RECOMMENDED PRACTICE FOR ELECTRIC SUBMERSIBLE PUMP

DESIGN, OPERATION, AND MAINTENANTE

TM6005 - Advanced Production Engineering
Lecturer: Silvya Dewi Rahmawati , S.Si., M.Sc., Ph.D.
XXth Month, Year

MASTER PROGRAM OF PETROLEUM ENGINEERING

INSITUT TEKNOLOGI BANDUNG
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Outline
1. Operation, Troubleshooting, and Maintenance
2. Inspection and Teardown Reporting
3. Testing Procedure
4. Sizing and Selection Process
5. Application and Testing of Cable System
6. Application and Testing of Seal Chamber System
7. Pump Systems Vibration
8. Case Study
9. Reference

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Operation, Troubleshooting,
and Maintenance

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Operation
A standard electric submersible pump operation consists
of the following process:
1. Checks before start-up,
2. System start-up,
3. Adjustments after well stabilization,
4. Operating data gathering, and
5. Analyzing operating data.

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Operation
Checks before start-up:
1. Make certain that the flowline hookup is completed, that all valves are of proper
pressure ratings and are properly installed, including an adjustable tubing choke. All
valves should be in their proper operating position (open or closed, as appropriate).
2. Check no-load voltage, potential, and current trans- formers for proper ratios, and
adjust the underload and overload relays to proper setting for start-up according to the
manufacturer’s or user’s specifications. Check to see that all the power fuses are sized
properly for the downhole equipment.
3. Assure that other system relays and controls are in proper adjustment or position, and
electrical connections are clean and tight. The system must be properly grounded and
the junction box properly installed, including a cable vapor seal between the junction
box and motor control panel.

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Operation
Checks before start-up:
4. Make certain that the proper scale ammeter chart paper is on the
recorder, that the pen is operating properly and that the setting
for the day and time are correct.
5. The control panel should contain a label or “Pull/Run Report” that
gives “name plate” information pertinent to the present
equipment in the well.
6. Electrical checks, phase-to-ground, and phase-to- phase, should
be made prior to start-up and readings recorded. Phase-to-phase
readings must be balanced.
7. If scale. or corrosion is a well problem, the preventative measures Figure 1. Well Equipment (API
must be initiated before pump start-up. RP 11S)

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Operation
System start-up:
1. If the well has been killed with heavy mud it should be displaced with a light fluid before
pump start-up.
2. For larger horsepower units (above 250 HP) regardless of setting depth and low capacity
units (less than 600 barrel/day) set deep (with static fluid level below 7,000 feet),it is
recommended that the tubing be filled before start- up. This means these installations
must be equipped with tubing check valves and drain valves. The tubing should be filled
with light, clean fluid.
3. With all checks completed, start the equipment. For control of the pump discharge rate,
the pump can be started against a restricted choke setting, but, should not be started
against a closed choke or valve. For immediate control of the pump discharge rate, a
tubing check valve and drain valve could be installed and the tubing filled prior to start-
up.

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Operation
System start-up:
4. Immediately after start-up, check the line current with a “clamp-on” ammeter and
record. Using this information, calibrate the recording ammeter
5. Check the load voltage and record. Exercise extreme caution when doing this.
6. Rotation should be verified as soon after start-up as possible by using either “pump up”
time, wellhead tubing discharge pressure and flow production test, or other appropriate
method as recommended by the pump company or operating company procedures. If
sand or debris is present in the well, it is recommended that the pump not be shut
down for rotational check until solids have been displaced from the tubing.
7. If actual “pump up” time is exceeding calculated “pump up” time, it should be assumed
that the pump is in re- verse rotation and appropriate action taken.

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Operation
Adjusments after well stabilization:
1. After motor current stabilizes, the overload, underload and the restart timer should be reset for
proper “normal running” condition as specified by manufacturer’s or user’s specifications.
2. Overload setting is normally set at 120 percent of motor nameplate amperage.
3. Underload setting is generally set at 80 percent of normal motor operating amperage. Gassy wells
may require even a lower underload setting, but caution should be exercised to insure underload
protection for pump off or gas lock conditions.
4. The restart timer is normally set at 10 minutes per 1000 feet of operating fluid level depth,
however, not less than 30 minutes.
5. If an adjustable underload time delay control relay is provided in the motor control panel, it is
normally set at 20 seconds. Local well operating conditions may require a different setting.

