ELECTRICAL SUBMERSIBLE PUMP

-!HANDBOOK

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 SAFETY
i Section 1

1.1 SWITCHBOARD SAFETY TIPS

LIsted below are several safety tips that should be followed In

I addition to any local safety requirements.

switchboards always remember:
When working with

HIGH VOLTAGE CAN KILL!

1 Stand to the right side of a switchboard when stanlng or

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

I explosion.

2. If checking high voltages. make sure proper meters and

safety gloves are being used.
I 3. Always check a switchboard for proper grounding.

I 4 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.

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MONITOIRING AND REPORTING

Monitoring is the key to efficient ESP opera tions. Usted below are

some da1:a to be monitored:

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Dally amp charts

Unusual operating characteris ics
Auid levels
Casing and tubing pressure
Gauges (tubing & casing)
I 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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'-""IG'lUa'IUI'~ ..., ua "UlIUId~t:U.
I Rangley Shuttle Valve

A second alternative Is the shuttle valve developed In

I 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
I to equalize. The side opening will allow chemicals to be
pumped down the tubing, but not through the ESP. When
the ESP Is restarted the check valve rises and seals the side
opening.

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 2.3 EQUIPMENT

TI,e ESP system can be divided Into subsurface and surface

components. rhe major downhole components Include an electric
motor. seal section. muill-siage cenlrifugalpump wilh an Intake and
discharge. and power cable. Optional downhole equipment may

I 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.

Subsur1ace EoulDment
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I Motor

ESP motors are two-pole. threEt-phase, squirrel cage

a 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.

I 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

I 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.
I 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
I 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

I VSO's lor testing.

 :;: .., , ..." :,"".,",;C

L.z TREATING (ACID, SCALE)

!!JatinG PartiallY PluGGed ES~

Occasionally, ESPs become partially PlUgged

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

Wax

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

Pump hot oil or water down t; ! tubing if possible.

I Excessively hot fluids down the nnulus could exceed

the ESP cable temperature ratin .

I Scale
It well bore scale problems are presen in your field. you will
likely have scale build up in your ESP. Frequently you can

I treat the pump for scale by pumping t e recommended

tor your type ot scale through the pu p. The following
acid
are

some points to consider:

annulus.
Try to pump
This
the
oHers
acid
bener
down
co
th
; Irol
tubing over instead
the treatment of the

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and the acid will nol contact t ,armored cable.

Corrosion inhibitors can be ad ed to acid treatments

to protect the steel armor a ound the cable. (Be
careful! Corrosion inhibitors c r\ cause emulsions that
could be damaging to the for' tion) Not to mention
tormation plugging trom tines eleased from scale.
 Asphaltenes

I 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 are suspected a wlreline knife can be used to

I cut material
analyzed.
loose In the tubing. This material can be
If It proves to be asphaltenes. the propl!r treatment
can be applied before the pump becomes Irreversibly
plugged.

Hat all

I If a check valve exists

pumped down the annulus.
above the ESP, the hot 011 must be
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
I all. Cable may be damaged
exceeds the cable's
If the temperature
temperature rating.
of the 011
Good rules of thumb
awe:

When pumping down the tubing, use two tubing

volumes at 80% to 100% 01 the lormatlon tlemperature.

I When pumping down the annulus, use one and a hall

annular volumes at 80% to 100% of the formation

I temperature.

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

I volume and lower temperatures.

Hot watering wililrequently have better results thiin hot oiling

C;oncerns about scaling. corrosion, bacteriel, formation
I clamage. and emulsion problems can be overcome by using

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:;~::...:;:.:::.:.,-,_c~ ,.:,.: ,.

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

~Cid Selection

t 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 acid with good

c:orrosion inhibition additives.

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

Always use a larger volume and weaker solution, rather than

t 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:

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 Rate
Description Volume (bbls/mln)
1 Pump until acid Is 11ublng
above the ESP. The volume of
first '/. tubing volume acid
01ack1 Is used up, or

I spent. as It dissolves
scale Irom the tubing

2. Pump the V. tubing 'h tubing ~

I volume 01 spent acid
Into the annulus and
the next '/. tubing
volume
acid
of

volume of acid Into

the ESP.

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

4. Pump a Iresh, y. lubing ~

unspent Y. tubing volume 01
volume 01 acid Into acid
the ESP.

5. Let soak
approximately six
hours.

6. Turn on the ESP and 'h

produce the spent
acid down the
flowline.

