EQUIPMENT HANDLING AND

INSTALLATION

HANDLING AND INSTALLATION 2

HANDLING PROCEDURES DOWNHOLE EQUIPMENT 2

EQUIPMENT TRANSPORTATION 2
EQUIPMENT HANDLING 3
PLACEMENT 4
CABLE HANDLING 4
TRANSPORTATION 5
SWITCHBOARD AND TRANSFORMER HANDLING 5
SAFETY 5

INSTALLATION NOTES 5

WELLSITE LAYOUT 6
EQUIPMENT INSTALLATION 7
MOTOR INSTALLATION 7
PROTECTOR SERVICING 7
PUMP ASSEMBLY 7
CABLE INSTALLATION 8
INSTALLATION OF SURFACE EQUIPMENT 8
MOTOR CONTROLLERS: 9
TRANSFORMERS: 9
JUNCTIONVENT BOX 10
SWITCHBOARD CHECKOUT 10
NO-LOAD VOLTAGE CHECK 10
DETERMINING ROTATION 10
WELL TEST 11
STARTING 11
TESTING 11
DATA GATHERING 12

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Handling and Installation

The transportation and handling of Schlumberger equipment is a very important

factor in the success of submersible operations. Schlumberger can only give
recommendations from our experience on the proven procedures that we feel are
essential. It is the producing company that must enforce good working practices
in order to enable successful submersible operations.

Handling Procedures Downhole Equipment

The nature of Schlumberger equipment requires special handling procedures

over and above the procedures normally used in the handling and transportation
of pumping systems. The physical length of components in relation to their
diameters can be quite large, in particular for motors and pumps. For example, a
thirty foot long motor, just 5.5” in diameter, will deflect considerably if not lifted
properly. Schlumberger goes to considerable effort to ensure that the stator is
straight to within +/- 0.002” per foot. With this in mind, it is irresponsible to allow
the motor to deflect excessively as this will lead to catastrophic failure. for this
reason, Schlumberger ships all downhole components such as motors, protectors,
pumps, etc., in steel shipping boxes. The boxes also protect the motor from
damage during transportation. It is important to note however, that the
protection the box can give to the component is only as good as the care the box
itself is given.

In the course of shipping equipment from one location to the next, attention
should be given to three areas. These are transportation, handling and
placement. Although placement may not appear to be important, it has a
surprising influence on the entire process. Each time a box or a piece of
hardware is placed in the correct location the first time, it eliminates/reduces the
need for further handling and therefore eliminates the risk of damage to the
equipment.

Equipment Transportation

Schlumberger recommends the use of and provides steel shipping boxes for the
transportation of motors, protectors, pumps, intakes, gas separators and
downhole monitoring equipment. Steel shipping boxes are provided in a wide
range of lengths from 5.5’ to 32’ and from 6.25” to 8.06” diameter (nominal
diameter of component being shipped). Each box has one end painted red. It is
important to note that the metal shipping boxes provide some protection during
handling and transportation but do not make the contents indestructible. The
shipping box therefore does not eliminate the need for special care and attention
for downhole equipment.

Equipment should be placed in the steel shipping box with the top of equipment
in the end of the box that is painted red. Ensure shipping caps are installed
before the equipment is placed in the box.

When loading equipment into a shipping box, use the two-piece rubber shipping
blocks and check that the shipping box and shipping blocks being used are the
correct ones. Two blocks are used per box. Position each block in the box, at a
distance equal to 1/4 the component length, from each end of the box.

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 EQUIPMENT HANDLING AND
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As an example, for a component 28 feet in length, the blocks would be placed at

7 feet from the end of each unit, with 14 feet of component unsupported in the
centre. Do not use an additional block to support the middle of the unit.

Place the unit in the box, on the shipping blocks, using an overhead hoist and a
spreader bar. Centre the unit in the box as it is being lowered, leaving equal gap
distances at each end between the unit and the shipping box. Use two cut to
length wooden blocks to fill the gaps between the unit and the shipping box at
each end. Leave 1/8” clearance. Place the top half of the shipping blocks in the
box directly above the bottom half. Secure the box carefully.

Equipment Handling

Before a piece of equipment leaves Schlumberger’s manufacturing facility, it is

packed in the metal shipping box with rubber inserts to help absorb vibration and
shock. At no time should the boxes be dragged, dropped or bounced to facilitate
movement. In general, all equipment (both in or out of shipping boxes), must be
handled using a spreader bar or a lifting clamp. Never use a single winch line
attached to the centre of a component in order to lift it. Not only will the
component potentially be damaged, but serious injury to personnel could occur.
Always use a spreader bar with chains or slings attached 1/4 length distance from
each end. The sole use of a chain bridle or sling is not recommended. When
lifting a shipping box, never use the handles of the box for support.