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Operation
Operating data gathering:
1. Accurate operating data is required to monitor the system under normal operating condition, give
information about troubleshooting, and for resizing consideration, if required.
2. Operating data should be filed individually by well, and should always include:
1) Start-up ammeter
2) Well test data sheets with corresponding ammeter chart attached
3) Current regular ammeter chart
4) Any other pertinent system and well operating data

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 Figure 2. Production Test Data
Sheet (API RP 11S)

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Operation
Analyzing operating data:
1. Analysis of operating data must consider both permanent well installation data (i.e., tubing size and
length, casing size, perforation depth, fluid characteristics, etc.) as well as production test data.
2. Once the pump is in the well and operating, it should be analyzed to determine if it is functioning
properly.

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Troubleshooting
General operating parameters and limitations that have been found to be true
historically in the operating area should be considered when troubleshooting.
The operating data that has been gathered during normal operation should be
analyzed together with any data that is available during problem.
Analysis of data may not only aid in determining reason for shutdown or poor
performance, but may indicate that equipment should be resized.
Prior equipment inspection data can aid in determining possible well problems
such as scale, temperature, corrosion, erosion, and solids problems.

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Troubleshooting – Ammeter Chart
A number of changes in operating conditions can
be diagnosed by proper interpretation of the
ammeter chart, and corrective action taken.
Properly utilized and understood, the ammeter
chart can be a very valuable tool.
The following are hand drawn examples of
ammeter charts that are representative of actual
ammeter charts that may be encountered.
Actual charts may vary somewhat from these
charts; but with experience and the example
charts as a guideline, actual ammeter charts can
be analyzed with a high degree of accuracy.
Figure 3. Normal Operation
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Troubleshooting – Ammeter Chart

Figure 4. Pump Handling Solids Figure 5. Primary Power Fluctuation

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Troubleshooting – Ammeter Chart

Figure 6. Pump Gas Locking Figure 7. Pump Off with Gas Interference
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 Troubleshooting – Ammeter Chart

Figure 8. Pump Off without Gas Interference Figure 9. Pump Off with Restart Failure
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 Troubleshooting – Ammeter Chart

Figure 10. Short Duration Cycling Figure 11. Gassy Well Condition
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 Troubleshooting – Ammeter Chart

Figure 12. Immediate Undercurrent Shutdown Figure 13. Underload Shutdown Failure
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 Troubleshooting – Ammeter Chart

Figure 14. Pump Control by Tank Level Figure 15. Normal Overload Condition
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 Troubleshooting – Ammeter Chart

Figure 16. Pump Handling Solids Figure 17. Excessive Manual Restart Attempt
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Basic Problem Troubleshooting
See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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See API RP 11S Tabel 3.3

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Maintenance
Preventative maintenance with well down and with primary power
disconnected:
1. Motor control panel check and maintenance
2. Transformer checks and maintenance
3. Electrical connections and ground wires
4. Power factor corrections

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Maintenance
Preventative maintenance checks with system operating:
1. Wellhead cable pack-off
2. Power factor analysis
3. Ammeter maintenance

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Maintenance
Equipment and system maintenance:
1. Corrosion and scale
2. Sand
3. Cable maintenance
4. Tubing maintenance
5. Production and testing facilities

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Inspection and Teardown
Reporting

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Figure 18. Typical Motor Section Figure 19. Typical Seal Chamber Section Types
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Figure 20. Typical Pump Section Figure 21. Typical Seal Chamber Section Types
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Testing Procedure

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Definitions
acceptable test point: Test points that fall within the allowable pump test acceptance criteria.
allowable head-flow rate performance band: A region on either side of a published head-flow
rate performance curve. The limits of this band are defined by a series of vectors with their
origin on the published head-flow rate performance curve. The vectors are defined by
application of the head and flow tolerances
best efficiency point (BEP): Defines pump performance parameters at the maximum value on
the efficiency curve.
brake horsepower (BHP): The power required by the pump corrected for a fluid with a specific
gravity of 1.0.
efficiency (EFF): A measure of power out divided by power in.
flow rate: The volumetric rate of fluid delivered by the Pump.
open flow: The pump flow rate at zero head.

