1、Recommended Practice for the Operation, Maintenance and Troubleshooting of Electric Submersible Pump InstallationsAPI RECOMMENDED PRACTICE 11STHIRD EDITION, NOVEMBER 1994REAFFIRMED, OCTOBER 2013Recommended Practice for the Operation, Maintenance and Troubleshooting of Electric Submersible Pump Insta
2、llationsUpstream SegmentAPI RECOMMENDED PRACTICE 11STHIRD EDITION, NOVEMBER 1994REAFFIRMED, OCTOBER 2013API RP*LLS 94 W 0732290 0539049 297 m SPECIAL NOTES API publications necessarily address problems of a general nature. With respect to par- ticular circumstances, local, state, and federal laws an
3、d regulations should be reviewed. API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or
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8、, Washington, D.C. 20005. This document was produced under API standardization procedures that ensure appro- priate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or comments an
9、d questions concerning the procedures under which this standard was devel- oped should be directed in writing to the director of the Exploration and Production Depart- ment, American Petroleum Institute, 700 North Pearl, Suite 1840, Dallas, Texas 75201. Requests for permission to reproduce or transl
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12、ndards are published to facilitate the broad availability of proven, sound engineer- ing and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication
13、of API standards is not intended in any way to inhibit anyone from using any other practices. Any manufacturer marking equipment or materials in conformance with the marking re- quirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. A
14、PI does not represent, warrant, or guarantee that such prod- ucts do in fact conform to the applicable API standard. Copyright O 1994 American Petroleum Institute CONTENTS SCOPE . OPERATION . 2.1 Checks Before Start-up . 2.2 System Start-up . 2.3 Adjustments After Well Stabilization 2.4 Operating Da
15、ta Gathering 2.5 Analyzing Operating Data . TROUBLESHOOTING . 3.1 Historical Operating Information for the Producing Area . 3.2 Ammeter Chart Analysis 3.3 Basic Problem Troubleshooting . MAINTENANCE . 4.1 Preventative Maintenance with Well Down and with Primary Power Disconnected . 4.3 Equipment and
16、 System Maintenance . 4.2 Preventative Maintenance Checks with System Operating Figures l-well Equipment . 2-Production Test Data Sheet 3 . 4 . 5 . 6 . 7 . 8 . 9 . 10 . 11 . 12 . 13 . 14 . 15 . 16 . 17 . Page 1 1 1 1 2 2 2 2 2 3 10 15 15 15 15 1 3 4 4 4 5 5 6 6 6 7 7 8 8 8 9 9 API RP*33S 94 m 073229
17、0 0539053 945 W FOREWORD This recommended practice (RF) is under the jurisdiction of the American Petroleum In- stitute (API) Committee on Standardization of Production Equipment. This document presents recommended practices for the operation, maintenance, and troubleshooting of electric submersible
18、 pumps and auxiliary equipment. This recommended practice is provided to meet the need for guidelines, procedures, and recommendations cov- ering electric submersible pumping equipment. These recommended practices are those generally considered necessary for successful submersible pump operation. Th
19、is standard shall become effective on the date printed on the cover but may be used voluntarily from the date of distribution. v API RP*llS 94 0732290 0539052 881 Recommended Practice for the Operation, Maintenance and Troubleshooting of Electric Submersible Pump Installations 1 Scope This recommend
20、ed practice covers all of the major components that comprise a standard electric submersible pumping system, their operation, maintenance, and trou- bleshooting. It is specifically prepared for installations in oil and water producing wells where the equipment is installed on tubing. It is not prepa
21、red for equipment selection or application. 2 Operation 2.1 CH.ECKS BEFORE START-UP 2.1.1 Make certain that the flowline hookup is completed, that all valves are of proper pressure ratings and are properly installed, including an adjustable tubing choke. All valves should be in their proper operatin
22、g position (open or closed, as appropriate). WARNING: A master or wing valve on the tubing could be exposed to the maximum discharge pressure of the pump when the fluid in the annulus is at the surface. Therefore, these valves must be able to withstand this pressure. 2.1.2 Check no-load voltage, pot
