ESP Installation Procedure

Well: 802/MSP-8; 803-MSP-8

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 ESP Installation Procedure
Well: 802/MSP-8; 803-MSP-8

Table of Contents
1. Purpose ..................................................................................................................................................4
2. Responsibility of Parties .......................................................................................................................4
3. General Safety Information .................................................................................................................6
3.1 High pressure possible. .................................................................................................................6
3.2 Possible release of hazardous gasses. ...........................................................................................7
3.3 Electrical tests. ...............................................................................................................................7
3.4 Heavy equipment. Possible injury from lifting heavy objects. ..................................................8
3.5 Proper personal protective equipment (PPE) .............................................................................8
3.6 Pinch/cut points and hand safety .................................................................................................8
3.7 Oil containers must not be distributed to anyone outside the company ..................................8
4. Equipment Required for Install ........................................................................................................10
5. Pre-Installation....................................................................................................................................12
5.1 Offloading Procedure ..................................................................................................................12
5.2 Pre-Inspection ESP Equipment .................................................................................................13
5.2.1 ESP Preparation at onshore/ workshop .............................................................................13
5.2.2 Job preparation at operating location / rig site. ................................................................14
6. ESP Installation...................................................................................................................................15
6.1 Pre-Caution during installation .................................................................................................15
6.1.1 Taking Photograph ..............................................................................................................15
6.1.2 Well control during installation ..........................................................................................15
6.1.3 Electrical testing during installation ..................................................................................15
6.1.4 ESP Cable Splicing...............................................................................................................16
6.1.5 Annulus bleeding off ............................................................................................................16
6.2 Installation procedure .................................................................................................................17
6.2.1 ESP Installation ....................................................................................................................17
6.2.2 Cable attachment .................................................................................................................18
6.2.3 Installing Production Tubing ..............................................................................................19
6.2.4 Landing the equipment in the wellhead .............................................................................20
7. Pre-commissioning ..............................................................................................................................21
7.1 Verifying Software Update .........................................................................................................21

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7.2 Forming Capacitor ......................................................................................................................23

7.3 No-load Tests................................................................................................................................23
7.4 Communication Test ...................................................................................................................25
8. Well start up procedure .....................................................................................................................25
8.1 Surface Equipment Preparation ................................................................................................25
8.2 ESP Start up.................................................................................................................................25
8.3 ESP Re-start (Normal Operation) .............................................................................................26
APPENDIX .................................................................................................................................................27
Reference Procedure Document ...............................................................................................................38

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 ESP Installation Procedure
Well: 802/MSP-8; 803-MSP-8

1. Purpose
This document provides an overview of the preparation and installation of ESP Single and Zenith
Downhole gauge. To run the ESP Standard Completion string in a safe manner and record all data, to ensure
the ESP is set and operational as per the client requirements.

These procedures apply to all Baker Hughes Electrical Submersible pump personnel involved in the
shipping and the running of ESP tooling and equipment under customer Contract at both Baker Hughes
Electrical Submersible pump base and customer operating locations.

2. Responsibility of Parties
R: Responsible I: Informed C/S: Consultant/ Support
Assembly, RIH, Start-up and Commissioning of Well
№ PVDBakerHughes Vietsovpetro
equipped with Electrical Submersible Pumps (ESP)

Well preparation for ESP installation

1 - I R
as per procedure

ESP downhole and surface equipment

mobilization to platform. Offloading
2 - C/S R
ESP downhole and surface equipment
at platform.

Positioning Cable Spooler on

3 cantilever deck, Cable Sheave and - C/S R
Installation toolbox on Rig Floor

Installation of Wellhead Spool

4 - C/S R
Adaptor as per procedure

ESP downhole components assembly,

5 - R S
cable Splicing

6 ESP Run in Hole - R I

7 ESP Run in Hole – Control RIH Speed - I R

Cable spooler operation, ESP

8 Downhole electrical test. - R C/S
Refer no.1 ESP Procedure (SOP)

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 ESP Installation Procedure
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Assembly, RIH, Start-up and Commissioning of Well

№ PVDBakerHughes Vietsovpetro
equipped with Electrical Submersible Pumps (ESP)

CCCP installation - Refer no.1 ESP

9 - R S
Procedure (SOP)

Wellhead penetrator splicing and

10 - R S
installation

Nipple Up Christmas Tree, Rig Down

11 - C/S R
ESP Toolbox

ESP passport to be signed and given to

12 commissioning R C/S
Production Technologist

Laying of surface cable on cable racks

from wellhead to step up transformer, aftre wellhead
13 C/S R
VSD, Filter, Power supply switchgear/ installation
JB

Surface Cable termination, glanding,

14 feeding to connectors inside VSD, C/S R
SUT, JB, Filter

Layout for VSD, SUT and JB

15 prior to start up C/S R
installation, Filter

Ground system for VSD, SUT, JB,

16 prior to start up C/S R
Filter

Preparation of Power Transformer and the same day of

17 I R
Power Cable for energy supply of VSD request

the day before

18 VSD idling test R C/S
commissioning

Alarm trip settings VSD, list of

19 parameter settings VSD, instruction commissioning R C/S
for start-up/ operation

the same day after

20 Logs downloading (from VSD) start up, then every R C/S
day till stabilization

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 ESP Installation Procedure
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Assembly, RIH, Start-up and Commissioning of Well

№ PVDBakerHughes Vietsovpetro
equipped with Electrical Submersible Pumps (ESP)