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Definitions
rated flow: The flow rate at the recommended operating point of the pump. The flow rate is
generally at BEP.
recommended operating range: Located between the maximum and minimum recommended
flow rates.
shut off head: The head at zero flow.
test open flow: The maximum pump flow rate attainable on test. This rate is between the
maximum recommended flow rate and open flow.
test shut off: The minimum pump flow rate attain- able on test. This point is between zero flow
and the mini- mum recommended flow.
total head: The difference between the pump outlet and inlet head in feet. This is the vertical
distance, in feet, from the pumping fluid level to the centerline of the pressure gauge, plus the
pressure gauge reading converted to feet, plus the friction loss between the pump discharge and
pressure gauge in feet.
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Definitions
affinity laws: Relationships between pump perfor- mance and pump speed ratios. For test
purposes, the speed ratios are between rated rpm and test rpm.

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Pump Performance Curve
The published curves show the discharge head, brake horsepower, and efficiency of the
pump as a function of flow rate. Although tests are made on multistage pumps, the
published curves represent performance for one or more stages of each pump type. All
curves are based on multistage performance tests and do not include horsepower of
other components such as gas separators or seal chambers.
The curves are based on fresh water at 60°F (S.G.= 1.O),give a recommended operating
range for the pump, and are commonly available for both 50 Hertz (Hz) and 60 Hertz
(Hz) operation.
Manufacturers typically publish representative polynomial equations for head and brake
horsepower curves. Numerical representation for efficiency is a calculated value from
these head and brake horsepower polynomials at a given flow rate. Using polynomial
equations is more accurate than using published curves; therefore, when possible,
polynomials should be used to verify conformity with certified test points.

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 Figure 22. Typical
Pump Performance
Curve

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Test Points
Performance tests shall be conducted at the following five points on the published
pump performance curve :
a. Test open flow
b. Maximum recommended flowrate
c. Rated flow (generally BEP)
d. Minimum recommended flowrate
e. Test shut-off
Data for a-d will be certified and test for these data must be conducted within 2% of
the specified flow. Head and BHP will be reported at actual test flow.

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Efficiency
The efficiency of the pump will be calculated at the rated flow test point.
An example of an efficiency calculation using a typical published pump performance
curve is shown below

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Test Fluid
The published pump performance curves are based on fresh water at 60°F. If alternate
fluids are used for testing, performance test results must be corrected to the fresh
water performance.

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Speed Variations
Pumps may be tested with standard motors other than the actual motors used in
application. As a result, there may be some speed variations from the nominal value
of 3500 rpm for 60 Hz power.
All pump tests should be corrected back to the nominal speed of 3500rpm. The
affinity laws are used to correct to the rated value or for other power line frequencies.
If tests are desired for frequencies other than 60 Hz, the same procedures are to be
applied with proportional adjust- ments (e.g., use 2916 rpm for 50 Hz with the same
percentage tolerances).

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Speed Variations
An example of speed correction calculations using test data and rated rpm is shown:

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Inlet Pressure Requirements –
Instrumentation Accuracy
The inlet pressure to the pump must be above the minimum required by the
manufacturer. If there are any inlet or dis- charge pressure limitations, these should be
specified by the manufacturer.

All measurements are inevitably subject to

inaccuracies. The following table provides
the maximum tolerance for instruments
used during test. Pump brake horsepower
will have a + 3.0 percent accuracy.
Calculated pump efficiency, being a
composite of other accuracies, should not
exceed + 5.0 percent.

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Test Certification
The limits listed in the following shall
apply to manufacturer's published
performance curves.
The following table shows the
acceptance criteria for pump test

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 Figure 23. Pump
Test Acceptance
Limit From
Published Curve

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 Figure 24. Typical
Pump Performance
Curve Showing
Tolerance Band

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Sizing and Selection Process

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Design Procedure
Figure 25. ESP
The flow chart illustrated below is an Design Process
overview of the entire design
procedure. The diagram illustrates ESP
design as a linear process, but it
actually may require a few iterations
since one particular piece of
equipment may impact previously
selected equipment.

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Step 1 - Gather Base Data
The data input sheet can be used to gather the data required for an ESP installation
design. The data elements required for an ESP design can be segregated into six
categories:
1. General Information
2. Wellbore Geometry
3. Surface Information
4. Fluid Properties
5. Inflow Characteristics
6. Design Criteria specifies the desired performance from the ESP installation.