FRONT SIDE VIEW - OPEN

FRONT SIDE VIEW - CLOSED

TOP VIEW

DESCRIPTION INSIDE I.D. LENGTH WEIGHT

Steel Shipping Box Type L, 375-540 Series 6 Inches 12.5 Feet 210 Pounds

Steel Shipping Box Type L, 375-540 Series 6 Inches 15.5 Feet 270 Pounds

Steel Shipping Box Type L, 375-738 Series 8 Inches 18.5 Feet 500 Pounds

Steel Shipping Box Type L, 375-738 Series 8 Inches 23.0 Feet 621 Pounds

Steel Shipping Box Type L, 375-738 Series 8 Inches 26.0 Feet 750 Pounds

SHIPPING BOX

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The handles are to open and close/secure the box. They are not designed to take
the weight of the box and the equipment inside. In the lifting procedure, the box
should be supported in at least two places, each approximately one quarter the
distance from the end in question. Only use a forklift when properly distributed
support can be given to the box. For long boxes, the use of a forklift may not be
possible. In cases where a crane is being used, again ensure that the box is
supported securely in at least two places, approximately one quarter the distance
from each end. The use of a crane with a spreader bar and secured slings
threaded through the handles and underneath the box is allowed only if the
positions of the handles correspond with the 1/4 length requirement. By
threading through the handles and underneath the box, the handles are not
taking the weight of the box and the equipment inside it.

Placement

When being placed on a truck or on the ground, the boxes should be placed on 4”
x 4” wooden planks 3’ from each end and in the middle. If the boxes are to be
stacked, planks should be placed between each layer of boxes. When placed on
a truck, no part of the box should hang over the end deck of the truck. From a
32’ box, at least a 32’ trailer should be used. Shipping boxes should be tied down
securely to the deck or truck at the location of the planks prior to transportation.
Movement of the shipping boxes relative to the vehicle should be avoided at all
costs.

Cable Handling

Because of the long lengths required, power cable is shipped on large reels. The
purpose of the reel is to allow easy feeding of the cable into and out of the well
and also to afford some protection to the cable during transportation and
handling.
78
Inches
57 Inches

42
Inches

Cable Reel -
78”

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 EQUIPMENT HANDLING AND
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To move a reel of cable, insert a piece of pipe through the reel to serve as an axle
and lift with a wire line or chain slings with a spreader bar attached to this axle.
Never handle a reel of cable by making a sling of wire line or chains that touch
the cable. Protect the cable from being smashed or cut.

Never allow the reel of cable to roll against objects that might crush or damage
the cable or reel. If a fork lift is used, lift the reel through the spokes from the
side. Never touch the cable with the forks.

Transportation

Cable should be always be transported on cable reels. In the event that a power
cable on a reel is being transported with the spliced flat cable extension on it,
secure the extension, and also the power cable itself. Reels should be secured to
the truck when transported and securing procedures and layout should allow for
adequate and safe on and off loading techniques. Never touch the cable with
fork lifts, always use a crane and spreader bar.

Switchboard and Transformer Handling

During transportation and indeed at all times, the interior of the switchboard
should be kept free from moisture. Extreme care should be taken when handling
switchboards. When uncrating, pry bars should be used in place of hammers.

Transformers are provided with lifting hooks for loading, unloading and handling.
A spreader bar and cables should be used to maintain the transformer in a
vertical position to avoid damage. Always ensure the cover is bolted in place
before moving.

Safety

Safety should not be compromised at any time for any reason. The equipment
being used is heavy and potentially dangerous. Some special attention is
required to the following:

1. Use the correct motor clamps.

2. Do not lift a unit in the centre only.
3. Take care of vertical units swinging.
4. Never stand in front of the cable reel or in the centre of a looped length of
power cable lying on the ground.
5. Secure the cable sheave with chain and safety backup.
6. If in any doubt, don’t do it, ask a field service representative.
In addition to the above, please practice company safety procedures. The
operating company is responsible to implement safe operating procedures.

INSTALLATION NOTES

Prior to a new installation, the condition of the casing should be checked. A

gauge tool slightly larger than the O.D. of the equipment should be run to ensure
adequate clearance. If there was difficulty in pulling the pump from an existing
well, a close investigation as to the cause should be made prior to running a new
one. Cable damage, missing bands, or tight spots may warrant the use of a
scraper to clean up the well and eliminate potential running problems. In any
event it would be good operating practice to run the bit and scraper to remove
any sharp edges, scale or paraffin from the casing.