21 Data Sending – VSD to SCADA R C/S

22 Daily report commissioning R C/S

continuously after
23 Flow rate measurements I R
start up

every day after start

24 Solids and PVT samples I R
up till stabilization

Troubleshooting in case of emergency immediately after

25 R I + C/S
ESP stops incident

Company Production report with plan

26 daily I R
for few days

once a week till

27 Commissioning report R I
stabilization

28 Frequency mode changing prior to changings R C/S

3. General Safety Information

Every application should begin with a Job Safety Analysis (JSA) sometimes referred to as a
Qualitative Risk Assessment (QRA) in appendix safety document control. The well control while
installation should be considered by using physical barrier check form in appendix. This analysis is a key
portion in providing a safe working environment and is designed to identify and correct where feasible any
items that may cause personal injury, damage to equipment or work stoppage or slowdowns.

To aid in providing a safe and productive workplace some of the known dangers associated with
this operation have been highlighted in this summary section. However, these same alerts are found
throughout the document where they apply to the operation. This section is not intended to take the place
of a QRA as the site analysis could point to additional hazards that have not been mentioned here.

3.1 High pressure possible.

i. lockout and tag out to avoid hazard.
ii. proper PPE required minimizing the hazard.
iii. proper isolation devices to secure the hazard.
Lockout/tag out programs establishes safe and consistent procedures to prevent injury or damage.
Unexpected equipment activation, energizing of equipment, direct contact with energy sources, or released
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hazardous agents could cause serious injury, death and/or damage equipment. Consider all potential
exposure hazards including electrical, mechanical, pressure, thermal, radiation, stored energy, and
hazardous agents.

3.2 Possible release of hazardous gasses.

i. Wear safety glasses.
ii. A respirator may be required or ensure fresh air flow.
iii. Required portable gas detector.
The ESP system sometimes operates in a hazardous environment where dangerous gasses might be
present, such as hydrogen sulfide (h2s), carbon dioxide (co2), methane (ch4) or others. Some of these gasses could
become trapped in the equipment and remain in the system when removed from the location. The equipment
should be dismantled in a well-ventilated area.

3.3 Electrical tests.

3.3.1 Electrical test (ESP Installation)

Electrical tests shall be performed at a safe distance upwind or crosswind from the wellhead.
Possible injury of fire hazard:

i. Static discharge.
ii. Possible fire hazard.
iii. No electronic implants allowed.
Establish safe and consistent procedures to prevent injury or damage. Unexpected equipment
activation, energizing of equipment, direct contact with energy sources, or released hazardous agents could
cause serious injury, death and/or damage equipment.

Consider all potential exposure hazards, including electrical, mechanical, pressure, thermal,
radiation, stored energy, and hazardous agents.

3.3.2 VSD commissioning and start-up

The drive should be installed, adjusted, and serviced by qualified electrical maintenance
personnel. Improper installation or operation of the drive may cause injury to personnel or damage to
equipment. The drive must be installed and grounded in accordance with local and national electrical
codes. Potentially lethal voltages exist within the cabinet. Extreme care must be taken to ensure all power
sources are disconnected before starting installation, maintenance, and repair jobs.

Electrical Disconnect Handle with Interlock and Override.

The electrical disconnect has an interlock feature which will not allow it to be turned on unless the
cabinet door is closed. The technician can temporarily override this safety feature by turning the interlock
with a slot screwdriver. This allows the cabinet door to be opened while the drive continues to operate,
and power is still applied.

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Safety Procedures

Work inside the cabinets should be performed with the power off. Isolate energy source(s) and use
proper Lock Out/Tag Out (LOTO) procedures and Personal Protective Equipment (PPE) to ensure
personnel safety. The drive also contains stored sources of energy in the form of capacitors. Allow
sufficient time after power is removed for those capacitors to discharge to a safe level below 50VDC. The
bleed resistors attached to the capacitors will reduce the voltage to safe levels within five minutes of
power down. Confirm removal of energy source using a proven voltage indicator device. As a Baker
Hughes procedure BH-HSE-023 Electrical safety.

3.4 Heavy equipment. Possible injury from lifting heavy objects.

i. Lift cautiously with proper equipment.
ii. Crane or hoist is required for lifting equipment.
iii. Use taglines to help control the equipment while lifting.
The process of lifting equipment to the wellhead is hazardous and can cause severe injury if the
lifting equipment fails. Verify the lifting rating and certification of all lifting equipment prior to each use
and have a certified test each year.

3.5 Proper personal protective equipment (PPE)

should be worn at all times in designated areas. Possible injury if not protected.

i. Hard hats.
ii. Safety shoes.
iii. Safety glasses with side shields.
iv. Flame retardant clothing (FRC).
v. Safety gloves. Hot glove (For VSD Pre-commissioning)
All personal protective equipment (PPE) should be worn at all times in designated areas. Individual
well sites have special equipment requirements for PPE, and it is the field service technician’s responsibility
to be aware of these requirements prior to arriving on site.

3.6 Pinch/cut points and hand safety

i. Safety gloves.
ii. Lockout/tag out.
iii. Never operate without proper guarding and shutdown system in place.
Familiarize yourself and others with the work activities that will be taking place. Evaluate to ensure
that there is adequate isolation and avoid positioning yourself or others where entrapment could occur
between moving objects. Keep hands away from flanges when handling equipment. All guards must be in
place.

