient fluid is passing by
the motor to cool it and the
Normal sample of diagnostic chart used for interpretation. UL is not set below the no-
load amperage of the motor.
This type of operation could also be caused by a defective relay
in the switchboard, and it must be corrected immediately.
®
5.8 OVERLOAD (OL)

The current load started below its
rating, as shown, then gradually
built up to normal load ( a normal
occurrence with certain types
and sizes of pumps).
The ammeter chart indicates that
the unit pulled nameplate amps
for approximately 1 1/2 hours and
the current began to climb and
started leveling off at 59 amps
(14% overload). This unit went
Normal sample of diagnostic chart used down on OL at 8:15 a.m.
for interpretation.
Notice the unit will not restart automatically as indicated on the
chart because of the overload condition.
®
5.8 OVERLOAD (OL)

(Continued)
This unit must be completely
checked out electronically
downhole and at the surface
before a restart is attempted.
The cause of the running
overloaded condition must also
be determined. It could be due
to mechanical problems with
the pump, sand entry, emulsion,
overheat, etc.

for interpretation.

®
5.9 FALSE STARTS - DOWN

TIME TOO SHORT
This chart indicates that the
unit started normally and the
amperage gradually declined
until the unit went down on
underload (UL).
The unit timed out for 1 hour
and tried to restart but
immediately went down on
UL. It then timed out for
for interpretation.
another hour and tried to
restart. The cycle repeats
itself.

®
5.9 FALSE STARTS - DOWN

TIME TOO SHORT (Continued)
The time duration for the fluid
build-up is too short to provide
an adequate volume of fluid to
load the pump. The downtime
must be increased and this
pump operated in cycles. The
downtime should be increased
to the extent that the minimum
amount of starts and stops is
achieved to produce the well’s
Normal sample of diagnostic chart used capacity.
for interpretation.
This unit is too large and must
be resized or lowered.

®
5.10 ERRATIC LOADING

The amperage shown on this
chart was erratic but
symmetrical between 6:00 a.m.
and 9:00 a.m. After 9:00 a.m.,
the amperage became erratic
and the unit went off due to
overload at 11:45 a.m.
The erratic behavior of the
amperage could indicate sand,
emulsion, higher viscosity
than anticipated, worn pump,
Normal sample of diagnostic chart used plugging intake, well bore
for interpretation. behavior, or fluctuating
pressures at the surface in the
gathering system.
®
5.10 ERRATIC LOADING

(Continued)
The unit must be checked
out electrically downhole
and at the surface.
The possibilities are a
stuck pump, burned motor,
burned cable, tripped
overload relay, blown fuse,
or a blown line fuse
(primary disconnect).
for interpretation.

®
5.11 UNDERLOAD (UL)

SHUTDOWN FAILURE
This chart is included to
illustrate what can happen
if the underload settings
are set below the motor no-
load amperage.
The unit started normally at
3:05 a.m. and gradually
pumped the well off. The
unit should have gone
Normal sample of diagnostic chart used down at 7:00 a.m., but the
for interpretation.
UL settings were too low.

®
5.11 UNDERLOAD (UL)

SHUTDOWN FAILURE
(Continued)
The unit continued to run
(spinning through itself)
and produced no fluid from
7:00 a.m. to 9:15 p.m., with
no fluid to carry away the
heat buildup. At 9:15 p.m.
the unit was shut down by
the overload setting or a
blown fuse.
for interpretation.

®
5.12 EXTERNAL CONTROLS

This chart indicates a
normal operation with the
unit shutting down from a
low or high level control.
However, this chart also
shows that the downtime
(15 minutes) set on the
timer is not sufficient to
safely prevent the unit
from restarting again a
Normal sample of diagnostic chart used backspin.
for interpretation.

