ELECTRICAL SUBMERSIBLE PUMP

. HANDBOOK

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 TABLE OF CONTENTS

1 Secllon 1 SAFETY

1.1 Swltchboard S 3fety Tlps

1 1

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Sectlon 2 NORMAL OPERATIO~ S

2.1 Monltorlng anc Reportlng

1 2.2
2.3
Treatlng (Acld, Scale, Asphaltenes)
Equlpment

I Sectlon 3 IDENTIFY PROBLEM ROUBLE SHOOTING

3.1 Trouble ~ ng General

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3.2
3.3
Trouble Sllaot ng Amp Charts
Trouble Shoot ng Flow Charts

Sectlon 4 ANALYZE PROBLE~

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4.1
4.2
Equlpment Te >ling
Standard Ope allng Procedure

1 Sectlon 5 DEVELOP SOLUTION

5.1 Deslgn

1 Sectlon 6
5.2 Oeclslon Analysls Economlcs

PULLING ANO STA [T-UP

1 6. t
6.2
lnstallatlon/Pt lng Procedures
Start-Up Proc ~ures

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 SAFETY
Seie ion 1

1.1 Svritchboard :Safe'ty lp's

 SAFETY
Secton 1

1.1 SWITCHBOARD SAFETY TIPS

Usted below are several safety tlps that should be followed In

1 addltlon to any local safety requlrements. When worklng wlth

swltchboards always remember:

HIGH VOLTAGE CAN KILLI

Stand to the rlght sida of a swltchboard when startlng or

stopplng a unlt. The door can blow open In casa of

1 2.
exploslon.

lf checklng hlgh vollages, make sure proper meters and

safety gloves are belng usad.
1 3. f.Jways check a swltchboard for proper groundlng.

1 4 11 unusual or loud nolses are comlng lrom a swltchboard, call

a quallfled electrlclan.

5. lf arclng nolses are present, wear proper salety gloves untll

source ol arclng Is located and llxed.

6. Leave voltages alone lf untralned or nervous. Have a

qualifled electrlclan ~heck a swltchboard lf neceaaary.

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NORMAL 0PERATIO,NS 1

Se cti,o n 2

2..1 Monitoring and Reponmg

2.2 Treaf1g ,(Acid. Scale Asphattenes)

2.3 Equipment

Ul:I II UII-., elll.

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NORMAL OPERA TIONS
1 Section 2

MONITORING AND REPORTING

Monitoring is the key to efficlent ESP opera!i.. ns. Usted below are
sorne data to be monitored:

Dally amp charts

Unusual operating characteris ics
Fluid levels
Casing and tublng pressure
Gauges (tubing & casing)
1 Tear-down reports
Cause analyses

Daily Monitorinq

Sufficlent 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 ordlnary operating characteristlcs should be noted In
the well's file. Amperage chans should be maintalned and usad as
a dally monltoring procedure (see Trouble Shootlng Amp Chans).
Seven day ar day charts should be used. lf electronic data
gathering systems are used then a hard copy should be kept
periodlcally so the entire pump llfe can be examined. Proper
malntenance and callbratlon of the recordlng devices should
also be done. Section 4.2 shows a Standard OpArating Procedure
used by Sacroc to monitor well performance.

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1 Rangley Shutlle Valve

A second alternallve Is the shuttle valva developed In

1 Rangely, Colorado, and Is similar lo a check valve. The maln

dlfference Is when the ESP shuts down, the check valve
drops, preventlng Huid lrorn llowlng through lhe ESP, and

1 exposes a slde openlng whlch allows the tublng'and annulus

to equalize. The slde openlng wlll allow chemlcals lo be
pumped down the tublng, but not through lhe ESP. When
the ESP Is restarted the check valve rlses and seals the slde
openlng.

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2.J EQUIPMENT

The ESP system can be divlded lnto subsurface and sunace

., 1 components. lhe majar downhole components lnclude an electric

motor' s eal secllon, multl-stage centrifuga! pump wlth an lnlake and
discharge, and .power cable. Optlonal downhole equlpment may
lnclude a bottomhole pressure/temperature sensor, check and draln
valves, motor shroud. anda gas separator. The sunace components
include a junctlon box, switchboard. and lranslormers. A lyplcal ESP
lnstallallon Is shown In Figure A. A descrlptlon ol each componenl

:l. Is glven below ,beglnnlng downhola and movlng up the well.

subsuace EQulpment
1 Motor

ESP motora are two-pole, threE1-phase, squlrrel caga

1. lnductlon motora whlch aparata at 11 nominal apead ol 3500

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rpm al 60 Hz. Voltages ranga lrom 480 to 4,125 volts, whna
. amperages ranga from 14 to 143 amps. Horsepower Is
lncreased by lncreaslng motor length lor a glven dlameter

slza or motor serles. Larga horsepower requlrements usually
requlra two ar mora motora, ce>mmonly referred lo as

i tandam- motors.

Motors . ara lilled wllh a nonconductlva oil wlth a hlgh

dlelectf'1: strength whlch provldes lubrlcatlon lor bearlngs
and god thermal conductlvlty. Produced fluid movlng pasl
lha outslda ol the motor camas heat away; coollng tha motor
(rnlnlmum recommended fluid veloclly Is 1 ft/sec). lf tha fluid
velocltyls not sufflclenl to cool tha motor, or lf lhe motor Is
localed ~elow tha perforallons, a shroud should be placed
around' tha motor.

1 Seal1 Protector, Equallzer

The seal secllon (also known as a protector or equallzer) Is

located between the motor and Huid lntake of lhe pump. The
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seal s~n.,~s liva main functions:

1 fl,
1 e11lralned In lhe cable to escape to lhe atmosphE1re befare
reachlng lhe switchboard. The uncllon box also provldes

1 easily accesslble test polnts far electrlcally checklng

downhole equlpmenl. (To be used wilh pacc-otf type
subpump hangar. Nol necessary with EFT (Eleclronlc Feed
Through) hangar.
1 Swllchboard

Swilchboards (molar conlrollers) conslst of a motor starter,

relays lar ovel1oad and undenoad prolectlon, a clrcuit
breaker, time delay relays, and a recording ammeter. The
swltchboard also fealures a llghted display so that a pump's

1 operatlng condltlon can be seen lrom a dlstance.

Ovenoad and undel1oad relays protect the motor from

1 drawlng excesslve amperage and lnsutflclent amperage,

respecllvely. A syslem does not automatically W!.ruj H lt goes
down on over1oad. Time delays are used lo allow enough
time lo pass alter a shutdown befare a restart attempl Is
made; lhe lime delay should be long enough to all,ow Huid In
the tublng to equallze with the annular fluid. Time delays are
also used wilh externa! conlrol devlces, such as tank level
controls or line pressure switches. Excesslve cydlng Is not
recommended due to the high amperage occurrlng al
start-up.