3.7 Oil containers must not be distributed to anyone outside the company
i. It presents a possible environmental hazard.
ii. Return empties to the local service center.
iii. Do not distribute to anyone outside the company.
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Empty or partially empty containers of motor oil shall not be distributed to any person or company
but shall be returned to a local service center for disposal according to local HSE regulations.

Required Well Information

Before starting any installation, the field engineer must have and check the following information
to perform the job efficiently:
• Latest mechanical diagram and proposed tally to check all the well parameters (depths, ID’s, ODs’,
etc.).
• Well Survey, to check deviation and dog legs to estimate speed limits and special spots during RIH.
• Well Program available with all the procedures clearly discussed and signed by clients.
• Production Data, pressures, fluid properties, H2S ppm.
• Well Head information.
• Rig Site layouts.
Note: See more detail in document:
i. BH-HSE-023 Electrical safety
ii. BH-QHSE-002 Stop Work Authority
iii. BH-QHSE_006 Manual Handling and hand safety

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4. Equipment Required for Install

Client Vietsovpetro
Block 09-1
Well 802/MSP-8
ESP Set. Angle (deg) - Prod. Casing 6.625”
ESP Set. DLS (deg/100ft) - Prod. Tubing 2-7/8”, 6.5 lb/ft, EUE
Prepare by. Pongphan J / Ngan Cao Date 19-Feb-24

ESP PN SN Description O.D. Length

Schematic (Inch) (Meter)
2-7/8” Production Tubing
C343063 Bleed-off valve 2-7/8"EUE assembly (with pup 3.96
joint)
C343062 Check valve 2-7/8"EUE assembly (with pup joint) 3.96

11480004201 DSCHG PRESS SUB 2-7/8 EUE BXP FOR 1/4 4.00 0.05

C63029 DSCHG B/O Pump 400 - 2-7/8x8" EUE 4.00 0.07

500011296 PMP 400PHV M CS SSD 083 E3000 1:4 HS 4.00 6.4

500011296 PMP 400PHV M CS SSD 083 E3000 1:4 HS 4.00 6.4

500011296 PMP 400PHV M CS SSD 083 E3000 1:4 HS 4.00 6.4

500004551 GASSEP 400GM2V H6 FER STD_PNT 4.00 0.81

C308390 SEAL FSB3DB UT STD_PNT AB/AB SSCV 4.00 1.86

PFSA
C308389 SEAL FSB3DB LT STD_PNT AB/AB SSCV PFSA 4.00 1.86
105100428 MTR 450SP S CS 165/2585/41_15R 4.50 6.55

10460001406 E7 MW 456 400 Bar 175C AFL 4.56 1.39

CCHNC616-00E CNTRZR BULLNOSE 7" CSG 2-3/8 EUE CS 5.85 0.09

C78450M-110 MLE CENTRILINK 12 110FT

10460001406 DISCHARGE PRESSURE LINE ASM 1/4 160FT
C337491 MLE Protectoliser Motor x1
C330197 MLE Protectoliser Pump x5

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Client Vietsovpetro
Block 09-1
Well 803/MSP-8
ESP Set. Angle (deg) - Prod. Casing 6.625”
ESP Set. DLS (deg/100ft) - Prod. Tubing 3-1/2”, 9.3 lb/ft, EUE
Prepare by. Pongphan J/Ngan Cao Date 19-Feb-24

ESP PN SN Description O.D. Length

Schemati (Inch) (Meter
c )
3-1/2” Production Tubing
Bleed-off valve 3-1/2" EUE assembly (with pup 3.96
joint)
Check valve 3-1/2" EUE assembly (with pup joint) 3.96

11480001202 DSCHG PRESS 3-1/2 9.3# EUE BXP CS 4.00 0.05

CSE4594P01 DSCHG B/O PMP 400 HV 3.5X8 EUE 1040 4.50 0.07

500011297 PMP 400PHV M CS SSD 096 E3000 1:4 HS 4.00 7.3

500011297 PMP 400PHV M CS SSD 096 E3000 1:4 HS 4.00 7.3

500004551 GASSEP 400GM2V H6 FER STD_PNT 4.00 0.81

C308390 SEAL FSB3DB UT STD_PNT AB/AB SSCV PFSA 4.00 1.86

C308389 SEAL FSB3DB LT STD_PNT AB/AB SSCV PFSA 4.00 1.86
13460155403 MTR 450SP S CS 165/2585/41_15R 4.50 6.55

13460155403 E7 MW 456 400 Bar 175C AFL 4.56 1.39

CCHNC616- CNTRZR BULLNOSE 7" CSG 2-3/8 EUE CS 5.85 0.09

00E

C78450M-70 MLE CENTRILINK 12 110FT

10460001406 DISCHARGE PRESSURE LINE ASM 1/4 160FT
C337491 MLE Protectoliser Motor x1
C330197 MLE Protectoliser Pump x5

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5. Pre-Installation
5.1 Offloading Procedure
Equipment could be shipped loose, in wooden crates or in metal shipping boxes. When offloading the
shipping box, it is essential that it be supported properly to avoid excess bending of the box which will
make it difficult and possible dangerous to open. The proper lifting method would be to use a spreader bar
of sufficient length to stabilize and support the box.

Step Description
1 From 1 ft (0.3 m)–20 ft (6 m) a single point lift can be used.

2 From 20 ft (6 m)–30 ft (9 m) will require the use of at least an 8 ft (2.4 m) spreader

bar. Above 30 ft (9 m) will require a spreader bar of at least 12 ft (3.7 m).

