Professional Documents
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Chapter 10
Table of Content
1.0 Purpose 2
2.0 Post Failure 3
3.0 Pre-Pulled Requirements 3
4.0 Pulling the ESP 4
4.1 Critical Pull Observation 4
4.2 Disassembly of the ESP at well site 5
5.0 Dismantle, Inspection, & Failure
Analysis (Difa) 10
5.1 Preparation 10
5.2 Cable 11
5.3 Pumps 11
5.4 BOI/GS 16
5.5 Protector(s) 17
5.6 Motor(s) 21
5.7 Downhole Monitoring Device (Sensor) 26
6.0 Root Cause Analysis (RCA) 26
7.0 Difa Report Format 28
7.1 Cover 28
7.2 Table of Contents 29
7.3 Distribution 29
7.4 Well Information 29
7.5 Trend Analysis 29
7.6 ESP Identification information 30
7.7 Dismantle Inspection Findings 30
7.8 Summary of Results 30
7.9 Recommendations 30
7.10 Photograph Gallery 30
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Introduction
This document outlines the standard for
dismantle inspection and failure analysis (DIFA) of electric
submersible pumps (ESPs). The local engineering manager shall
authorize a DIFA for any pulled ESP equipment. The electric
submersible pump vendor is responsible for conducting and
producing the DIFA and DIFA report, respectively. However,
significant portions of the required data must be provided by
customer. Customer, and its affiliates, shall be a partner in
reviewing and approving the DIFA and DIFA report.
11.1. Purpose
The purpose of this standard is to determine the root cause
of an ESP failure. Identification of this root cause should
lead to operational and/or equipment modifications which
ultimately result in improved runlife performance. It is
imperative that the analysis commence prior to the pulling of
the failed equipment. It is equally important that the DIFA
recommended changes be implemented by customer, its affiliates
and the vendor. All too often, maximizing run life is not
accomplished because ESP failures are not properly identified.
Many factors must be investigated and documented to determine
the ultimate cause of failure. The first flaw discovered in
the failure of an ESP system is often times given full
responsibility for the failure. This identified method of
analysis can result in a much shorter average run life in a
given well and/or field. Maximizing run life of ESP's can be
accomplished through proper analysis of failure modes and
investigating all aspects of the ESP system. This process can
take many hours and/or weeks, particularly if the field is
being analyzed for the first time. It is important to note
that when investigating a single failure, one must also take
into account the entire field operation and procedures along
with the complete history of ESP performance in that field.
Customer personnel shall be responsible for the administration
of this standard in the respective business units. Each
manufacturer shall have a specific DIFA Procedure that
meets, or exceeds, the requirements as outlined in this
standard. Any variation from this standard must be approved by
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Balance Ring
Vane
Ring Groove
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o Check for any signs of heat that would result from spinning
diffusers.
Shaft Settings & Inspection
o Check the shaft for ease of rotation (typical nomenclature
is: free, rough, hard or stuck).
o Confirm the shaft is rotating at the opposite end of the
pump.
o Take the appropriate head and base measurement for the
shaft settings. Compare these to the manufacturers factory
settings.
o Push the shaft to the down position and take measurements;
repeat in the up position. This will determine the shafts
axial movement. Compare to the manufacturers factory
settings.
o If applicable attach a dial indicator on the inside of the
shaft spline, or on a coupling, to measure run-out when the
shaft is rotated. Repeat this procedure on either-end of
the pump. Compare to the manufacturers factory settings.
Head & Base Inspection
o Remove the head and inspect the bushing for wear, plugging,
corrosion, erosion. Inspect the condition of the threads on
the head.
o If the pump has a threaded bearing support, measure the
distance from the end of the housing to the top of the
bearing support to determine the gap between the head and
support.
o Inspect the bearing support for wear with particular
attention to corrosion and erosion.
o If it is a compression type pump remove the compression per
the manufacturers instructions. Thereafter, remove the
base and complete a similar inspection as was conducted on
the pump head.
o Pull/push the impeller and diffuser stack from the housing.
Note: insure that the snap rings and 2-piece rings are in
place (consult with the manufacturer for each pumps
specific design).
o Note on the dismantle report if the impeller and diffuser
stack are difficult to pull from the housing.
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O-rings
o Check all o-rings for damage such as extrusion, feathering,
explosive decompression, compression set, etc. Observe for
any signs of leak past the o-ring.
o Give particular attention to any o-rings on the OD of the
diffuser. Observe the o-ring for swelling and hardness (due
to heat, etc).