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Step 2 – Estimate Operating Condition
To properly select the pump, well performance must be estimated.
Fundamentally, well performance estimates define what additional energy (i.e.,
volumetric flow rate and differential pressure or head) must be supplied by the
pump to deliver a desired stock tank flow rate.
Ideally, this behavior should be understood or estimated taking into account not
only the current well data, but also for forecasted changes in reservoir or system
performance over the expected life of the ESP (usually, considering a 3 – 5 year
period is sufficient). Specific attention should be paid to expected changes in aver-
age reservoir pressure, water cut, producing gas-oil ratio, required wellhead
pressure and inflow performance.

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Step 2 – Estimate Operating Condition
Pump Intake Pressure (PIP):
Pump intake pressure can be estimated through the use of Productivity Index
calculations obtained from well tests or more complex Inflow Performance
Relationships.
In most single-phase fluid applications, 100 psi inlet pres- sure is sufficient. For
unusual flow characteristics (such as high volume), pump Net Positive Suction
Head requirements should be checked.
In gassy applications, it is common to set the pump inlet as deep as possible to
keep pump inlet pressure as high as possi- ble, so less gas evolves from the fluid
before it reaches the pump inlet.

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Step 2 – Estimate Operating Condition
Pump Intake Pressure (PIP):
A simplified procedure for calculating pump inlet pressure is as follows:
1. Calculate Well Fluid Composite Gravity:
2. Calculate Well Fluid Gradient:
3. Calculate Well Flowing Pressure at Desired Flow Rate:
4. Calculate Pump Intake Pressure (PIP):
5. Calculate Intake volume at pump:

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Step 2 – Estimate Operating Condition
Total Dynamic Head (TDH):
For applications pumping a single phase fluid, the term Total Dynamic Head can
be used to summarize the differential pressure or head the pump must supply to
lift fluid at a desired flow rate from an operating fluid level in the well to the
surface.
1. Calculate Net Vertical Dynamic Lift:
2. Determine Friction Loss (from Hazel-Williams):

1. Calculate Wellhead Tubing Pressure Head:

2. Calculate Total Dynamic Head (PIP):

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 Figure 25. Hazel-
Williams Chart to
Determine Friction Loss

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Step 2 – Select Pump and Intake
A pump with capacity matching desired well production should be selected based
on a expectation of well performance based on pump performance data from a
manufacturer's catalog. Additional operating constraints are taken into account
during this selection. These constraints include casing size, housing burst pressure
limit, shaft strength, corrosive, abrasive or gassy environments. The steps are:
1. Select the appropriate pump stage design for the desired pump flow rate.
2. Determine number of stages required.
3. Determine power required by pump (horsepower).
4. Ensure the pump shaft and housing strengths are within acceptable limits.
5. Ensure the proper metallurgy for produced well fluid is selected.

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Step 2 – Select Pump and Intake
1. Determine Stage Type :
Depending on casing size and desired flow rate, there may be several possible
pump stage types available for a given application. The pump stage type should
normally be selected primary on the basis of which pump will be most efficient at
the desired operating flow rate. As a rule, a pump should be selected such that
the desired operating flow rate is as near as possible to the best efficiency point
and, as a minimum, within the recommended operating range stipulated by the
manufacturer.

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Step 2 – Select Pump and Intake
2. Determine Power Required by Pump
Read the horsepower per stage required by the pump from the curve at the
desired pump flow rate. Calculate the total motor horsepower required to drive
the pump by multiplying horsepower per stage by the number of stages and
composite fluid specific gravity.

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Step 2 – Select Pump and Intake
3. Determine Number of Stages Required
Given a desired flow rate, Total Dynamic Head (TDH) required and pump stage
type, read the head per stage corresponding to the desired pump flow rate. The
number of stages required to achieve the desired flow rate will be the TDH
divided by the head per stage at the desired pump flow rate.

Pumps are normally available with a discrete number of stages in predetermined

pump section lengths (often referred to as housings).

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Step 2 – Select Pump and Intake
4. Ensure the pump shaft and housing strengths are within acceptable limits
1. Shaft Strength
The amount of horsepower that the pump shaft can transmit (torque at a given speed)
should be checked to insure it is within acceptable limits stated in the manufacturer's
catalog. Exceeding this limitation can result in premature failure.
2. Housing Strength
The pump differential pressure under operating and shut-in conditions should be
checked to insure it is does not exceed burst pressure limitations.

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Step 2 – Select Pump and Intake
5. Ensure the proper metallurgy for produced well fluid is selected.
1. Pump Thrust
The pump shaft thrust should be calculated to use in seal chamber section thrust
bearing design selection.