The ammeter records lhe amperage drawn by the motor on

a 24-hour or 7-day amp chart. Amp charts are a vilal means
ol ESP dlagnoslics. They glve lndications of power
Huctuallons. gas locklng, pump-olf, false slarts, cycllng,
undercurrenl loads, over1oad, debris, and normal conditions
(see Trouble Shooling Amp Charts).

1 Variable Speed Orive (Opllonal)

ESPs are relalively Inflexible In lhelr productlon range when

operated at a lixed lrequency. Variable speed dri11es (VSOs)
allow an operator to vary the lrequency, and thus the How
rate, to better match well conditlons. However, 1/SOs have
hlgh lnitial and maintenance costs. Most ESP companles rent

1 VSO's lar tesling.

 TAEATING (AClO, SCALE)

Treating Partlally Pluqged ESps.

Occasionally, ESPs become partially plugged! with scale, wax ar

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asphaltenes. reducing pump performance di creasing fitting cost.
Suggesled trealing is as lollows.
,]f:\'f>~~:~rfi~:?(
Wax

1 Wax can build up In the upper secti al the productian

tubing as in a rod pump well. These pr blems can citen be
remedied by hot oiling or hot watering down the tubing or

1 down the annulus through the pump. he lollowing is a key

point to consider:

1 Pump hot oil ar water down t;e tubing il possible.

Excessively hot lluids down the nnulus could exceed
the ESP cable temperature ratin .

1 Scale

11 well bore scale problems are presen in your lield, you will

1 likely have scale build up in your ESP Frequenlly you can

treat the pump lar scale by pumping t e recommended acid
far your type of scale through the pu p. The lollowing are
sorne points to consider:

1 Try to pump the acid down th; tubing instead of the

annulus. This otters bener co rol over the treatment

1 and the acid will not contact t , armored cable.

Corrosion inhibitors can be ad ed to acid treatments

to protect the steel armar a ound the cable. (Be
1 care!ull Corrosion inhibitors c n cause emulsions that
could be damaging to the lar tion.) Nol to mention
tormation plugging trom fines eleased from scale.

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 Asphallenes

1 11 you diagnose an asphaltene problem. arornalic solvents

(such as xy1ene and toluene} must be used to disperse the
asphaltenes, breaking them up so they can b1! removed.
Chemical manufacturers have eddillves to hellp irnprove
solvent per1ormance. Be sure to check with the ~~
manutacturer ~ pumping solvents to be sure what allect
they will have on elastomers (rubber materia!} i1r1 the cable
and pump.

lf asphaltenes are suspected a wlreline knile can be used to

1 cut material loase In the tublng. Thls material can be

analyzed. lf lt proves to be asphaltenes, the prop1H treatrnent
can be applled befare the pump becomes irreverslbly
plugged.

Hat 011

1 U a check valva exlsts above lhe ESP. the hot oil must be
pumped down the annulus. Otherwlse, the hot oil can be
pumped down the tublng. lt Is more deslrable to purnp down
lhe tublng In arder to preven! exposlng the cable lo the hol
olt. Cable may be damaged if lhe temperalure al lhe ali
exceeds the cable's temperatura ratlng. Good rules of thumb
are:

When purnping down the lublng, use lwo tublng

volumes al 80% to 100% al the formalion tiernperature.

1 When pumplng down the annulus, use one and a half

annular volumes al 80% lo 100% ol the lormalion
temperatura.
1 Hlot Walerlng

1 The procedure far hol watering is the sama as hot oiling

excepl produced water is used. The advantage ol uslng water
,~. that lt holds heal longer than oil, thereby rnqulring less

1 volume and lower temperalures.

t-lot waterlng will lrequently have beller results than hot oiling

1 Goncerns about scallng, corrosion, bacterilt, formation

damage, and emulsion problems can be overcorne by using

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1appropriijte chemical additives. Rules ol thumb for hot
l'alering lare lhe same as for hot oiling.

'\cid Seleclion

he type of scale presenl will determine the type of acid

equired. AH larga acid supply companles will analyze a
' produced water sample from the well lo predlct the type of

l cale present Once the type of acld and corroslon lnhlbitors

re selected, the volume and strenglh of acld requlred can be
i1etermlned by the quantity of scale present. Good rules of
lhumb are:

l, U~e a 5% solullon al appropriale acld with good

corrosion inhibtion additves.

U~e 2 bbls/ 1000 feet of tubing.

tAlways use a larger volume and weaker solutlon, rather than

smaller volurne and stronger solullon, because the bottom
or1lon of the cable and sorne cable bands will unavoldably
come In contact wilh the acld. 11 lhe acld is weaker the
rorrosive elfecls are lessened.

9rreallng

ffllhe acidizing procedure lar a seized ESP lnvolves a lined

ftpressure truck wilh a lined or nonreactive pump. The acld
should be thoroyghlv mlxed prior to pumplng down the
ltubin~.lh: suggested acid procedure Is as lollows:

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 Rale
Descrlpllon Volume (bbls/mln)

1. Pump until acid Is 1 lublng 1

above the ESP . The volurne ol
lirsl '/, tubing volume acid
of acid Is used up, or
spenl , as II dlssolves
scale lrom the tublng .

2. Pump the '/, tublng tublng

volurne ol spent acld volurne of
lnto the ennulus and
the next tublng
vofurne of acld lnto
acld
t
the ESP .

3. Allow a 15 minute
soak time lor the acld
to work .

4. Pump a lresh, tublng

unspent tublng volume ol
volume ol acld lnto acld
the ESP.

5. lel soak
approxlmately slx
hours.

6. Turn on the ESP and 'h

produce 1he spent
acid down the
llowllne.

The lnal '/, tublng volume al acld Is nol pumped through the
ESP because 11 wlll be dlluted by the fluid used lo displace
the acid (usually water) . f
Acldlzlng Asphallenes

Asphaltic crudes are sensilive to the presence ol lerric iron

durlng acidizing operallons . The iron acts to crosslink the
asphaltene molecules, lormlng added-oll sludges. lron

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1 rreallng

The asphallene removalprocedure lar a selzed ESP lnvolves

a pressure truck wllh a pump contalnlng tenon seals. The
solvent Is thoroughly mlxed prior to pumplng. ll Is then
pumped down the lublng. A typlcal asphaltene removal
program is as follows:

Deacrlpllon Volume Rale

(bbls/mln)

1. Pump untll solvent Is 1 lublng 1

above the ESP. The volume ol
llrsl Y, tublng volume of solvent
solvent Is used up, or

1 spenl, as it removes
asphaltene lrom the
tublng

1 2. Pump the lublng

volume ol spent solvent
lnlo the annulus and the
tublng
volume ol
solvent
'h

next tubing volume ol

1 solvent lnto lhe ESP.

3. Allow a 15 minute soak

1 time lor the solvenl lo

work.

Y, tublng
4. Pump a fresh, unspenl 1-i

1 tublng volume ol
solvenl lnto lhe ESP.
volume of
solvent

5. Lel soak approximately

1 slx hours.

6. Turn on the ESP and

produce the spent

1 solvenl down the

ftowline .

