1、Recommended Practice for Electrical Submersible Pump Teardown ReportAPI RECOMMENDED PRACTICE 11S1THIRD EDITION, SEPTEMBER 1997EFFECTIVE DATE: DECEMBER 15, 1997REAFFIRMED, OCTOBER 2013Recommended Practice for Electrical Submersible Pump Teardown ReportUpstream SegmentAPI RECOMMENDED PRACTICE 11S1THIR
2、D EDITION, SEPTEMBER 1997EFFECTIVE DATE: DECEMBER 15, 1997REAFFIRMED, OCTOBER 2013SPECIAL NOTESAPI publications necessarily address problems of a general nature. With respect to partic-ular circumstances, local, state, and federal laws and regulations should be reviewed.API is not undertaking to mee
3、t the duties of employers, manufacturers, or suppliers towarn and properly train and equip their employees, and others exposed, concerning healthand safety risks and precautions, nor undertaking their obligations under local, state, or fed-eral laws.Information concerning safety and health risks and
4、 proper precautions with respect to par-ticular materials and conditions should be obtained from the employer, the manufacturer orsupplier of that material, or the material safety data sheet.Nothing contained in any API publication is to be construed as granting any right, byimplication or otherwise
5、, for the manufacture, sale, or use of any method, apparatus, or prod-uct covered by letters patent. Neither should anything contained in the publication be con-strued as insuring anyone against liability for infringement of letters patent.Generally, API standards are reviewed and revised, reaffirme
6、d, or withdrawn at least everyfive years. Sometimes a one-time extension of up to two years will be added to this reviewcycle. This publication will no longer be in effect five years after its publication date as anoperative API standard or, where an extension has been granted, upon republication. S
7、tatusof the publication can be ascertained from the API Authoring Department telephone (202)682-8000. A catalog of API publications and materials is published annually and updatedquarterly by API, 1220 L Street, N.W., Washington, D.C. 20005.This document was produced under API standardization proced
8、ures that ensure appropri-ate notification and participation in the developmental process and is designated as an APIstandard. Questions concerning the interpretation of the content of this standard or com-ments and questions concerning the procedures under which this standard was developedshould be
9、 directed in writing to the director of the Authoring Department (shown on the titlepage of this document), American Petroleum Institute, 1220 L Street, N.W., Washington,D.C. 20005. Requests for permission to reproduce or translate all or any part of the materialpublished herein should also be addre
10、ssed to the director.API standards 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 apply-ing sound engineering judgment regarding when and where these standards should beutilized. The f
11、ormulation and publication of API standards is not intended in any way toinhibit anyone from using any other practices.Any manufacturer marking equipment or materials in conformance with the markingrequirements of an API standard is solely responsible for complying with all the applicablerequirement
12、s of that standard. API does not represent, warrant, or guarantee that such prod-ucts do in fact conform to the applicable API standard.All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, record
13、ing, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.Copyright 1997 American Petroleum InstituteFOREWORDThis recommended practice is under the jurisdiction of the American Petroleum Institu
14、te(API) Subcommittee on Field Operating Equipment.This recommended practice shall become effective on the date printed on the cover butmay be used voluntarily from the date of distribution.API publications may be used by anyone desiring to do so. Every effort has been made bythe Institute to assure
15、the accuracy and reliability of the data contained in them; however, theInstitute makes no representation, warranty, or guarantee in connection with this publicationand hereby expressly disclaims any liability or responsibility for loss or damage resultingfrom its use or for the violation of any fed
16、eral, state, or municipal regulation with which thispublication may conflict.Suggested revisions are invited and should be submitted to the director of the Explorationand Production Department, American Petroleum Institute, 1220 L Street, N.W., Washing-ton, D.C. 20005.iiiCONTENTSPage1 SCOPE . . . .