Lifting Equipment Using Angled Slings

Lifting Equipment Using Angled Slings

If the angled slings are chosen care must be taken to prevent the cable from slipping along the box. A
double-wrapped choker will help but the cable might still slip. Placing the connection behind one of the
box hinges will help. Protection should also be used to keep the slings from possibly being cut by the sharp
corners of the box.

Equipment Placement
When placing the equipment on location before installation the equipment should be placed as close
as possible to the well and oriented so that the top of the equipment is oriented nearest the well.
Placement of the equipment should be with the same spacing as with the lifting procedure which is 25 % of
the total length of the box from each end of the box.

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Slings should be chosen that will not mar or gouge the finish of the equipment. Baker Hughes suggests a
synthetic material such as nylon or polyester to control slip and marring

Sling attached to the Equipment

The load will be balanced to make moving easier and control of the unit can be maintained. If control over
the equipment can’t be assured, secure help before proceeding with the lift. Take care that the equipment
does not roll when placed on the supports. Chocking the equipment on both sides will prevent rolling.
Note: See more detail in document OPS-GLB-ESPS-100546_Electrical Submersible Pumping
Systems Lifting Procedures
5.2 Pre-Inspection ESP Equipment
5.2.1 ESP Preparation at onshore/ workshop
1. Sub-assembly
1) EUE thread tubing joint will be torqued onshore to a discharge head.
2) Physical inspection and clen flange face.
3) Install shipping cap when transfer.
2. Pump
1) Inspect pump housing.
2) Record nameplate details and pump length.
3) Remove shipping caps, attached coupling check, and ensure good coupling fit.
4) Shaft rotation should be smooth, shaft extension and correct axial movement noted.
5) Clean both flanges of the pump Replace shipping caps and note details.
3. Seal sections
1) Inspect seal housing.
2) Record nameplate details and seal length.
3) Remove the end caps and check for smooth shaft rotation, shaft extension with go/no-go gauge
and good coupling fit.
4) Clean both flanges of seal. Replace shipping caps. Change out lead washers.
4. Motor
1) Inspect motor housing, record nameplate details and motor length.
2) Electrical checks to be carried out to verify continuity, insulation resistance and phase rotation.
3) Electrical test results to be recorded into cable integrity sheet.
4) Remove motor end shipping cap.

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5) Check coupling fit, ensure smooth rotation of shaft. The motor heads should be slightly elevated
to maintain contact between the thrust runner and the thrust bearing.
6) Attach sensor and test the sensor reading.
5. Sensor
1) Inspect sensor housing,
2) Record nameplate details and length.
3) Remove the caps, electrical check to verify insulation resistance,
4) Sensor reading test at various temperature and pressure
6. Main cable, MLE, Taurus equipment
1) All main cable, motor lead extensions (MLE) and taurus equipment should be checked for
continuity, Insulation resistance both phase to phase and phase to ground.
2) Record the serial numbers, test certificate numbers and lengths.
3) All results need to be recorded into the cable integrity sheet.
4) The primary MLE cable will be spliced onshore to a length of main cable long enough to reach
the packer.
7. Accessories
1) banding equipment
2) cable protectors
3) workshop/tools
4) spooler
5) worktable/stovepipe
6) cable sheave
7) cable clamp
8) installation kit
9) air hoses and air gun
All equipment and tooling should be checked for operation and function tested. The spooler should
be positioned, powered up and checked for leaks. Load the cable reel. All consumables required for the
installation should be ready and not expire.
Note: See more detail in document AL-GLB-CEN-ESPS-102431_Electrical Submersible Pumping
Procedure
5.2.2 Job preparation at operating location / rig site.
i. Load all equipment to operating area. Equipment should be placed on location or cantilever deck
in such a way that it does not interfere with wellsite activities.
ii. Walk around and perform visual check of all operating area and note any discrepancies or safety
issues. Address any risk issues immediately with VSP representative. Note all other issues and
address during toolbox meeting.
Note: Carefully load equipment from supply boat up to operating area. make sure crane operator
use low speed to avoid a knock-on equipment. tag line must be attached to every equipment during loading.
iii. Lay out position for spooler in a safe condition. Take into consideration the line of cable to
minimize of all tripping and other potential hazard.

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iv. Walk around spooler if any unsafe condition. Connect power line to power supply of rig, set up
ground line and secure spooler by safety chain.
v. Prepare all tools, lifting equipment and consumable for performing installation.
vi. Lift ESP equipment out of shipping box and lay down on support. (wooden, pipe support.)
vii. Visual check equipment to ensure ESP have no damage. Confirm equipment length, OD, PN, SN
of equipment that follow ESP installation program.
viii. Fit lifting clamp to ESP. Do not over tighten the bolt to avoid distortions of head section.
Note: Before start installation, conduct toolbox talk and Job Safety Analysis to make sure everyone
understands the work and risk.

6. ESP Installation
6.1 Pre-Caution during installation
6.1.1 Taking Photograph
During ESP installation/Pulling process request hot work permit to allow taking the photograph.
6.1.2 Well control during installation
During ESP installation/pulling it is most important that well control can be achieved in a quick and
efficient manner in the case of emergency. In some situations, the use of BOP blind and shear rams may be
required, but in the less serious conditions the following procedures could be utilized:
NOTE: Cable cutters to be always readily available on the rig floor during ESP installation or
pulling.
If it becomes necessary to close the well while building up ESP:
(a) Pull units completely out of the hole if sufficient height is available, and then close the well.
Or
(b) Close annular ram around ESP unit below pump intake / gas separator.
Or
If running/pulling tubing and time allows, cut the ESP cable just above a cable clamp then run tubing
in the hole so that the cable end is below the annular. Close the annular ram around the tubing and connect
circulating head to the top of tubing to conduct well killing. After the well has been controlled, the
completion string can be pulled back to allow the cable to be spliced back on and continue as per program.
In severe cases, close the shear ram to shear the tubing and cable, and then close the well.

