ESP Troubleshoot Guide

ESP Troubleshoot Guide 

Use the following table and charts to troubleshoot the common problems of the ESP :

1- ESP Troubleshoot Table :

2- Undercurrent Shutdown :

3- Overcurrent Shutdown :

Commissioning and Start up procedure for ESP

Commissioning and Start up procedure for ESP

Before Starting the ESP you must take theses Safety  precautions :

1- General electricity handling :

• Ensure that the equipment is installed in a secure and upright position in a properly ventilated location.
• Making sure equipment is clean, dust free, and dry from the inside as this can cause electrical failure.
• All plugs and cables that interface to any printed circuit boards, shall be checked at both ends as those connectors can become loose during shipping.
• All high current connections are to be checked for tightness as loose connections can develop arcing which in turn can cause damage to both the surface unit and the equipment that the surface unit is operating.
• The wiring shall be checked before energizing the equipment to ensure that the surface unit is wired correctly for the application.
• Do not work on energized electrical parts without adequate illumination.
• Do not work on energized electrical parts if there is an obstruction that prevents seeing your work area.
• Do not work on energized electrical parts if you must reach blindly into areas which may contain energized parts.
• Bare live parts shall be guarded against accidental contact by means of approved cabinets or other forms of approved enclosures except where the bare live parts are located in an enclosed area, which is accessible only to qualified persons.
• Never use a megger on the rig floor to check insulation integrity.
• Always discharge each winding internally into the megger after test, NEVER spark discharge the motor windings.
• Always stand to one side of the controller for system start up.
• Only approved PPE should be worn when working on the equipment. Its never a good practice to wear: metal hard hats, jewelry (rings, watches, necklaces, etc.), wire rim glasses (unless insulated or covered with proper safety glasses), large metal belt buckles, or clothing containing conductive material. Typically the Nomex coveralls should be worn when working on this type of equipment. These coveralls provide a margin of safety against electrical shock as well as arc burns.

2- Grounding Of Electrical Equipment :

• The act of providing a pre-determined safe path for stray electrical current
• A properly installed ground offers a low resistance path for electricity to flow to the ground system helping to prevent dangerous shocks.
• System grounding protects electrical components within the circuit from damage by excess voltage or line surges.
• The best earthing point (most commonly used) for all electrical surface equipment on a well site is the well casing.

3- Lock Out and Tag Out (LOTO) :

• Lock Out / Tag Out is the procedure that notifies and limits access to unauthorized personnel to the equipment. This is typically done with the gang locks and tags shown to the right. When all work is done the locks can be removed by the qualified personnel to allow the equipment to then be operated
• OSHA reports approximately 120 deaths and 10% of all serious industrial accidents annually are caused by unexpected start-up or release of stored energy

4- Electrical Surface Equipment Hazards :

• All field personnel must not power the switchboard until the entire operation manual is reviewed and understood
• Install the switchboard in a secure and upright position; a minimum distance of 50 feet from the well with a junction box in between is mandatory
• Once the switchboard is installed at the site it is necessary to check all wiring connections, a ‘tug and pull’ test will help locate any loose connections as well as all pre commissioning checks listed in the specific operations manual and Artificial Lift Field Service Manual
• Whenever replacing a blown fuse always install the same type and rated fuse that was originally supplied
• Course-trained personnel should be accompanied and mentored by experienced personnel until deemed competent to work unsupervised. At this point they will be considered qualified personnel and should be able to service the equipment without issue
• Qualified personnel should have their reference material on hand for troubleshooting and repair issues
• Field personnel must not work on energized switchboard unless necessary
• All field personnel must be fully aware of each component of the switchboard and its function and able to locate the high & low voltage parts of the panel
• With power applied to the switchboard, qualified field personnel should verify the incoming voltage at the main disconnect using the proper meter & PPE
• All switchboards must be grounded properly to reduce the risk of electrical shock and to reduce electrical noise
• Appropriate PPE must be used when verifying the 120 VAC control voltage on the PT secondary since a live  high voltage is present on  the near primary side
• With the switchboard switched off (vacuum contactor is open) and the main disconnect switch disengaged there is still hi-voltage present at the three phase input of the disconnect switch
• Field personnel must not rely on the current status of the stopped (tripped) switchboard since there is a good chance of auto restarting (if not locked out or manually switched off)
• Before commencing any troubleshooting / maintenance to the switchboard field personnel must switch off, lock out and tag out incoming power prior to working on equipment
• Verify with an appropriate voltage measuring device that all circuits do not have voltage applied to them . Failure to do so may result in severe injury or death to personnel and major damage to or destruction of equipment

