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ELECTRICAL SUBMERSIBLE PUMP

-!HANDBOOK

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SAFETY
i Section 1

1.1

SWITCHBOARD

SAFETY TIPS

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LIsted below are several safety tips that should be followed In addition to any local safety requirements. When working with switchboards always remember:

HIGH VOLTAGE CAN KILL! 1

Stand to the right side of a switchboard when stanlng or stopping a unit. The door can blow open In case of explosion.
If checking high voltages. make sure proper meters and safety gloves are being used. Always check a switchboard for proper grounding. II unusual or loud noises are coming from a switchboard. call a qualified electrician. If arcing noises are present, wear proper safety gloves until source of arcing Is located and fixed. ,

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3. 4

5.
6.

leave voltages alone If untrained or nervous. Have 8 qualified electrician ~heck a switchboard If necessary.

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MONITOIRING AND REPORTING


Monitoring some da1:a is the to be key to efficient ESP opera

tions.
..

Usted

below

are

monitored:

Dally amp charts Unusual operating characteris ics Auid levels Casing and tubing pressure Gauges (tubing & casing) Tear-down reports Cause analyses Daily Monitorina

Sufficient records should be kept to allow the engineer or foreman to get an overview of the pump's operation and well performance. Any out of the ordinary operating characteristics should be noted In the well's file. Amperage charts should be maintained and used as a daily monitoring procedure (see Trouble Shooting Amp Charts). Seven day or daUy charts should be used. If electronic data gathering systems are used then a hard copy should be kept periodically so the entire pump life can be examined. Proper maintenance and calibration of the recording devices should also be done. Section 4.2 shows a Standard OpArating Procedure used by Sacroc to monitor well performance.

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Rangley Shuttle Valve


A second alternative Is the shuttle valve developed In Rangely, Colorado. and Is similar to a check valve. The main dlHerence Is when the ESP shuts down, the check valve drops. preventing "uld !rom flowing through the ESP, and exposes a side opening which allows the tubing 'and annulus to equalize. The side opening will allow chemicals to be pumped down the tubing, but not through the ESP. When the ESP Is restarted the check valve rises and seals the side opening.

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2.3

EQUIPMENT TI,e ESP system can be divided Into subsurface and surface components. rhe major downhole components Include an electric motor. seal section. muill-siage cenlrifugalpump wilh an Intake and discharge. and power cable. Optional downhole equipment may Illclude a bottomhole pressure/temperature sensor. check and drain valves. motor shroud. and a gas separator. The surface components illclude a 'unction box. switchboard. and transformers. A typical ESP Illstalialion Is shown in Figure A. A description of each component I~ given below ,beginning downhole and moving up the well.
..I Subsur1ace EoulDment

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Motor
ESP motors are two-pole. threEt-phase, squirrel cage Induction motors which operate at fl nominal speed of 3500 rpm at 60 Hz. Voltages range from 480 to 4,125 volts, whOe amperages range from 14 to 143 amps. Horsepower Is Increased by Increasing motor length for a given diameter size or motor series. Large horsepclwer requirements usually require two or more motors, commonly referred to as tandem motors. Molors.. are lilled with a nonconductlve oil with a high dieleclr!c strength which provkJes lubrication lor bearings and good thermal conductIvity. Produced fluid moving past the outside 01 the motor carries heat away; cooling the motor (minimum recommended fluid velocity Is I ft/sec). lIthe fluid veloclty'\s nor sufllclenllo coollhe motor, or if Ihe motor Is located below the per1orations, 0 shroud should be placed around'the motor.

Seal~Pro'ec'or, Equalizer
The seal section (also known a!i a protector or equalizer) Is located between the motor and lIuld Intake 01 the pump. The seal sery~s live main junctions: ;"

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eliliained In Ihe cable 10 escape 10 Ihe almOsphE!re before reaching Ihe switchboard. The junction box also provides easily accessible test points for electrically checking downhole equipment. [fa be used wilh pac.,-off type subpump hangar. Not necessary with EFT (Electronic Feed Through) hangar. Switchboard
Switchboards (motor controllers) consist of a motlor starter, relays for over1oad and under1oad protection, a circuit breaker, time delay relays, and a recording ammeter. The switchboard also features a lIghted display so that a pump's operating condillon can be seen from a distance. Overload and underload relays protect the ml)tor trom

drawing excessive amperage and Insufficient simperage, respectively A system does not automatically ~:11f It goes down on overload. Time delays are used to aliolN enough time to pass after a shutdown betore a restart attempt Is made; the time delay should be long enough to alli)w nuld In the tubing to equalize wilh the annular fluid. Time jjelays are also used with external control devices, such as tank level controls or line pressure switches. Excessive cyciling Is not recommended due to the high amperage occ:urrlng at start-up.