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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I 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 Volume RIle

(bbls/mln)
1 Pump untH solvent Is 1 tubing 1
above the ESP. The volume 01
first Yo tubing volume of solvent
solvent Is used up, or

I spent, as it removes
asphaltene from the
tubing

I 2. Pump the Y. tubing

volume 01 spent solvent
~ tubing
volume 01
~
Into the annulus and the solvent

I next Y. tubing volume 01

solvent Into the ESP.

3. Allow a 15 minute soak

I lime lor the solvenl to

work.

-4 Pump a fresh, unspent 'I. tubing !-i

I V. tubing volume of
scjvent Into the ESP.
volume
solvent
of

5. Let soak approximately

six hours.

6. Turn on the ESP and

produce the spent
solvent down the
nowtine.

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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.

I Most miscible flooding operalions

deposition
breakthrough.
In the well during
will have asphallene
Initial stages 01 gas
A good rule 01 thumb lor treatment volumes

I Is 1 bbl/IOOO leet ollubing 01 aromatic solvent/asphallene

dispersant as a preflush to the acid.

Solvent-Rubber Reaction
I 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
r this happens the cable armor may burst and/or an electrical

II short will occur.

Check with the ESP manufacturer before pumping any

I 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
I. I The Iwo most common and eHective aromatic solvents are
xytene and toluene. Both are equally eHectlve at repetizing

I asphaltenes. The various chemical manufacturers have

sur1actants and dispersants which will Improve the perfor-
mance 01these aromatic solvents. Chemical companies will
test a sample 01 asphaltene and determine which Is the best

I lormula lor the sample given. This Is usually done quickly,

but the testing Is extremely biased. For complete. unbiased

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testing, send a sample to COFRC. The testing time Is longer
but the recommendations will be nonbiased.
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 The volume of solvent will be determined by the quantity of
asphallene present. A good rule of thumb Is IIC) use 2
bbls/ I 000 feel of tubing.

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 program described below.

Aeduclna Treatment 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
I 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 reslart-
Ing. 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

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PUMP OFF
~roblems
.Unit 100 large
Solutions
.Redesign syslem with smaller pump (currenl syslem 100 large)
I .Stimulate well

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",c,. .~7 '..i;..~~~:::::::::

FALSE STARTS
Problem~
.Auto restart delay not of sufficient lenglh to allow adequate
fluid build-up.
SolutIOQ~
.Increase restart delay
.Redesign ESP

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 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. :1

2 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 10 see Ii

Ihey are coni rolling the switchboard. , .,

4. II down due 10 an over1oad condition, call an electrician to i. ~I

j. ;.
check lor a shan downhole before anempting to reslan. !! .
f.
5. Check primary fuses to see If they are open. These Ituses will
open when there is a surge of power on one leg. I;
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6. Visually inspect transformer hookups.
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7 Insure the electrician checks the unit downhole I:rom the

lowest point of connection.

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 Problem #2: Unil shuls down due to undercurrent.

Possible Causes Possible Corrective Actlcinl

Low well productivity - .Check amperage downhole

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

Plugging of pump Intake .Check to see if pump Is pumping

I 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.

I .Change out pump. Have the pump

ackilzed and tested beliore sending
lor repair. This may avoid the

I unnecessary cost of repairing a

scaled pump.

Underioad set too high .Check amperage dowrlhole on all

three phases and comlpare with
nameplate amperage 01 motor.
Reset under1oad lilt Is above 80%
01 nameplate amperage. Do nol go
below 60% 01 molar arnperage.

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 Broken shah In unit .Compare downhole amperage with
Idle load amperage (typically

~ 45-55% 01 nameplate amps).

Reverse unit In switchboard by
changing two downhole leads.
Check amps again; they should be
within :t 10% of lirst reading.
Reverse leads again. Pump water
down backside if available. Start
unit again. " amperage Is constant
through this procedure. a broken
shaft exists and the unit must be
pulled.
Is gas locked .Pump water down backside to
break gas lock.

.Vent casing to flowline II possible

.Check setting depth to see if unit

can be lowered closer to
perforations.

.Install shroud or gas separator.

Faulty remole conlrols 10 .Check pressure control circuit or

switchboard other auxiliary that could cause
shutdown.

Flowline restrictions .Check all valves to make sure the',

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

~Pump
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8rOb'em #51: Unit will not restart atter underload shutdown.

