ESP Failure Analysis of Forties Experience Apache

FORTIES ESP
FAILURE ANALYSIS
EXPERIENCE
2014 EUALF
INTRODUCTION
Dismantle Inspection and Failure Analysis (DIFA) has driven a number of key
ESP improvements for Apache by properly establishing failure mode and
providing good, workable recommendations. Establishing the correct root
cause is ultimately where the value lies in this process.
This presentation will look at the following:
How has failure analysis benefited Apaches Forties Field over the past 10
years?
How can improved identification of true root cause of failure help to
improve ESP runlife?
AGENDA
Forties Field
DIFA driven improvements
ESP failure by categories
DIFA standard API 11S1
DIFA developments
Trends and challenges
Additional analysis
Improvement opportunities
FORTIES FIELD
5 platforms, one satellite platform, one

subsea tieback: Forties (A, B, C, D, E, FASP
and Bacchus)
190+ ESP installations in Apache era
~60 ESP wells, 35 gas lifted wells and

three subsea gas lifted wells.
Production potential of 51Mbd
~43% of field production through ESPs.
ESP runlife on upward trend thanks to

high efficiencies, good operational
procedures, incentivised contract with
service provider, more focus on ESP
reliability and DIFA.
DIFA DRIVEN IMPROVEMENTS

ESP electrical /
motor failures
Sand related
well failures
MLE damage
during
installation/
operation
ESP failure due

to sand fall back
/ pump bearings
failing
Keyless pump
bearings,
minimum sand
lift speeds
Full bearing
housing
pumps, adv.
Protector head
and shedder in
top of pump
MLE tensioner
Implementation of fit
for purpose sand
control
Sinewave filtering,
power quality
metering, more
viscous motor oil and
mine duty motors.
ESP FAILURES BY CATEGORY
Manufacturing and Electrical (design)

cover motor/general electrical failures
Green underline considers problem to
be eradicated with implemented
measures under present conditions
Reservoir covers ESPs that did not fail;
watered out etc.
Awaiting 13 DIFA reports and root
causes Reason for pull mainly
electrical with 1 elective pull.
DIFA STANDARD (API 11S1)

Most ESP vendors use recommended practice API 11S1 as a guide which provides a
good framework to ESP dismantle. Some of the key points to consider are as follows:
Pros
Comprehensive enough to cover ESP dismantle in detail
Ensures comments are recorded at each step in a structured and methodical
manner
Provides details of additional information required prior to starting any
dismantle/failure analysis
Cons
Does not give guidelines for lab analysis upon finding any unknown substances in
pump
Does not offer guidelines on root cause analysis which is left to the failure analyst
Can direct the analysis towards the cause of the system failure rather than that of
the component initiating the path to failure
DIFA DEVELOPMENTS
Better understanding of failure modes

Schlumberger feeding back to engineering
Schlumberger/Apache have been
routinely carrying out lab analysis on
foreign items found in pulled ESP systems
Usable and focused recommendations in
reports
Excellent detail in explanation of root
cause
Penetrator system suppliers providing
comprehensive tear down reports upon
discovery of system failures
Attention to the ESP lifecycle in every
report
Preliminary dismantle findings available
upon viewing equipment
TRENDS AND CHALLENGES

Electrical failures have been the most common failure mode, particularly
motor failures, since the widespread implementation of sand control.
Initial DIFA findings from motor failures

recommended using higher viscosity oil and
add one snap ring per rotor
Further succession of motor failures and
general electrical failures prompted an
investigation into electrical power quality
Common themes in failed motors
prompted further analysis to be carried out
on bearings:
Lab analysis of oil

Specialist analysis of bearing assemblies
ADDITIONAL ANALYSIS - ELECTRICAL

Electrical power study and lab testing carried out by specialist consultants MagneyGrande and David Shipp of Eaton.
Test set up to mimic offshore installation using typical
medium voltage VSD, tuneable sinewave filter (SWF) and
power quality meter.
10
Findings concluded addition of SWF eliminated high

frequency voltage and current
SWF helped balance motor current
Power quality meter will also allow for monitoring
therefore better operation of ESPs
Power quality meter will prove helpful for determining if
power quality played a role in system failure
identification of root cause
Without SWF
With SWF
ADDITIONAL ANALYSIS - BEARINGS

Expert bearing investigation carried out by Andrew Marshall of Scots Bearings.
11
Findings indicated mechanical wear rather than

previously suspected electrical
Sample oil analysis from test bearings showed kinematic
viscosity to be lower than the data sheets stated
Root cause of damage was determined to be poor
lubrication between surfaces
Reduction in hydrodynamic film could be caused by:
Increase surface roughness of bearing mating

surfaces
Mixing of oil during filling process

Recommendation: #6 oil deemed to be adequate as long
as it is not diluted i.e. no less than 220cSt @40degC
(agrees with SLB earlier recommendations)
Staining etched to
raceway surface
Radial scoring
circumferential
across rolling contact
zone
IMPROVEMENT OPPORTUNITIES
12
More detailed analysis of failure trends (like

bearing trend)
Avoid just accepting a higher spec without
attempting to find root cause
Understanding of the cause of electrical failures
still remains one of the weakest parts of the DIFA
process
DIFA reviews between SLB and Apache to tackle
divided opinion
Inclusion in the DIFA report of the Apache cause
analysis map drafted by the offshore team as part
of plant upset report (PUR)
IMPROVEMENT OPPORTUNITIES
Apache PUR Cause Map
Actions items
shown in green
Interventions /
observations
shown in red
13
ACKNOWLEDGEMENTS
14

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How has failure analysis benefited Apache’s Forties Field over the past 10 years?

How has failure analysis benefited Apache’s Forties Field over the past 10 years?

What are some of the improvements that have been driven by failure analysis?

What are some of the improvements that have been driven by failure analysis?

FORTIES ESP

5 platforms, one satellite platform, one

190+ ESP installations in Apache era

~60 ESP wells, 35 gas lifted wells and

Production potential of 51Mbd

~43% of field production through ESPs.

ESP runlife on upward trend thanks to

DIFA DRIVEN IMPROVEMENTS

ESP failure due

ESP FAILURES BY CATEGORY

Manufacturing and Electrical (design)

DIFA STANDARD (API 11S1)

Better understanding of failure modes

TRENDS AND CHALLENGES

Initial DIFA findings from motor failures

Lab analysis of oil

ADDITIONAL ANALYSIS - ELECTRICAL

Findings concluded addition of SWF eliminated high

ADDITIONAL ANALYSIS - BEARINGS

Findings indicated mechanical wear rather than

Increase surface roughness of bearing mating

Mixing of oil during filling process

More detailed analysis of failure trends (like

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