The ammeter records the amperage drawn by thel motor on a 24-hour or 7-day amp chart. Amp charts are a vital means 01 ESP diagnostics. They give Indications 01 power nuctuations. gas locking, pump-a", false starts, cycling, undercurrent loads, overload, debris, and normal conditions (see Trouble Shooting Amp Charts).
Variable Speed Drive (Optional)

ESPs are relatively Inllexible In their production range when operated at a fixed frequency. Variable speed dri'/es (VSOs) allow an operator to vary the frequency. and thus the flow rate, to bener match well conditions. However. '/SOs have high Initial and maintenance costs. Most ESP comlpanles rent VSO's lor testing.

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TREATING (ACID, SCALE)

!!JatinG PartiallY PluGGed ES~

with scale. wax or Occasionally, ESPs become partially PlUgged asphaltenes. reducing pump performance and i creasing lifting cost. Suggested treating is as tollows. .
c:ii:'!if::,;~:'1i Wax

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Wax can tubing as remedied down the

build up in the upper secti nl of the production in a rod pump well. These pr blems can often be by hot oiling or hot watering down the tubing or annulus through the pump. he following is a key

point to consider: ; Pump hot oil or water down t ! tubing if possible. Excessively hot fluids down the nnulus could exceed
the ESP cable temperature ratin .

Scale
It well bore scale problems are presen in your field. you likely have scale build up in your ESP. Frequently you treat the pump for scale by pumping t e recommended tor your type ot scale through the pu p. The following some points
annulus. Try to

will can acid are

to consider:
pump This the oHers acid bener down co th

Irol tubing

over

instead the

treatment of

the

and

the

acid

will

nol

contact

,armored

cable.

Corrosion inhibitors can be ad to protect the steel armor a careful! Corrosion inhibitors c could be damaging to the for' tormation plugging trom tines

ed to acid treatments ound the cable. (Be r\ cause emulsions that tion) Not to mention eleased from scale.

Asphaltenes

II you diagnose an asphaltene problem, aromatic solvents (such as xyiene and toluene) must be used to disperse the asphaltenes. breaking them up so they can be removed. Chemical manufacturers have additives to hellp Improve solvent penormance. Be sure to ~ ~ the ~~ manufacturer ~ Dumolng solven~ to be sure what allect they will have on elastomers (rubber material) Ilrl the cable

and pump.

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If asphaltenes cut material

are suspected a wlreline knife can be used to loose In the tubing. This material can be

analyzed. If It proves to be asphaltenes. the propl!r treatment can be applied before the pump becomes Irreversibly

plugged.

Hat all
If a check valve exists above the ESP, the hot 011 must be

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pumped down the annulus. Otherwise, the hot 011 can be pumped down the tubing. It Is more desirable to IPump down the tubing In order to prevent exposing the cable to the hot all. Cable may be damaged If the temperature of the 011 exceeds the cable's temperature rating. Good rules of thumb

awe:
When pumping down the tubing, use two tubing volumes at 80% to 100% 01 the lormatlon tlemperature.

When pumping down the annulus, use one and a hall


annular volumes at 80% to 100% of the formation \ Hlot Watering

temperature.

Th~ procedure lor hot watering Is the same as hot oiling except Droduced water is used. The advantage 01 using water I~i that It holds heat longer than oil, thereby rE!qulrlng less volume and lower temperatures. Hot watering wililrequently have better results thiin hot oiling C;oncerns about scaling. corrosion, bacteriel, formation clamage. and emulsion problems can be overcome by using

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appropri"te chemical additives. Rules 01 thumb I:atering lare the same as lor hot oiling. Selection

lor

hot

~Cid

he type of scale present will determine the type of acid equirecJ. All large acid supply companies will analyze a proouced water sample from the well to predict the type of S cale present Once the type of acid and corrosion Inhibitors re selected, the volume and strength of acid required can be ""determined by the quantity of scale present. Good rules of

Ihumb are:
I. U~e a 5% solution 01 appropriate c:orrosion inhibition additives. acid with good

U~e 2 bbls/ I 000 leel 01 lubing.


Always use a larger volume and weaker solution, rather than smaller volume and stronger solution, because the bottom ortlorl 01 the cable and some cable bands will unavoidably come In contact with the acid. II the acid is weaker the ~orroslve ellects are lessened.

8r,eatlng
! T al:idizing procedure lor a seized ESP Involves a lined The Ifpressllre truck with a lined or nonreactive pump. The acid shoul(]1 be thoroUGhly mixed orior to pumping down the Itubin~11;'~ suggested acid procedure is as lollows:

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Rate Description 1 Pump until acid Is above the ESP. The first '/. tubing volume 01ack1 Is used up, or spent. as It dissolves scale Irom the tubing 2. Pump the V. tubing volume 01 spent acid Into the annulus and the next '/. tubing volume of acid Into the ESP. 3. Allow a 15 minutelor soak lime the acid
10 work.