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

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

'~t:.'~;;:
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 Possible Cause. Possible Corrective Ac:tlonl
Undercurrent shutdown .Check downhole arTlperage. II
~or~al~ust setting.
Remote controls have .Check for open or closed contacts
opened and shut unit on remote circuits and clean or
down repair as necessary.
Unit starts but shuts down .Check remote contclcts and clean

I withIn 5 seconds or repair as neces~lry.

.Check lor correct phasing on

I 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

I are open.

.Underload Is set too low. "

underload 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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I FIGURE A

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::::::::-i:"

~'::::i~i:;;,
Connects the drive shalt of the motor directly to the
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pump shatto :c. .::,
2. Absorbs the axial thrust from the pump. -~:;; ::[;;~:.;
3 Protects the motor oil from contaminalion by the well ,;. ii,' :.:~;~~';
fluid.
4 Allows pressure equalization between Ihe well annulus ~~~.i.:;:;~~'
pressure and the molar internal pressure.
t~".::o.:-~.::
5. Provides a reservoir for volume changes as the motor

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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
~I
high density fluid for special applications. Seals may also
contain a positive elastomeric barrier, or BAG. In combination
with a labyrinth chamber. Several operators have Increased
run lives using tandem seal sections as an added means of
protection.

Gas Separators (optional)

Gas reduces the efficiency of ESPs; therefore. gas separators

may be Installed between the seal and pump to reduce the
~Ie~ ..
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
'~!~I ;;~;;,:i';;'
,' ',-" "';

The submersible pump Is a multi-stage centrifugal pump; ;:~~i.~1t~

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
;,';'
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.

I 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

I developed which must be absorbed by the thrust bearing In

the seal.

Impellers are classified as either radial flow or mixed flow

type. For 8 given diameter pump. radial flow Impellers will
have higher head pressure but slightly lower rate capacity
than mixed now Impellers.

Impellers may be made 01 dl"erent materials. The most

common is a melal alloy called NI-Resist which Is composed
mainly 01 iron and nickel. Other Impellers are made 01 a
I plasllc called Ryton. Ryton Is advantageous
corrosive envlronmenls
in scaly or
since scale does not lorm on the
Ryton. and since corrosion does not affect plastic. NI-Reslst

I Is belter for deep wells, high temperatures.

fluids.
and abrasive

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

I 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

I 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 -up to 37 Imps
#4 -38-57 Imp.
#2 .58-65 amps
#1 -66+ amps

I As B general rule. voltage drop within the Installed length of

cable, corrected for boltomhole
exceed 30v /1000 It.
temperature. should not

I 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

I A vented
switchboard.
junction box is located between the wellhead
In high pressure wells, gas may permeate tile
arid

cable and migrate to the surlace. The 'unction box allows gas

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

 +-ANA L YZE PBQ~L-.EM
I Section 4

, I 'ii~~U1
,!4.1

EQUIPMENT TESTING

I When ESP equipment Is pulled from a well its disposition may vary
i from running h back Into a well, to sending it to the manufacturer to
i be rebuilt, to having h tested by a manufacturer or testing company.
I 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
I 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
I 90%. Sending equipment to be tested Is of particular Importance
when equipment has been subjected to a hostile well environment .
!

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(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.

3 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.

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

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1
 5

I 6.

7.

8.

Molar Testlo.g

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

should be balanced among all leads.

b. Check the phase-to-ground (lead-to-housing)

resistance. Typically, h should be more than 2000
megohms on a megohm meter with no pressure
device.

c.

9.
.IROUBlE ~HOOTlt~G AMMETER CHARTS

rnalyzing ammeler charts Is one of Ihe best ways to diagnose a

.~ulllber of problems. LIsted on the next few pages are examples of
ammeter charts lor various operating conditions. These charts are
reprinted from the .Submerslble Pump Handbook" with permission
Ilroin Centrilift.

Comparing these amp charts to your amp chart may give an

B Indication 01 the type 01 problem you have.

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

are normal.

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o. ..o'~;:;;O'
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"':,' "oJ
:,' ',; '; lJ~!;., -J
Oil""
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83
.
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I
I
POWER FLUCTUATIONS
Problems
.Fluctuation of Primary Power Supply (Start-up of large HP
motors Injection pumps etc.)
SolU1lons
.Investigate Power Fluctuations
.10 causes 01 fluctuations (Start-up of larget HP mott
Injection pumps)
.Call power company

:1
.I -::°. ' "
 Cle~n molor
Sleam clean body to within one foot of motor head.
a
I Do not steam head.

