Survey of Electrical Submersible Systems
Design, Application, and Testing
M.O. Durham, SPE, U. of Tulsa, and J.F. Lea, SPE, Amoco EPTG
Summary
The electrical submersible pump industry has numerous recom-
mended practices and procedures addressing various facets of the
operation. Ascertaining the appropriate technique is tedious. Sel-
dom are all the documents available at one location. This synopsis
of all the industry practices provides a ready reference for testing,
design, and application of electrical submersible pumping systems.
An extensive bibliography identifies significant documents for fur-
ther reference.
Introduction
Electrical submersible pumps are a complex, sophisticated electri-
cal and mechanical system. The maturing industry has developed
numerous recommended practices and procedures to identify vari-
ous facets of the operation. Seldom are all these documents avail-
able when they are needed. Many of the documents contain in-
formation too detailed to include. This synopsis will provide a ready
reference of the documents addressing submersible systems.
The American Petroleum Inst. (API) supports most of the opera-
tions and mechanical references. The Inst. of Electrical and Elec-
tronic Engineers (IEEE) publishes most of the electrical references.
Other agencies and technical papers have references that are the ba-
sis of some of the discussions. Each of these will be investigated.
Between them, the authors have been chairmen or members of most
of the committees that have developed submersible recommended
practices. This compendium is prepared from their experiences.
The documents represent the state of technology and generally
accepted procedures. Nevertheless, every installation is unique and
engineering judgment must be used for each situation.
Operation, Maintenance, and Troubleshooting
API Recommended Practice 11S1 relates field considerations rather
than specification or testing. It contains data critical to a successful
installation and operation. Once these data are gathered, appropriate
adjustments can be made to the installation. Comparison with oper-
ating conditions indicates trends and possible problem areas.
Ammeter chart analysis points to operating problems. Anything
other than a smooth line reveals questionable areas. Comparison of
amp charts with past charts directs attention to changes that will en-
hance performance of the installation.
Increasing current indicates power overload. The pump should
not be restarted without checking the electrical readings. Decreas-
ing current represents a reduction in required horsepower, leading
to a pump off. Generally, the pump can be restarted after a reason-
able time delay to allow fluid buildup. Time cycling of equipment
should be avoided.
Current relays provide protection for the electrical and mechani-
cal equipment. The overload relay should be set at 105% to 110%
of the rated motor current. Any higher setting will allow the motor
to burn. The underload should be set at 80% or more of the motor
rated current. The idle current may be only slightly below 80%. It
may be difficult to ascertain that a system is pumped off if a motor
is lightly loaded.
Copyright 1996 Society of Petroleum Engineers
Original SPE manuscript received for review April 3, 1995. Revised manuscript received Feb.
19, 1996. Paper peer approved Feb. 21, 1996. Paper (SPE 29506) first presented at the 1995
SPE Production Operations Symposium held in Oklahoma City, April 2–4.
102
Teardown Report
API Recommended Practice 11S12 is a detailed checklist and guide
for inspection of equipment during teardown. Several articles have
been written that describe teardown procedures for all equip-
ment.3,4
API RP 11S1 provides a description and four-digit codes for each
failure mechanism. The codes are designed for computer correla-
tion of problem areas.5 Comment sections allow observations.
Pump Testing
API Recommended Practice 11S26 recounts techniques for perfor-
mance testing of the pump. Product consistency results during
manufacturing. The same test conducted on previously used equip-
ment determines acceptability for reuse of the unit.
Because of load variations and motor slip, each pump will spin at
a different speed. Performance is normalized by adjusting parame-
ters to a common reference. Because the induction motors have a
slip near 3%, the nominal speed is 3,500 rev/min. Approximations
of performance are related by commonly called affinity laws.
Flowadjusted+(rated rev/minBtest rev/min)1 Flowtest
Headadjusted+(rated rev/minBtest rev/min)2 Headtest
BHPadjusted+(rated rev/minBtest rev/min)3 BHPtest
Pump efficiency (eff), which is the ratio of power out to power in-
put, includes all the performance measures. The typical conversion
factor is 136,000 bbl-ft/horsepower (HP)-D.
eff+(head flow rate)B(conversion factor BHP). . . . . (1)
API RP 11S2 recounts techniques for performance curves based
on fresh water at 60°F. Correct the factors for alternate test fluids.
Headwater+Headtest Hviscosity
Flowwater+Flowtest Qviscosity
BHPwater+BHPtest/SpGr BHPviscosity
Engineered centrifugal pumps have a limited number of stages.
Each of these can be custom trimmed to meet precise performance
specifications. Multistage manufactured pumps have variations in
each stage, so the tolerances necessarily are somewhat broad. Limits
(Table 1) are over the recommended operating range and employ
flow rate as the abscissa.
Installations
API Recommended Practice 11S37 identifies wiring methods for
surface equipment. API Recommended Practice 5008 and National
Electrical Code Article 5009 specify environmental situations that
restrict installation options. API RP 11S3 is presently under review,
but continues to provide guidance for the equipment.
The supply from the transformer to the control panel and from the
control panel to the junction box are installed as conduit and wire.
An acceptable alternative is appropriately rated direct burial cable.
Numerous agencies, such as Canadian Standards Association
(CSA) and Factory Mutual (FM), evaluate performance of cable for
use in the U.S. A safety bonding conductor is connected between the
panel, vent box, and the wellhead.