Volume 11ublng
volume acid of

(bbls/mln)

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'h tubing
volume of

acid

4. Pump a Iresh, unspent Y. tubing volume 01 acid Into the ESP. 5. Let soak approximately six hours. 6. Turn on the ESP and produce the spent acid down the flowline.

y. lubing
volume 01

acid

'h

The final Y. tubing volume 01 acid Is not pumped Ihrough the ESP because II will be diluted by tile nuid used 10 displace Ihe acid (usually waler)

Acldlzlng Asphaltenes
Asphaltic crudes are sensitive to the presence ollerric iron during acidizing operations. The iron acts to crosslink the asphallene molecules, lormlng added.oil sludges. Iron

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Treallng
The asphaltene removal procedure lor a seized ESP Involves a pressure truck with a pump containing tenon seals. The solvent Is thoroughly mixed prior to pumping It Is then pumped down the tubing A typical asphallene removal program is as follows:

Description 1
Pump untH solvent Is above the ESP. The first Yo tubing volume of solvent Is used up, or spent, as it removes asphaltene from the

Volume
1 tubing volume 01

RIle (bbls/mln)
1

solvent

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tubing 2. Pump the Y. tubing volume 01 spent solvent Into the annulus and the next Y. tubing volume 01 solvent Into the ESP. 3. Allow a 15 minute soak lime lor the solvenl to work. Pump a fresh, unspent V. tubing volume of scjvent Into the ESP.
Let soak approximately

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~ tubing volume 01 solvent

-4

'I. tubing
volume of

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solvent

5.

six hours. 6. Turn on the ESP and produce the spent solvent down the nowtine.

sequestering agents are IneHective at preventing ackt-oU sludging since the sludges are formed before the sequestering agents function. These sludges can best be controlled by a prenush of aromatic solvent/asphaltene dispersant which removes any existing asphaltene deposits plus acts as a spacer between the acid and oil. The aromatic will also clean the tubing and ESP. Improving the eHectiveness of the acid.

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Most miscible flooding operalions will have asphallene deposition In the well during Initial stages 01 gas breakthrough. A good rule 01 thumb lor treatment volumes Is 1 bbl/IOOO leet ollubing 01 aromatic solvent/asphallene dispersant as a preflush to the acid.

Solvent-Rubber Reaction
Solvent Is usually pumped down the tubing and rarely down the annulus. II solvent Is pumped down the annulus at lull strength, h will come in contact with the cable and destroy the Integrity 01 Its nuld jacket. Most fluid jackets are nltr~e-based and most solvents will swell nitrite 25 '0 50%. II this happens the cable armor may burst and/or an electrical short will occur. Check with the ESP manufacturer before pumping any solvents through an ESP. Some manufacturers use nitrite bushings in the pump. and these will swell and seize the ESP if they are contacted by a solvent.

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Solvent Selection
The Iwo most common and eHective aromatic solvents are xytene and toluene. Both are equally eHectlve at repetizing asphaltenes. The various chemical manufacturers have sur1actants and dispersants which will Improve the performance 01these aromatic solvents. Chemical companies will test a sample 01 asphaltene and determine which Is the best lormula lor the sample given. This Is usually done quickly, but the testing Is extremely biased. For complete. unbiased testing, send a sample to COFRC. The testing time Is longer but the recommendations will be nonbiased.

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The volume

of solvent will be determined rule

by the quantity

of

asphallene present. A good bbls/ I 000 feel of tubing.

of thumb

Is IIC) use 2

II the tubing or ESP Is plugged solkj and pumping

clown the

tubing Is impossible, a coiled tubing unit can be used to clear the plug In the tubing and/or squeeze solvent through the ESP Plugging can be avoided by implemer1tlng the monitoring Aeduclna program described below.

Treatment

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Check Valve VI. No Check Valve Check valves are Ihe mosl common melhod of prevenllng nuid from passing Ihrough Ihe pump. The advanlages are Ihal check val\/es are inexpensive. prevenl sand or particles In Ihe fluid fr,Qm plugging pump during shuldown.' allow Immediale reslarting, and Immedlale producllon upon reslartIng. The major dlsadvanlage is Ihat check valves do nor allow clrculallon down Ihe tubing; reverse circulating down Ihe annulus can be done inslead. Back Spin Relay

PUMP OFF

~roblems
.Unit 100 large syslem with smaller pump (currenl syslem 100 large) well

Solutions

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.Redesign .Stimulate

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FALSE STARTS Problem~ .Auto restart delay not of sufficient lenglh to allow adequate

fluid build-up.
SolutIOQ~ .Increase .Redesign restart delay ESP

Transformers
Transformers are used to convert primary line volta'ge to motor voltage requirements. Three types of transformers used In conjunction with ESPs are: banks 01 three single-phase transformers. three-phase sta~ard transformers. arKi three-phase auto transformers. The transformers are oill-filled and self-cooling. For oHshore platiorms where oil-filled transformers might be prohibited. dry type transformelrs are available. The transformers are equipped with taps to provide maximum flexibility In voltage outPut.