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 sequeslering agenls are lnetteclive at prevenllng acld-oil
sludging slnce lhe sludges are forrned befare lhe
sequesterlng agents funcllon. These sludges can best be
controlled by a preHush of arornallc solvent/asphaltene
dispersan! whlch removes any e><isting asphallene deposits
plus acls as a spacer between lhe acid and ol. The aromatic

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will also clean the tubing and ESP, lmproving lhe
ettectiveness of the acid

1 Most miscible llooding operations will have asphallene

depositlon in the weil during initlal stages of gas
breakthrough. A good rule of lhurnb for treatrnenl volumes

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Is 1 bbl/1000 feel of lubing of arornatic solvent/asphallene
dispersan! as a preHush lo the acld.

Solvent-Rubber Reacllon

1 Solvent Is usuaily pumped down the tublng and rarely down

the annulus. 11 solvent Is purnped down the annulus al lull

!I strength, lt will come In conlact with the cable and deslroy

. , the lntegrity ol lts Huid jacket. Most lluld jackets are

nltrie-based and most solvents wUI swell nltrile 25 to 50%. 11
this happens the cable armar may burst and/or an electrlcal
short will occur.
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Check with lhe ESP manufacturar befare pumplng any
solvents through an ESP. Sorne manufacturers use nilrite

1 bushings in lhe pump, and these will swell and selze the ESP
if they are contactad by a solvent.

Solvent Seleclion

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The IWo most common and ettective aromallc solvenls are
xytene and toluene. Bolh are equally ettecllve al repetizlng

1 asphallenes. The varlous chemical rnanulacturers have

sur1actants and dlspersants which will lmprove the perfor-
mance ol these aromallc solvents. Chemlcal companles will
tesl a sample ol asphallene and determine whlch Is the best

1 lormula lor the sample given This is usually done quickly,

but lhe tesling Is extremely biased. For complete. unblased
testlng, send a sarnple to COFRC. The testing time Is longer
but the recommendalions will be nonbiased.
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Tite final lublng volume ol solvenl Is nol pumpeol lhrough

lhe ESP because il will be diluled by lhe Huid used lo
displace lhe solvenl (usually oil).

The volume ol solvenl will be determlned by lhe quantily ol

asphallene present. A good rule ol thumb Is t10 use 2
bbls/ 1000 teet ol lubing.

11 lhe 1ublng or ESP Is plugged salid and pumplng clown lhe

1 lubing Is impossible, a cailed tublng unit can be used lo

clear &he plug In the tublng and/ar squeeze salven! through
the ESP. Plugging can be avolded by lmplemenllng the
monitoring program described belaw.

Reduclng Treaiment Costs

1 Minar deslgn and operatlonal modilications wlll resull In less

downtime and reduced oyeran lreatmenl costs.

Check Valve vs. No Check Valve

Check valvas are lhe mosl common melhod of prevenllng

Huid lrom passlng through &he pump. The advantages are
lhal check valves are lnexpensive. prevenl sand or partlcles
In the fluld from plugging pump during shutdown,' allow
lmmediate reslarting, and lmmedlale producllon upan reslart
lng. The majar dlsadvantage Is lhat check valves do nol
allow clrculallon down lhe lubing; reverse circulaling down
the annulus can be done instead.

Back Spln Relay

An alternativa to a check valve is a backspln relay. A

backspin relay Is part ol lhe molar conlroller. lt monilors
vollage generaled by the motor aher the ESP has been shut
down 11 will nol allow lhe ESP to sl art unlil the motor has
slopped spinning. The advanlages are lhal il allows lor
pumping down lhe lubing and reduces lhe number al
restrictions in the tubihg slring. The disadvanlages are that
slart up is only possible aher the tubing and annulus have
equalized, and the device doas not ditlerenllate whlch
direclion the ESP Is lurnlng. In other words, the well could
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PUMP OFF
Problems
Unit too large
Solutlons

1 Redesign syslem wilh smaller pump (currenl syslem loo larga)

Slimulate well

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FALSE STARTS
Problerns
Auto restart delay not ol sullicient lenglh to allow adequale
luid build-up.
Solutlons
increase restart deiay
Redesign ESP
 Transtormers

Transformers are used to convert primary llne volta,ge to

motor voltage requlremenls. Three types of translormers used
In conjunctlon with ESPs are: banks of three single-phase
transformers. three-phase standard transtormers, and
three-phase auto translormers. The transformers are oU-filled
and sell-cooling. For oflshore plat1orms where oil-lilled
translormers mlght be prohibited. dry type transformers are
available. The translormers are equipped with taps to pl'ovide
maximum nexibility In voltage outout.

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 "-

IDEN'TrFY PRO,BLEM
"TROUBLE SH00 TlNG ' 1

Section 3
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3.1 Trouble Shoong GeneraW

3.2 rouble Shooting Amp Charts

3.3 Trouble Shootng Flow Chatts

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TROUBLE SHOOT/NG
Section 3

3. t TROUBLE SHOOTING GENERAL

Check the switchboard's indicator lights to see ti ihe unit is

running. 11 down. check to see ti it is down due to under1oad
ar over1oad.

2. Check the amp chart to see if any unusuaJ lines ar blips are
present. Far help In inlerpreting amp charts seo Trouble
Shooling Amp Charts.

3. Check the murphy switch or the externa! switches to see rt

they are controlling the switchboard.

4. 11 down due to an ovenoad condition, call an electrician to

check far a short downhole befare anempting to restan.
LI!! .
J. ;.

5. Check primary fuses to see 11 they are open. These !uses will
t
open when there is a surge al power on ene leg. l
6. Visually inspect transtormer hookups.

7. lnsure the electrician checks the unit downhole lrom the

lowest point al conneclion.

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 Trouble Shooling - Common Problems

Problem N 1: Unlt will not start.

Posslble Causes Posslble Correc\lve Actlons

No voltage to switchboard . Check luses In swilchboard and

replace blown swltchboard luses.

. Check lncomlng voltage .

. Check prlrnary luses ebove

transformer and replace blown
luses.

. Check transformer for open

windings and replace H needed.

. Have power company check

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distrlbullon system.

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 o cor uo voila ge 11, Chec incornil"lg oHage.
, 11chboard
Check aU lu5i!S 1n iu:hboard and
replace blown !uses.

, Check -OA contacls and over1oad

con\acts. C1ean or .replaca if bad.

Chacli conl,ol powef traos,or:mer.

" et e,c,k m1e1lo:id resst by turning

OA switch otl and lhon bacl< to
Auto.

11 Check ramoH1 wLri-n g 10 shut

sw,itcllboard down.

Check cornof:n by lemporadly

bypassk1g To bypass Aetlalrdl,,
lumpe.r ~ellatr-ol 'I 11 \o gr-o nd. To
bypass Vol1ex, lumper Vo:r18!X #111
11 lo ground, To bypa,s:a Centrlgard,
umper P1 to ground. To btpass
Redalen, jumpef f U to 1. In a:ny
o' H1esa caSies. U lhe t111l1 runs the
controHe-r s bad.