®
5.12 EXTERNAL CONTROLS

(Continued)
This backspin is caused
by fluid falling back
through the pump when
the unit shuts down. A
start against a unit
backspinning can result in
a twisted shaft.
The downtime period on
any submersible pumping
Normal sample of diagnostic chart used operation should be set at
for interpretation.
a minimum of 30 minutes.

®
5.13 EXCESS RESTARTS

This unit was running
normally and pulling
nameplate amperage.
Between 4:30 a.m. and 7:50
a.m., several “kicks”
(power fluctuations
occurred. At 8:00 a.m. the
unit went down on
overload.
Normal sample of diagnostic chart used From 11:00 a.m. to 11:40
for interpretation. a.m., there were five
attempts to start the unit
manually.
®
5.13 EXCESS RESTARTS

(Continued)
These excessive attempts to
start in an overloaded
condition are detrimental to
the equipment and only tend
to damage the equipment
more.
A lightening storm may have
caused the kicks and blown
the primary fuse at 8:00 a.m.
When start up is attempted
Normal sample of diagnostic chart used with a primary fuse blown, the
for interpretation.
result is a single phase.

®
5.14 DEBRIS
This chart indicates that
debris such as scale, mud,
paraffin, or some other
solid substance was being
produced with the fluid for
approximately two hours
after start-up.

for interpretation.

®
5.14 DEBRIS (Continued)

The amperage begins to
smooth out as debris is
removed and finally
reaches the point of
running smoothly at a 50
amp load.
This can occur when a
well is not properly
cleaned out, killed with a
heavy weighted mud, or
Normal sample of diagnostic chart used recently treated for scale.
for interpretation.


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ARTIFICIAL LIFT SYSTEMS

Extended performance of Electrical

ARTIFICIAL LIFT SYSTEMS

5.1 NORMAL OPERATION

5.1 NORMAL OPERATION

ARTIFICIAL LIFT SYSTEMS

ARTIFICIAL LIFT SYSTEMS

5.3 GAS LOCKING

5.3 GAS LOCKING

ARTIFICIAL LIFT SYSTEMS

ARTIFICIAL LIFT SYSTEMS

5.4 PUMPOFF (Continued)

5.5 GASSY WELL

Normal sample of diagnostic chart used

ARTIFICIAL LIFT SYSTEMS

5.5 GASSY WELL

ARTIFICIAL LIFT SYSTEMS

5.5 GASSY WELL (Continued)

5.6 EXCESSIVE CYCLES

Normal sample of diagnostic chart used

ARTIFICIAL LIFT SYSTEMS

5.6 EXCESSIVE CYCLES

5.7 UNDERLOAD (UL)

NOTE: The unit is going down on UL because it is timing out

5.7 UNDERLOAD (UL)

ARTIFICIAL LIFT SYSTEMS

5.7 UNDERLOAD (UL)

5.8 OVERLOAD (OL)

5.8 OVERLOAD (OL)

Normal sample of diagnostic chart used

ARTIFICIAL LIFT SYSTEMS

5.9 FALSE STARTS - DOWN

ARTIFICIAL LIFT SYSTEMS

5.9 FALSE STARTS - DOWN

ARTIFICIAL LIFT SYSTEMS

5.10 ERRATIC LOADING

5.10 ERRATIC LOADING

ARTIFICIAL LIFT SYSTEMS

5.11 UNDERLOAD (UL)

ARTIFICIAL LIFT SYSTEMS

5.11 UNDERLOAD (UL)

ARTIFICIAL LIFT SYSTEMS

5.12 EXTERNAL CONTROLS

ARTIFICIAL LIFT SYSTEMS

5.12 EXTERNAL CONTROLS

ARTIFICIAL LIFT SYSTEMS

5.13 EXCESS RESTARTS

5.13 EXCESS RESTARTS

ARTIFICIAL LIFT SYSTEMS

Normal sample of diagnostic chart used

ARTIFICIAL LIFT SYSTEMS

5.14 DEBRIS (Continued)

ARTIFICIAL LIFT SYSTEMS

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