ELECTRICAL SUBMERSIBLE PUMP

-!HANDBOOK

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SAFETY
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Section

SWITCHBOARD

SAFETY TIPS

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!

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Stand to the right side of a switchboard when stanlng or

stopping a unit. The door can blow open In case of
explosion.

2.

If checking high voltages. make sure proper meters and

safety gloves are being used.

3.

Always check a switchboard for proper grounding.

II unusual or loud noises are coming from a switchboard. call

a qualified electrician.

5.

If arcing noises are present, wear proper safety gloves until

source of arcing Is located and fixed.
,

6.

leave voltages alone If untrained or nervous. Have 8

qualified electrician ~heck a switchboard If necessary.

MONITOIRING AND REPORTING

Monitoring

is the

key

some

to

monitored:

da1:a

be

to

efficient

ESP

opera

tions.

Usted

below

are

..

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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..., ua "UlIUId~t:U.

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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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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.
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Subsur1ace EoulDment

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.
.
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Wax

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

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the ESP cable temperature

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

ratin

and

will
can
acid
are

to consider:

to

pump

the

acid

This

the

will

oHers

acid

bener
down

nol

contact

co

Irol
tubing

,armored

th

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

over

instead
the

treatment of

the

cable.

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.
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

I.

valve

exists

above

the ESP, the hot 011 must be

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.

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When pumping down the annulus, use one and a hall

annular

volumes

at 80% to 100%

\
Hlot Watering

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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of the formation

temperature.

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

~Cid

lor

hot

Selection

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
! The
T
al:idizing procedure lor a seized ESP Involves a lined
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:

Rate
Description

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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.

Volume

(bbls/mln)

11ublng
volume
acid

of

'h tubing
volume

of

acid

3. Allow a 15 minutelor
soak lime
the acid
10 work.

4. Pump a Iresh,
unspent Y. tubing
volume 01 acid Into
the ESP.

y. lubing
volume 01

acid

5. Let soak
approximately six
hours.
6. Turn on the ESP and
produce the spent
acid down the
flowline.

'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

RIle
(bbls/mln)

1 tubing
volume 01

solvent

tubing

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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.

-4

Pump a fresh, unspent

V. tubing volume of
scjvent Into the ESP.

5.

Let soak approximately

six hours.
6.

Turn on the ESP and

produce the spent
solvent down the
nowtine.

~ tubing
volume 01
solvent

'I. tubing
volume

of

solvent

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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.

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.

The volume

of solvent will be determined

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

rule

by the quantity

of thumb

of

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

Treatment

described

below.

CQl1J

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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

Solutions

.Redesign
.Stimulate

syslem with smaller pump (currenl syslem 100 large)

well

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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.

3.

Check Ihe murphy switch or the eX1ernal switches

Ihey are coni rolling the switchboard.

4.

5.

10 see Ii

, .,

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.

6.

Visually

Insure the electrician checks

lowest point of connection.

inspect transformer

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f.

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hookups.

the

unit downhole

I:rom the

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Problem #2:

Unil shuls down due to undercurrent.

Possible Causes
Low well productivity
pumped-oN

Corrective

Actlcinl

.Check

amperage downhole

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

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Possible

Plugging

of pump Intake

.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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.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

Broken shah In unit

pulled.
.Pump
water down backside
break gas lock.

Is gas locked

.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

~Pump

.Check all valves to make sure the',

are open. Check pressure on
wellhead and lIowline. Check to
see it pu~p is pumping fluid.

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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 Controlrelaystuck
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Problem#7: Unit will not shut down by underloador overlclad.

'~t:.'~;;:
~

Possible Cause.

Possible Corrective Ac:tlonl

Undercurrent shutdown

.Check

downhole

~or~al~ust
Remote controls have
opened and shut unit

down
Unit starts but shuts down
withIn 5 seconds

arTlperage. II

setting.

.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 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

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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~'::::i~i:;;,
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

fluid.
4
5.

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.

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

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t~".::o.:-~.::

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protection.

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.

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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I
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.

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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

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

I
I

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

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

~.j~:;~;:.

,--"'---'

"-

,~::~~- -"'.

+-ANA

L YZE PBQ~L-.EM

, I

Section

'ii~~U1
,!4.1
EQUIPMENT TESTING

I
i
i

I
,

I
I

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.

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.

.
!

.!

6.

9.

7.

8.

Molar Testlo.g

a.

b.

Check the phase-la-phase (lead-to-lead) resistance II

should be balanced among all leads.
Check
resistance.
megohms
device.

c.

the

phase-to-ground

(lead-to-housing)

Typically, h should be more than 2000

on a megohm meter with no pressure

.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.
I

I
I

I
I
I

NORMAL

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

~!)!I

~~j~iJ
0.',

o. ..o'~;:;;O'
."I;':
:,.

"':,'
"oJ
:,' ',; '; lJ~!;.,
Oil""

-J

J.4 At

I-(~

I Z

83

...
.~

.'

:.~'
1\"ifs

:1
.I

POWER FLUCTUATIONS

Problems
.Fluctuation
of Primary Power Supply
motors Injection pumps etc.)

(Start-up

of large

SolU1lons
.Investigate
Power Fluctuations
.10
causes 01 fluctuations
(Start-up

of larget HP

Injection pumps)
.Call
power company

-::.