Low urleco volt g,e Check vollage.!I and cone,ct U

necessal)',__

Dowohol'e
''
Check phase-lophasu, res :stanco
low ohm shons .readlng aind
shons lo seo il balanc,ed. Check
phasa -\o-phase gr-ound 1esl!ilanc-e.
o h:l,gh ohm r.e.a.drngi {20 + meg,
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ol1m) . lower eading aooeplable 1
VSO connoller
 Problem #2: Unll shuts down due to undercurrenl.

Posslbla Cauaaa Posalbla Correctiva Actlc1n1

Low well producllvlty - . Check amperage downhole .

pumped -oH conditlon
. Shoot lluld level. Purnp water down
backslde II no lluld leve! Is

1 available. 11 there Is lluld In the

well, conslder purnp change.

Plugglng ol pump lntake . Check to see if pump Is purnplng

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fluid.

Pump acld down tublng and

through pump II tublng Is open to
pump dlscharge. (see Secllon 2,
Treallng)

. Purnp acld down backslde and

spot around pump lntake.

. Changa out pump. Have lhe purnp

1 acldlzed and tesled belore sendlng
tor repair. Thls may avold the
unnecessary cost ot repalrlng a

1 Under1oad set too hlgh .

scaled pump.

Check amperage downhole on all

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three phases and compare wlth

nameplate amperage ot motor.
Reset underload II lt Is above 80%
al nameplate emperege. Do nol go
below 60% ol motor arnperage.

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, Compare downhole amperaga with
ldle load amperage (lyplcally
45 -55% al nameplale amps) .
Reverse unil In swilchboard by
changing IWo downhola leads.
Check amps again; lhey should be
wilhin :t 10% al frst readlng.
Reverse leads again. Pump water
down backsida if available. Start
unit agaln. 11 amperage Is constant
through thls procedure, a brokan
shaft exlsls and tha unlt must be
pulled.

Pump Is gas locked Pump water down backslde to

break gas lock.

Vent casing to llowllna II possible.

Check settlng depth to see II unlt

can be lowered closer to
perforatlons.

Instan shroud ar gas separator.

Faully remole conlrols 10 Check pressure control clrcuil ar

swilchboard olher auxillary that could causa
shuldown.

Flowline restrlctlons Check all valvas to make sure they

are open. Check pressure on
wellhead and llowlina. Check to
see il pump is pumplng lluld.

1 Lt
 Problem #3: Unlt Is running but produces little orno fluid.

1 Possible Causes Posslble CoITectlve Actlona

lncorrect rotatlon . Reverse unlt In swllchboard by

changing two downhole leads
(electrlclan only).

Tublng leak . Pressure test lublng. Check nuld

level In well end check amperage
ol runnlng unlt . 11 hlgh fluid leve!
and normal amperage, suspecl
hola In tubing. Pull tublng to fhc
leak.

Plugglng ol pump lntaka . Rel er to Correctiva Aclions

descrlbed under Problem 'li2 .

Brokan shaft In unit . Retar to Correctiva Actlons

described under Problem # 2.

1 low well productlvlty

pumped-olf condlllon
. Reler lo Correctiva Aclions
descrlbed under Problem #2 .

1 Problem #4: Unll wlll not stay runnlng dueto hlgh amperage.

Posslble Causes Possible CoITecllve Acllons

Low voltage . Check incomlng voltage to

switchboard. Changa laps on

1 Changed well amperage .

translormers lf necessary.

Check lluld al wellhead lar sand or

mud. Check on ali three legs to

1 determine II unil Is balanced

downhole. Check lo see II water
cut has increased causing higher

1 .
Holding coil In main
conlactor
horsepower requirernents.

Check lo make sure ali coils are

pulling 111 ali lhree contactors 11

1 one is not, !he motor Is

single -pllasing and causing high
amperage. Replace bad coil.

1
1. ..,,-""'!'I"!'!'~------___, ___ ____.. ,. . . .--
""' ::. ....
. ::i-r;;.
-,C:,:_"'!~!'1~'-
1'11!.:.f!!l.
.:;\ ~~ -i:~l~.r-~g
,Q:. - 11111_
IIIIIIJk
- '
 , 11 1.ml J . sn , dagleg1ar lghl
:ipot, hlgn amperage may 't esulL
ais r low r uml oul o! dog eg
Of 1,igl1 spOI.

Unll will nol restart atler underload ahutdown.

Poulblt C1uae1 Posslble CorTectlve Acllona

Tlmer motor or contrallar . Check and replace limar motor ar

not lunctlonlng proper1y contrallar if necessary.

1 Control lusas blown . Check luses and replace ti blown.

HOA switch defectiva ar . Check HOA sw11ch and clean ar

el dlrty

Extemal murphy, ar a
pressure swilch set In
replace II bad.
. Check ali eX1ernal swllches lar
operallng levels and correct as
wrong posltlon necessary.
L
e Problem #6: Unlt will nol ahul down wilh HOA switch.

Posslble Causes Possible CorTective Actlons

.
:J
Control relay stuck Pull one control lusa in 11 O volt
[ / , ,!
circuit. DQ aot ogen mala
con1ac1or with ynil [Ynnlng. Clean
relay conlacls.

1 Matnlcontactor contacls . Have an electrician physlcally open

welded together conlactor.

1 Problem #7: Unit will not shul down by underload or overload.

Possible Causes Possible Correctiva Aclions

~
-1 Coptroller shorted ar . Remove jumper lrom contrallar.
tumpered out Pull 110 volt shorted ar control

1 ( -.Ct D %.
!uses.

4f$,bidi~ . E Ub . .P., A :
 Problem #8: Controller problema - excesslve lrlps.

Posslbla Causes Posslbla Correctiva Ac:tlon1

Undercurrent shuldown . Check downhole amperage. 11

normal, adjust settlng.

Remole conlrols have . Check lor open or closed contacts

opened and shut unlt on remole clrcults and clean or
down repalr as necessary.

Unlt starts but shuts down . Check remole conlacls and clean

1 wllhln 5 seconds

.
or repalr as necessary.

Check lor corree! phaslng on

control power transiormer.

1 .
Changa II necessarf.

Check CT phaslng. Changa 3-5-7

1 Unll wlll not tlma-olf .

to controller H necessarf.

Check remole clrcults. Unlt wlll not

start In tlme-oll II remate contacts
are open.
1 . Underload Is sel too low. 11
underload Is set pa1sl the lowesl

1 settlng mark, tlmer sequence Is not

operatlonal. Check CT rallo and
adjusl underload as needed.

il
1
1
1
1
 'l .~

i
s.... ,. diha.!11' _,
F 1~ g;~~~~::u)
....L.=--
.
r Ammd t,. ,
J,~IJIClllon Ba:,t
......~:a;.. __J_

1 S ptiCI!.
fob 1n9
[f ~tbt CciM~
,~.n:9,on _ __ J 1.t

1 aoU ' Cfl ~ 0 (1

,- -Pump

1
1
1
:1
1
1
1 FIGURE A

1
 Connects the drive shaft of the motor directly lo the
pump shatt.
2. Absorbs the axial thrust from the pump.
3 Protects the motor ol lrom contamination by lhe weU
fluid.
4. Allows pressure equalizallon between the wetl annulus
pressure and the motor internal pressure.
s. Provides a reservoir far volume changas as the motor
oil heats up and cools down.

