ESP Installation Procedure

ESP Installation Procedure :

1- Cable Sheave Assembly :

The cable sheave should be hung in the derrick, inline between the cable reel and wellhead and aligned with the wellhead to avoid any rubbing against tubing support.

Ensure the cable sheave is attached securely with a chain and has a cable or chain safety backup.
The sheave should be no more than 30 feet above the ground in order to permit flexibility and avoid shock against the cable during running and pulling operations. During installation, the sheave should be supported approximately 10 feet above the ground to feed the flat cable extension (FCE) and splice through. After the FCE splice has been supported by cable bands, the sheave can be raised to the operational height of 30 feet. This procedure reduces stress on the pothead connection and FCE splice.

able running equipment and dimensions are shown in Figure 1-1. The cable must be supported at point B during installation and pulling operations. The cable weight of distance A to B should not exceed 150 lbm.

2- Checking Equipment :

Check all materials and equipment to determine if everything necessary for installation is on location. This should be done immediately upon arrival at the wellsite. Check against the shipping order, quote and workover schedule in the following sequence :

1. Remove box covers and record all information directly from nameplates on motors, pumps, gas separator, protector, flat cable extension, well cable, and switchboard.
2. Ensure that all other completion accessories are available at the wellsite and are functional.
3. Ensure that backup equipment (when required) is at the wellsite and is functional.
4. Ensure that all installation consumables are available at the wellsite and are serviceable.
5. Ensure that all installation tooling is available at the wellsite and is functional.
6. Note the type of tubing support and confirm the proper size of casing, tubing, and cable .
7. Check the switchboard for proper fuses, potential transformer setup and CT ratio.
8. Ensure each coupling to verify that it is the correct size.
9. In the case of tandem pumps, determine which pump needs to be picked up and installed first.
10. Ensure the flat cable is the proper length and series for the motor.
11. Check the design of pump (head) against setting depth, rate, etc.
12. Check the power bank transformers for correct primary and secondary voltage ratings and kVA rating.

Note :

When installing tandem pumps ensure that the pump with a high-strength shaft (designated HSS on the nameplate) is installed closest to the motor.

3- Motor Testing :

Phase-To-Phase Measurements :
The integrity of the motor’s insulation should be tested prior to installation.
Phase-to-phase measurements can be taken most accurately using a digital multimeter. Record the measurements and compare them to the data shown in the motor resistance tables in the Technical and Engineering Information chapter. Measurements must be balanced within 2% and the value cannot be less or more than 10% of the published value. 

If the motor is an upper tandem or center tandem, a wye or star connection is required to take the measurements. Remove the lower shipping cap and interconnect all three male terminals using three jumper wires. The phase-to-phase measurements can now be taken from the top of the motor

Always perform a final visual inspection of the motor terminals for proper spacing in the slot and check for phase resistance after assembling the UMB. 

Phase-To-Ground Measurements :

The megger is used to check the motor insulation resistance to ground.

The meter test lead marked earth is clipped onto a bolt head where a good ground can be established. The other probe lead is connected to each phase individually. Each phase on a new motor must measure a minimum of 1500 megohms to ground.


4- Cable Testing :

Any cable damage should be located and repaired prior to installation. Never take a chance that unrepaired damage will have no effect.
Cable testing can be performed using the following procedure:

1. Remove the shipping cap on the flat cable extension. Conductors at opposite ends must be clean, dry and clear of the cable reel and each other.
2. Using and ohmeter, connect the ground lead to the cable armor and the probe to each individual lead. Record the measurements.
3. Using the ground lead and the probe lead, check phase A-B, B-C and A-C. Record the measurements. New cable should read near infinity both phase-to-ground and phase-to-phase. Depending on weather and humidity, measurements of only 1500 megohms are obtainable and considered normal.
4. Discharge each of the legs to ground after testing. A long piece of cable can hold a very high charge that can take over a minute to discharge.

5- Motor Oiling Procedure (Single-Section) :

The motor is ready for servicing once it is in a vertical position over the well.