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TROUBLE SHOOTING
Section 3

3.1

TROUBLE SHOOTING GENERAL


Check the switchboard's indicator lights 10 see it ihe unit is running If down. check to see it it is down due 10 IJnder1oad

or over1oad.
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Check the amp chart 10 see if any unusual lines or blips are present. For help in Inlerpreling amp charts see Trouble Shoaling Amp Charts.
Check Ihe murphy switch or the eX1ernal switches Ihey are coni rolling the switchboard. 10 see Ii

3.
4.

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II down due 10 an over1oad condition, call an electrician to check lor a shan downhole before anempting to reslan.
Check primary fuses to see If they are open. These Ituses will open when there is a surge of power on one leg. Visually inspect transformer hookups. the unit downhole I:rom the

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Insure the electrician checks lowest point of connection.

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Problem #2:

Unil shuls down due to undercurrent.


Possible Corrective Actlcinl

Possible Causes
Low well productivity pumped-oN condition

.Check

amperage downhole

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Plugging of pump Intake

.Shoot fluid level. Pump water down backside II no fluid levEllls available. \I there Is lIullj In the well, consider pump ctllange. .Check to see if pump Is pumping

fluid. .Pump acid down tubin!) and through pump II tubing Is open to pump discharge. (see 13ectlon2, Treating)
.Pump acid down backside and spot around pump Intake.

.Change out pump. Have the pump ackilzed and tested beliore sending lor repair. This may avoid the unnecessary cost of repairing a scaled pump. Underioad set too high .Check amperage dowrlhole on all three phases and comlpare with nameplate amperage 01 motor. Reset under1oad lilt Is above 80% 01 nameplate amperage. Do nol go below 60% 01 molar arnperage.

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Broken shah In unit

.Compare downhole amperage with Idle load amperage (typically 45-55% 01 nameplate amps). Reverse unit In switchboard by changing two downhole leads. Check amps again; they should be within :t 10% of lirst reading. Reverse leads again. Pump water down backside if available. Start unit again. " amperage Is constant through this procedure. a broken shaft exists and the unit must be

pulled.
Is gas locked .Pump water down backside break gas lock. .Vent casing to flowline to

II possible

.Check setting depth to see if unit can be lowered closer to perforations. .Install Faulty remole conlrols switchboard 10 shroud or gas separator.

.Check pressure control circuit or other auxiliary that could cause shutdown.

Flowline restrictions

.Check all valves to make sure the', are open. Check pressure on wellhead and lIowline. Check to see it pu~p is pumping fluid.

~Pump

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8rOb'em

#51: Unit will not restart atter underload shutdown.

[prOblem #6: Unit will not shut down with HOA switch.
II Possible Causes Possible Corrective Actions

C II Control relaystuck
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I Problem#7: Unit will not shut down by underloador overlclad.

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Possible Cause.
Undercurrent shutdown Remote controls have opened and shut unit

Possible Corrective Ac:tlonl


.Check downhole arTlperage. II

~or~al~ust

setting.

down

.Check for open or closed contacts on remote circuits and clean or repair as necessary. .Check remote contclcts and clean or repair as neces~lry. .Check lor correct phasing on control power Irans10rmer. Change II necessarf. .Check CT phasing. Change 3.5.7 10 controller If necessary.

Unit starts but shuts down withIn 5 seconds

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Unit will not tlme-olf

.Check remote circuits. Unll will nol slart In lime-oil II relmole contacts are open. .Underload underload Is set too low. " Is set pa,st the lowest

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se"lng mark, timer sequence Is not operational. Check CT ratio 8~ adjust underload as needed.

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FIGURE A

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2. Connects the drive shalt of the motor directly to the pump shatto Absorbs the axial thrust from the pump. Protects the motor oil from contaminalion by the well
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-~:;; ::[;;~:.; ,;. ii,' :.:~ ;~~';

3 4
5.

fluid.
Allows pressure equalization between Ihe well annulus pressure and the molar internal pressure. Provides a reservoir for volume changes as the motor oil heats up and cools down.

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Seals contain a labyrinth chamber with a blacking fluid between the well fluid and motor ail. The blocking fluid is commonly the same ail used In the motor. It may also be a high density fluid for special applications. Seals may also contain a positive elastomeric barrier, or BAG. In combination with a labyrinth chamber. Several operators have Increased run lives using tandem seal sections as an added means of protection.

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Gas Separators (optional)


Gas reduces the efficiency of ESPs; therefore. gas separators may be Installed between the seal and pump to reduce the amount of tree gas entering the pump. Both reverse flow and rotary separators are available with the latter being more efficient at gas separation. Some operators run tandem gas separators In high GaR wells 10 more effectively remove gas trom the pump intake. Gas separators QQ !:!Q! handle significant volumes of free gas efficiently.