Seals contain a labyrinth chamber with a blocking fluid

1 between the weli Huid and motor o. The biocking fluid is
commonly the same o used in the motor. lt may aiso be a
high density Huid far special appilcations. Seals may also
contain a positiva elastomeric barrier, or BAG. In combinallon
wilh a labyrinth chamber. Several operators have increased
run Uves using tandem seal sections as an added means ol
protection.

Gas Separators (optlonal)

' ... ;; ~
Gas reduces the etflciency of ESPs: therefore. gas separators
may be instaed between the seal and pump to reduce the
amount al free gas entering the pump. Both reverse flow and .,
rotary separators are available with the lanar being more
elficient at gas separalion. Sorne operators run tandem gas
separators in high GOR weils to more etfectively remove gas
from the pump intake. Gas separators Q.Q !lQ! handle

1 significan! volumes of free gas efficiently.

Pump

1 The submersible pump is a muiti-stage centrifuga! pump;

each stage consisting ot a rotating lmpeller and a stationary
diffuser. that produces a given amount al head tor a given

1
volume. lmpeers may be either floalinq or tixed. Floating
imoellers. which are the most common, move axlatly along
the shaft and are free-lloating when the pump is operating
within the recommended capacity range (sea Figure B).

1 However. jf the pump is operating ~ (to the left of) the

recommended capacity ~ . the impeller will be in a
downthrust condi\lon. Conversmy, il the pump is operating
~ (to the righl of) the recommended capacily ~ the
 0.,..Unt
0owntn111SI Ranc.i- Uphuat
r,..-..
~

1 J
r;
e:
.!
.Y

1
l:
5

1
1 Pumpl119

1
1
1
1 F1GURE

1~-- --- ~---~

1
impeller will be In an uplhrusl condilion Bolh downlhrusl and
uplhrusl can cause excessive wear and can be delrlmental
to the pump.

Flxed Impeliera

1 Flxed lrnpellers are directly connected to the pump shah and

cannol move axially. Allhough thls saves impeller and diffuser
waar, llxed lmpellers may allow lar a hlgh axial thrusl to be

1 devaloped which must be absorbed by the thrust bearing In

tha seal.

.1 Impeliera are classifled as elther radial ftow ar mlxed ftow

lype. Far a glven dlameter pump, radial ftow lrnpellers will
hava hlgher head pressure but slightly lower rala capacily
lhan rnlxed Oow lmpellers.

1 lrnpellers may be made ol dlfferent materlals. The mosl

common Is a melal alloy called NI-Resist whlch Is composed

1 mainly ot lron and nlckel. Olher lmpellers are made ol a

plasllc called Aylon. Rylon Is advanlageous In scaly or
corrosiva envlronments slnce scale does not lorm on the
Rylon, and since corroslon does not affect plasllc. NI-Reslsl

1 Is beller lar deep wells, hlgh temperaturas, and abrasiva

Oulds.

Check and Draln Valvea (Opllonal Equlpment)

1 A check valva, localed two to three joints above the pump;
prevenls the pump lrorn rotatlng In the reverse dlrecllon

1 when tha unil shuts down. Thls reverse rotatlon occurs when
the Huid In the tublng talls back alter the unlt has stopped.
An attempt to start the system while the pump Is rotatlng
backward could result In a twlsted shatt. Tha check valva, H

1 not plugged open by debris, will keep the fluid lrom lalllng,
lhus protectlng tha pump lrom reverse rolallon.

A drain valve, located one toint above the check valve,

1 prevenls pulling a wet tubing slring. Draln valves also allow
circulatlon al the wall when a check valva Is run. Draln valvas
are nol requlred unless a check valve Is used.
 Power Cable

Eleclrlc cable slrapped lo the tublng supplles power from the

swilchboard to the motor. The cable Is made up ol three
copper conduclors, either solld or mulllstrand. l he
conduclors are lndividually lnsulaled; varlous lnsulallons are
avallable dependlng on well flulds, temperalure, and
pressure. A tackel malerlal surrounds lhe lnsulaled
conductora far protection agalnst mechanlcal damage and
the envlronment. A metal armar Is wrapped around the jackel
lar further protacllon agalnst mechanlcal damaga. The metal
armar also helps prevent swelllng when gas or llquld
permeates the tacket material al hlgh pressures.

Cables are avallable In round or nat conllgurallons and In

varlous alzas. Flal cables are used where clearance between
lhe unlt and casing Is small. The most common conductor
slzes are No. 1 (largesl), No. 2, No. 4, and No. 6 (smallesl).
General amperage ratlngs far the diHerent cable slzes are:

#8 - up to 37 amps
#4 - 38-57 amps

1 #2 - 58-65 amps
# 1 - 66+ amps

As a general rule, voltage drop wlthln the lnstalled length of

1 cable, corrected lar bottomhole lemperature, should not
exceed 30v / 1000 h.

1 Motor Flat Cable

A motor ftal cable, connected 10 the top ol the motor, Is run

along the length ol the ESP system and spllced lnto the maln
power cable lust above the pump. The motor ftat Is necessary
due to the lack ol clearance between the ESP and casing

Sur1ace Equlpment
Juncllon Box

1 A venled juncllon box is located between the wellhead and

swirchboard. In hlgh pressure wells, gas may permeate lhe
cable and migrate to lhe surlace. The junctlon box allows gas
 u N T AR

. fl

'
AWl'II!
1 Mal!t!Jiilll

L
O"
,i.[QI
,._~
~fil---
.
'flllllii1,J
1

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r1 ~
"*'"10 'tZ
- :1

Q N Jl'!R.Jti,i,Mt,1,_i,
1 n
l
...-.;;,
r
11
r,-.01-0
~
IOR

,-1

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l
A,,N ALYZ,E P'ROBLEM,
S1
ecti,on 4

4.1 Equi,pm,ml eisling

4.2 Standard Opera~ ng Procedure

 l---1--------_.:,A~N:...:.;~~L.:. .:YZ=.::E=---P__.._R-=0-=B=-=LE=-=-M.:. :.
Section 4

,1
4. 1EQUIPMENT TESTING

1When ESP equipment Is pulled from a well lis d ispositlon may vary
from running II back into a well, to sending lt to the manufacturar to
be rebuilt, to having II tested by a manufacturer or testlng company.
l.
11 the equlpment was pulled far sorne reason other than a failure, a
. weil site inspeclion may be adequate to determine whether il is
suitable lar rerunnlng. However, if lhe equipment Is not golng lo be
rerun immediately, ar II there Is doubt as to lts condlllon. ll is
1 recommended that il be lesled. Tesling Is an lnexpenslve means of
determlnlng lhe conditlon of used equipment. In lhe motor lestlng
program, e)(penslve repalr costa can also be reduced as much as

1 90%. Sendlng equlpment lo be lesled Is of particular lmportance

when equlpmenl has been subjecled to a hosllle well envlronmenl
(hlgh water cut, C0 1 , H 1S, etc.). The cleaning of equlpment and
preparatlon far storage that Is lncluded In lhe lesling procedure. Is as
1 Importan!, 11 not more so, lhan the testing ltself. Pumps, in particular,
leh stored on the rack without ftushlng can "lock down and become
Inoperable.