6.1.3 Electrical testing during installation

i. Before any Megger (IR) testing is carried out, all relevant Safety Documents must be in place.
These may include Work Permit(s), Sanction for Test, and portable gas detectors. Customer and
Baker Hughes safety procedures and processes must be complied with and all ESP crew members
briefed on testing procedures.
ii. After each Megger test, the voltage in the cable MUST be discharged through the Megger and at
no time should the cable be discharged by shorting it out to ground. After discharge, the cable must
keep earthed (via cable armor, cable drum etc.) to ensure no electrical charge builds up due to
capacitance. If this is not possible, then the cable must be fully discharged prior to any further
testing.
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iii. Keep personnel not involved in the testing away from the equipment under test.
iv. Ensure non-discharged megger cables are not left unattended.
NOTE: Make sure the test leads are connected positive to ground and negative to conductor
(so as not to damage the sensor).

6.1.4 ESP Cable Splicing

All ESP Cable Splicing will be carried out in accordance with the latest revision of the BHI ALS
Cable Splice Procedure (AL-GLB-CEN-CABLE-102445)

6.1.5 Annulus bleeding off

There are many instances where the ‘A’ annulus needs to de-pressurized. The ESP cable and
penetrator systems are in the ‘A’ Annulus and their elastomers absorb gas. The rate of pressure change
during depressurization must be controlled to allow the absorbed gas time to migrate out of the cable
insulation and prevent insulation damage and reduced ESP run life. So, the pressure must be bled off slowly
to the desired pressure in accordance with BHI ALS Bleed-Off Procedure.

NOTE: To maximize the reliability of the ESP system, both packer and wellhead feed thru
should be subjected to the minimum stress. The magnitude and the rate of change of the annulus
pressure needs to be carefully monitored and controlled.

There are two main sources of pressure imbalance, both created by gas present in the annulus, either
free or in solution.
i. Diffused gas present within the cable and the feed thru materials at the wellhead itself.
ii. Diffused gas present within the cable being able to migrate towards the wellhead feed thru.
Therefore, careful control and monitoring of annular pressure is required to minimize the risk of
ESP system failure due to decompression.
For any pressure that occurs in the annulus (including pressure testing the annulus):
- The pressure should be reduced by half at a maximum rate of 50 psi/minute.
- A dwell period of 10 minutes should then follow.
- The process should then be repeated until the desired annulus pressure is achieved.

For example, an annulus pressure of 500 psi reduced to 0 psi would take 45 minutes.

Pressure Time taken to reduce pressure at Dwell Accumulative Time

(PSI) maximum rate of 50 psi per Period
minute
500 5 minutes 5
250 30 minutes 35
250 5 minutes 40
0 45

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Overall, the longer the duration that can be allocated to the pressure schedule, the less stress is placed
on the penetrators and cable.

6.2 Installation procedure

6.2.1 ESP Installation
1) Prior to running the completion, hold a pre-job safety meeting to review completion procedures and
communicate individual responsibilities to all parties on location. Repeat safety meeting at any crew
change while running the completion.
2) Verify with the Baker Hughes Representative that the pump and cable are the proper equipment
designed to be run in this well. (verify equipment nameplate, physical check)
3) Verify that the rig is centered over the well prior to running the completion.
4) Rig up electrical Spooling Unit and ESP cable running tools. Check wind wall opening location
and angle to insure no stress is place on power cable during entry. Function test Spooling Unit with
ESP cable and spools in place. ESP cables should be loaded at least 48 hours prior to running
completion.
5) Co-ordinate with rig crews for equipment lay down on cantilever deck. Ensure each step follow
offload procedure and equipment placement procedure.
6) Install lifting clamp. Install the lifting chain or wire rope.
Note: Before lifting, slightly lift the head of the equipment using appropriated bars and move the
lifting clamp radial and axially to verify that it is the proper lifting clamp for the equipment to be
handled (clamp’s series must match with the equipment’s head).
7) Pick up motor assembly and centralizer using winch on rig and run into well.
8) Connect ¼” discharge pressure control line to discharge pressure port of downhole sensor. The
preform pressure test 500 psi / 3000 psi and hold on 10 min.
9) Service / fill oil to motor. Connect the oil pump fill adapter in the motor base fill valve after pumping
through the hose and adapter to purge contaminates and air from the hose and adapter. Pump the oil
slowly at about one liter per minute until oil emerges from the motor head. Wait from two to three
minutes to allow air to exit the motor. Pump the oil again slowly at about liter per minute until oil
again emerges from the motor head. Wait from two to three minutes to allow air to exit the motor.
Repeat this process until motor oil flows from the top of the motor.
10) Down ESP motor installation table. Remove shipping cap and inspection motor flange face. Check
rotation.
11) Pick up seal. Position the item to be installed directly above the motor with the bottom of the item
at a comfortable working height.
12) Clean the bottom of the item so that contaminates do not enter the motor when connecting.
13) Remove the bottom shipping cap. Remove and discard the O-rings that are used for shipping. Inspect
the O-ring groves for damage and cleanliness. Install new O-rings into the groves. Ensure that the
shaft turns freely.