ESP Power requirements :

1- Surface Voltage :
Which can be calculated using the rated voltage and amperage of the motor nameplate, the length and size of the power cable, by using the following equations and cable voltage drop chart :

2- Operating Current :

Calculate what the operating current might be based on the horsepower requirement of the pump at the initial operating frequency which could be determined by using the following equation :

3- Surface KVA :

From the required surface voltage, calculate Surface KVA. For installations that include a step-up transformer, the surface KVA can be determined from the following equation :

Example:

Determine the required surface voltage. Assume a motor rated at 890 V and 58A and 120 HP with 3600 ft of No. 4 AWG copper cable in a well and pump 90 HP Find the (Surface voltage), (operating current), (Required KVA).

Surface voltage :

      surface voltage required = motor nameplate voltage + cable voltage drop/1000 ft

      surface voltage required = 890 V + 104 V

      surface voltage required = 994 V

Operating current :

operating current = (pump HP) (nameplate current) / (motor HP).

operating current = (90) (58) /  (120)= 43.5A.

operating current = 43.5A

Surface KVA :

Surface KVA = (Required Surface Volts * Amps * 1.73) / 1000 

Surface KVA = (994* 58 * 1.73) / 1000

Surface KVA = 99.7

Transformer :

1- Transformer power specification check :

The transformer nameplate as shown below should be checked carefully, the KVA rating must be greater then the surface KVA, also voltage and current are compatible with surface voltage and operating current.

2-Setting the transformer taps :

Transformer should be properly tapped to provide the correct voltage which should be +/-10% of required Surface voltage, as the following example will show.

Example :

How should the transformer be adjusted to obtain a secondary voltage of 2450 Volts when the primary voltage is 480 Volts?

The secondary winding is connected "Wye", Switch No 1 should be set at position 2, and for the correct voltage switch No 2 should be set at position 4.

3- Commissioning Transformers :

• All bolted connections to be checked and tightened as per the Manufacturing of the transformer
• Tank and fittings should be inspected for damage or leaks
• Leaking bushings should be tightened prior to applying power to the transformer
• Tap settings should be recorded and measured voltages should be recorded
• Resistance measurements should be taken on both primary and Secondary windings Results should be recorded
• Windings should be tested with 1000 volts DC megger. Primary and secondary phases may all be joined together for measurement, readings should be recorded
• Remove backspin shunt if used. Readings are to be taken from Primary to Ground, Secondary to Ground, and Primary to Secondary
• Oil sample should be taken at customer’s request only
• Operating temperatures should be recorded during loaded operation
• All safety devices/shields should be replaced and secured

Junction box :

The junction box is used for connecting the power cable and venting gas (in case gas has migrated up the power cable) between the well and switchboard.

It should be in line with the switchboard if possible, and at a distance of approximately 15-25 feet from the well and should be wired as the figures.

Switchboard :

1- Components :

As the figure shown below all switch board components should be visual checked for physical damages from transportation and correctly adjusted.

2- Location Considerations :

Install the switchboard in an upright and secure position, and bolt it to a stable base, in a minimum of 50 feet from the well. Also avoid installation in areas of extreme vibration or heat, or near sources of electrical noise.

3- Cable Entry and power Wiring :

It is recommended that power and control cables enter at the bottom or on the left side of the enclosure as the figure shows input and output terminals on the switchboard.