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Pump
The submersible pump Is a multi-stage centrifugal pump; each stage consisting ot a rotating Impeller and a stationary diffuser, that produces a given amount ot head for a given volume. Impeilers may be either floatinq or fixed. Aoating imoellers, which are the most common, move axially along the shaft and are tree-floating when the pump is operating within the recommended capacity range (see Figure B). However. jf the pump is operating ~ (to the left of) the recommended capacity ~, the impeller will be in a downthrust condilloQ. Conversely. if the pump is operating ~ (to the right of) the recommended capaCity~ the
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impeller will be in an u~Ihrust condition Both downthrust and upthrust can cause excessive wear and can be detrimental to the pump.

f:lxed Impeller.

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Fixed Impellers are directly connected 10 the pump shalt and cannot move axially. Allhough this saves impeller and diHuser wear. fIxed Impellers may allow lor a high axial thrust to be developed which must be absorbed by the thrust bearing In the seal. Impellers are classified as either radial flow or mixed flow type. For 8 given diameter pump. radial flow Impellers will have higher head pressure but slightly lower rate capacity than mixed now Impellers. Impellers may be made 01 dl"erent materials. The most common is a melal alloy called NI-Resist which Is composed mainly 01 iron and nickel. Other Impellers are made 01 a plasllc called Ryton. Ryton Is advantageous in scaly or corrosive envlronmenls since scale does not lorm on the Ryton. and since corrosion does not affect plastic. NI-Reslst Is belter for deep wells, high temperatures. and abrasive

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fluids.

Check and Drain Valve. (Optional Equipment)


A check valve, located two to three joints above the pump; prevents the pump trom rotating In the reverse direction when the unit shuts down. This reverse rotation occurs when the fluid In the tubing tails back aher the unit has stopped. An attempt to start the system while the pump Is rotating backward could result In a twisted shalt. The check valve, if not plugged open by debris, will keep the fluid trom tailing, thus protecting the pump trom reverse rotation. A drain valve, located one loint above the check valve. prevents pulling a wet tubing string. Drain valves also allow circulation ollhe wall when a check valve is run. Drain valves are not required unless a check valve Is used.

Power Cable
Electric cable strapped to the tubing Supplies power from the switchboard to the motor. The cable Is made up of three copper conductors. either solid or mullistrand The conductors are Individually Insulated: various Insulallons are available depending on well fluids, temperature. and pressure. A jacket material surrounds the Ins~ated conductors for protection against mechanical damage and the environment. A metal armor Is wrapped around the/acket lor further protection against mechanical damage. The metal armor also helps prevent swelling when gas or liquid permeates the jacket material at high pressures.

Cables are available In round or "at configurations a~ In various sizes. Flat cables are used where clearance between the unh and casing Is small The most common conductor sizes are No.1 (largest), No.2, No.4, and No.6 (smallest). General amperage ratings for the diHerent cable sizes are:

#8 #4 #2 #1

-up to 37 Imps -38-57 Imp. .58-65 amps -66+ amps

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As B general rule. voltage drop within the Installed length of cable, corrected for boltomhole exceed 30v /1000 It. temperature. should not

Motor Flat Cable A motor "at cable, connected 10 the lop 01 the motor, Is run along the length 01 the ESP syslem and spliced Into the main power cable lust above Ihe pump. The molar fiat Is necessary due to the lack 01 clearance belween the ESP and casing

Sul1ace Eaulcmenl

Junction Box
A vented junction box is located between the wellhead arid

switchboard. In high pressure wells, gas may permeate tile cable and migrate to the surlace. The 'unction box allows gas

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L YZE PBQ~L-.EM
Section 4

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'ii~~U1 ,!4.1
EQUIPMENT TESTING

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When ESP equipment Is pulled from a well its disposition may vary from running h back Into a well, to sending it to the manufacturer to be rebuilt, to having h tested by a manufacturer or testing company. lf the equipment was pulled for some reason other than a failure, a well site Inspection may be adequate to determine whether it Is suitable lor rerunning. However, if the equipment Is not going to be rerun Immediately, or If there is doubt as to hs condition, It is recommended that it be tested. Testing Is an Inexpensive means of determining the condition of used equipment. In the motor testing program, expensive repair costs can also be reduced as much as 90%. Sending equipment to be tested Is of particular Importance when equipment has been subjected to a hostile well environment (high water cut, COl, HJS, etc.). The cleaning of equipment and preparation for storage that Is Included In the testing procedure, is as Important. if not more so, than the testing Itself. Pumps. in particular. left stored on the rack without flushing can "lock down. and become Inoperable.

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PumR Tesllng
Each section 01 a pump should be Inspected lor problems, such as a twisted shah, hole in the housing, or any problem that would require h to be sent lor repairs rather than testing.

2.

The pump should be steam cleaned Inside and out 10 remove paraffin and well fluids. Olher chemical washes are also avaUable 10 remove sulfate scale. gyP. paraffins. and asphaltenes.