Solvent wash molor head and lill valve areas

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.
All boll holes and pothead cap a.rings should be checked lor
damage. The lead washers on Iill valves should always tie

I replaced. The motor should be lIushed Irom top down while

qurning rotor stack occasionally. Check oil during Ilush lor I~
obvious Indicators 01 nXltor problems. Flush the oil unit the ! I,'
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.
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The phase-to-ground megohms trom the hi-pot test should be ,"
6 r
~
greater than 5,000 megohms. r.
17 The spin test Is per1ormed by running the motor at Name .,
;

Plate Voltage until the temperature reaches 100°F. The motor

then coasts down alter running. Coast time should be smooth
,.'
't
I;

I and last 6 to 8 seconds. Spin testing should be per1orl1ned

tor both the clockwise and counterclockwise directions. ,
;

I ., \I \he motor does no\ mee\ \he above cri\eria, it c'Duld i

) possibly be salvaged by sending it \hrough a "mini dryIDu\." f
This procedure Involves placing \he mo\or in an Insulated ~
~ compartment and applying DC current to the stator until the :
1 lJ tempera\ure reaches 250°F. While the motor Is cooling it Is

~~i(~!!~~j~l~i~;i~.~;~. --" ::~\;~::;r.\:~. :..:.~;;;.1.!~~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
~2I STANDARDDOERATINGORDCEDURE
1 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'

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I

GAS LOCKING
~.Lowering fluid 'e~el

I .Gas

.S-Q!Y1!~
e~oI~es In pump

.Lower pump
.Choke production back
.Put on \imer
.Redesign pump

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, -:'~.~..1f-:--- I 111
 WORKOVER AJrnFlClAL UFT SELECll0N
n.ta Sheet. Inltl.1 ~uipment Selection

w. rn-wo nul. unit

D n. c.lia, PnllUrt ..Comm..u

UII
(F't

v. Commt8U: 8~, 1111

m8pr roalldtnllt081 lor ~alpmtDIItI«kd:

VI. W.. tqUlpm'8' fWlllb. 18m. ..orillD811, mlled for! (YIN!

If 80,II" brirf r'pl.a8uoD:

I Do..WOc..pIoW:
E.acn
Do...
 ~

1\
WORKOVER DATA

VII. Poll Workower Tell 0818

D4TE 80 BW GV CO1~
1\
Ii

VIII. POll Work ower fluid lAwell

fllnD CASING
DAn: u:vEl PRESS. COMMENTS

IX. Resl" Dall

Equip. Equip.
Dale Pulled RUD RUIOD os

Up/D-
Up/D..
Up/D..
Up/D..
Up/D..

X. Comments:

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 "I DESIGN!
"-
Capital and operating costs, well conditions, reservoir
perlormance, equipment and service performance. and ease of
..opera~ing and maintaining the equipment are key considerations
'e when designing an ESP.
I An IBM PC computer program called ESPO (Electric Submersible
Pump Optimization' is available from COFRC for ESP design.
ESPO selects the most economic system for each manufacturer
considering both capital cost and power cost. Although computer
I 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.

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' .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

!;
~ ---
I PUL1Jl':/J
G A~ TABI: UP
Ssction 6

I
INSTALLATION/PULLING PROCEDURES

Pre-Job Checklist

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

Eaulcment ReQuired Ogtlonal EglliPJillll!'.

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

Services Required

.Cable Reel (54" or larger!

.Cable Bands and Bander (Hand band with precut bands
or power band with reel 01stainless steel bands!
.Electrician (lor disconnecting and connecting ESP and
testIng cable!
" Subpump SeNlce Technician (on 10catlof1lor length 01
lob) !
.Chevron Representative (coordinale Iplacement 01
equipment, timing 01 deliveries. and supeNislon 01 the
installation!.

00 NOT RUSH. Preolannina is an investment for success.

I Wellbore PregaraliQn

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

I
 bottom perforation Is recommended If cost ellectlve. Note
any past and present "tIght spots.,

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 Is dropped. damaged. or appears already

damaged. II should be checked by the service technician on
location.

Note: Slightly more than 50% of III ESP failures In

Chevron Ire cable failures, so speclll care must be
taken In handling the cable.

Never pick the cable reel up by the cable.

Never let any load be placed on the cable during loading,

unloading, or storing.

