ESP Failure Analysis Reliability for Step Change ImprovementEuALF 202 - PDF document

1 ESP Failure Analysis & Reliability for S
ESP Failure Analysis & Reliability for Step Change ImprovementEuALF 2020 (2021)Jeff DwigginsArtificial Lift Solutions Pte Ltd Outline This presentation will briefly discuss Failure Analysis and Reliability to implement step change improvement The

2 “Genesis” of this TopicPetrole
“Genesis” of this TopicPetroleum Development Oman (PDO) Words of Wisdom The ESP IndustryThe ESP industry is littered with failures that are repetitiveMany (maybe even most) are avoidablereputation“highvolume” but not always reli

3 ableSomeoperatorswillsacrificeproduction
ableSomeoperatorswillsacrificeproduction because of this reputationSo where do we do things go wrong? Life CycleMostpeoplehaveseenthiscyclecirclebefore.You are participating willingly, or unwillingly A Few Common MisconceptionsAll ESPs are the same

4 Top quality will be deliveredFailure ana
Top quality will be deliveredFailure analysis will be objective and without biasShort cuts will not be taken Common Deficiencies Often, operators fail to recognize the value of focused attention on ESP quality and reliability. Often, focus only oc

5 curs after a failure(s).Operators do not
curs after a failure(s).Operators do not possess the inhouse skill setFailuretofollowproper/established protocolsFailuretofollowprotocolsleadstolossinformationthereforetheabilitytoimprovWhen someone is the “designated” ESP person, they ma

6 y not be qualified in all areas of the l
y not be qualified in all areas of the life cycle E.g.; may understand ESP applications, but are not qualified as manufacturing and reliability expertAssume that the goals are aligned between operator and supplier Common Deficiencies The nuances, o

7 r differences, between suppliers can be
r differences, between suppliers can be significantThird party supplied items often are overlookedRepeated failures (don’t learn from a previous mistake)Inability to have an overview of strengths and weakness between suppliers/equipment Exampl

8 es of Repeat FailureMotor Leads Problem
es of Repeat FailureMotor Leads Problem Shaft Fretting Examples of Repeat FailureSpinning Diffusers Scaling Examples of Repeat FailuresCollapsed Diffuser Cracked Carbide Bearings OptionsGet betterAccept the cost of failureMove to another AL type an

9 d absorb the cost of that decision Failu
d absorb the cost of that decision Failure Analysis Methodology DIFA flow diagramDIFA Flow Diagram Overview ESP Design & SelectionESP Manufacturing ESP Shipment & HandlingESP InstallationESP StartUp ESP Operation ESP Pull ESP Return to Service Cent

10 re ESP Preparation for DIFA DIFA DIFA Fu
re ESP Preparation for DIFA DIFA DIFA Full or Partial?Full Partial SME/Supplier SME Prepare DIFA Package Review Document Package in Advance SME/Supplier SME Prepare DIFA Package DIFA flow diagram Motor Inspect Motor for straightness FLOP Test Visua

11 lly inspect all D/F Valve & Plug Locatio
lly inspect all D/F Valve & Plug LocationsPressure Test with MLE PotheadElectrical Readings with MLE PotheadElectrical Readings without MLE Pothead Remove Rotor StringNumber Rotors & Visual inspection of Rotor StringVisual inspection of Stators, En

12 d CoilsCollect Fluid Samples from Motor
d CoilsCollect Fluid Samples from Motor Remove Rotors & Rotors Bearing from ShaftConfirm Oil Circulation Holes & Rotor Bearing Sleeves AlignIdentify Samples for Future ReviewObserve Rotor Bearing Spacing & Anti Rotation Pins Inspect Thrust Bearing

13 and Runner MOTOR DIFA FLOW CHART Remove
and Runner MOTOR DIFA FLOW CHART Remove Head/BaseInspect for WearCheck Shaft settings & RotationRemove Thrust Bearing & RunnerVisual Inspection of Bushing Areas on ShaftInspect Shaft Bushing locations, Shaft Splines DIFA flow diagramSEAL DIFA FLOW

14 CHART Seal Protector Proseal Equalizer V
CHART Seal Protector Proseal Equalizer Visual InspectionObserve for any Damage and Temperature at Thrust ChamberPressure TestCheck Shaft Rotation and SettingsDisconnect Tandem Seals (if applicable)Determine Seal to be disassemble? Visually inspect

15 all D/F valve locationRemove Mechanical
all D/F valve locationRemove Mechanical Seal and HeadRemove Upper HousingRetain Fluid Sample from Upper ChamberPressure Test Upper Mechanical Seal and confirm integrity Pressure Test Upper Mechanical Seal and confirm integrity, if applicableRemove

16 Next HousingRetain Fluid Sample from Cha
Next HousingRetain Fluid Sample from ChamberRepeat Process as Required to Thrust Chamber SectionRemove Mechanical Seal (if applicable) and Guide Remove Housing from Thrust Chamber; Collect Fluid SampleVisually inspect Upthrust Bearing, Runner & Dow

17 nthrust Bearing Remove Thrust Bearing Re
nthrust Bearing Remove Thrust Bearing Retainer & Upthrust BearingRemove Shaft, Runner & Downthrust Bearing, Disassemble Yes Inspect Shaft Bushing Locations, Shaft Spline DIFA flow diagramPUMP DIFA FLOW CHART Pump (s) Visual Inspection for Spinner D

18 iffusersCheck Shaft Play and Rotation Ch
iffusersCheck Shaft Play and Rotation Check for straightnessRemove Head & BaseDetermine which Pump to Disassemble first? Pull Pump Stack from HousingNumber Stages, Remove from ShaftInspect Stages for WearComplete Visual Inspection for Spinning Diff

19 users, indications of High Heat Examine
users, indications of High Heat Examine Shaft Bushing, Bearing Locations. Inspect SplinesCollect Samples (if applicable); Analyse Select 3 Stages ( One each from Head, Middle, Base) & measure wear surfacesInspect O Ring, Heat & Erosion TechnologyTh

20 eDIFAprocessremainsmanpowerintensive in
eDIFAprocessremainsmanpowerintensive in the majority of caseseffortunderwaydigitize thisdatautilize technology“DIFA”beingutilized NomenclatureTheretendencyconfuse, or complicate, our efforts based upon nomenclatureOurdescriptions can be s

21 ubjective (I.e., moderate versus heavy,
ubjective (I.e., moderate versus heavy, etc.)11S1(currentlydevelopment) will give guidance on nomenclature, etc. For Example ClosinConducting failure analysis requires focused attention from “someone” PDO’s effort is the best example

22 of focused improvementDetailed and repe
of focused improvementDetailed and repeatable methods should be appliedSuppliersOperatorsalways share the same goalsProper training and utilization of technology is imperative. Proper focus on all aspects of the life cycle should produce improveme