1. At the bottom of the motor locate the drain-and-fill valve. Tighten this assembly to 35 lbf.ft.
2. Lower the motor into the well. Remove the top shipping cap, coupling and the Allen screw (shaft plug) from the center of the shaft.
3. Reinstall the shipping cap with a lock washer between the cap and motor head flange to provide a vent during the oil filling procedure.
4. Lift the motor out of the well and remove the vent plug and lead washer from the drain-and-fill valve.
5. Select the appropriate oil for the application and connect the oil filling pump, hose and adapter assembly to the oil can. Note :Purge the air from the oil filling hose with oil before filling the motor.
6. Install the adapter and slowly pump (45 rev/min) oil into the motor until it flows out of the motor head. Wait for five minutes to allow air bubbles to migrate out the top of the motor and then pump again until oil flows. Continue this process until it takes only one turn of the oil pump to cause oil to flow from the top of the motor.
7. Remove the adapter and hose from the motor and install the vent plug with a new lead washer into the drain-and-fill valve. Torque the vent plug to 15 lbf.ft.
8. Lower the motor into the well until the clamp rests on top of the BOP. Remove the motor shipping cap and slowly pump oil down the center of the shaft to ensure all air is expelled from the motor. Rotating the shaft rapidly with a spline wrench will help displace any air. Note : Ensure no moisture or debris enters the motor.
9. Replace the shaft plug and tighten. Be sure the plug is not protruding past the end of the shaft when tight.
10. Replace the coupling. Ensure the shaft rotates smoothly. Servicing is now complete.

6- Tandem Motor Connection : 

The motor is ready for servicing once it is in a vertical position over the well.

1. At the bottom of the motor locate the drain-and-fill valve. Tighten this assembly to 35 lbf-ft.
2. Lower the motor into the well. Loosen the top shipping cap and place a lock washer between the cap and motor head flange to provide a vent during the oil filling procedure.
3. Lift the motor out of the well and remove the vent plug and lead washer from the drain-and-fill valve.
4. Select the appropriate oil for the application and connect the oil filling pump, hose and adapter assembly to the oil can. Note :Purge the air from the oil filling hose with oil before filling the motor.
5. Install the adapter and slowly pump (45 rev/min) oil into the motor until it flows out of the motor head. Wait for five minutes to allow air bubbles to migrate out the top of the motor and then pump again until oil flows. Continue this process until it takes only one turn of the oil pump to cause oil to flow from the top of the motor.
6. Remove the adapter and hose from the motor and install the vent plug with a new lead washer into the drain-and-fill valve. Torque the vent plug to 15 lbf-ft.
7. Lower the motor into the well until the clamp is approximately 18 in from the top of the BOP.
8. Slide the motor jack assembly into position on the BOP. Ensure that both hydraulic jacks are in their retracted position.
9. Lower the motor until the clamp rests in the cradle on top of the jacks.
10. Remove the motor shipping cap and slowly pump oil down the center of the shaft to ensure all air is expelled from the motor. Rotating the shaft rapidly with a spline wrench will help displace any air. Note : Ensure no moisture or debris enters the motor.
11. Place the alignment tool on the motor coupling and turn the motor shaft until the sleeve slides down over the guide pin on the motor head. (There is an alignment groove machined into the motor head and base indicating the location of the guide pin.) Figure 1-2 shows the alignment tool in place.

• 12. Pick up the next motor and remove the lower shipping cap. Place the alignment tool on the upper motor shaft and turn until the pin of the alignment tool slips into the alignment hole on the motor base. The splines on the two shafts are now mated to ensure proper engagement of the motor coupling.
• 13. Select O-ring(s) from the connection tables. Remove the paint color code and lubricate the O-ring with Dow Corning Lubricant . Remove the old O-ring and carefully install the new one into its correct position.

Note : 

It is important when connecting tandem motors that the rig is centered over the wellbore and that the traveling blocks are not swaying. In strong wind conditions, it may be necessary to have someone at the monkey board holding the blocks stationary, centered over the wellhead.