4- Switchboard Commissioning :

• Once the switchboard is installed at the site it is necessary to check all wiring connections, including the grounding connection between the switchboard and earth ground. A ‘tug and pull’ test will help locate any loose connections.
• The PT settings must be verified against the drawing located on the inside door of the high-voltage compartment of the switchboard for the available PT taps.
• Ensure that the main disconnect, breaker CB-1, and breaker CB-2 are all OPEN.
• With the disconnect switch closed, the voltages on the PT secondary should be verified to be within the controller input range (0-120 volts AC).
• The CT burden module rating must be consistent with the motor Current rating in the , The ampere rating of the switchboard must not exceed the range of the CT burden module, and if only CT is used correct CT ratio should be determined using the equation; CT size = expected amps through switchboard X 1.6

Example :

Assume 59 A will pass through the switchboard.

59 A x 1.6 = 94 A

Choose a CT with the primary winding rating closest to 94 A. In this case a100:5 CT is appropriate. This ratio will keep the recording amp-meter pen in the middle of the chart during normal operating conditions.

• Verify the phase wiring is correct: Phase A (RED) on the left, Phase B(BLACK) in the center, and Phase C (BLUE) on the right. It is Important to ensure that the phase wiring is correct at the main disconnect, vacuum contactor, transformer primary inputs, transformer secondary inputs, wellhead junction box, and motor lead connections.
• With power applied to the switchboard, a qualified electrician should verify the incoming voltage at the main disconnect.
• Test all fuses and check for correct current handling.

Surface choke installation :

The surface choke should be installed and wired as shown below :

Start up procedure :

1- Motor start up :

• Perform a complete visual check of the cabinet
• Remove all wire insulation stripping, pieces of conductor, and debris from the bottom of the cabinet (ensure the cabinet is clear of all debris)
• Ensure all bolt torque requirements have been met
• Install all necessary shields and covers
• Conduct an electrical insulation resistance test to verify the switchboard wiring integrity. A 5 kV megohmmeter (megger) is recommended for this test
• Close the cabinet door and tighten the door handle.
• Ensure that all steps in the Switchboard/UniConn are done correctly with no problems.
• Verify that no alarms are active and/or latched and the unit is not locked out. If any of these conditions are active, unlock the unit, unlatch the active latched alarm(s) and clear all other active alarms by rectifying their cause(s).
• Install a pressure gauge on the wellhead and a choke (for controlling flow) in the flowline.
• Notify the wellsite personnel production department that the system is about to be started.
• Ensure all valves are in their correct operating position.
• Clear all personnel from the area and start the pump.
• Select HAND/AUTO operation mode, then press START. If the unit is locked out or any alarm is still latched, the START button will not appear in the display when HAND/AUTO mode is selected.
• The OVERLOAD and STALL alarms may temporarily display during startup, These alarms should clear within the alarm time delay and will not shut down the drive under normal circumstances
• Note the three-phase current measurements with an ammeter and adjust the UniConn readings if required.
• Observe the Start Amps value. If the STALL alarm is used, its set point must be set below the Start Amps value.
• Closely monitor the current to ensure the motor is not overloaded, and record the starting current and current readings every five minutes.

2- Pump rotation :

• Partially close the flow choke, until the tubing pressure is 200 to 300 psi (13.8 to 20.7 bar) greater than the open-choke operating pressure.
• Without adjusting the choke, shut down the motor and reverse the rotation by switching any two leads in the junction box. Observe electrical safety procedures before switching leads.
• Start the motor again and observe the tubing pressure at the wellhead. If the pressure exceeds the previously recorded pressure, then the pump is rotating in the correct direction. If the pressure does not exceed the previously observed pressure, the present rotation is backwards.

3- Final installation checks :

• Switchboard and junction box properly grounded.
• Recording ammeter drive wound and fitted with the correct chart.
• Ammeter pen is marking properly.
• Overload and underload properly calibrated.
• All alarms and trips are properly adjusted.
• Ensure that no-load and load voltages have been observed and noted on run report.
• Run report complete with all information.
• Name tags have been tied together and stored in a safe place inside the switchboard.
• Shipping caps properly assembled and stored under or close to switchboard. record the exact location of the caps on the run report.
• Purchase order number and field signatures obtained as required.
• No tools or instruments left on location.
• Legible copy of run report left in switchboard.
• Ensure all access covers and doors are closed on the switchboard, transformer and junction box.
• All trash disposed of properly.
• All work has been performed in a neat, professional manner.