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14) Place the proper bolts with washers in each bolt hole. Start each bolt to ensure that the threads are
aligned. When all bolts are started, lower the equipment onto the motor and tighten the assembly
bolts to the proper torque, as outlined in the specifications. When all bolts are properly torqued,
raise the equipment assembly and remove the lower Lifting/Assembly clamp. Store the clamp away
from the wellbore in a safe place.
15) Pick up pump receptacle assembly (Pump tandem with intake) to connect to top upper seal. Remove
the bottom shipping cap. Remove and discard the O-rings that are used for shipping. Inspect the O-
ring groves for damage and cleanliness. Install new O-rings into the groves. Ensure that the shaft
turns freely. Then follow (14)
16) Raise up the ESP string until the motor pothead reach on acceptable working. Open pothead
shipping cap and check electrical integrity. Rig up cable sheave, feed MLE with power cable
through and connect to the motor terminal.
17) Perform electrical check at the end of power cable (Electrical Spooler)
18) Service seal. Start pumping oil into the seal from the motor drain/fill valve until oil starts coming
out of the first vent hole.
19) Pump more oil into the seal again until more oil/air comes out of the vent again and pause. Continue
this process until only oil comes out of the vent.
20) Install a vent plug with a new sealing washer. Then torque the plug to the proper torque as outlined
in plug specifications. Continue this process for the additional sections of the seal assembly.
21) Lower assembly in well while continuing to attach the MLE cable to the ESP with properly MLE
clamp (Protectolizer for MLE).
22) Lower assembly until top of pump. Open shipping cap. Clean the top of pump flange. Test shaft
rotation by electrical phase rotation test at the end of power cable at electrical spooler.
23) Pick up tubing pup joint with pump discharge to connect with pump. Remove the bottom shipping
cap of pump discharge. Remove and discard the O-rings that are used for shipping. Inspect the O-
ring groves for damage and cleanliness. Install new O-rings into the groves.
24) Lower the pup joint with pump discharge onto the pump and tighten the assembly bolts to the proper
torque, as outlined in the specifications. When all bolts are properly torqued, raise the equipment
assembly remove lifting clamp.

Note:
i. See more detail in document AL-GLB-CEN-ESPS-102431_Electrical Submersible
Pumping Procedure
ii. Specific Torque value, O-ring Part number, Coupling PN refer ESP Schematic and checklist
in Preparation Report. (Appendix)

6.2.2 Cable attachment

6.2.2.1 Cable Bands
The weight of the cable determines the required number of bands or clamps and the placement on
the tubing. Shop testing determined that a properly installed cable band would support about 75 pounds (34
kg). To provide a margin of safety, use 25 lbs. (11.3 kg) per band as a guide to provide a 3:1 safety margin.
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Divide the total weight of the cable by 25 lbs. (11.3 kg) and this result will be the number of evenly spaced
bands required. However, close inspection of the installed clams is required to verify they are securing the
cable properly. Placement of the band or clamp is important to allow ease of installation and removal from
the well.
Typically, it is not recommended to place a band or clamp within six feet (2 m) of the bottom of a
tubing collar. This space will allow the service unit operator room to set the tubing slips without any
interference of the cable and allows the crew to pull the cable away from the tubing slips when setting them.
Note:
Do not over-tighten the band or clamp, as it will damage the cable.
Do not under-tighten the band or clamp, as it will be loose. If the band is loose, you will need
to remove it and install a new band.
Note: Regardless of the clamping device chosen, it is very important to keep an accurate count
of the number of cable bands or clamps installed. Please log the information on the paperwork so
that when the unit is pulled, it will be obvious if any bands or clamps remain in the well.

6.2.2.2 Cable (MLE) Protector

Motor lead extensions can become damaged if the MLE becomes trapped between the casing and
equipment going down hole. This problem becomes even more evident as the move is made to tight casing
applications or systems with a dog leg greater than 15° per 100ft. The cast protector fits around the
equipment base flanges and provides lobes on clamp to provide additional MLE protection.

6.2.3 Installing Production Tubing

The pump setting depth should be calculated to ensure that the bottom of the motor is above the
perforations in the well, as the only thing that cools the motor is the fluid moving past it into the pump
intake.
Install the equipment into the well at a rate of 500 to 1,000 feet per hour. This includes time to stop
and check the cable periodically. This may seem like a slow installation, but the cable and the internal check
valves within the seal section need time to adjust to the increasing pressure.
Stop and check the insulation value of the cable while installing. Suggested checks should occur
every hour of the installation or every 500 to 1,000 feet; whichever works the best for the application.
Stop and check when equipment enters fluid and when a splice enters fluid to make sure that
everything is still in proper working order. This will help to eliminate nonproductive time (NPT) should the
electrical readings deteriorate.
If the ESP system is installed in a deviated well or any well with high dog leg severity (DLS) > 6
deg/100 ft:
i. Identify the “tight spots” using the well survey and include them in the well program.
ii. Discuss tight spots in the pre job safety meeting with the rest of the well site personnel to bring
awareness to the rest of the crews.
iii. Reduce the RIH speed to < 500 ft/hr. or less in the tight areas identified previously in the well
survey to reduce any additional stress to the downhole equipment.