• 14. Inspect the terminal pins and insulators to ensure they are not bent or broken. Have the rig operator lower the top motor until it is approximately 4 to 6 inches above the lower motor. Then pump both jacks simultaneously to slowly raise the lower motor and engage the coupling, making sure the alignment pin slides into the respective hole and that the motor terminals are properly engaged. Use care not to damage the terminal insulators or O-rings.
• 15. Install the bolts and lock washers. Torque to the specifications listed in the connection table.
• 16. Lower both motors into the well. Loosen the top shipping cap and place a lock washer between the cap and the motor head flange to provide a vent.
• 17. Pull the motors completely out of the well and repeat the oil filling procedures; this time filling both motors. In the event that all motors cannot be pulled from the well because of limited crown room, fill from the motor head of the lowest possible motor. Replace the vent plug with a new lead gasket and ensure all other plugs are tight.
• 18. Phase-to-phase resistance checks should be made after each connection. Resistances are additive and should always be balanced.

• 19. Repeat the above procedures for each motor that is added.

7- Upper Tandem Motor Oiling Procedure :

Before servicing the upper tandem motor, remove the allen screw (shaft plug) located in the center of the shaft. Service the motor with oil, replace the shaft plug and tighten.

Note : 

Ensure the plug is not protruding past the end of the shaft when tight.

Replace the coupling and check to ensure the shaft rotates smoothly. Service is now complete.

8- Protector Installation :

Protectors are lifted using the same methods used to lift motors. Motor lifting procedures are provided in the Motor Installation section.

1. Lift the protector to a position two to three feet above the motor.
2. Remove the lower shipping cap and gasket.
3. Remove the O-ring and carefully install a new O-ring.
4. Use the spline wrench to ensure the motor and protector turn free and smooth.
5. Place the coupling on the motor shaft and have the rig operator slowly lower the protector until the shafts are engaged.
6. Turn the protector so that the flat cable slots on the protector flange and motor flange line up with each other. Lower the protector until the flanges meet, making sure not to damage the O-ring. Install the bolts and torque to specification.
7. Pick up the assembly, remove the motor clamp and lower the assembly until the weight rests on the protector clamp.

Note :

Always test couplings on a test shaft prior to be sent to the field. Also, once crew is on the rig site, test couplings on the equipment that is going to be used in the installation. Do not rely on part numbers only.

Installation Caution, All Series Protectors to All Series Motors :

If the upper snap-ring (coupling adapter retainer) is left in place on the protector’s lower shaft spline, there is a possibility of a tolerance stack-up which can cause a protector problem, motor problem or both. Observe the following procedures when installing all series protectors to all series motors.

When a Universal Coupling Adapter is on the Protector Lower Shaft Splines :

1. Remove the retaining snap-ring from below adapter.
2. Remove the adapter from protector shaft.
3. Remove the upper retaining snap-ring from protector shaft.

When a Universal Coupling Adapter is not on the Protector Shaft :

1. Feel the lower protector shaft to determine if either snap-ring is in its groove. if either is present, remove and discard.
2. Proceed with installation procedure.

9- Tandem Protector Assembly :

When installing tandem protectors remove the spline, adapter from the shaft of the upper protector. Remove the adapter with an ice pick.

10- Oil Filling Procedures for Protectors :

Protectors are filled with oil prior to shipment from the manufacturing facility.

Oil is lost from the protector during field assembly, therefore, some refilling is required. Oil filling procedures for the various protectors are provided below.

PFSB (Pre-Filled Single Bag) Type :

The following procedure is for the single and double bag 540– and 400–series pre-filled protectors. Filling techniques are the same as the 66L, but the design utilizes a short and long vent plug in conjunction with an inner valve.