Pump Jesling
Each section of a pump should be inspected far problems.
such as a twisted shah, hola in the housing, ar any problem
that would requlre II lo be sent lar repairs rather than testing.

2. The pump should be steam cleaned inslde and out to remove

paratfin and well ftulds. Other chemlcal washes are also
available to remove sulfate scale. gyp, paralflns, and
asphaltenes.

3. HCL contalnlng an inhibitor and dispersan! should be

pumped through the pump far a mnimum ol two hours, or
until acld reactlon is complete, if scale is present.

1 4. The pump should be ftushed wilh clear water prior lo lesling.

1
 S. The pump shall Is checked for play, extension. and that lt
lurns easily. Failure to meet selected standards precludes the
pump hom luture testing .

1 6. The pump may be tested at the speed that the pump

manufacturer stales on lts published curves . The pressure,
rate, lorque, and re11olutions per minute lor thls polnt are

1
recorded . The back pressure Is then lpcreased lncrementally
untll the llnal flow rate ol zero Is reached. Calculatlons are
done to determine the percentage ol de11iation lrom the
curve. The pump shalt Is again turned by hand, and any
slgns ol roughness are noted.

7. The pump's houslng Is lnspected wlth an ullrasonlc meter to

determine whelher there Is Interna! corroslon near lhe
dlscharge end. Experlence has pro11en lhat the dlscharge end
ol a pump Is most vulnerable lo eroslon and corroslon. Many
pumps ha11e parted In thls area resulllng In costly llshlng jobs.

8. Atter the final lnspectlon, the pumps are prepared lor storage
by llrsl flushlng wlth glycol and then wllh ol. AII coupllngs
and shlpplng caps are replaced and the lnlake por1s are
plugged and taped.

9. A declslon Is made as to whether the pump passes or fails by

comparlng test resulls wlth the manulacturer's curve.

Motor Testlng
1
Remo11e pothead cap and lake initial readings : 1
a. Check the phase -10-phase (lead-to -lead) reslstance . 11 \
should be balanced among all leads.

b. Check the phase-lo-ground (lead-lo-houslng)

reslstance. Typlcally, lt should be more lhan 2000
rnegohms on a megohm meter wilh no pressure
\
devlce.

,
c. Record all readings. Stop testing il motor Is shor1ed .

.
.ITROUBLE ~HOOTING AMMETER CHARTS

rnalyzing amrneler charts Is one of lhe besl ways lo diagnose a

-~umber of probiems. lisled on lhe next few pages are examples of
ammeler charts lar varlous operallng condilions. These charts are

I"'"
reprinled lrom lhe submerslble Pump Handbook" wilh permlsslon
Cenlrilif\.

Comparlng lhese amp charts lo your amp chart may glve an

B lndlca:lo~ -~i: lhe lype al problem you havo.

1
1
1

1
- - . .'
" ":-_,
1

1
1
1

NORMAL
Under normal condillons the ammeler should draw a smooth
symmelrical curve near nameplate curren!. Splkes al start-up
are normal.

1
!t2 -J
1
1
1
1
POWER FLUCTUATIONS

1 Problems
Fluctuallon of Prlmary Power Supply (Slart-up ol larga HP
molors lnjecllon pumps etc.)

I Solullons
lnvesllgate Power Fluctuallons
ID causes ol lluctuallons (Start-up ol larga HP mott
lnjecllon pumps)

1 Call power company

 l Cle~n molo_
r

1 a. Sleam clean body lo within one lool of motor head.

Do not sleam head.

b. Solvenl wash motor head and fill valve areas.

Physlcally lnspecl motor for unusual wear from

runnlng/pulllng and operatlons: wear on rub buttons and
houslng rubs; general corroslon; and wear on bolls and bolt
holas are sorne items of concern.

Tt'le motor oil should be drained and checked for bronze contenl
(lndlcator of bearlng wear). water contenl:, "'
varnish/epoxy conlenl, and mellad babbil contenl (silver lnoilj. ~.
AH boll holas and pothead cap 0-rings should be checked lor ..
1
'f~:
damage. The lead washers on fill valvas should always be
replaced. The motor should be llushed from top down while
iurning rotor stack occasionally. Check oil during flush f1Jr
obvlous lndicalors of motor problems. Flush lhe ol unit the
.1 dlscharge is ele ar. Olelectric slrenglh of the oll should be al lea,st
25KV. Once llush Is COl1'4)1ele, cap motorwhile 11 Is slill full of oil.
~F
r.-
15. The P.l. (leakage) of lhe motor should be calculated and ha.ve
a grealer value than 2.0. The hl-pol test should be run al a'
r:
t
vohage which can be calculaled by lhe followlng equat~Jn:

1 6.
l(NPV) x 1.5 + 1.7. (NPV) = Nameplale Vollage)

The phase-10-ground megohms from lhe hl-pot lest should be

1
,:1:
..
I!

i
grealer than 5,000 megohms.
"'
1 7. The spln test Is pertormed by runnlng lhe motor al Name
Plata Voltage until lhe temperalure reaches 1D0F. The mc11or
f-
'..
_
~i.
lhen coasts down alter runnlng. Coasl lime should be smoolh ,,~-
1 and lasl 6 lo 8 seconds. Spln tesllng should be pertormed
lor both the clockwise and counlerclockwlse directions.
t

1 -~
11 \he motor does no\ meel lhe above crilerla, it could
pTossibly be salvaged by sending it through a "mini dryout.
hls procedure lnvolves placlng the motor In an lnsulated
,r
1

compartment and applylng DC current to the stator until the

~ lemperature reaches 250F. WhHe the motor Is coollng it Is -

....
1
 . -=------==~ ~

1 purged wilh nilrogen Alter lhe dryoul. lhe molor is relesled

as prevlously described. Replacement of the motor insulalon
block In lhe lerminal head Is recommended as part of any
"mini dryout.
1
1
1
1
1
1
1

1
1
1
1
1
1
JSTANDARD OPERA TING PRDCEDURE

1The tollowing torms were generaled by a SACROC Ouallly Acllon

Team. 11 Is curren1ly used In SACROC as &he Standard OperaUng
Procedure lar designing and redeslgning submersible pumps.