Any rotation of the cable will cause damage.

~gJRunnlna Eaulomeot
Hold a safely meeting 10 discuss the scope of work 10 be
performed. Note any special problems or concerns.

Suggested personnelon location:

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

.
 1 Service Technician
1 Chevron Supervisor

Handle equipmenl as recommended by the subpump

technician.

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 to prevent cable from dragging

through the dirt.

Banding

It Is very Important that the cable be run straight up

the tubing.

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 side of

the seal sectlof11 and pump. Start Immediately above
the pothead with a section of flat guard which has the
bonom end slightly tapered. Continue with the flat
guard to lust below the "at cable-round cable splice.

.
.I
2.
3.'
 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.

I Cable band should slightly deform cable armor. A

power bander should use about 125 psla.

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

Well conditions and field experience will dictate what type 01

I splice Is appropriate.
cable related failure.
Good splices are the key to reducing
Quality control of the splicing
procedures and materials determine the success of splice.

I 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

I procedures and recommendatIons

Rangely oHlce.
can be obtained from the

Running/Pulling Cable

1 QQ1!Ql apply tension to the cable. This could elongate

the cable and destroy the protective Insulation Avoid
sharp edges and rubbing 01 the cable during running
QQ.!!Q! allow the tubing to rotate.

5.
'"1
I I
I
!

I 2 Clleck cable and molar every 2000' going in the hole

(ulecllical conlinuilY and j'lsulalion resistance checks).

I J Check \he cable visually and electrically coming out 01

IIle hole.

4 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)

I 5 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.

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

B. Always use lihlng subs lor raising or lowering ESP

I equipment.

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 62 START-UP PROCEDURES

Load tubing before slart-up if possible.

2. Install proper amp cllart

I 3 Set overload
nameplate
amperage
amperage.
at 110-120 percent of motor

4. Sel underload amperage al 80 percenl 01 running amps.

5. Set time delay for a minimum 01 30 minutes.

6. Check all valves between the wellhead and lank battery to

Insure they are In their proper position.

7. Set the seleclor 5wilch to the "Hand" or "Auto" posilion and

start the pump.

If pump falls to start, consult a service technician or

I 9.
electrician.

Make sure the load voltage Is within 10 percent 01 the

required surface voltage.

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

a. Observe the ammeter and flowline pressure during

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

I to supervisors when charts are changed.

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

8.
I

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GASSY
Problems
.Gas Is being produced through the pump
Solutions
.Lower pump (use shroud if pump lower than lowest peri)
.Install gas separator

~--",~-.~~..~~,-",~~~,
: "';: ;::
 EXCESSIVE CYCUNG
I PrQblem~
.Detrimental to ESP motors
.Too large a Unit

I .Plugged
.Tubing
TBG
leak
Solutions
.Obtain a nuid level alter shut-down
.Check lor high TBG pressure

,.
-
 UNDERCURRENT
lOAD
P.!.g~
.No /luki In hole
.Failure of timing relay
~~
.Lower Undercurrent settings (by ESP specialist)
.Remedial ackJ.

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UNDER CURRENT BELOW NO LOAD
Problem~
.Unit oversized

I .Under
Actions
.Shut
current

well In
set below Idle amperage

II , '"

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,.. ..
: ': :i:;::~;:
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I CONTROLS
Eroblems
I .Controlled shut down
(By tank level, elc)
~
.Set auto start delay timer above thirty minutes

I .Use
.Check
HOA switch to delay start
controls

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I
OVERLOAD
Problems
.Increase In nuld viscosity. sand production, emulsions. or
mechanical problems (lightning), motor overheat or worn
I equipment
~ctions
.Have electrician check out unit
I .Do not restart

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 1,fA/ :.:-o:--~~
"-Ill:
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I I :
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0:-
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.:if:

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",.
I ",d~
~~'

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I DEBRIS
Proble~
.Debris (scale, sand, muds)
SolutlQll~
.Use clean workover lIuids
.Clean well prior to ESP installation
.See treating

I
 I

I
EXCESS RESTARTS
Problems

I .Power
Solulions
.Have
problems

unit ctlecked out by an electrician

.Do not restart

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I

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I

ERRATIC

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

.Change In specific gravity

I Solutions
.Do not restar1 until unit Is checked out.
 --he lollowing tWo pages are Ilow chans generated by Chevron's
~angeIY, Colorado oHice to help in trouble shoaling.

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