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The Schlumberger field service engineer will inspect all of downhole equipment
on location and confirm name plate details as per shipping list. Care should also
be taken to inspect cables, connectors and penetrator’s for electrical and/or
physical damage. Measurement of the ESP components should be taken and
noted.

Wellsite Layout

The equipment boxes should be placed on the operator's side of the rig. This
represents the best location as it is in direct line of vision with the rig operator but
not in a position where it will be a hazard when being hoisted. The boxes should
be placed on wooden planks as close to the outside edge of the rig floor as
possible, with the red ends of the boxes facing toward the wellhead. If the
equipment is unboxed, place the top end of each piece towards the wellhead.

The cable spool should be placed directly in line with the well, approximately 75-
100 feet from the well. Note: In an offshore environment this is not feasible,
however the spool should be placed as far back as possible. A clear path should
be provided for the cable to prevent it from being hooked or damaged during
installation. Several planks should be used to keep the cable off the ground to
prevent it from picking up any debris that may contaminate the well.

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The cable sheave should be hung by a sling from the tubing board at a height of
no more than 30 feet. It is important that this height not be exceeded and that
the cable be kept on the planks during pull/run operations to prevent excessive
insulation stresses caused by stretching.

Equipment Installation

The notes below are generic and do not constitute a running procedure. There
are many variations on equipment type. The Schlumberger field service engineer
will be familiar with them all.

Motor Installation

The service rig must be centered over the wellhead and its mast raised into a
vertical position. The motor is the first component to be lifted by the rig and
placed over the wellbore using a specially designed lifting clamp. The motor is
lowered into the wellbore until its lifting clamp sits on top of the wellhead. The
shipping cap is removed and the motor is filled with an oil, which is specially
formulated to provide lubrication and dielectric strength. The motor shaft is
rotated to insure that it rotates freely.
Use of phase rotation equipment is recommended so that the proper direction of
rotation is attained at start. This eliminates the need to stop and change rotation
in those cases where the initial operation was in the incorrect rotation.
Protector Servicing

The next component to be lifted and coupled to the motor is the protector
section. ‘0’-rings located on the protector base are used to seal the connection
between motor and protector and if damaged could allow contamination of the
motor oil. The protector is a vital part of the ESP system and correct servicing
procedure is a critical part in preventing premature failures.

The protector section is serviced with the same mineral oil that's used in the
motor. Injecting the oil into the protector is another important step of the
installation procedure and should never be hurried. After servicing with oil, all
vents, drains, and injection ports are sealed with the proper cap screws and
washers, the upper shipping cap is removed and the shaft extension and rotation
are checked in preparation for installing the next component.

Pump Assembly

The pump is the next component lifted and placed above the protector section for
assembly. The intake and discharge are checked for obstructions. The shipping
cap is removed from the pump base, the shaft rotation is checked and the pump
lowered onto the seal section. Caution is taken during this process to insure the
proper engagement of coupling to pump and protector shafts.
Cable Installation

The cable reel is placed 75-100 feet away from the service rig and in visual sight
of the rig operator. The cable guide wheel, over which this cable passes, is
usually never more than 30 feet from the ground, although, during the
installation of the motor lead cable, it is lowered to no higher than 15 feet above
the rig floor. Running the cable over the largest possible sheaves during installing
or pulling reduces flexure of the cable. A 54" sheave is used when possible.
Care is taken to keep slack between the cable reel and the cable guide wheel,
while preventing it from touching the ground recognising that tension applied to