Impeller & Diffuser, Bearing Sections Inspection
o Wipe off the OD of the diffuser stack and number the stages
from bottom (stage #1) to top (stage #X).
o Remove the stages and shaft from the housing. Slide all
stages off the shaft with sleeves and spacers.
o Note any diffusers that show signs of spinning on the
exterior.
o Inspect the o-rings that are in the pump stages (diffuser
OD).
o Inspect all impellers for any signs of thrust, abrasive
wear and/or radial wear. Give particular attention to the
pads, bores and hubs. Check for one-sided wear.
o Observe all components for discoloration that would
indicate wellbore fluid damage or possible heat damage.
o Randomly remove some of the thrust washers and check for
thickness and brittleness. Note the type of thrust washers
and compare with a new thrust washer. Confirm the same type
of thrust washers were used throughout the pump.
o If any foreign material is found in the pump, collect a
sample for further analysis and testing. Label on the
collection bag the location of the material.
o With the pump components laid out from base to head, take
key measurements in the top five stages, middle five stages
and bottom five stages. All wear surfaces should be
measured (e.g. skirts, bores, hubs, sleeves, bushings
etc.). This information will be used later to plot a trend
analysis. Note, the manufacturers dimensions and
tolerances of all components will be required. The
manufacturer should supply this information in advance or
at the time of the dismantle.
o Inspect the bushings and sleeves between the stages for
wear, cracks or abrasive indications. Note the material
type of the bushings and sleeves and the spacing of any
abrasion resistant (AR) bearings.
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Intake Screen
o Observe condition of intake screen, noting presence of
foreign materials or screen collapse. Note if an intake
screen was not present. If the intake screen is not present
was it noted on the installation report?
5.5. Protector(s)/Seal(s)
The following provides the minimum requirements for
dismantling the protector/seal section(s) of an ESP. Required
reference documents, or information from vendor:
Manufacturers specific dismantle procedure for the
appropriate protector/seal to be dismantled.
Shaft settings & dimensions, tolerances
Head & base bushing dimensions and tolerances
Specification for bag material hardness (Shore A)
Seal Test Report (new)
Reference vendor documents for testing bag type and labyrinth
protectors/seals.
Standard for testing dielectric breakdown of insulating
liquids. (Reference ASTM D-877-Standard Test Methods for
Dielectric Breakdown Voltage for Insulation Liquids using
disk electrodes).
Protector/Seal Dismantle (while is it necessary to follow the
dismantle guidelines of the specific manufacturer, it is
imperative that the following items be inspected, at a
minimum. Compare the two documents to insure that all of the
following steps are met.)
Verify the protector/seal serial number on the nameplate.
Inspect the condition of the protector/seal housing
o Check for scale buildup, collect samples if present.
o Inspect the housing for corrosion and/or holes in the
housing.
o Check for mechanical damage (dents, vibration from the
cable, scratching and bends).
o Visually inspect the housing for straightness.
o If the protector/seal has a flame spray corrosion coating,
visually inspect the coating and note any areas where the
coating is not intact.
o Inspect the vent holes for plugging or debris.
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o Visually inspect the drain and fill valve locations for any
extruded lead gaskets.
Coupling(s)
o Inspect the coupling closely with a flashlight.
o Look for any stress damage in the splines.
o If debris is found, collect a sample.
Perform a housing leak test at the various vent ports (this
will be manufacturer specific; refer to the appropriate
manufacturer for the exact locations and pressure sequence).
The goal of this step is to test each housing connection
point to verify integrity. Use soapy water to inspect for
leaks. Give particular attention to lock plates and/or joint
welds (if utilized).
Cut lock plates/joint welds if required.
Disassembly of the protector/seal (Note: it is imperative to
refer to the specific manufacturer guidelines for
protector/seal disassembly. Each protector/seal type will
vary depending on the manufacturer and type of protector/seal
utilized.)
o Check the shaft for ease of rotation (typical nomenclature
is: free, rough, hard or stuck).
o Confirm the shaft is rotating at the opposite end of the
protector/seal.
o Push the shaft to the down position and take measurements;
repeat in the up position. This will determine the shafts
axial movement. Compare to the manufacturers factory
settings.
o Attach a dial indicator on the inside of the shaft spline,
or on a coupling, to measure run-out when the shaft is
rotated. Repeat this procedure on either-end of the unit.
