Powerlift ESP Industry

ESP troubleshooting during operation

and Data Analysis
Objectives

At the end of this presentation, you will be able to identify: Common reasons
for the ESP Shutdowns, trips and premature failure due to surface and downhole
Problems The proper way for troubleshooting

Most Common Problems

Surface

• Power supply (Generator, power source)

• Running against closing valve (wellhead chock, SSV, flowline valve,)
• ESP controller set point (Protection, Base and running frequency,)

Subsurface

• Pump stuck
• Gasses
• Sand and abrasive
• Reservoir depletion
• Tubing hole @ Running against closing valve
Surface problem

Generator
One of the important tasks as VSD specialist and application engineer is to size
the proper generator for the ESP application

The basic rule has three parts:

• Oversize the generator by 25 to 50% based on the load.
• It is not necessary to oversize the engine.
• Do not use a generator that has a KVA rating that is less than
the KVA rating of the VSD.

Generators Problems
Unstable frequency (set point =50Hz)
Normally this problem occurred in the Engine. Most probably it is a diesel filter. It
is required for a mechanical technician.
• Adjusting the Hi and low frequency set point at ±2 Hz, protecting
against this problem
• This issue also cause undervoltage and overvoltage.
Unstable volt
This problem normally happens due to a problem in the voltage regulator. It is required for
alternator electrician.
• If the voltage fluctuation within the acceptable range (±10%), using the option of base
voltage fixed instead of input it could help.

Weak Power supply

There are two problems created from this system:
ESP Start up
• At the point of start up a voltage dip occurred in the system. It could fail to start up or trip
other ESP system running on the same power supply
• In this case it is required to increase the ramp time of the start up
Running against closing valve (wellhead chock, SSV, flowline valve,)

• The main set point used to catch this problem is the Under load (UL),(Pd) and (Tm)

• Based on the standard it should be 80% from the running amps, Pd set is 5000 psi and Tm

set is 135C (5000 and 135 depend on Rumaila oil filed)

• It is required to use the pump and motor characteristic curve to define the

proper UL set point.

ESP controller set point (Protection, Base and running frequency,) (VSD)
There are some of alarm related with VSD as follow:

Table in next slide will explain some of VSD alarm

 Alarm Description Corrective action

OvrVlt The input voltage to the drive is Check the input power or adjust the
higher than the overvoltage overvoltage setpoint
setpoint

UndVlt The input voltage to the drive is Check the input power or adjust the
lower than the undervoltage undervoltage setpoint, also SCR and
setpoint CSB

voltage unbalance Different between 3 phases Check input power

Low speed trip Drive output frequency has fallen Motor draws high current and VSD
below the low speed clamp try to slow F
setpoint

Overload The output current of the drive has Either decrease the output current
exceeded the overload setpoint by changing the operating
frequency, or increase the overload
setpoint

Underload The output current of the drive has increase the output current by
fallen below the underload changing the operating frequency,
setpoint or decrease the underload setpoint.

PCM converter fault PCM has determined that the Check converter or inverter
PCM inverter fault converter or inverter software software
6 module has quit operating.
 Alarm Description Corrective action

Ambient The internal ambient This temperature sensor is located on the system base
temperature temperature has board. Therefore it measures the internal drive
alarm exceeded 85°C. temperature. First, check the small fan(s) blowing air
through the air-to-air heat exchanger. If they are
inoperative, check the power supply board fuses first
and then check the fans themselves
Heat sink The temperature of Heat of internal part of VSD increase it is T and we
the designated heat should check fans colling, sensor and the board itself
sink has exceeded the
pre-set value.
CRT Generator issue or At first, check generator must be done or we check
VSD filter VSD filter (capacitors and inductors)

Communication Communication Error We must check the wiring connection between VSD
Error internal part

U-PHASE SHORT Short-circuit in IGBT, Change out all 3 IGBTs in the phase plus both
CIRCUIT bad IGBT snubber boards
V-PHASE
SHORT CIRCUIT
Subsurface problem

Pump stuck
- This is a common problem in most of the fields, There are many reasons for this
problem (ESP mechanical, Sand, scale)
- There are many options in the VSD to release the shaft (Voltage boost, rocking start)

Gas problem

Gassy reservoirs often result in fluctuations in operating current

Based on that the UL set point is the main protection Steps required to proper setting the UL
It is required to monitor the downhole parameters closely (intake pressure, differential
pressure, motor temperature)
Sand and abrasives problem

Most of the time the problem occurred during start up, because the sand accumulates inside
the pump.
The following points should be considered:
• It is preferable to start up smoothly
• Sometimes it is required to conduct pump back wash
• Sometimes it is required to use the techniques used for stuck pump
• In running operation it is preferable to run the pump at low speed to reduce the erosion
• It is also required to monitor closely the ESP vibration

Reservoir depletion
In this one is required to monitor the downhole condition very closely. (Intake pressure, Motor
temperature) Proper UL set point is very important in this case also Pi alarm and Tm alarm.

Tubing hole @ Running against closing valve

Tm, Pi, UL alarm
ESP shutdown due to overload trip
Causes of overload trip could be as following:
• Pump seizure because of clogged stages
• Wrong tap changer selection
• Fluid ingress into the motor
• Improper setting-up of a VSD

ESP shutdown due to no-load trip or flowrate decrease

Causes of no-load trip could be as following:
• Gas plug in a pump
• Paraffin deposits inside a tubing
• Tubing leakage
• Clogged choke on a Christmas tree
• Low fluid dynamic level
• Pump wear
• Broken shaft

Training Course for BP | Day 3 | ESP troubleshooting during operation

Tripping by Insulation control unit

Causes of low insulation could be as following:

• Fluid ingress into the motor
• Downhole cable fault
• Surface cable fault

Training Course for BP | Day 3 | ESP troubleshooting during operation