1. Beginning from the top, torque the vent plug in PF#3 to 15 lbf-ft, then remove the vent plug and lead washer from PF#4. This vent plug is longer than the rest and should be kept isolated from the others.
2. In the lower section of the protector are two vents (PF#1 and PF#2) and a drain-and-fill valve (D). Remove the vent plug and lead washer from PF#1.
3. This is a short plug used to prevent the shipping valve (located behind the plug) from opening.
4. Locate the drain-and-fill valve in the motor head and tighten. Remove the vent plug from the center of the valve.
5. Purge the air out of the oil pump and hose/adapter assembly, then screw the adapter into the drain-and-fill valve.
6. Connect the oil hose to the adapter and begin pumping oil into the motor head.
7. When bubble-free oil is flowing from vent PF#1, replace the vent plug with the long plug originally taken from PF#4 Use a new lead washer.The long plug can be identified by a slot across its head that resembles a screwdriver slot. This long plug opens the shipping valve, allowing communication with the inside of the bag. Note : Failure to install the long plug in PF#1 will render the protector useless.
8. Continue to pump through the motor head until bubble-free oil flows from PF#4. Install the short vent plug in PF#4 (originally taken from PF#1) with a new lead washer. Ensure only one lead washer is installed and that the plug is not over tightened.
9. Continue to pump until oil flows from the weep hole located in the base of the pump.
10. Remove the adapter from the drain-and-fill valve in the motor head and install the vent plug with a new lead washer. Servicing is now complete.

11- Flat Cable Attachment to the Motor :

Use the following procedure to prepare the motor for cable attachment :

1. Raise the assembly until the motor head is approximately five feet above the rig floor.
2. Feed the flat cable through the cable sheave. Using a winch line, hoist the sheave to a height ten feet above the rig floor. Do not bend the cable excessively when feeding it through the sheave. The flat cable splice should be supported by a person when it is being pulled from the spool to prevent it from being stretched.
3. Temporarily band the flat cable to the protector so that the pothead is just above the motor terminal cover. The numbers on the pothead should be facing out, otherwise it will not connect to the motor.
4. Remove the pothole cover and check the motor phase-to-phase resistance. Note : Resistances are additive when tandem motors are connected. The phase-to-ground motor resistance will be measured at the cable reel after the flat cable is connected to the motor.
5. Remove the shipping cap from the flat cable extension and the terminal cover from the motor head. Note : Ensure this area remains free of moisture and debris.
6. The O-ring on the pothead must be changed before the terminals can be connected.

12- Flat Cable Tie-In :

1. Using motor lead pliers and a small hammer, grip the motor lead marked A just below the terminal. Connect this lead to the corresponding pothead terminal. Note : Do not pull more than 2.5 inches of lead from the pothole when making this connection. Do not damage the insulation.
2. Using approximately three feet of Teflon® tape, start at the bottom and apply two half-lap layers of tape to the connection. Repeat this taping procedure for the other leads. Note : For motors with terminal voltages greater than 2500 V, three (four if space permits) half-wrap layers should be applied to each lead.
3. Bind the three leads together using two half-wrap layers of Teflon tape, and then two half-wrap layers of cotton linen tape .
4. Ensure the pothole is full of oil.
5. Carefully push the leads into the motor head. Ensure there is no foreign material between the flanges.
6. Tighten the pothead flange. To ensure a good connection, the pothead flange must be drawn down evenly, alternating from bolt-to-bolt a few threads at a time.

13- Power Cable Banding :

Inspect the condition of the rig equipment to ensure that it is in good working order. Tubing slips should be clean and sharp. The backups on the power tongs should be in good condition to prevent the tubing from rotating when making up a joint. Inspect the backup dies for buildup of paraffin that would allow the tubing to slip. Any questionable equipment should be reported to rig supervisor before proceeding with the installation.

Note :

Many power cables have been damaged because the backups were not turned over or slipped while making up the first joint.

The rig must be centered over the hole to provide adequate clearance for the cable and cable bands. This alignment should be checked periodically when running the equipment in the hole.

Instruct the person operating the automatic cable spooler to ensure the cable feeds off the reel at an even speed and tension. The practice of allowing the cable tension, as the unit is being lowered, to furnish spooling power should not be tolerated. The cable should always be spooled off the top of the reel.

Fifty-four inch (1.4 m) cable sheaves are recommended because larger cable sheaves reduce stress to the cable. Once the flat cable extension (FCE) splice is banded to the tubing, the cable sheave can be raised to its running height of not more than 30 ft (9 m) above the ground. It should be secured with its load sling and a safety sling attached to a separate support.