17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 ADDITIONAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1APPENDIX ARECOMMENDED PRACTICE FOR API RP 11S1 TEARDOWN REPORTING DATABA
18、SES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11APPENDIX BTEARDOWN REPORT QUERIES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Figures1 Typical Motor Section 32 Typical Seal Chamber Section Types. 53 Typical Pump Section. 74 Typical
19、 Gas Separator Section Types. 9A-1 Relationship Diagram for Teardown Reporting 15A-2 Recommended Observation Codes for ESP Teardown. 16A-3 Pertinent Data . 18A-4 Teardown Observation Data. 19A-5 Pertinent Data (Equipment Identification). 20A-6 Common Terms for Remarks Teardown Observation Code Break
20、down Table 21A-7 Common Terms for Remarks Observation Code Breakdown. 22A-8 Reason for Pump Pull. 22A-9 Failure Codes 22B-1 Example 1: Teardown Report Queries. 25B-2 Example 2: Teardown Report Queries. 27v1Recommended Practice for Electrical Submersible Pump Teardown Report1 ScopeThis recommended pr
21、actice covers a recommended electri-cal submersible pump teardown report form. It also includesequipment schematic drawings which may provide assistancein identifying equipment components. It should be noted thatthese schematics are for generic equipment components, andthere may be differences betwe
22、en manufacturers on the exactdescription or configuration of the assemblies.2 Additional InformationIn order to properly interpret the information gatheredusing this API recommended practice, the following data alsoshould be provided:a. Equipment amp charts.b. Production data prior to failure.c. Inf
23、ormation on any unusual conditions such as sand orscale production, power interruptions, bad weather or storms,changes in chemical treatments, etc. d. Equipment pull and run reports, service reports, andequipment test records. 2 API RECOMMENDEDPRACTICE11S1Form 1Motor Inspection ReportOperator: _ E.S
24、.P. Manufacturer: _Lease: _ Well: _S/N: _ HP: _ Voltage: _ AMPS: _ Model: _Date Installed: _ Date Pulled: _ Run Time: _1. HEAD:Terminal cavity: OK _ Burned _Cavity corroded: Yes _ No _Evidence of water track: Yes _ No _Head corroded: Yes _ No _2. BASE:Corroded: Yes _ No _Base blushing: OK _ Worn _Fi
25、lter (if applicable): OK _ Plugged _ Dirty _3. HOUSING CONDITION:OK: _ Corroded: Yes _ No _Pressure test: Passed: _ Failed _Scaled on OD: Yes _ No _Thickness:_Acid soluble: Yes _ No _Coating: OK _ Bad _ (REM)4. SHAFT CONDITION:Turns OK: Yes _ No _Broken: Yes _ No _Shaft high strength: Yes _ No _Spli
26、ne Condition:Twisted: Yes _ No _Corroded: Yes _ No _Extension: OK _ Out of Spec. _Burned: Yes _ No _5. COUPLING:OK _ Worn _ Broken _ Missing _6. THRUST BEARING ASSEMBLY:Thrust bearing: OK _Down thrust: Negligible _Moderate _ Severe _Hi-load bearing: Yes _ No _Bearing collapsed: Yes _ No _Thrust Runn
27、er:Thrust runner: OK _Down thrust: Negligible _Moderate _ Severe _7. ROTOR BEARING ASSEMBLY:OK _ Heat noted: Yes _ No _Spun: Yes _ No _Thrust Washers: OK _Brittle _ Cut _ Impressioned _Rotor bearing sleeve: OK _ Worn _Discolored: Yes _ No _8. STATOR:Electrical: (A - B) (A - C) (B - C)Phase to phase
28、_ _ _Phase to ground _ _ _Megohm reading:_Hypot test: OK _ Failed _Burned top end turn: _Burned bottom end turn: _Burned leads: _Laminations:Burned: Yes _ No _ Location: _ID: OK _ Worn _9. POTHEAD CONNECTOR ASSEMBLY:Plug IN: _ Tape IN: _OK _ Burned _ Damaged _Pothead:OK _ Damaged _ Heat noted _“O” R
29、ing: OK _ Hard _ Seized _Cut _ Melted _Terminal block: OK _ Stained _Burned _ Damaged _10. ROTORS:Corroded: Yes _ No _Worn on OD: Yes _ No _Location of wear:_Burned on OD: Yes _ No _Location of burn: _11. OIL CONDITION:Clear: _ Free water: _ Dark: _Emulsion _ Solids: _Notes: 1. For any item not cove
30、red, use comment section or back of this page, if necessary, to document condition.2. REM means remanufacture.Comments however, the suggested field sizes should bemaintained.A.3.5 OBSERVATIONSThe forms in the main body show the observations recom-mended by this recommended practice in a form format.