23、ential, and current trans- formers for proper ratios, and adjust the underload and over- load relays to proper setting for start-up according to the manufacturers or users specifications. Check to see that all the power fuses are sized properly for the downhole equip- ment. 2.1.3 Assure that other s
24、ystem relays and controls are in proper adjustment or position, and electrical connections are clean and tight. The system must be properly grounded and the junction box properly installed, including a cable vapor seal between the junction box and motor control panel. 2.1.4 Make certain that the pro
25、per scale ammeter chart pa- per is on the recorder, that the pen is operating properly and that the setting for the day and time are correct. 2.1.5 The control panel should contain a label or “Pull/Run Report” that gives “nameplate” information perti- nent to the present equipment in the well. See F
26、igure 1 for an example form that gives the data required. 2.1.6 Electrical checks, phase-to-ground, and phase-to- phase, should be made prior to start-up and readings recorded. Phase-to-phase readings must be balanced. 2.1.7 If scale. or corrosion is a well problem, the preventa- tive measures must
27、be initiated before pump start-up. For further discussion of this matter, see 4.3. 2.2 SYSTEM START-UP 1 2.2.1 If the well has been killed with heavy mud it should be displaced with a light fluid before pump start-up. 2.2.2 For larger horsepower units (above 250 HP) regard- less of setting depth and
28、 low capacity units (less than 600 barreldday) set deep (with static fluid level below 7,000 feet), it is recommended that the tubing be filled before start- up. This means these installations must be equipped with tubing check valves and drain valves. The tubing should be filled with light, clean f
29、luid. 2.2.3 With all checks completed, start the equipment. For control of the pump discharge rate, the pump can be started against a restricted choke setting, but, should not be started against a closed choke or valve. For immediate control of the pump discharge rate, a tubing check valve and drain
30、 valve could be installed and the tubing filled prior to start-up. 2.2.4 Immediately after start-up, check the line current with a “clamp-on” ammeter and record. Using this informa- tion, calibrate the recording ammeter. 2.2.5 Check the load voltage and record. Exercise extreme caution when doing th
31、is. 2.2.6 Rotation should be verified as soon after start-up as possible by using either “pump up” time, wellhead tubing discharge pressure and flow, production test, or other appro- priate method as recommended by the pump company or op- erating company procedures. If sand or debris is present in t
32、he well, it is recommended that the pump not be shut down for rotational check until solids have been displaced from the tubing. 2.2.7 If actual “pump up” time is exceeding calculated “pump up” time, it should be assumed that the pump is in re- verse rotation and appropriate action taken. MOTOR DATA
33、: IN!jTALLED: -H.? VOLTAGE-N.P. AMPS PUMP DATA: INSTALLED: -TY# - STAOES TYPE INTAKE PUMP DESIGN CAPACITY B/D CABLE DATA: TYPE-LENGTH-SIZE TRANSFORMER DATA: TAP SETTINGS VOLTAGE RANGE VOLTAGE DATA : SECONDARY VOLTAGE NO LOAD LOAD WLTKE COMMENTS: I Figure 1-Well Equipment 2 API RECOMMENDED PRACTICE 1
34、 1 S 2.3 ADJUSTMENTS AFTER WELL STABILIZATION 2.3.1 After motor current stabilizes, the overload, under- load and the restart timer should be reset for proper “normal running” condition as specified by manufacturers or users specifications. 2.3.2 Overload setting is normally set at 120 percent of mo
35、tor nameplate amperage. 2.3.3 Underload setting is generally set at 80 percent of normal motor operating amperage. Gassy wells may require even a lower underload setting, but caution should be exer- cised to insure underload protection for pump off or gas lock conditions. 2.3.4 The restart timer is
36、normally set at 10 minutes per 1000 feet of operating fluid level depth, however, not less than 30 minutes. Note: Never restart pump by hand before recommended time lapse. 2.3.5 If an adjustable underload time delay control relay is provided in the motor control panel, it is normally set at 20 secon