ESP Selection, Deployment and Operation

ESP Selection, Deployment and Operation

1. ESP SELECTION :

Effective Electrical Submersible Pump (ESP) selection is the key to optimizing well production and increasing ESP run life.  Three main categories of factors that affect the selection process of ESP are : 

1. Well Conditions 
2. Field Conditions 
3. Field Challenges

1.1 WELL CONDITIONS :

Well Construction :
Main well parameters that must be taken into consideration while selecting ESP are : 

• Age of the well
• Casing size
• Tubing size
• Well integrity: - cement quality  - casing quality 
• Deviation
• Drilled depth
• Perforation intervals & depth and density

Work Over Events :
Proper Work Over (WO) preparation of the well is based on the following : 

• Current bottomhole conditions
• Detailed information about all previous / historical WO repairs - scraper, reamer, drift diameter and running depth
• Injection capacity test
• Pressure test

Production Characteristics :

Before sizing and selecting an ESP, it is recommended to review well production history and artificial lift methods used. If an ESP was used concentrate on : 

• Previous ESP type, parameters, setting depth
• Well production rate (liquid and oil)
• Well flowing bottomhole pressure (FBHP)
• Current watercut of the well 
• Gas / oil ratio 
• ESP failures root causes 

1. 2 FIELD CONDITIONS :

Each parameter that gives information about the field properties is very important as it represents reservoir and overall field characteristics and gives clearer picture of it. There are numerous parameters that are available nowadays  from  the  client  and  can  be  used  for ESP  sizing  and  designing.  Some  of  the  most  important parameters affecting pump performance will be enumerated in this manual. 

These can be divided into two groups :  

• Primary parameters  
• Secondary parameters

Both those groups are described below : 

Primary Parameters :

• Initial formation pressure
• Current formation pressure (build-up test results, bottomhole gauges)
• Current reservoir temperature
• Permeability (indirectly)
• Porosity (indirectly)
• Oil density
• Oil viscosity
• Productivity Index 
• Reservoir type 
• Oil bubble point pressure

Secondary Parameters : 

• Oil formation volume factor
• Gas oil ratio
• CO2, N2, H2, CO and H2S content
• Salinity
• Specific gravity
• Solids 
• Wax content

1.3 FIELD CHALLENGES : 
The most common field challenges are described below:

Well and Mechanical challenges : 

• Corrosion  (CO2,  H2S  content  information  should  be  studied  attentive  prior  to  design,  selection  and installation of ESP)
• Solids (solid build-up test information about particle mass per volume of fluid) 
• Power supply
• Tubing/casing quality 
• Tubing casing sizes 

Human Challenges :    

• Data collecting
• Improper design 
• Improper well preparation
• Improper installation
• Improper operation
• Improper commissioning 

2. ESP AND SURFACE EQUIPMENT STORAGE, TRANSPORTATION, 

MANIPULATION AND HANDLING :

2.1 ESP AND SURFACE EQUIPMENT STORAGE :

Equipment transportation and handling is another influencing factor in ESP deployment operation. 

Firstly, after ESP’s are manufactured, repaired and tested, they have to be stored in compliance with technical requirements of the Manufacturer and in accordance with safe operating procedures. 

Some of the technical requirements are as follows :  

• All sections must be sealed with shipping caps 
• Motors and protector must be filled with oil. The type of oil will depend on application and whether  conditions
• Pump sections must be filled with antifreeze
• Shelves or racks for equipment storage must have three points of support and must be equipped with placards/labels showing part number, type and model of the section(sections), equipment must not be bended (See Picture #1,#2 – Incorrect ESP Storage) 
• Motors and protectors’ must be stored in the warm warehouse during winter conditions. If there is no facility to keep the equipment in the warm warehouse all the time then 24 hours before installation, motor and protector must be moved into the warm space to be heated up 
• Cable must be stored on reels, safely secured from mechanical damage in the special storage place

SURFACE EQUIPMENT STORAGE :

• In certain countries such as Russia where extreme weather conditions are encountered, additional care and precaution must be taken while storing electrical equipment. It is strongly advised to store items not-in-use in a closed and protected environment.  
• If  electrical  goods  are  to  be  stored,  these  must  be  uncrated  and  stored  in  a ventilated  building  to reduce the accumulation of condensation in the VSD’s, SWB’s etc.  
• If any foreign particles, such as sand, are observed inside the unit, it is necessary to thoroughly clean the unit before putting into operation.  