2. Variabel Speed Design : need to convert pump performance data at variable speeds
3. Gassy Wells/ High Vapor-Liquid Ratios : each pump has free gas limitation, or use
separator
4. Abrasives : needs abrasion resistant pump and trim features

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Step 3 – Select Motor
A motor must deliver the horsepower required to run the pump, seal chamber
section, and gas and water separator, if required.
1. Determine the motor horsepower by adding the required horsepower for the
pump, gas separator and seal sections.
2. Determine diameter of motor required.
3. Check fluid flow velocity for motor cooling.
4. Ensure that the estimated motor winding temperature is within
manufacturer’s limits.
5. Determine motor starting capability.

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Step 3 – Select Motor
1. Determine the motor horsepower by adding the required horsepower for the
pump, gas separator and seal sections.
From the previous section, the required pump horsepower and gas separator (if
needed) is known. In addition, you will need an estimate of the horsepower
required for the seal section). Add these values together to determine the motor
horsepower required.

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Step 3 – Select Motor
2. Determine diameter of motor required.
The motor outside diameter is limited by the casing I.D. or in some cases by the
pump type selected.

3. Check fluid flow velocity for motor cooling.

It is recommended to use a minimum fluid velocity of 1 ft/s to get proper motor
cooling but a maximum value of 12 ft/s (in an abrasive environment, 7 ft/s) to
prevent housing erosion.

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Step 3 – Select Motor
4. Ensure that the estimated motor winding temperature is within manufacturer’s
limits.
Most submersible motor manufacturers list a bottom hole temperature (BHT) in
which their motor can operate. Some of the conditions that will affect the
operating temperature of the motor in the well are:
horsepower required, bottom hole temperature (flowing and static), water cut,
Oil API gravity, rate of fluid flow by the motor, amount of gas flow by the motor,
whether a variable speed drive is used (and at what frequency), presence of scale,
existence of special motor housing coatings, voltage unbalance and the motor
efficiency at the operating load point.

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Step 3 – Select Motor
5. Determine motor starting capability.
The submersible motors are connected to the surface by a length of cable. However,
the motor is designed to run at its nameplate voltage. As a rule of thumb, 50% of
nameplate voltage at motor terminal is required for starting.
The starting limitations can be overcome in the following three ways:
a. Use a larger diameter cable. Reduce the cable voltage drop during starting. May
mean higher cost for cable.
b. Use a higher voltage motor. For the same horsepower, the current will be lower.
c. Use a VSD with sufficient voltage boost to get a higher starting torque for less
current at a lower frequency.

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Step 4 – Select Seal Chamber Section
The seal chamber section is selected from the manufacturer's catalog. Major considerations
include: compatibility with pump and motor, casing clearance when cable is installed, use of
labyrinth or bladder type design, fluid expansion capacity, ratings for temperature and exposure to
chemicals.
1. Determine seal chamber section OD/flange size based on pump and motor requirements.
2. Determine expansion volume requirements based on motor HP and well conditions (primarily
temperature).
3. Evaluate the required shaft torque capacity.
4. Determine approximate operating temperature.
5. Evaluate special conditions and operating temperature and select elastomers, shaft seals, and
material.
6. Calculate operating and no flow thrust loads and then select thrust bearing.
7. Select design style and configuration based on application and level of protection redundancy
desired.

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Step 5 – Select Cable
Cable conductor size is selected based on the voltage and amperage requirements of the down hole
motor, voltage losses over the length of the cable and clearance in the well- bore.
1. Determine seal chamber section OD/flange size based on pump and motor requirements.
2. Determine expansion volume requirements based on motor HP and well conditions (primarily
temperature).
3. Evaluate the required shaft torque capacity.
4. Determine approximate operating temperature.
5. Evaluate special conditions and operating temperature and select elastomers, shaft seals, and
material.
6. Calculate operating and no flow thrust loads and then select thrust bearing.
7. Select design style and configuration based on application and level of protection redundancy
desired.