37、ds. Local well operating conditions may require a dif- ferent setting. 2.4 OPERATING DATA GATHERING 2.4.1 Accurate operating data: a. Is required to monitor the system under normal operating conditions. b. Will provide information that will be useful in trou- bleshooting the well under abnormal oper
38、ating conditions. c. Will be useful in accurate resizing of the equipment, if required. d. Should be filed individually by well, and should always include: 1. Start-up ammeter chart 2. Well test data sheets with corresponding ammeter chart attached 3. Current regular ammeter chart 4. Any other perti
39、nent system and well operating data. 2.4.2 Frequency of data gathering: a. When well is initially put on production, data should be collected daily for first week, weekly for first month, and at least monthly thereafter. 2.4.3 Production well test data that should be taken and entered on a Productio
40、n Test Data Sheet similar to Figure 2 includes: a. Date, time and duration of test b. Oil, water and gas (both tubing and casing gas) c. Tubing pressure and choke size d. Fluid level, flowline pressure, casing pressure, and choke size. e. Operating bottomhole pressure (BHP) f. Ammeter chart (24-hour
41、) properly marked with date and time of test g. Other data as shown on Production Test Data Sheet (Fig- ure 2). 2.5 ANALYZING OPERATING DATA 2.5.1 Analysis of operating data must consider both per- manent well installation data (i.e., tubing size and length, casing size, perforation depth, fluid cha
42、racteristics, etc.) as well as production test data. 2.5.2 Once the pump is in the well and operating, it should be analyzed to determine if it is functioning properly. (The importance of collecting operating data was covered in Sec- tion 2.4.) This data should be analyzed as follows: a. Date, Time
43、and Duration of Test 1. Recording the date, time, and duration of the testing period, along with any other events occurring in the field, allows correlation of the events with the test ammeter chart. Examples of field events that may be important to data analysis are: nearby injection or producing w
44、ells down, large electrical equipment coming on-line, etc. l. The fluid volumes being produced through the tubing should be used to determine if the pumping is properly sized and operating at maximum efficiency. 2. The water-oil ratio should also be analyzed to deter- mine if any changes are occurri
45、ng. c. Tubing Pressure and Choke Size l. This data is used to check pump sizing and efficiency. d. Fluid Level, Casing Pressure and Choke Size 1. This data should be used to determine pump efficiency and well inflow performance (IPR or PI). 1. Used to verify PI of well and in conjunction with the fl
46、uid level it can be used to determine average annulus fluid density. 1. The ammeter chart is an extremely important data source for monitoring well operation and for trou- bleshooting. The ammeter chart should be observed daily to insure proper operation. 2. Use a 24-hour chart during production tes
47、ting or dur- ing periods of troubleshooting and use 7-day charts dur- ing normal weekly operation. g. Other Data as Shown on Production Test Data Sheet (Fig- ure 2). b. Oil, Water and Gas (both tubing and casing gas) e. Operating Bottomhole Pressure f. Ammeter Chart (24-hour, properly marked) 3 Trou
48、bleshooting 3.1 Historical Operating Information for the Producing Area RECOMMENDED PRACTICE FOR THE OPERATION, MAINTENANCE AND TROUBLESHOOTING OF ELECTRIC SUBMERSIBLE PUMP NSTALIATIONS 3 3.1.1 General operating parameters and limitations that 3.2 AMMETER CHART ANALYSIS have been found to be true hi
49、storically in the operating area should be considered when troubleshooting. 3.2.1 A number of changes in operating conditions can be normal operation should be analyzed together with any data corrective action taken. Properly utilized and understood, the that is available during problem. 3.1 -2 The operating data that has been gathered during diagnosed ProPer Of the chart, and ammeter chart can be a very valuable tool. 3.l.3 Of data may not Only aid in determining 3.2.2 The following are hand drawn examples of ammeter reason for shutdown or poor performance, but may indi- charts
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