HCL

containing

an Inhibitor

and

dispersant

should

be

pumped through the pump lor a minimum 01 two hours. or unlU acid reaction Is complete. if scale is present.

The pump should be flushed with clear water prior 10 lesli"g.

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6.

7.

8.

Molar Testlo.g

a.

Check the phase-la-phase (lead-to-lead) resistance II should be balanced among all leads.
Check resistance. megohms device. the phase-to-ground (lead-to-housing)

b.

Typically, h should be more than 2000 on a megohm meter with no pressure

c.

9.

.IROUBlE

~HOOTlt~G AMMETER CHARTS

rnalyzing ammeler charts Is one of Ihe best ways to diagnose a .~ulllber of problems. LIsted on the next few pages are examples of ammeter charts lor various operating conditions. These charts are reprinted from the .Submerslble Pump Handbook" with permission

Ilroin Centrilift.
Comparing these amp charts to your amp chart may give an B Indication 01 the type 01 problem you have.
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NORMAL

.Under normal conditions the ammeter should draw a smooth symmetrical curve near nameplate current. S'plkes at start-up are normal.

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POWER FLUCTUATIONS

Problems
.Fluctuation of Primary Power Supply motors Injection pumps etc.) (Start-up of large HP

SolU1lons
.Investigate Power Fluctuations .10 causes 01 fluctuations (Start-up Injection pumps) .Call power company of larget HP mott

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Cle~n molor

Sleam clean body to within one foot of motor head. Do not steam head.

b.

Solvent wash molor head and lill valve areas

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T"8 nXltor oil should be drained and checked lor bronze content (Indicator 01 bearing wear), water content:, varnish/epoxy content, and melled babbit contenl (silver In oil'l. All boll holes and pothead cap a.rings should be checked damage. The lead washers on Iill valves should always lor tie

replaced. The motor should be lIushed Irom top down while qurning rotor stack occasionally. Check oil during Ilush lor obvious Indicators 01 nXltor problems. Flush the oil unit the discharge is clear. Dielectric strength 01the 011should be atlealst 25KV. Once Ilush Is co~lete, cap nXltorwhile It Is still lull 01oil.

I~

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r~

The P .1.lleakage) oflhe molar should be calculated and have a grealer value than 2.0. The hi-pot lesl should be run al a' vollage which can be calculaled by the following equalion: (NPV) x 1.5 + 1.7. (NPV) = Narneplale Voltage)
6

,: t:
O.
I

The phase-to-ground megohms trom the hi-pot test should be


greater than 5,000 megohms.

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17

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The spin test Is per1ormed by running the motor at Name Plate Voltage until the temperature reaches 100F. The motor then coasts down alter running. Coast time should be smooth and last 6 to 8 seconds. Spin testing should be per1orl1ned tor both the clockwise and counterclockwise directions.

r. ;

. ,
;

,.' 't
I;

, i f ~ : ~

\I \he motor does no\ mee\ \he above cri\eria, it c'Duld possibly be salvaged by sending it \hrough a "mini dryIDu\." This procedure Involves placing \he mo\or in an Insulated compartment and applying DC current to the stator until the tempera\ure reaches 250F. While the motor Is cooling it Is

~~i(~!!~~j~l~i~;i~.~;~. --"

::~\;~::;r.\:~.

:..:.~;;;.1.!~~1-:~":=~.:1

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purged with nitrogen After the dryout. the motor is retested as previously described. Replacement 01 the motor Insulation block In the terminal head Is recommended as part 01 any "mllli dryou.".

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~2 STANDARD RATING I DOE ORDCEDURE

1h' loll~,", lo,m' w", g,o",'ed hV, SACROC O",II'V A,"oo


T"m "","",o"V""d'05AC'OC"""5"oo"dOO"""" O""d,,' 10' d"',rno, '00 ,ed""o,", ,"hm,""" o"mp'

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.;

.
f,
1-

GAS LOCKING

~ .Lowering
.Gas

fluid 'e~el e~oI~es In pump

.S-Q!Y1!~
.Lower
.Choke .Put

pump
on \imer

production pump

back

.Redesign

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-:'~.~..1f-:--- I
111

WORKOVER AJrnFlClAL UFT SELECll0N


n.ta Sheet. Inltl.1 ~uipment Selection

w. rn-wo nul. unit


D

n.

c.lia, PnllUrt ..Comm..u

UII

(F't
v. Commt8U: 8~, 1111 m8pr roalldtnllt081 lor ~alpmtDIItIkd:

VI. W.. tqUlpm'8' fWlllb. 18m. ..orillD811, mlled for! If 80,II" brirf r'pl.a8uoD:

(YIN!

Do..WO c..pIoW:

Do...

E.acn

1\
WORKOVER
VII. Poll Workower Tell 0818 D4TE
80 BW GV

DATA

1\
Ii
VIII.