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Step 6 – Select Switchboard/VSD and
Transformer
Surface equipment, such as the switchboard or VSD, trans- former, and surface cable must be
selected to deliver electrical energy at the voltage and amperage required by the downhole motor.
1. Calculate the surface voltage requirement (at highest frequency of application for VSD).
2. Calculate the KVA requirement (at highest frequency of application for VSD).
3. If the primary power source requires a step-down trans- former, select the appropriate
transformer to feed the controller the required voltage.
4. If using a fixed speed controller, select the appropriate voltage/amperage unit to feed directly to
the motor or to feed to a step up transformer that will increase the voltage to that required by
the motor (plus cable losses).
5. If using a variable speed controller, select the appropriate unit based on KVA requirements at the
highest frequency of the application.
6. If using a variable speed controller, select the step-up transformer rated for VSD application that
will provide the required voltage to the motor.
7. At all phases of the selection process, consider equipment efficiency losses.

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Application and Testing of
Cable System

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 Application of Cable System

From API RP 11S5

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 Application of Cable System

From API RP 11S5

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 From API RP 11S5

Application of Cable System

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 Application of Cable System

From API RP 11S5

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 Application of Cable System

From API RP 11S5

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 Cable Types Guide

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Testing of Cable System
Cable testing, in general, can be broken into two basic categories: Factory Testing
and Field Testing. API Recommended Practice 11S6 only addresses procedures for
Field Testing. Factory Tests provide assurance that the finished product meets the
anticipated performance criteria for the intended application. All the tests involved
are used to detect gross cable defects in materials and workmanship. Typical tests
on new cable include AC, DC, IR and Conductor Resistance, and are covered under
such standards as IEEE 400, IEEE 1017, IEEE 1018, and IEEE 1019. Visual inspection
must be performed.

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Testing of Cable System
1. Visual Inspection:
This procedure involves the visual inspection of a cable system prior to and following electrical
testing. The first application is to detect physical damage or deterioration that requires
corrective action before electrical testing. A second application is to determine the cause of
changes in electrical properties identified during testing.
2. Acceptance Testing
Acceptance testing may be performed by the user upon receipt of new cable systems from the
manufacturer. The purpose is to confirm that the cable system has not been damaged during
shipping or handling, and to reveal any gross manufacturing defects. The test may also be
performed on the cable system prior to installation in the well, if the unused cable system has
been stored. Acceptance testing consists of an insulation resistance (IR) Test followed by a DC
high potential test.

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Testing of Cable System
3. Maintenance (Proof) Testing:
Maintenance (proof) testing consists of high voltage tests made on used cable systems prior to
installation in a well. The purpose of maintenance testing is to confirm that the cable is
acceptable for reuse. Maintenance testing should be performed every time a cable is pulled or
repaired, or has been in storage prior to reuse. Maintenance testing consists of an Insulation
Resistance (IR) Test followed by a dc high potential test. The maximum test voltage for dc
maintenance testing is less than the original acceptance testing level.
4. In-Situ Testing
In-situ testing consists of low energy tests made during and after installation of the cable system
in the well. These tests are intended to evaluate the in-situ condition of the electrical system in a
non-destructive manner. Because low energy levels are used, these tests will generally only
reveal gross defects in the overall integrity of the electrical system elements including
connectors, penetrators, cable, pothead and motor. Testers include megohmmeters, volt-
ohmmeters, and time domain reflectometers.

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Testing of Cable System
5. Diagnostic (Fault) Testing:
Diagnostic testing is performed after a cable system has failed an acceptance, maintenance
(proof) test or in-situ test. Several test methods are used. Diagnostic test methods to locate a
fault are listed in order of increasing destructive capability: physical inspection, IR tests, time
domain reflectometer tests, high voltage Murry loop (bridge fault locator) tests, DC high
potential tests, and evaluation with a capacitive discharge instrument (thumper).
6. Insulation Resistance (Megohmmeter) Tests
Cable system insulation resistance (IR) is measured with a dc megohmmeter which is a device
that measures extremely high resistance values. The test equipment is generally compact,
inexpensive and widely used by cable manufacturers and operators. IR testing can be used as a
quality check on the insulation of a cable system and to determine catastrophic faults and gross
defects in used cable.