Compare to the manufacturers factory settings.
o The protector/seal is to be positioned at a minimum 45
degree angle to insure the mechanical seal is covered with
oil.
o Starting at the head of the protector/seal, apply 5 psi of
air pressure through the appropriate vent hole and rotate
the shaft in both directions. If no bubbles are observed,
the mechanical seal is good. Air pressure is to be applied
for minimum of (2) minutes
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and submerse the bag frame into water and look for air
bubbles.
o Locate the markings on the bag and identify the material
(the manufacturer may utilize a specific code). Check the
bag for splits, bubbles, evidence of decompression, etc.
o Where applicable, remove the bag from the guide/frame and
inspect for well fluid or other foreign material. If any
foreign material is found, collect a sample for further
evaluation. Once again, collect fluid samples from inside
the bag and identify appropriately. Additionally, collect a
sample of the bag material and place in a plastic bag for
possible future laboratory examination.
Thrust Bearing Inspection
o Remove the thrust bearing from the thrust chamber per the
manufacturers recommended procedure.
o Inspect the base bushing for any wear such as scoring, one-
side wear or galling.
o Inspect the thrust bearings and both sides of the runner
for any signs of operating in water, up thrust, down
thrust, uneven wear, deflected thrust runner, scoring,
excessive heat, fretting, etc.
o Fretting (or fretting corrosion) - The ASM Handbook on
Fatigue and Fracture defines fretting as: "A special wear
process that occurs at the contact area between two
materials under load and subject to minute relative motion
by vibration or some other force."
Head & Base Bushing & Shaft Inspection
o For the head and base locations, examine for bushing wear,
scoring, leak tracks, oring groove condition and
internal/external corrosion.
o Examine the shaft at the bushing and seal surfaces and note
any unusual wear (e.g. one-sided), scoring, etc.
o Visually inspect the shaft spline on both ends. Observe the
splines for straightness and coupling engagement. If a
coupling is only partially engaged damage may be noted with
damage at the upper end of the spline.
o Observe the shaft for any frosting that may occur.
Frosting is defined as the transfer of base bushing
material on to the motor shaft.
o Place the shaft on a bench and observe the shaft for
straightness or twisting.
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Evidence Gathering
o While this recommended practice is concerned primarily with
analysis of evidence, it should be understood that evidence
gathering itself, is an essential part of a quality
investigation. The people who gather evidence must
understand what evidence should be gathered and how to
gather that evidence. They must be able to interpret the
information, and they must have the ability to accurately
convey that information. Anyone designated to gather
evidence should have received proper training or be under
the direct supervision of someone who has been so trained.
Root Cause Analysis Determination
o As stated earlier in this section, a Root Cause Analysis
shall identify the physical, human and latent cause(s), of
the undesired event or issue. If the physical, human and
latent cause(s) are not identified and corrected, then the
undesired event or issue may repeat if the same cause
triggers similar undesired events or issues in the same or
other equipment, systems, processes, etc.
o Undesired events begin with a physical cause. For example,
the shaft broke (undesired event) because it failed in
fatigue as a result of rotating bending stresses (physical
cause). This is where many investigations stop. The root
cause analysis shall not stop at this point. Identification
of the true physical cause is not a mere formality - it is
critical that the physical cause is accurately determined.
Going further to identify human and latent causes for an
incorrectly identified physical cause will not necessarily
prevent recurrence.
o People do things, or dont do things, that enable or
trigger physical causes, and these are the human causes;
for example, the mechanic misaligned the motor and the
pump. In the case of human error, there are only two
categories: 1) knew, but didnt do, or 2) didnt know, and
therefore couldnt do.
The Why Analysis
o The Why Analysis is conducted by repeatedly asking the
question "Why". Using this technique you can peel away the
layers of symptoms which can lead to the root cause of a
problem. Very often the apparent reason for a problem will
lead you to another question. To complete the why analysis
ask Why? the immediate cause occurred and write that
answer down. If the answer doesn't identify the root cause
of the problem, ask Why? again and write that answer
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Pump Photographs
Coating flaking
Drag Marks
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Scoring
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Spinning Diffuses
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Upthrust on Impeller
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Broken Hub
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Severe downthrust
Severe upthrust
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Severe Erosion
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Broken Inducer
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Hole in GS (Corrosion)
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Water in a Seal/Protector
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Shaft Break often a shaft break will occur at, or near, the
spline area of the shaft as this is the weakest area.
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Motor Photographs
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Blowout of Pothead
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Failure in protector(s)/seal(s)
Rotor Strike
Rotor Strike
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