2.2 EQUIPMENT TRANSPORTATION AND HANDLING

The nature of artificial lift equipment requires special handling procedures which are not commonly used when handling and transporting many other types of pumping systems.  

The most vulnerable parts of equipment while loading/unloading and transportation are : 

• Motor stator – can be bended, it is not acceptable 
• Radial bearings of pump sections 
• Seals of protector
• VSD’s, SWB’s, etc.- electrical components 

 See pictures #3,4 

To reduce the risk of equipment damage, it is necessary that : 

•  All items must be handled in a manner which minimizes shocks. In no case, should an item be allowed to drop
• Follow the instructions of ESP sections and cable strapping 
• The traffic intensity must be taken into consideration at all time as well as the road cover, and cargo special features, and transportation vehicle condition. 
• It is recommended to deliver the equipment to the wellsite directly before installation.  (For prevention of accidental damages of equipment while waiting installation) 
• To transport ESP’s and cables use specially constructed :

          - Shipping boxes

          - Transporting skids (See Draft #1,Picture#5); 

          - Wooden Boxes (Manufacturing packing) (See Picture#6); 

          - Fit for purpose transportation vehicle. 

Construction and principle of Transportation skid operation :

Transportation skid is a welded frame made of metal bended profile. ESP sections must be placed on transverse lath with rubber spacer inside of the frame and must be secured by clamping lath from the above. There are 4 strapping loops situated along the skid. There are some catchers in the upper part of the deck to make it stored within several layers available.

NOTE:
Fig.1 showing how to lift motor section

2.3 SURFACE EQUIPMENT STRAPPING REQUIREMENTS 

Strapping rules :

• Use only four-strops hook for surface equipment strapping (See Fig.2) 
• Hook must enter the loop opening smoothly (See Fig.3) 
• Load must be stropped with the help of all loops that are foreseed for lifting by the project 
• Strops must be loaded with the same tension and the angle between them must be less than 90 deg 
• Strops must be applied without any nodes and kinks

2.4 HANDLING ESP SECTIONS AT THE WELL SITE 

•  ESP unloading operations can be performed using hoisting device, which is located on the transporting vehicle or cathead only. 
• ESP section must be unload to the cleaned from oil and sand workover receiving catwalk; cable reel must be unload directly to the spooler.   
• ESP sections must be unload to the wooden spacers (not less than two units) placed on the receiving sledge – catwalk. 
• ESP sections and cable must be prevented from hitting while handling. 

3. ESP DEPLOYMENT AND START UP PROCEDURE 

3.1 PREPAIRING ESP FOR OPERATION

Individual serial number and type of unit shall be entered in installation report which shall ccompany an ESP at all phases from assembly to pulling and returning ESP for repair to Service center.  

Prior to shipment to a well site have to be checked :

• Electric motor and ESP cable shall be completely tested subject to effective check up program approved by manufacturer
• Protector shall be tested for free shaft rotation and proper seating in spline connection couplings, shaft spline end beat and shaft offset compliance with design drawings, pass hydraulic test, spin testing, including power consumption, vibration of all bearing long three coordinate axes, pumping out (to check tightness of threaded connections), checking the temperature of thrust bearing assembly
• Pump section shall be tested for free shaft rotation and proper seating in spline connection couplings, shaft spline end beat and shaft offset compliance with design  drawings, pass to test bench to etermine such characteristics as the head, pumping  capacity, power consumption, vibration and efficiency 
• DMT has to be tested for pressure, temperature test, vibration test and electrical test. 
• In winter operating sections of a pump shall be coated with frost-proof grease (industrial oil grade or spindle oil type)

3.2 ESP INSTALLATION TOOLS PREPARATION PRIOR TO ASSEMBLING

It is very important to be attentive while installation tools preparation. 