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the cable could cause elongation of the conductor and/or weaken the cable
armour that provides protection for the jacket and conductor insulation.
It is very important that the cable be run straight up the tubing. Rotation of the
tubing must not be allowed while running the pump. Once the integrity of the
cable insulation is destroyed, well fluids will contact the conductors and result in a
short circuit.
Cable bands or cable protectors are used to attach the power cable to the tubing.
A minimum of two bands per joint of tubing is recommended, one band above
the collar and one placed at mid-joint. The cable bands are attached
perpendicular to the tubing and care taken not to over lighten causing distortion
of the armour. Loose bands are avoided. If a band is loose, it is removed and
replaced before proceeding
The recommended running speed for the cable is 1,000 feet to 2,000 feet per
hour depending on the experience of the service rig crew. Under no
circumstances should the operator install the tubing and cable at a speed where
he is actually pulling the cable from the reel A backup is used on every joint
where there is any chance of the tongs turning the pipe in the slips.
While running the equipment, the service technician should be allowed to check
the cable electrical properties every 1,000feet. If cable damaged is detected it
can be returned to the surface for repair.
Where deviated holes are encountered, it may be necessary to run centralises or
protectors to provide additional protection for the cable and keep the motor
centred in the casing. This will eliminate any hot spots that could result if the
motor is lying against the well casing. The centralises will also minimise the
amount of wear on the cable as it is being run in the hole.
Proper procedures in the care of the cable can and do reduce cable failures.
Carelessness with the cable during installation creates difficulty later which might
be diagnosed as cable failure or misapplication when it is in fact handling
damage during installation. Careful handling is imperative if cable life is to be
prolonged.
Installation of Surface Equipment

Power distribution literature generally states that distribution systems are better
protected if the system is grounded. Fast acting relays can be applied to detect
grounds on a live conductor, disconnect it and prevent excessive damage to the
system and to human life.

However, in a submersible pump installation the motor and all of the cable
except a few feet, which could be in conduit, is , or should be underground, and
not accessible. In this case, an ungrounded system is better. If the power cable
is damaged and it does have maximum exposure to the possibility of physical
damage, a single line ground will not prevent successful operation. This case
would be the equivalent of operating with one corner of the secondary delta
grounded.

In those installations with an individual isolation transformer for each pump, an

ungrounded secondary gives the best overall service. Multiple units operating
from a large single substation should be considered only when the logistics leave
little, if any choice. Individual units operating through auto-transformers attached
to an existing 480volt system are acceptable when the economics of another
method is not acceptable.

Motor Controllers:

It can not be over emphasised that careless procedures around the controller,
high potential cables and input or output transformers can result in equipment

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damage, injury or death. Check to see that the controller cabinet is securely
grounded.
The preliminary adjustments to motor controller prior to start-up vary depending
on the type of controller being used. Under normal circumstances the overload
current relay is set no higher than 120% of the motor's nameplate amperage.
The recommended setting is 110% of the motor's nameplate amperage.
If the overload circuitry shuts the system down, the surface and subsurface
equipment should be completely checked out before restarting.
The undercurrent relay should be set at a minimum of 80% motor amperage.
90% is recommended if the unit will start and operate normally. This will give
maximum protection under pump-off, gas locking, or pump intake plugging
conditions. In some instances, if the fluid gradient is very light, the relay may be
adjusted lower if there is adequate fluid production to permit reasonable
satisfactory pump operations and cooling of the motor.
The time delay on the automatic restart timer should be set for a minimum of 30
minutes or longer. This is to assure that a unit is not re-started while back-
spinning.
The recording ammeter is a mechanical device and should be wound up and
calibrated for operation. The correct ammeter chart is installed based on the
controller current transformer (CT) ratio, and the (CT) ratio is chosen so that
under normal operation the amp line is at least 50% of full chart scale.
Transformers:

Transformer can either be pole mounted or located on a pad. For personnel

safety, ensure that the transformer case is securely grounded, and if pad
mounted the transformer should be inside a locked fence.
Since most submersible's are designed to have low current, (approximately 100
amps or less) the voltage might be any number from 230volts up to 5000volts.
For example, a 975volts, 92amp, 150HP motor at 100feet setting would require
1005volts, but at 5000feet it would require 1125volts and at 8000feet -
1215volts.
The most trouble-free installation has one isolation transformer per pumping unit.
Multiple units operating from a large substation without individual isolation
transformers are sure to be more costly to maintain than single unit installations.
Single unit ungrounded installations can be operated with a line to ground cable
fault whereas substations with multiple units connected should be a grounded
system. In this case, without isolation transformers for each unit, a cable ground
means an inoperative unit and rework is necessary at that time.
JunctionVent Box

A vent box (junction box) should be used and should be securely grounded to the
wellhead. The vent box should be located approximately 50 feet from the
wellhead and motor controller (see API recommended practice RP1 153 for
details).
Switchboard Checkout

 Check to make sure all connections are tight.

 Check that all fuses are good.
 All AUX. contacts should be checked (chemical pump, float switch, pressure
switch).
 New recording amp chart is installed and meter is zeroed.
 Overloads should be set to 115% of nameplate motor amps.
 Underloads can temporarily be set at 65% of nameplate motor amps. They
are to be reset to 80% of running motor amps once the well has stabilised.
No-load voltage Check

The transformer should be properly tapped to provide the correct required

surface voltage. A cable volt drop chart can be found in the Schlumberger Field

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Service Manual. If the power transformer taps are changed, the taps on the
potential transformer in the switchboard will also have to be changed.