CO1~

POll Work ower fluid

lAwell CASING PRESS.

DAn:

fllnD u:vEl

COMMENTS

IX. Resl" Dall


Equip.
Dale

Equip.
RUD RUIOD

Pulled

os

Up/DUp/D.. Up/D..

Up/D..
Up/D.. X. Comments:

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~~:-: .;-,7':~;~'-;~'--- -' I


!:l!;;" "

"I DESIGN! "Capital and operating costs, well conditions, reservoir


perlormance, equipment and service performance. and ease of

..opera~ing and maintaining the equipment are key considerations 'e when designing an ESP. I
An IBM PC computer program called ESPO (Electric Submersible Pump Optimization' is available from COFRC for ESP design. ESPO selects the most economic system for each manufacturer considering both capital cost and power cost. Although computer programs make the technical task of ESP design easier. they should not preclude your engineering judgement and experience. Contact W. H. (Bill' Ford at COFRC for more information about or to obtain a copy of the program.

-ESPO,

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..-~

DECISION

At~AL YSIS ECONOMICS

Decision analysis can help you make Ihe best economic artificial lift decision. Merek. whict! utilizes many lools of decision analysis. Is a good program to base your economic decisions. TI19 foundation 01 good decisions Is historical data.

Please keep

go~ recordsl

!;

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PUL G A~ 1Jl':/J

TABI: UP
Ssction 6

I
INSTALLATION/PULLING PROCEDURES

Pre-Job Checklist
listed In this section are tips that will hopefully lead to fewer failures. For complete running and pulling directions please consult API RP IIR.

Eaulcment ReQuired

Motor

Ogtlonal EglliPJillll!'.

.Gas Separator

.Seal Section .Check Valve .Pump .Drain Sub .Cable Motor Flat .Motor Shroud .Switchboard .Variable Speed Driver .Round Power Cable .Junction Box .Transformers .ESP Tubing Hanger with Tubing Head .Tubing PUP (2'-6')

Services Required .Cable Reel (54" or larger! .Cable Bands and Bander (Hand band with precut bands or power band with reel 01stainless steel bands! .Electrician (lor disconnecting and connecting ESP and testIng cable! " Subpump SeNlce Technician (on 10catlof1lor length 01
lob) !

.Chevron Representative (coordinale Iplacement 01 equipment, timing 01 deliveries. and supeNislon 01 the installation!.

00 NOT RUSH.

Preolannina

is an investment

for success.

Wellbore PregaraliQn
Run a bit and positive scraper set to drih diameter at least 100 leet below nllmn !;Rnlnn npnlh A ~Ip~n ntillrin t)plnw IhA

.
I

bottom perforation Is recommended any past and present "tIght spots.,

If cost ellectlve.

Note

Eaulcment Handling When unloading ESP equipment, use a spreader bar with a chain allached near each end of the box. Never pick-up In the middle!
If the equipment damaged. location. Is dropped. damaged. or appears already

II should be checked by the service technician on

Note: Slightly more than 50% of III ESP failures In Chevron Ire cable failures, so speclll care must be taken In handling the cable.

Never pick the cable reel up by the cable. Never let any load be placed on the cable during loading, unloading, or storing.
Any rotation of the cable will cause damage.

~gJRunnlna
performed.

Eaulomeot
10 discuss the scope of work 10 be Note any special problems or concerns.

Hold a safely meeting

Suggested personnelon location:


-2 Roor Hands -Derrick Man 1 Operator -2 Cable Reelers (if by hand)

1 Service Technician 1 Chevron Supervisor

Handle equipmenl technician.

as recommended

by the

subpump

Clble ReellnQ/BandinglRunnlng
Reeling
1 Reel size should be 54" or larger.

Reel should be located 75-100' 'rom service rig. Cable guide on rig should be no more than 30' above ground. 4. Always have slack between the cable reel and guide wheel.
Always have the cable reel In the operator's line 01

5.

sight. 6.
Use cable stands through the dirt. to prevent cable from dragging

Banding
It Is very Important the tubing. 2. that the cable be run straight up

Band squarely across the cable. Tubing band should be at right angles to the tubing with the cable vertical. Band flat cable and flat guards straight up the the seal sectlof11 and pump. Start Immediately the pothead with a section of flat guard which bonom end slightly tapered. Continue with guard to lust below the "at cable-round cable side of above has the the flat splice.

3.

.
3.' 2. .I

4.

I
6.

Stainless steel bands are recommended (025 x .75 (31655)) as minimum. Where conditions warrant (hole deviations. doglegs. scale. etc..) larger bands (.035 X 1 25 (31655)) should be used. Cable band should slightly deform cable power bander should use about 125 psla. armor. A

Install two bands per 30' loint; one midway on the lolnt. and the other 18" above the collar. If using lead sheathed power cable, additional bands may be required In consideration of the cable weIght. STOP and contact a service technician damaged. if the cable Is

7,

8.