Tools or clamps choice always depends on planned to be assembled ESP type and series.  

As a back up it is always necessary to have the following while assembling :

• Spare couplings
• Plugs for protector fill valves
• Motor fill valves
• M&S (O-rings, lead gaskets, bolts) 

3.3 PREPARATION FOR INSTALLATION ON THE WELLSITE 

Preparation for installation on the wellsite :

• Check equipment delivered for installation.

NOTE :

Check Serial Numbers and equipment description of all ESP sections with those in request. 

3.4 ESP INSTALLATION  

ESP installation procedure is detailed in a previous post in this blog.

• All ESP assembling process must be done in accordance with the istallation prcoedures provided
• ESP Installation Checklist
• Installation Procedures For Drain and Fill Valves And Plugs 
• Proper O-Ring Installation on Motor Potheads

3.5 LOWERING ESP INTO THE WELL

3.6 ESP START UP PREPARATION 

4. ESP OPERATION 

4.1 ESP START UP AND PUTTING WELL INTO PRODUCTION 

1.  Start up procedure 
2. Determining Rotation 

4.2 SAFE OPERATION PROCEDURES 

Well start ups can be performed by specially trained and qualified personnel only. These personnel should have passed all required exams for working with electricity. 

Power  and  submersible  cables  connection/disconnection  works,  VSD  motor  service  and electrical measurements can be conducted by field service personnel who have appropriate training and certification. After measuring insulation resistance of the “cable-motor” system, the residual charge should be removed from every cable phase.Submersible cable connection must be done with switched off VSD. 

4.3 COMMISSIONING 

Practice recommendations :

•  While commissioning, it is advisable to consider if it is the first ESP after fracturing, ESP’s runlife and failure reasons for previous ESPs. If there were MLE melting, R=0 (cable or motor) so presumably the failure reason might be prolonged running without cooling or underload, i.e. running without flow rate. 
• If  ESP  is  not  equipped  with  DMT,  measure  well  dynamic  level  changes  every  15 min  in  case  if formation didn’t start producing; otherwise every 1 hour. Annulus pressure increase can be caused by indirect index of formation production, as it depends on dynamic level and is stipulated for the fluid degassing speed in the annulus.  
• All measurements like fluid level, pressure, current and frequency changes should be entered into the output  card.  If  previous  ESP  dismantling  showed  the  appearance of  mechanical  impurities  or  shaft section can’t rotate or move freely, then start up should be done with the minimum limited frequency of 37Hz. While doing this do not forget to control in accordance of the head characteristic with dynamic level; rise up frequency if needed (not more than for 1-2Hz). 
• Take  fluid  samples  to  identify  mechanical  impurities  build  up,  all  next  –  every other  day.  It  is undesirable to measure rate during first day of running to eliminate mechanical impurities inflow to gaging machine.  
• Recommended  commissioning  period  is  7  days.  This  period  will  allow  for mechanical  impurities flowback to decrease. 

The well can be determined as a stable if :

• Well dynamic level doesn’t change within an hour ± 50mins; 
• Well rate measurements fits pump head characteristic; 
• Flow rate is stable 

4.4 COMPLICATIONS DURING COMMISSIONING 

In case if VSD stops due to overloading (display shows “Overcurrent” sign) and cannot be started right after, next try to start must be not earlier than 30 min (if tubing check valve is leaking it is possible to have a backspin on the ESP).  

Flush method can be determined based on ESP or tubing check valve absence, circulation presence. Activate “Rocking start” regime, it will let accomplish of inching start up to free motor shaft or the pump. Set the value of kicks during start up, frequency for rocking start and rocking start method.  

During  start  up  VSD  motor  produces  kicks  with  direction  rotation  changing,  after several  kicks  it  tries  to accelerate  motor  to  the  operating  frequency  linearly.  Rocking start  methods  differs  by  character  and  kicks interchange. After 3-4 unsuccessful attempts to start up with direct rotation it is recommended to change initial rotation  direction  of  the  motor,  repeat  all  steps,  control  current  loadings  using display, “Bristol”  plotter deviations, measure with current tongs at the transformer output if needed. Period between start ups must be more than 15 minutes. Check insulation after several attempts to start up, so the equipment will be in safe mode.