To avoid damage to the flat cable make sure that it does not pass over any of the lock plates on the equipment. Once the FCE (Flat Cable Extension) is installed ensure it does not pass over a lock plate on the equipment as this will increase the O.D. of the equipment or this will reduce the available clearance and possibly cause a premature failure.

Pneumatic banding is preferred to hand banding since tension applied to the band can be controlled with far greater precision. Bands must be placed so that the buckle is located on the right hand side of the cable in the void between the cable and the tubing. This will prevent the buckle from being pushed into the cable and damaging it when the band is being tightened. 

Cable bands should be tight enough to distort the armor but not crush it. If a band is loose, remove and replace it. When placing bands on the flat cable extensions, make sure the cable fits against the flat spots on the head and base of each piece of equipment. The flat cable extension splice must be a minimum of 5 ft (1.5 m) above the pump discharge head and not across a tubing collar. Bands must be installed above and below all splices to prevent any cable load from being transmitted to the splice.

Typically, two bands per tubing joint is the minimum requirement for supporting the power cable. One band should be placed 4 ft (1.2 m) above the tubing collar and one in the middle of the joint. Consideration should be given to installing several bands (10 per joint) to the first two joints. This practice provides additional cable support in the area of “tubing cut off” that may occur during a fishing operation.

14- Installation of Cable Protectolisers with Non-Pre-Engaged Fasteners :

The following procedure should be used to install Lasalle cable protectolisers :

Note :

Use a standard pneumatic installation kit for this procedure.

1. Undo the saddle clamp fastener at the top of the protectoliser to enable access for the cable.
2. Undo the protectoliser capscrew fastener using the impact wrench (supplied). This will allow the collar to be opened.
3. Move the protectoliser up to the pump component flange neck and position the cable in the slot.
4. Close the protectoliser around the pump component flange neck and engage the capscrew fastener by at least two to three full threads into the protectoliser body using the T-bar supplied with the installation kit. (If any resistance is met, then the capscrew fastener is crossthreaded. Any further tightening will result in the protectoliser threads being damaged and the protectoliser having to be replaced.)
5. Tighten the capscrew fastener using the impact wrench until the unit stalls (between five to eight seconds). Note : The collar/body capscrew fasteners are torqued to 30 lbf ft. The saddle clamp/body capscrew fasteners (if used) are torqued to 20 lbf ft.
6. The capscrew fastener torque applied using the impact wrench should be periodically confirmed using the torque wrench supplied with the installation kit.

15- Removal Of Cable Protectolisers With Non-Pre-Engaged Fasteners :

The following procedure should be used to remove Lasalle cable protectolisers :

Note :

Use a standard pneumatic installation kit for this removal procedure.

1. Ensure the hexagonal bit of the impact wrench is fully inserted into the capscrew head before activating the impact wrench.
2. Activate the impact wrench and fully remove the capscrew from the saddle clamp and remove the cable.
3. Activate the impact wrench and fully remove the capscrew from the protectoliser body.
4. Remove the cable protectoliser from the pump string.
5. Using the T-bar (provided in the installation kit), engage the capscrew fasteners by at least two to three full threads into the protectoliser body and saddle clamp. If any resistance is encountered, the capscrew fastener is crossthreaded and any further tightening will result in the protectoliser threads being damaged and the protectoliser having to be replaced.
6. Tighten the capscrew fasteners using the impact wrench (provide in the installation kit).
7. The protectoliser can now be stored for future use.

16- Installation of All-Cast Cable Protectors :

The following procedure is used to install Lasalle all-cast cable protectors :

Note :

Use a standard pneumatic installation kit for this procedure.

1. Disengage the protector collar locking mechanism using the impact wrench. This involves ensuring the capscrew fastener is fully retracted from the toggle mechanism. Rotate the toggle 90 degrees then remove the toggle from the locating lug of the protector body.
2. Move the protector up to the tubing ensuring the cables/control lines are correctly positioned in the appropriate slots.
3. Close the protector around the tubing ensuring the toggle is secured within the locating lug of the protector body.
4. Torque the capscrew fasteners to 30 lbf ft using the impact wrench from the installation kit until the unit stalls (between 5 to 8 seconds).