Connect a phase sequence meter and a high voltage voltmeter to the power
supply at the junction box. This location is used because it checks the entire
integrity of the electric system before being applied to the motor.

Make sure all personnel are clear of the switchboard and junction box before
powering up the switchboard. Measure the no-load voltage. Checks should be
made phase to phase and phase to ground to ensure a good voltage supply.

The phase sequence meter will indicate which way the incoming power supply is
phased (ABC or CBA).

When the correct voltage has been established, power down the switchboard,
open the main disconnect and lock it out.

Determining Rotation

The downhole cable can now be terminated at the junction box. Make certain
that ‘A’ phase of the surface cable is tied to ‘A’ phase of the downhole cable, ‘B’
phase to ‘B’ phase, ‘C’ phase to ‘C’ phase.

The pipe fitting on the wellhead should include a pressure gauge on the tubing, a
choke for controlling the flow and a high pressure shutdown switch.

Prior to start-up the Production Department should be notified of the start and all
valves should be in their correct operating position.

Note: If the fluid is flowing up the tubing before the pump is started, the flow
must be stopped by closing the valve on surface. Start the pump against the
closed valve and open immediately after start-up. This action is necessary
because when the fluid flows up through the pump it will turn the pump in the
forward rotation. If the pump was started backwards on the first start the shaft
could be damaged. If there is no flow then all valves can be left in the open
position.

Clear all personnel from the wellhead and start the pump.

Motor current should be closely monitored to ensure that the motor is not
overloaded. The starting current should be recorded, as well as current readings
every five minutes.

Follow the instructions below to ensure correct rotation:

1. Partially close the choke until a tubing pressure of approximately 100 PSI
above operating pressure is observed, recorded and stabilised.
2. Without adjusting the choke, shut the pump down and reverse the rotation by
switching any two leads in the junction box.
Note: Ensure that the pump is not back spinning by connecting a voltmeter to
the downhole leads. If the pump is back spinning the motor will generate a
voltage that can measure anywhere from 0 - 20 volts. Wait for the pump to
stop back spinning (0 volts).
3. Start the motor again and observe the tubing pressure at the wellhead. If the
pressure exceeds the previously recorded pressure then the correct rotation is
the present one. If the tubing pressure does not build up as high as previously
recorded the present rotation is backwards.

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Well Test

Once motor rotation has been established, the well should be put on test to
ensure that the pump is operating in its recommended range. It may be
necessary to choke the pump back to keep it from over producing (up thrust).

- Underloads must be reset to 80% of running amps after the well has stabilised.
The underloads must never be set less than 65% of nameplate amps.
- Amp charts and well test results should be kept in a file to keep accurate data
of the pump’s history.
Starting

When a submersible unit is started, the load voltage should be no less than 95%
of no load voltage. If it is less than 95%, this could mean that there is inadequate
electrical capacity available, which may be insufficient transformation and/or
insufficient conductor size. With adequate capacity, the starting time is 20hertz.
The current inrush is 450%, or higher, in the first cycle and decreases
immediately. The average inrush over the 20hertz or less starting time is roughly
250%.
Testing

A means of gauging the pumping rate should be provided on start-up. The unit
should be closely observed for the next couple of days and good initial start-up
data obtained.
Periodic tests and equipment analysis are required to obtain the most efficient
service from any artificial lift system. The subsurface electric pump is no
exception.
A careful study should be undertaken on any pump installation that does not
produce as originally designed, since the problems may be either with the pump
and motor assembly or may be a wellbore deficiency. As much information as
possible should be collected to ensure that subsequent installations will be
satisfactory.
In many wells, it is difficult to obtain accurate fluid level shots because of
mechanical problems or more often because of foamy annulus fluids. A working
fluid level should be a direct indication of the pump suction pressure. With poor
suction pressure data, pump performance cannot be accurately established. To
eliminate this problem, use of the downhole-pressure measurement device is
recommended.
Data Gathering

The unit is in the hole and running, now comes the important task of collecting
and keeping good records on the well's operation. The importance of collecting
good production and operating data on an installation cannot be over
emphasised. This data will be used:
1) To check the installed design.
2) Re-sizing if necessary.
3) Catching and preventing possible problems that could cause a failure.
4) Economic evaluation.
5) As an aid in analysing and determining the reasons for any failures.

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