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iv. The rig operator is required to watch and monitor closely the weight indicator during tight areas
for potential weight loss. Once the equipment is Running in Hole (RIH), periodically stop and
check the sensor readings (if installed), electrical balance and insulation value of the cable-motor.
Carefully check the banding material or cable clamps when stopping for the cable checks to ensure
that they are installed correctly and not damaging the cable.

Note that cable insulation resistance (IR) will degrade with the increased heat of installing into a
well, which is typically hotter than the surface ambient temperature. This is not a concern as long as it is a
gradual change and not an abrupt change.

A gradual change indicates that the cable is in fluid and is heating, while an abrupt change would
indicate that the cable might have been damaged during the installation.
If at any time the phase-to-phase values become unbalanced or phrase-to-ground value become 0
ohm, there is no point of installing the equipment any further as it will not run when it is set to the desired
depth. If this happens, inform the customer that there is a problem and make arrangements to remove the
equipment from the well.

Note: When ready to land pump at determined depth, stop the cable install/pulling process, clear
the area of personnel, and release the sheave cables from the mast. Carefully lower the sheave and hang the
sheave about 12-15 feet (3.6 to 4.5 m) above the rig floor using the appropriate slings, chains and clamps.
Once the sheave is secure, allow only necessary personnel into the area, cut the cable to finish install if
necessary and lower sheave to ground and remove from work area.

6.2.4 Landing the equipment in the wellhead

As most of the wellheads are offset to allow the cable room to exit the wellhead, it is essential that
the cable always be oriented in the same direction to make the connection of the surface piping easier. A
good rule-of-thumb is to point the cable towards the motor controller to make it easier to remember the
orientation of the cable. Perform resistance test of cable/motor and sensor before packing off and apply the
flying lead cable connector to monitor the cable integrity and downhole sensor parameters during landing
the unit.
After Electrical test, apply tension to the cable String until you feel the back end of the Test lead
disconnect from Female Cartridge, Remaining connection in the BOP is pressure tight for BOP testing
Note:
1. Ensure to secure the flying lead properly during landing process to prevent it slip into the
well.
2. Flying lead operation should be sure not to apply excess tension that will cause the flying
lead to be disconnected when landing, or less tension that will cause landing cable to slack
and can be damaged when landing.

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7. Pre-commissioning
At this point is good to focus on safety. Keep in mind that driver will be tested in power and
current. On No Load Test and Shorted Output Test might be necessary to connect and disconnect input
jumper wires, and during arranging for shorted output test, we will have to connect and disconnect short
connection between out-put phases on driver or StepUp transformer. During this process, it is highly
recommended to verify absence on voltage before connecting input power cables to converter sections
and before connect / disconnect joint cables for outputs phases:

Note Verify No voltage condition. Always verify no voltage condition taking readings: phase to
phase voltage and phase to ground at the top of the input breaker of the driver, then at the bottom to verify
no voltage then put the meter back on the top of the breaker to verify the condition of the multimeter.
After that, always check absence of voltage across the DC Bus before testing internal components.

Figure 1: Verify Input voltage / absence

Figure 2: Verify Capacitor Voltage / absence

7.1 Verifying Software Update

1.1 First of all, you should have an USB memory stick with the latest software version for:
✓ Advantage Power Conversion (APC).
✓ Advantage Graphic Display (AGD).
✓ Advantage System Control (ASC).
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1.2 Software can be accessed and downloaded from BHI page. Software should be arranged in the
USB memory under a subdirectory named SW_Upgrd. Inside must be another three (3) subdirectories:
APC, AGD and ASC with the corresponding software upgrades.
1.3 Turn on the power using the main Breaker. Wait Display initialization.
1.4 Insert USB memory stick in the weatherproof USB slot in the front of the main door. Immediately,
drive will start scanning USB memory inserted, and if a later software version number than the current
operating software is founded, screen will show the Load Software Update option.

Upgrading Software option

1.5 Then, pressing ENTER when Load Software Update is selected will cause to ASC to check the
external USB memory for available software update. Once the process is finished, user will need to cycle
power to the drive to cause it to load and run the new software.

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7.2 Forming Capacitor

• Perform these steps only if the unit has not been

operating within 6 months.
• Perform the preceding steps for BASIC
PARAMETER SETUP.
• Disconnect load from output terminals of the
VSD.
• Set Run I LIMIT to the maximum value.
• Set SYNC I LIMIT to the maximum value.
• Set VOLTS AT 60HZ to 230 volts.
• Set OVERLOAD SETPOINT to maximum
rating of controller.
• Press the START button and confirm the
controller ramps up to 60 Hz.
• Monitor output volts, at 60 Hertz drive should
have 230 volts out.
• Increase VOLTS AT 60 HZ. in 50 volt
increments with five-minute pauses between
each increase until maximum output voltage is
reached.
• Press STOP to shutdown controller.

7.3 No-load Tests

1. Turn ON the drive.
2. Wait until on display you can verify a totally initialization process.
3. Verify settings according with table 1.
4. Press START button, verify that frequency should reach 30Hz and output voltage should be stable
at 50% voltage of the load. Frequency and output voltage should be steady.
5. Check rotation for 480VAC motors should be clockwise from the front to the back of the drive.
6. Check the rotation of the internal fans. Fuse fans should blow toward sinks aluminum (toward the
fuses). Interchange fan extract air from the interior of the drive into the Chamber with heat
exchanger aluminum tubes.
7. Then adjust the frequency to 60Hz. Frequency and voltage should ramp to 60Hz and voltage to
VClamp.
8. Press the MENU key so many times until you return to the main menu screen. From there, go to
the screen ANALOG SETUP. Use down arrow key to go to the screen IN VOLTAGE AB. Using
calibrated Multimeter, take readings of phases A and B, enter input voltage readings on the screen.
Repeat this step for phases BC and CA. Press button MENU so many times until you return to the
main menu screen.
9. Press MENU button once to return to the screen SYSTEM. Scroll up to UPDATE FLASH NOW
and set to YES. This records all the information from the previous steps in the FLASH memory
for a semi-permanent storage. Once the memory has been updated, the option will automatically
change to NO.