Extra care should be laken In runnIng cable Inlo a well where an ESP has nol been Installed before.

Splices

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Well conditions and field experience will dictate what type 01 splice Is appropriate. Good splices are the key to reducing cable related failure. Quality control of the splicing procedures and materials determine the success of splice. The person making the splice has the greatest Innuence over It. Cleaniness of the tapes, cables. and the splicer's hands Is a must. Tapes if used. must be smoothly wrapped and tight. The cable and conductors should not be manhandled or sharply bent during the splicing procedure. The lob should not be rushed because the care and time taken here wUI be recovered In longer run times lor your systems. Specific procedures and recommendatIons can be obtained from the Rangely oHlce.

Running/Pulling Cable
1

QQ1!Ql apply tension to the cable. This could elongate the cable and destroy the protective Insulation Avoid sharp edges and rubbing 01 the cable during running QQ.!!Q! allow the tubing to rotate.

5.

'"1

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Clleck cable and molar every 2000' going in the hole


(ulecllical conlinuilY and j'lsulalion resistance checks).

Check \he cable visually and electrically coming out 01 IIle hole.
STOP and have a service technician Inspect the cable If the cable Is broken, or the Insulation or armor is damaged (Remember: most cable fallurea reault from mishandling.) (Note depth of damage to cable) Keep slips In good condition with sharp dies of non-rotating type Be sure the swivel lock on the hook Is latched and that the hook Is not free to swivelRun and pull pump between 1000' and 2000' per hour Never pull the cable 'rom tile reel.

6.

All slops and slarts should be as smoolh as possi~e.


Always use lihlng subs lor raising or lowering equipment. ESP

B.

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,. , .,: ., .~: .

62

START-UP

PROCEDURES before slart-up if possible.

Load tubing 2.

Install proper amp cllart Set overload amperage at 110-120 percent of motor

nameplate

amperage.

4.
5.

Sel underload amperage al 80 percenl 01 running amps.


Set time delay for a minimum 01 30 minutes. and lank battery to

6.

Check all valves between the wellhead Insure they are In their proper position.

7.

Set the seleclor 5wilch to the "Hand" or "Auto" posilion start the pump. If pump falls electrician. to start, consult a service technician

and

or

9.

Make sure the load voltage required surface voltage.

Is within

10 percent

01 the

10.

Once the amps have stabilized after start-up do the following: a.


Observe the ammeter and flowline pressure during start-up. Low amperage and long pump-up time might Indicate reverse rotation. Insure that the restart time delay Is set for a minimum of 30 minutes. Install pressure gauge in tree and record pressure. Send 8 record of equipment to the well file. Check amp charts frequently and turn used charts In to supervisors when charts are changed.

b.

c.

I
11,

d. 8.

Use 24-hour charts for first three days alter ESP Installation (may go to 7 -day charts alter).

8.

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GASSY
Problems
.Gas .Lower .Install Is being produced through the pump

Solutions
pump (use shroud gas separator if pump lower than lowest peri)

~--",~-.~~..~~,-",~~~, : "';: ;::

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EXCESSIVE

CYCUNG

PrQblem~
.Detrimental to ESP motors .Too large a Unit .Plugged TBG .Tubing leak

Solutions
.Obtain .Check a nuid level alter shut-down lor high TBG pressure

,.

UNDERCURRENT lOAD

P.!.g~
.No /luki In hole .Failure of timing relay

~~
.Lower Undercurrent .Remedial ackJ. settings (by ESP specialist)

I
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UNDER CURRENT BELOW NO LOAD

Problem~

I
II

.Unit oversized .Under current

set below Idle amperage

Actions
.Shut well In

, '"

~-,...,...,..:. ,..
: ': :i: ;::~;:

. .

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CONTROLS Eroblems
.Controlled shut down (By tank level, elc)

.Set .Use
.Check

auto start delay timer above thirty minutes HOA switch to delay start
controls

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OVERLOAD

Problems .Increase

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In nuld viscosity. sand production, emulsions. or mechanical problems (lightning), motor overheat or worn

equipment ~ctions
.Have
.Do

electrician

check out unit

not restart

1,fA/

:.:-o:--~~
"-Ill:

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DEBRIS
0:-

-<

~
~

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...

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.-

.:if:

.-

",.
",d~

~~'

Proble~
.Debris (scale, sand, muds)

SolutlQll~
.Use clean workover lIuids .Clean well prior to ESP installation .See treating

I
EXCESS RESTARTS Problems

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.Power

problems unit ctlecked not restart out by an electrician

Solulions
.Have .Do

,..

,---

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ERRATIC

Problems
.Mechanlcallallure (locked pump. burn motor. .Change In suriace pressures .Change In specific gravity blown fuses)

Solutions
.Do not restar1 until unit Is checked out.

--he

lollowing tWo pages are Ilow chans generated by Chevron's Colorado oHice to help in trouble shoaling.

~angeIY,

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