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Testing of Cable System
7. DC High Potential Tests:
DC high potential testers measure the microamp leakage current value for the cable under test.
The particular value of leakage current measured will depend on a number of factors including:
insulation material, applied voltage, cable length, temperature, humidity and end terminations.
8. AC Testing:
Electric submersible pump cables are designed for AC operation. Therefore ac tests are used to
establish the integrity of the cable string.
9. Fault Location Tests:
1. Murry Loop Test (Bridge Fault Locator)
2. Capacitive Discharge Instrument (Thumper)
3. Time Domain Reflectometer (TDR) Tests

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Application and Testing of
Seal Chamber System

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 Application of Seal Chamber System

From API RP 11S7

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 Application of Seal Chamber System

From API RP 11S7

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 Application of Seal Chamber System

From API RP 11S7

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Application and Selection Consideration
1. Temperature:
Typical maximum service temperatures for several elastomers are : Nitrile - 250OF
(121OC), Highly Saturated Nitrile (HSN) - 275 OF (135OC), Fluoroelastomer compound -
325OF (163OC), Tetrafluoroethylendpropylenecopolymer (TFEF) - 350OF (177OC)
2. Fluid Characteristics
Water, oil, gas and brine are among the many fluids to be considered when selecting
materials for the "wetted" (in contact with well fluid) components of the seal chamber
section. It is important to consider the effect of produced and treatment fluids, such as
corrosion inhibitors and acids, when selecting materials. The metal components of the
seal chamber section should be selected so that destructive galvanic cells are not formed
between adjacent components. If solids are present in the well fluid, hard mechanical
seal faces may be required to avoid excessive face wear. When the internal oil has a
higher specific gravity than the well fluid, a bladder or a labyrinth chamber with blocking
fluid is required.
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Application and Selection Consideration
3. Well Geometry:
The resultant diameter of the seal chamber sec- tion with the motor flat cable on one
side should be smaller than the casing drift diameter to avoid damage when installing the
equipment.
4. Equipment:
When sizing a seal chamber section for an application, the following features must be
considered : shaft torque capacity, thrust bearing capacity, and oil expansion capacity
5. Operating Condition:
The seal chamber section must have adequate capacity to accommodate motor oil
expansion at the highest anticipated operating speed.

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Acceptance Testing of Cable System
1. Shafts 3. Idle Power Loss
a) Shafts End Play a) Calibrated Motor Method
b) Shaft Top Extension b) Speed/Torque Cell Method
c) Shaft Bottom Extension 4. Relief Valve
2. Shafts, Seal, Joints, and Vents 5. Bladder Pressure Test
a) Air Pressure Tests
b) Oil Pressure Tests of Seals
c) Internal Seals

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Pump Systems Vibration

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Vibration Limits
It is generally acknowledged that severe vibration can decrease ESP system run
life. Vibration limits for ESPs are given below.
For ESP systems or components, a maximum velocity amplitude of 0.156in/sec
(0.396 cm/sec) - peak at the intended synchronous operating frequency or over
the range of intended operating frequencies, with no other individual frequency
component greater than 0.100 in/sec (0.254 cm/sec) - peak as measured on the
housing or case, is recommended.

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Vibration on ESP Phenomena

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Vibration Severity Criteria

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Case Study

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Example Problem
The following data of a well is given, we will outline the procedure and calculation
needed to be done to complete the basic design for the ESP.

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Example Problem
The procedure is as follows:

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Example Problem

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 We see from the Pump Curve
that at 1500 bpd, the pump
generate 39.5 ft of head per
stage
Figure 26.
Example of a
60Hz – Single
Stage Pump
Performance
Curve

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Example Problem

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References

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 References
Recommended Practice for the Operation, Maintenance and Troubleshooting of Electric Submersible Pump Installations. API Recommended
Practice 11S Third Edition, November 1994.
Recommended Practice for Electrical Submersible Pump Teardown Report. API Recommended Practice 11S1 Third Edition, September 1997.
Recommended Practice for Electrical Submersible Pump Testing. API Recommended Practice 11S2 Second Edition, August 1997.
Recommended Practice for Electrical Submersible Pump Installations. Api Recommended Practice 11S3 Second Edition, March 1999.
Recommended Practice for Sizing and Selection of Electric Submersible Pump Installations. API Recommended Practice 11S4 Third Edition,
July 2002
Recommended Practice for Application of Electric Submersible Cable Systems. API Recommended Practice 11S5 First Edition, February 1993.
Recommended Practice for Testing of Electric Submersible Pump Cable Systems. API Recommended Practice 11S6 First Edition, December
1995.
Recommended Practice on Application and Testing of Electric Submersible Pump Seal Chamber Sections. API Recommended Practice 11S7
First Edition, July 1993
Recommended Practice on Electric Submersible Pump System Vibrations. API Recommended Practice 11S8 First Edition, May 1993.

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