1
1
' 1

1 '1 '

1
1
r1
1 .~r-~
:
"

1 f'.

r:..
;!
~

,-
:;~

11 --,.,
t
,,
1:
1

1
1
r GAS LOCKING
eroblem~
, Lowering fluid level
Gas evolves In pump

1 S9lytlon~
Lower pump
Choke productlon back
Put on limer
1 Aedesign pump

1 . :~ .. -,-~r::~ - -~ .,.._ _-- ~ . ,1 :

 .....,,,,,..-t!ll:iOt:----ll!a.!S!!!!II.~

WORKOVER AH.TIFICIAL UFT SELECTION

Data Sheet lnltl1I Equipmrnt Stltrtlon
l. w,noua
Wel Ha.

TYPE or WORKOVER
Priwlty -'na__ _ C....i.-- D01&:

-~
~
Aol.4_, ,-., _ _ 11

,.,--
.. a...... _ _
''
RtmmpltU Con .. n 1a Producrr
Weur s11a1.orr Rt lun 1a l'n>dutJoe
OrW Complcu Olktr _ _ _ _ __
OH

11. l'n-WO Tul Data

Oau 10 BW GV COl

___
- - -".,,
- - -"'
fL C:ulllc Pn11ure 6 Commeeu

Callac SI.a _ _ _ Uau Slu Top of Uau _ __

(V. Do. . Holt EqJpmHI

Dale No. Stacu X Sh.t X Moior SI.u .\lld,Raact UII

1 Pau.wo
l'n-WO
R (IFPDI (Fl)

j
1
V. CommHU: lmflJ lhl majar ronsldrnrtloH far rqalpmul Hlttl.td:

Vl. WH rq11lpmu1 rn lbt umr H or1clnallJ C11lled for? (Y/NI

lf ao, &in llr1tf nplaHoa: _ _ _ _ _ __ _ _ _ __ _ _ _ __

[.qn

1 DolC
Dole WO CepioW: .

1
1
 WOH.KOVER DATA

VII. Post Worko~,r Tul Data

D.\TE 10 BW GV COJ~

VIII. Po5l Workour fluld Lcvel1

FLUID C.\SING
D.\TE u:vEL PRESS. COMMENTS

IX. Rulu Dala

Equlp. Equlp.
Duc Pullc<I RuD Ru10a os
Up/D,...
Up/D,...
Up/Owll
u,ro ....
u,ro ....

X. Commenu:

1
1
1
1
1
DEVEL DP SOLUT1'0 N
1

Section 5

5.1 'Desi.gn

5.2 Decisicm Analys;s Economtcs

1
r
L
~.
DEVELOP SOLUTJON
Section 5

. , DESIGN i -

Capital and operating costs, well conditions, reservoir

perlormance, equipment and service performance, and ease of
operating and maintainina the equipment are key considerations
'-9 when designina an ESP.

1 An IBM PC computer program called ESPO (Electric Submersible

Pump Optimizationl is available from COFRC for ESP design.
ESPO selects the most economic system far each manufacturar
considering both capital cost and power cost. Although computer
1 programs make the technical task of ESP design easier, they
should not preclude your engineering judgement and experience.
Contact W. H. (BilU Ford at COFRC for more information about

-- ESPO, or to obtain a copy of the program.

1
1
1
1
:- : =z::--
1
OECISIOH ANAL VSIS ECONOMICS

Decision analysls can help you make lhe best economic artificial lift
decision. Merek. which utilizas many tools al decision analysls, Is a
good program to base your economic decisions.

The loundalion ol good decisions is historical data. Please keep

good recordsl
PULLING ANO STAHT-UP
Section 6,

6.1 \nstallaUon/ PuUing Procedure5

6.2
1 Slart-Up Procedures
J -

---- --.... -~ --- . . . . . . -- ...

-
,uu , .._~ 11.Jduw muna_i;Amnn r1Anlh A 1"JA;1n ntd lrln tu,,lnw tha
l

l~______ ....:..P~Uu.L:..!:L.!.!.INuG~A~N=-=D:;.....=S..i...;TAL..U..l.R...L.T~-U~P
Ssction 6

1
INSTALLATION/PULLING PAOCEDUAES

Pre-Job Checklist

Usted In thls sectlon are tips that will hopelully lead to fewer failures.
For complete runnlng and pulling directions please consull API RP
11A.

Eaulpment Aeaulred Optlonal Egu!rufill..i!

' Motor Gas Separator
Seal Secllon Check Valva
Pump Orain Sub

1 Cable Motor Flat

Swltchboard
Round Power Cable
Motor Shroud
Variable Speed Driver

Junctlon Box
Translormers
ESP Tublng Hangar with Tubing Head
Tublng PUP (2' -6')

Servlces Aequlred

Cable Reel (54 or largefl

Cable Bands and Bander (Hand band wlth precut bands
or power band wilh reel ol slainless steel bands)
Electrlclan (lor disconnecting and connecllng ESP and
testing cable)
Subpump SeNlce Technlclan (on localiofl for length of
jo~ .
Chevron Representativa (coordinale placement of
equlpment, timlng of dellveries, and sujeNislon ol the
inslallation).

00 NOT RUSH. Prgplanninq is an investment for sccuss.

1 Wellbore Preparalion

Aun a bit and positiva scraper set to drih diameter al least

100 leet below numn sRninn riPnlh A r.lP:1n n111 lrin 1-)Plnw tho
 bottom perforatlon Is recommended H casi elfectlve. Note
any past and presenl "light spots.

11 light casing Is suspect or lhe hote Is devlated, run a sllH

"Dummy" BHA to et least 100' below the pump settlng depth.
Note depths of light spols. Look for unusual wear. gouges
and marks on Dummy BHA.

Equlpment Handling

When unloading ESP equlpment, use a spreader bar wlth a

chaln attached near each end of the box. Never plck-up In
the mlddle!

11 the equlpment Is dropped, damaged, or appears already

damaged, h should be checked by lhe servlce technlclan on
locallon.

Nota: Sllghtly more than 50% of all ESP falluru In

Chevron ara cable fallures, so apeclal care must ba
taken In handling tha cable.

The cable reel should be handled with an axle and spreader

bar.

Never plck the cable reel up by lhe cable.

Never let any load be placed on lhe cable durlng loading,

unloading, or storlng.

Any rotatlon of the cable will cause damage.

Pulllnq/Running Equlpment
Hold a safety meeting to discuss the scope of work lo be
performed. Note any special probtems or concerns.

Suggested personnel on localion:

2 Aoor Hands
0errlck Man
1 Operalor
2 Cable Aeelers (if by hand)

1
1
 1 Service Techncian
1 Chevron Supervisor

Handle equipmenl as recommended by the subpump

techniclan.

1 C}ble Reellng/Banding/Runnlng

Reellng

1. Reel size should be 54" ar largar.

2. Real should be localed 75-100' lrom servlce rlg.

3., Cable guida on rlg should be no more than 30' above

ground.