 In case of ESP rocking start procedure don’t stop the VSD, change motor rotation direction (if the ESP turned on the reverse rotation), switch off the rocking start regime and let it run, controlling current loadings.  Motor operating current must stay limited under initial value.  

4.5 EXPLOITATION OF WELLS EQUIPPED WITH ESP’s WITH VARIABLE SPEED DRIVE (VSD) 

Exploitation of wells equipped with ESP’s with variable speed drive can gain in following :

• To make a decision about the further well production optimization beyond RIH with bigger ESP size (if running ESP on the maximum frequency doesn’t let to exploit full well potential). 
• To sustain work capacity of submersible equipment. 
• It  is  necessary  to  consider  the  possibility  of  submersible  equipment  parameters  changes  while frequency increases.   
• Maximum well rate achievement beyond optimizing submersible equipment work; (Russian customer’s requirements) 

Limiting factors when frequency rises up are :

• Submersible motor power capacity – motor power changes linearly after frequency was increased, at the same time power that is used by pump changes cubically; and then the moment comes when motor cannot produce power enough for pump (current increases and stop due to overcurrent occurs).
• Submersible equipment shaft strength – shaft loading increases when frequency rises up (as the head, productivity  and  shaft  receptivity  moment    change)  and  if  the  submersible motor  was  chosen  with  a  large power capacity the risk of shaft break may occur, especially when there a lot of mechanical impurities come out (shimming effect).
• Pump setting depth – pump head increases quadratic after frequency was increased and there is a risk occurs that the head can become more than PSD and it will lead to stop due to underload (pump will swap out all the fluid till  pump intake and will switch to idle regime).

Limiting factors when frequency lowers down are: 

• Pump head  - pump head decreases quadratic after frequency was lowered down  and the moment can occur when pump power (pump head) will not be enough to lift fluid column from dynamic level and rate will be  broken up, ESP will stop due to underload. 

To make a decision to increase the frequency the well some criteria must be estimated :

• Maximum estimated current loadings for surface equipment
• Maximum possible loadings for main switch in transformer substation
• Using submersible gauge placed on ESP relative fluid column over pump intake (submersion depth) can be calculated as per formula :

Where :

Pgauge – gauge pressure value at the pump intake, atm

Pannulus – annulus pressure, atm

Poil – oil density; kg/m3 

• if there is no submersible gauge on ESP relative fluid column over pump intake can be calculated as per formula:

Where 

Lri – PSD, m

Hdyn – well dynamic level, m

• solids content in pumping fluids at high frequencies must stay under :

          - for ARZ ESP - 500 ml/l

          - for ES ESP - 100 ml/l 

• ESP operating regime with considered current characteristics must be stable (no current shoves showing pump stuck or gas influx). 
• ESP current loadings level must stay under set limit for overcurrent. For that case it is necessary to optimize output voltage on step-up transformer (to select optimum voltage, when current value is minimum). Transformer voltage must be calculated  based on voltage necessary for the motor and voltage losses in the cable line relative to PSD and voltage drop down compensation in the net

There are some technological phases while well optimization :

• Frequency increase – ESP running due to specific program set to increase operating frequency
• Well stabilizing – temporary stopping of frequency increase when the definite frequency is achieved to make control  measurements  (rate  and  mechanical  impurities  must  be  measured  in  the  period  of  non-stop  well production from 6 to 12 hours)
• Stabilization - frequency increase stop at the definite level when ESP performance becomes worse or when mechanical impurities flow back to return parameters to normal range
• Optimal regime – regime when rate and frequency are optimal
• Deviation – operating frequency reduction because of protection devices kick-out, dramatically worsening of 
• ESP performance or volley mechanical impurities flowback

Frequency increase example: 

Normal frequency increase – increase program - 2Hz per day

Application criteria :

• stable ESP running regime (current loadings are flat)
• intake pressure is more than 40atm 

Careful frequency increase - increase program 1 – 1,5 Hz per day; 

Application criteria : 