'

"

mott

HP

Cle~n molor
Sleam clean body to within one foot of motor head.

Do not steam head.

b.

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.

Solvent wash molor head and lill valve areas

All boll holes and pothead cap a.rings should be checked

lor

damage.

tie

The lead washers

on Iill valves

should always

replaced. The motor should be lIushed Irom top down while

qurning rotor stack occasionally.
Check oil during Ilush lor
obvious Indicators

01 nXltor problems.

I~

! I,'

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.

-;;'

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)

,:
t:
O.
I

I' .

,"

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

greater than 5,000 megohms.

17

r.
;

.,

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.

,.'
't
I;

,
;

~
1 lJ

.,

\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

f
~
:
~

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

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

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

Ii

.::~-~

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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I

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I
~2I STANDARDDOERATINGORDCEDURE

1h' loll~,", lo,m' w", g,o",'ed hV, SACROCO",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'

I
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.;

.
f,
1-

GAS LOCKING

~.Lowering

.Gas

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

.S-Q!Y1!~
.Lower

pump

.Choke
.Put

production

on \imer

.Redesign

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

111

pump

back

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!

E.acn

Do...

Do..WOc..pIoW:

1\

WORKOVER
VII.

DATA

Poll Workower Tell 0818

D4TE

1\

80

BW

GV

CO1~

Ii
VIII.

POll Work ower fluid

DAn:

fllnD
u:vEl

lAwell
CASING
PRESS.

COMMENTS

IX. Resl" Dall

Equip.
Pulled

Dale

Equip.
RUD

RUIOD

os

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

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

I
I
I

~~:-:.;-,7':~;~'-;~'--- -' I
!:l!;;" "

"I DESIGN!
"Capital and operating

costs, well

conditions,

perlormance, equipment and service performance.

reservoir

and ease of

..opera~ing and maintaining the equipment are key considerations

'e when designing an ESP.

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

-ESPO,

or to obtain a copy of the program.

I
I
I

..-~

' .II;,:;!'

,:':'

;.

-.':i

O,

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

!;

---

PUL1Jl':/J
G A~

TABI: UP
Ssction

I
INSTALLATION/PULLING

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!.

.
I

PROCEDURES

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

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

~gJRunnlna

of the cable will cause damage.

Eaulomeot

Hold a safely meeting

performed.

10 discuss the scope

Note any special problems

Suggested personnelon location:

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

of work

or concerns.

10 be

.
.I
2.
3.'

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.

5.

Always

have the cable reel In the operator's

line 01

sight.
6.

Use cable stands

through the dirt.

to prevent

cable

from

dragging

Banding
It Is very Important
the tubing.

that the cable

be run straight

up

2.

Band squarely across the cable. Tubing band should

be at right angles to the tubing with the cable vertical.

3.

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.

4.

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.

6.

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.

7,

STOP and contact a service technician

if the cable Is

damaged.

8.

Extra care should be laken In runnIng cable Inlo a well

where an ESP has nol been Installed before.

Splices

I
I
I

5.

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.

'"1

I
I
I

I
!

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 swivel-

6.

Run and pull pump between 1000' and 2000' per hour
Never pull the cable 'rom tile reel.

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

B.

Always use lihlng subs lor raising or lowering

equipment.

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

ESP

62

START-UP

PROCEDURES

Load tubing

Install proper amp cllart

2.

Set

overload

nameplate

amperage

at

110-120

percent

of

motor

amperage.

4.

Sel underload amperage al 80 percenl 01 running amps.

5.

Set time delay for a minimum

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,

01 30 minutes.

consult

and lank battery

a service

technician

to

and

or

9.

Make sure the load voltage

required surface voltage.

10.

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

a.

b.

c.
d.
8.

8.

before slart-up if possible.

11,

Is within

10 percent

01 the

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.

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

I
I

GASSY
Problems
.Gas

Is being produced

through

the pump

Solutions
.Lower
.Install

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

pump (use shroud

gas separator

if pump lower than lowest peri)

I
I

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
I

I
UNDER CURRENT

BELOW NO LOAD

Problem~
.Unit
oversized
.Under
current

set below Idle amperage

Actions
.Shut

well In

II

, '"

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

..

I
I

I
I
I

I
I

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

I
I

I
OVERLOAD

Problems
.Increase

I
I
I

In nuld viscosity. sand production,

emulsions. or
mechanical
problems
(lightning), motor overheat or worn

equipment
~ctions
.Have
.Do

electrician

not restart

check out unit

:.:-o:--~~

1,fA/

"-Ill:

I
I

-r

-<

I
I
I
I

I :

I .
I

.-

0:-

...

."\J

.:if:

.-

",.

~~'
",d~

I
I

DEBRIS

Proble~
.Debris

(scale, sand, muds)

SolutlQll~

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

I
EXCESS RESTARTS
Problems

.Power

problems

Solulions
.Have
.Do

unit ctlecked
not restart

I
."
---j~"J

,..

,---

out by an electrician

I
I

I
I
I

I
I
I

ERRATIC

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

Solutions
.Do

not restar1 until unit Is checked

out.

blown fuses)

--he

lollowing tWo pages are Ilow chans generated by Chevron's

~angeIY,

Colorado oHice to help in trouble shoaling.

I',:
tj;

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/};,

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i:-t.::

[:~