31、 Fig-ure A-2 shows these same observations listed with acorresponding unique code for use in a database. The struc-ture and relationship of fields in the Observation Table(OBSTAB) are discussed below.A.4 Teardown ObservationsAll of the observations from a teardown are reported on thesame table (OBST
32、ABsee Figure A-4). Failure observationcodes can be stored in separate lookup tables based on com-ponents of the ESP. Only the observations made are kept onthe database. It is assumed that if no observations were madethe sub-component was in good condition. Observations canbe made on a large number o
33、f sub-components that existwithin an ESP. The fields in the OBSTAB table consist of three main com-ponents:a. EQUIPID (Equipment Identification).b. SUBID (Sub-component Identification).c. OBS# (Observation Number).A.4.1 EQUIPIDTo uniquely identify any observation, a unique observationcode must be li
34、nked to the EQUIPID as defined above inA.3.3. The EQUIPID is the primary key in the OBSTAB table.A.4.2 SUBIDThe SUBID is a two character TEXT field that identifiesthe subcomponents being described by the observation. Whenused in combination with the OBS#, the observationsrecorded become unique. Figu
35、re A-2 shows how the SUBIDis broken into two groups, where each item is either:a. common to more than one piece of ESP equipment(SUBID defined as “XY”), or b. unique to an individual device (SUBID defined as “WZ”).The variable pairs “XY” and “WZ” are all defined usingletters from the words that desc
36、ribe the sub-component. TheY component of the XY pair is defined for common sub-com-ponents like Bfor Base, Hfor Head or Gfor HousinG, while“X” is defined by the section of the ESP that is beingdescribed (pump, motor, etc.). For example: “X” = PforPump; Gfor Gas separator; S for Seal, and M for Moto
37、r.Hence, the Pump Head and the Motor HousinG are describedas PH and MG, respectively.For sub-components that are unique to a device, the char-acter pair, WZ, is defined uniquely by letters in the sub-com-ponent name. There is no direct reference between thecomponent and the sub-component. For exampl
38、e, SEdescribes the Stator Electrical condition, while BC describesthe Bag Chamber assembly condition. A.4.3 OBS#OBS# describes the observation code, where “#” can be asingle-digit number 1 through 9. Figure A-2 shows the rec-ommended four-digit integer codes that correspond with theteardown reportin
39、g forms presented in the main text of thisrecommended practice. Note that in each sub-componenttable there is no duplication of observation codes; however,the same code can exist once in each of many sub-componenttables.To facilitate unique needs of individual users, the codeschosen are set in a rec
40、ognizable pattern which is summarizedin Figures A-6 and A-7. For example, all corrosion observa-RECOMMENDED PRACTICE FOR ELECTRICAL SUBMERSIBLE PUMP TEARDOWN REPORT 13tions have the code 3700, but corrosion of one sub-compo-nent is distinguished from corrosion in another by theSUBID.Additional compo
41、nent observations can be handled usingthis nomenclature, allowing flexibility in the system yet mini-mizing the effort to make queries and transfer data betweensoftware.Concatenating the SUBID and the OBS# is an alternativemethod of reporting observation codes uniquely, but it is notrecommended.A.4.
42、3.1 Physical MeasurementsPhysical measurements taken are stored in the physicalmeasurement table, PHYTAB (see Figure A-5). TheEQUIPID is the primary key linking physical measurementssuch as the phase-to-phase and phase-to-ground readingsfrom a motor to the equipment and the event.A.4.3.2 Added Flexi
43、bility in Observation CodesTo add flexibility to the observations, follow a recognizablepattern as noted above. Figure A-6 describes the standardobservations that are shown in Figure A-2 in increments of100 in the “y” vertical axis and incrementally by 10 in the hor-izontal axis. Significant space i
44、s provided to allow additionalcategories to be added. The units digit can be also be used toprovide more details on several existing parameters withoutadding remarks. Common terms that can be used are shown inFigure A-7. These are referenced back to the relative catego-ries where they apply using fo
45、otnotes in Figure A-6.It should be noted that for the seal condition, only the top,middle, and bottom seal are described in Figure A-6 by the4900, 5400, and 5900 series. For additional seals, incrementsof 100 can be used between 4900 and 5900, where the middleseal remains the 5400 series. Note that some of this data canbe lost if provisions are not made for this increase in detail.A.4.4 REMARKSRemarks are important in any teardown report to allow fur-ther description of the observations, but
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