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10. It’s important to highlight that if the process of substitution of components included the
replacement of at least one 15500 μf capacitor from one capacitor module, must be required to
carry out a process of formation of capacitors. Clamp to 500, VBoost to 0, startup the drive at 30
Hz. Increases Hz at a rate of 10Hz each 5 minutes up to 60Hz; per step check voltage DC balanced
between capacitor modules. The formation of capacitors can be considered a No Load Test.
11. Turn OFF the drive. Apply Lockout / Tag out.
12. Verify absence of voltage on DC Bus.

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7.4 Communication Test

The ADV (advantage drive) case, menu SCADA & SECURITY SYSTEM, in SCADA
SETUP submenu, check the direction of the RTU port, BAUD, Protocol, and synchronization of
communication by cable (Handshake) type. Also check the State of communication using RS232 or
RS485 option Com Stats, showing error messages, as well as the packets sent and received. All
setting will be according with customer system.

8. Well start up procedure

8.1 Surface Equipment Preparation

Ensure all cables used have excellent electrical integrity and carry out full electrical test
once system is being commissioned: phase to phase continuity, 1000V insulation resistance test
and physical check will be required.

1. Test downhole ESP cable from wellhead.

2. Test medium voltage surface cable from wellhead to HV JB and SUT.
3. Test low voltage cable from VSD to SUT.
4. Test low voltage cable from VSD to power source.
5. Check grounding / earth point on all equipment.
6. Check P-P and P-G resistance from secondary side of transformer to downhole ESP. And TDR
record of each well.
7. Ensure transformer is tapped to correct voltage and base frequency is correctly set in VSD (60
Hz)
8. Set up VSD parameters as per VSD setup sheet, set underload trip to 0%: Complete pre-
commissioning checklist and conduct VSD no-load test with output cables disconnected as per
drive procedure.
9. Once satisfied with results, connect all cables, and confirm downhole gauge data is valid.
8.2 ESP Start up

Once given all clear by Centre Control Room (CCR), the well may be started. Maintain clear
communication at all time between CCR, VSD Engineer and production team.

1. Line well up to process as normal. Open all in-line valves, i.e. master valve and wing valve. Close
swab valve.
2. Monitor pressure in CCR. Open downhole safety valve (SCSSV) by cycling three times at correct
opening pressure. Check hydraulic returns at wellhead to ensure valve is open.
3. Open the choke at minimum opening – preferably at 5%
4. Start ESP at minimum speed – 35 Hz.
5. Production tech monitors tubing pressure, flow line pressure and flow line temperature.
a. Rotation should be confirmed and verified immediately after start-up. If rotation is incorrect
shut down ESP, reverse rotation and repeat start up. ESP rotation can also be identified by
downhole parameters.
b. It is vital that when a well flows naturally, the ESP must always be started against a closed
valve (preferably the choke valve). This is to prevent the risk of a reverse start. Having
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proven forward rotation does not guarantee there is no risk of starting and ESP under flowing
conditions as the shaft could be rotating at a higher frequency than the start frequency.
c. For the wells with no data please ensure that the motor amps are increasing with frequency
and observe wellhead pressure and temperature as an indicator of good flow. If the well does
not surface fluids within the expected time frame, please shut the well down and consider
the pump rotation may be incorrect.
6. CCR monitors the process and downhole sensor reading. Adjust choke and speed to achieve target
rate.
7. Route the well into well test to confirm flow rate.
8. If any abnormal trend change is noticed, stop ESP for further analysis and troubleshooting.

8.3 ESP Re-start (Normal Operation)

In an event the ESP stops running, this recommendation should be strictly followed to
minimize the chance of damage to the ESP.
1. Any fault stop, should be find root cause before next start.
2. After ESP stop wait until Intake pressure and discharge pressure have equalized.
a. In case of no downhole data available, wait at least 30 minutes.
3. Re-start the ESP at minimum speed.
4. Increase speed to previous set point at 2 Hz increment.

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APPENDIX
Qualitative Risk Assessment (QRA)

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PHYSICAL BARRIER CHECK

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Safe to Perform (STP)

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Safe to Perform (STP)

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Reference Procedure Document

1. BH-HSE-023_Electrical safety
2. BH-QHSE-002_Stop Work Authority
3. BH-HSE-006_Manual Handling and hand safety
4. OPS-GLB-ESPS-100546_Electrical Submersible Pumping Systems Lifting Procedures
5. AL-GLB-CEN-ESPS-102431_Electrical Submersible Pumping Procedure
6. BHI ALS Bleed-off Pressure from Casing Annulus Recommendation.
7. AL-GLB-CEN-CABLE-102445_Cable Splicing Procedure
8. AL-ESPS-S003-20-04-008_Cable Banding and Clamping
9. 907140 Electrospeed Advantage Variable Speed Drive, Installation and Operation Manual.

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