• satisfactory ESP running regime (current loadings ripple do not lead to ESP stop due to underload or overload)
• intake pressure is more than 40atm 

Fast frequency increase - increase program 1 Hz per 20mins – 1HZ per 60mins; 

Application criteria :

• this regime is used when it is needed fast to return ESP to operating frequency after current or planned ESP stops during stable running regime before stop (current loadings are flat)

4.6 ACTIONS OF PERSONNEL WHEN ESP IS SHUTDOWN WHILE RUNNING 

Recommendations based on experience of several oilfields :

Power supply switch off (planned or emergency) : 

• start up at frequency reached before ( it is admitted to lower the frequency to 10 Hz value)
• to check and to correct underload protection if needed
• in compliance with results make a decision to continue frequency increase or not

Overload in power supply substation : 

• start up ESP at the low frequency (it is admitted to lower the frequency to 10 Hz value) to maintain stable running without switches off
• to check and to correct underload protection if needed 
• check the loadings on power supply, agree the switch replacement is needed

Underload ( switch off due to underload protection kick out) :

• analyze the reason of loading reduction (dynamic level decrease, tubing leakage, frozen surface line, not enough head, shaft break up, etc.)
• start up problems removal
• start up ESP;- to check and to correct underload protection if needed
• take preventive measures for the further stable ESP running and to continue frequency increase

Overload (switch off due to overload kick out) :

ESP stops due to current increase more than a set limit (stop due to overload) may occur due to the following : 

• high resistance to rotation in ESP pump (abrasive contamination, salt precipitation, etc.)
• not enough motor power or power supply power
• not optimal voltage selection on power supply transformer
• cable isolation damage

When ESP stops due to overload the personnel must :

• determine  time  and  operating  frequency  when  the  stop  occurred(  to  determine what  a  start  up frequency must be and what an operating frequency must be; after start up and frequency increase it is not recommended to increase previous ESP frequency for more than 2-3Hz till stability or overloading reasons removing)
• wait till fluid column is discharged from tubing (tubing dynamic level rises up, turbine ESP rotation stops)
• perform not more than 3 attempts to start up ESP at the frequency of 10Hz less  that achieved on manual regime on different regimes of rocking start with in-between start up periods not less than 30 mins (to cool down the engine) 
• measure insulation of “cable-motor” system; 
• if insulation is ok, start up ESP with at least one cistern of oil circulation after full drainage , creating excess pressure in annulus to ease ESP start up. Number of unsuccessful starts up must stay under 3 with in-between start up periods not less than 10 mins (to cool down the motor )
• if  ESP  startup  went  successfully  let  it  run  at the  start  frequency  to  stabilize  mechanical  impurities flowback (1-5 days), continue to increase frequency afterwards in “careful regime”. 

4.7 ESP PERFORMANCE CONTROL 

When operating ESP production shop shall 3 times a month check up operating parameters: dynamic level, production, buffer, linear and annulus pressures, insulation resistance, check valve function. Operating currency and voltage shall be checked up on a daily basis.  At low dynamic level (especially in winter when Sputniks do not provide measurements) it is obligatory to pressure test tubing with closed valve, register pressure build-up time and enter results in ESP passport.  

Under engineering supervision adjust VSD (make sure valve is closed) and enter corresponding information in ESP service passport  when operation mode is changed, and when dynamic level is close to the ESP rated head value. Water cut sampling shall be performed on a monthly basis and solid particles content and six-component test shall be provided when necessary. Acquired information shall be promptly entered in ESP passport. 

When necessary and in compliance with specific schedule a well shall undergo treatment jobs to eliminate wax scaling, salt and mechanical impurities followed by a corresponding entry in ESP passport. After long down time (exceeding 10 days) put well to production providing dynamic level measurement and stop monitoring ESP performance only after bringing well to stable production. 

To control ESP performance and to react in time for all changes in ESP runlife process it is recommended to regularly check active working wells (more than ones in tree month) and to measure all current parameters of ESPs. 

4.8 ESP FAILURE, PULLING AND DISMANTLE OPERATIONS 

4.9 EQUIPMENT RERUN  

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.