Note :

The capscrew fastener torque applied using the impact wrench should be periodically confirmed using the torque wrench supplied with the installation kit. The torque applied on the first 10 protectors should be confirmed followed by 10% of the remainder. A change of installation personnel should also initiate a confirmation of torque values.

17- Removal of All-Cast Cable Protectors :

The following procedure is used to remove Lasalle all-cast cable protectors :

Note :

Use a standard pneumatic installation kit for this removal procedure.

1. Ensure the hexagonal bit of the torque wrench or T-bar is fully inserted into the capscrew.
2. Release the tension of the fastener a few turns prior to fully unscrewing the fastener with the impact wrench.
3. Remove the cable protector from the tubing.
4. Using the T-bar engage the capscrew fastener into the protector body.
5. Fully tighten the capscrew fastener using the impact wrench from the installation kit.
6. The protector can now be stored for future use.

18- Lowering Equipment into the Well :

This practice will ensure that the motor is physically connected to the rest of the equipment. There is a tool available that will allow the complete string of equipment to be rotated.

Once the last pump assembled to the string the complete assembly should be rotated using the correct tool, while this is being done a rotation meter should be connected to the motor leads to determine that the motor is turning. This can also be used to determine phase rotation. If a rotation meter is not available a Fluke or Triplett may be used to detect the EMF.

When running the unit into the well, the rig operator must be aware of the cable at all times. Maintain a running speed of approximately 1000 ft/hr (305 m/hr) to allow the spooler to provide minimum cable tension. All stops and starts must be slow and smooth to prevent the tubing from bouncing. Bouncing will damage the cable and protector seals.

19- Check Valve :

A check valve may be installed at the pump discharge when installing a pump in a well where no gas problem exists. In gassy wells, the check valve should be installed one to six joints above the pump depending on the amount of gas.

This practice provides a compression chamber for the purpose of avoiding a gas lock in the pump.

20- Bleeder Valve :

The bleeder valve is installed one to two joints above the check valve. Be sure to check the bleeder plug for tightness.

21- Checking Cable :

Take cable readings approximately every 1000 ft (305 m). Phase-to-phase continuity tests should indicate a balanced reading that will increase as the cable is subjected to increased well temperatures. Phase-to-ground insulation tests should show a high megohm reading (greater than 1500 megohms) at the beginning and slowly drop off as the unit is lowered into the well. After the BOPs have been removed, a final cable check should be made to ensure the integrity of the power cable and motor.

22- Pump Setting Depth :

The pump setting depth should be calculated to ensure that the motor bottom is above the perforations. If the pump will be set in the perforated area, a motor shroud must be installed to provide adequate motor cooling.

23- Clearance Check Before Running in the Wellbore :

The field service technician should verify that the wellhead is full gauge and the blocks are centered over the wellbore. Often, the BOP stack will be installed prior to the technicians’ arrival at the wellsite, making visual verification difficult.

If this is the case, the following procedure should be used to confirm proper alignment and adequate clearance for the cable to pass through unobstructed :

1. After installing the initial joint of tubing, it should be pulled back up and inspected to ensure there is no evidence of the cable rubbing or damage to the cable bands. Any interference, rubbing or snagging of the bands, clamps or cable must be investigated and corrected before continuing run-in-hole operations.
2. Perform clearance checks at regular intervals during run-in-hole operations to confirm the rig has not settled or shifted or other clearance problems have not developed. These checks can prevent loss of the cable and downhole equipment in the well.
3. The practice of pulling-out-of-hole one or two tubing joints should be performed several times during run-in-hole operations. This will help identify any settling or shifting of the rig, or if conditions in the wellhead or BOP change.

24- Landing the Tubing Hanger :

The tubing hanger should be landed carefully to prevent cable damage. Because a tubing hanger is often offset, it should be landed with the cable facing in the same direction as it was pulled. This will provide a much easier task of pipe fitting the wellhead.