4. Always have siack between the cable reel and guida

wheel.

5. Always have the cable reel In the operalor's llne al

sight.

6. Use cable stands to prevent cable lrom dragglng

lhrough the dirt.

Banding

11 Is very lmportant that lhe cable be run slraight up

lhe aubing.

2. Band squarely across the cable. Tublng band shouid

be at right angles lo lhe lubing with the cable vertical.

3. Band flat cable and flat guards slraight up the sida of

the seal sectlon and pump. Slart immediately above
lhe pothead witlh a sectlon ol ftat guard which has the
bottom end sllghtly tapered. Continua with the flal
guard lo jusi bulow lhe Hal cable-round cable splice.
 4. Stafnless steel bands are recommended (.025 x .75
(J 16SS)) as minimum. Where condillons warrant (hole
devlatlons, doglegs, scale, etc .. ) larger bands (.035 X
1.25 (316ss)) should be used.

1 5. Cable band should sllghlly delorm cable armar. A

power bander should use about 125 psla.

6. lnstall two bands per 30' foinl; one midway on lhe

folnt, and lhe other 18" above the collar. lf uslng lead
sheathed power cable, additlonal bands may be
requlred In consideratlon of the cable welghl.

7. STOP and contact a servlce techniclan H lhe cable Is

damaged.

e. Extra cara should be laken In runnlng cable lnlo a well

where an ESP has not been lnstalled belore.

1 Spllces

Well conditlons and fleld experlence wiil dlctate what type ol

1 spllce Is approprlale. Good spilces are the key lo reduclng

cable related lallure. Ouallly control of lhe spllclng
procedures and materlals determine the success of spllce.
The person maklng the spllce has the greatesl lnnuence over
1 lt. Cleanlness of the lapes, cables, and the spllcer's hands Is
a must. Tapes if used, must be smoothly wrapped and light.
The cable and conductors should not be manhandled or
sharply benl durlng the spliclng procedure. The fob should
not be rushed because the care and time laken here wUI be
recovered In longer run times lor your syslems. Speciflc
procedures and recommendallons can be obtalned from the

1 Rangely ottlce.

Runnlng/Pulllng Cable

Do no\ apply tenslon to the cable. Thls could elongate

the cable and destroy the protectlve lnsulatlon. Avoid
sharp edges and rubblng ol lhe cable durlng running.
Do not allow the lublng to rotate.
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!

1 2 Check cable and molar every 2000 going in lhe hola

(oleclrical conlinuily and lnsulalion ,esislance checks).

1 3 Check lhe cable visually and eleclrically comlng out ol

lhe hale.

4 STOP and have a service technlcian lnspect the cable

11 lhe cable Is brnken, or lhe lnsulation or armor is
damaged. (Aemember: most cable fallurea result
from mlshandllng.) (Note deplh of damage to cable.)

1 5. Keep slips In good condillon with sharp dles ol

non-rotallng type. Be sure the swlvel lock on the hook
Is lalched and that lhe hook Is not free to swillel.

6. Aun and pull purnp between 1000' and 2000' per hour.

1.
Nevar pull the cable lrom the reel.

. .,._~ 7 AII slops and slarts should be as smoolh as possible.

8 Always use lihlng subs lor raising or lowering ESP

1 equipment.

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 6.2 START-UP PROCEDURES

Load tublng befare slart-up if posslble.

2. lnslall proper amp chart.

1 3 Sel overload amperage at

nameplale amperage.
110-120 percent of motor

4. Sel underload amperage al 80 percenl ol runnlng amps.

5. Sel time delay for a mlnlmum ol 30 minutes.

6. Check ali valvas between lhe wellhead and lank battery lo

lnsure they are In lhelr proper posltlon.

7. Set the seleclor swilch lo lhe "Hand" or "Auto poslllon and

start the pump.

8. 11 pump lalls to slart, consult a servlce technlclan or

1
eleclrlclan.

9. Make sure the load voltage Is withln 1O percent ol the

requlred surface voltage.

10. Once the amps have stablllzed alter start-up do the followlng:

a. Observe the ammeter and flowllne pressure durlng

start-up. Low amperage and long pump-up time mlght
lndlcate reverse rotatlon.
b. lnsure that the reslart lime delay Is set for a mlnlmum
ol 30 minutes.
c. lnstall pressure gauge In trae and record pressure.
d. Send a record of equlpment to the well file.
8. Check amp charts frequently and turn usad charts In

1 11.
to supervlsors when charts are changed.

Use 24-hour charts for first three days alter ESP lnstallation
(rnay go to 7-day charts alter).
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1 GASSY
Problems

.1 Gas Is belng produced through the pump

Solutions
Lower purnp (use shroud if purnp lower than lowest peri)
, Instan gas separator

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EXCESSIVE CYCUNG

1 Pr2blems
Delrimental lo ESP molors
Too large a Unil

1 Plugged lBG
Tubing leak
Solutlons
Oblain a fluid level alter shul-down

.I Check lor high TBG pressure

....,.: ,. . . ,,
 UN0ERCURRENTLOAD
Pro~
No Huid In hola
FaUure al tlmlng relay

1 ~~
Lower Undercurrent settings (by ESP speclallst)
Remedia! acid.
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, UNDER CURRENT BELOW NO LOAD
Problems
Unlt oversized

1 Under curren! set below ldle amperage

Actions
Shut well In

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1 CONTROLS
Problems

1 , Controlled shul down

(By tank level, etc.)
Actions
, Set aula start delay timer above thirty minutes

1 , Use HOA switch to delay slart

, Check controls

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1 OVERLOAD
Problems
lncrease In fluid vlscosity, sand production. emulslons. ar

1 rnechanical problems (lightning), motor overheat or worn

equipment
Actions

1 Have electrician check out unit

Do not restart
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,., ,.., S1 ~t hii
11 +0,,11,,1

1 C.-Hrt1 .. f Lr1
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~:a:

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1 DEBRIS
Problern~ f1
Debris (scale, sand , muds)

1 ~''
Use clean workover lluids
Clean well prior lo ESP inslallalion
See lreating

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1 EXCESS RESTAATS
Problems

1 Power problems
Solulions
Have unit cflecked out by an electrlclan
Do not restart

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 ESP TROUBLE SIIOOTING FLOWCIIART

..,...., '""-
i ,l'IQ g!!i
l
P'Qwt~ (o...,..,

1 >-- ...----
',,t V'!.n ,
..,.....
w 1 ,--f'lQI

,,~
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.. -. . ~ ~ .....
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l. ERRATIC

1 Problems
Mechanlcal lallure (locked pump, bum motor, blown fusas)
, Changa In surface pressures
Changa In sp~cilic gravity

1 Solutlons
Do not restan until unlt Is checked out.

-- - - ----- -- --
. . .,.,~ . :, :: :;.~:: .
.. ' . .
ti.he lollowing two pages are llow chans generated by Chevron's
11angely, Colorado ottice to help in trouble shootrng.

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