The vent box allows depressurization of the cable before the mo-
tor control panel. It should be 15 ft from the wellhead or the control
SPE Production & Facilities, May 1996
 TABLE 1—PUMP TEST PERFORMANCE TABLE 2—SIZING PARAMETERS
Head 5% over range BHP 8% over range Gradient (psi/ft)+Net SpGr water gradient (0.433 psi/ft)
Flow 5% over range Eff 90% at rated flow Fluid over pump (ft)+Pump intake pressure (psi)/gradient
Vertical head, HD (ft)+VD (ft)—fluid over pump
panel. A seal is installed on the conductors entering the vent box
Tubing friction, HF (ft)+Loss per 1,000 ft Length (ft)
from the control panel.
Area classification is based primarily on the probability of having Producing head, HT (ft)+Pressure (psi)/gradient (psi/ft)
a fuel source that will be ignited by the electrical equipment. Divi- Total dynamic head, TDH (ft)+HD)HF)HT
sion 1 anticipates this under normal conditions. Division 2 locations
are likely to have the vapors or gases only under abnormal condi- Cable voltage drop (VD) in V/1,000 ft determines the cable size.
tions. Otherwise, the location is unclassified. A Division 2 area is Correct the motor voltage (VM) for the drop (5%) in the cable to de-
defined for 5 ft around the wellhead and around the vent. Neither the termine transformer supply voltage, VT.
vent or the wellhead are expected to release hydrocarbons under
normal conditions. VT +VM 1.05, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (4)
The vent box makes the transition from the well to surface wiring. VD+VT 0.05/length (1,000 ft). . . . . . . . . . . . . . . . . . . . . (5)
Downhole cable is installed directly to the well. The cable should
be protected from mechanical damage by a fence or running in a Use performance curves from IEEE RP 1018 and 101912,13 to
correct for the operating temperature. With the voltage drop and the
pipe or trough. Armored submersible cable is bonded to the vent box
current rating of the motor, a cable size is established.
and wellhead.
The surface electrical equipment has been previously de-
During installation and removal of the equipment, safety is para-
scribed.14 Transformer size depends on the surface voltage, the mo-
mount. Back-up tongs are used to prevent the tubing from turning. tor current, and a three-phase electrical factor. The capacity can be
A cable spooler controls the reeling rate of the cable. A guide wheel obtained from one three-phase transformer. Standard values are 75,
diameter greater than 54 in. prevents cable damage. 100, 150, 225, 300, and 500 kilovolt ampere (KVA). Alternately,
three single-phase transformers can be combined if imbalance is
Sizing and Selection considered. Standard sizes are 15, 25, 37.5, 50, 75, 100, 125 and
API Recommended Practice 11S410 incorporates numerous consid- 167.5 KVA.
erations for sizing a pumping system. The well parameters in Table KVA+VT motor amps 1.732. . . . . . . . . . . . . . . . . . . . . (6)
2 determine the quantity of fluid available and the producing pres-
sure required. The control panel has a voltage rating greater than the transformer
A pump type is selected from the flow rate. With multiple possibi- voltage and a current rating greater than the motor. The panel size
lities, select one operating on the right side of the flow curve. From is based on current, shown in Table 3.
the flow vs. head curve, read the head per stage at the projected flow
rate. Calculate the number of stages from total dynamic head Application of Cable Systems
(TDH). API Recommended Practice 11S511 defines materials and construc-
tion of the power-cable system. The document is broken into sec-
No. of stages+TDH/head per stage. . . . . . . . . . . . . . . . . . (2) tions describing individual conditions or materials. The format of
From the flow vs. horsepower curve, select the maximum horse- each section is description, applications, and limitations. A broad
power for the stage type. Calculate the pump horsepower required. range of materials are prescribed for cable components. Table 4 lists
the nomenclature for the possible constituents.
Pump HP+No. of stages HP per stage composite SpGr. (3) The prevalent insulation materials are polypropylene (poly) and eth-
ylene propylene diene monomer (EPDM) rubber. The usual jackets are
Add seal-chamber power and gas-separator power to obtain need-
nitrile or EPDM rubber. Additional materials satisfy operating
ed motor power. Pick a motor with greater horsepower capability. constraints. The conductor is generally copper in sizes of American
From our experience, in general employ a motor with a nominal wire gage (AWG) No. 1, No. 2, No. 4, and occasionally No. 6. Noncor-
1,200 V rating, if appropriate cable can be selected. Losses and di- rosive environments permit galvanized steel armor while corrosive
ameter impact the cable selection. Higher voltage motors are more wells dictate stainless steel or monel. A flat profile may be required in
prone to problems from transients. wells with close tolerance between the tubing and the casing diameters.
The pump operation is influenced by well conditions, including Table 5 is a summary of appropriate materials based on conductor
gas production, viscosity, emulsion breaking, and temperature. To temperature. The conductor temperature includes ambient condi-
obtain optimum performance, correct for these variations. tions as well as heat rise caused by current flow in the wire.
The following additional information and correlating data are
provided to assist in appropriate decision making besides that in RP
TABLE 4—CABLE COMPONENT LEGEND
11S4.
The National Electrical Code9 suggests a maximum 5% voltage 1 Conductor 8 Barrier Layer
drop in cable for reasonable efficiency. If this value is used, there 2 Strand Gas Block 9 Braid
will seldom be starting problems. Starting inrush current for induc- 3 Conductor/Ins. Gas Block 10 Lead Sheath
tion motors is about 600%. With a 5% voltage drop in the cable, the 4 Auxiliary Insulation, type 11 Bedding Layer
resulting drop in voltage to the motor terminal will be approximate- 5 Basic Insulation, type 12 Struts
ly 30%. This is well within the range of most motors. 6 Physical Filler 13 Armor
Select cable materials based on the operating temperature. Later 7 Jacket, type
Recommended Practices for cable will be individually ad-
dressed.11-13 The documents on cable application and specification TABLE 5—CABLE MATERIAL
list the primary material constraints based on temperature.
°F Insulation Jacket
t200 Polypropylene
TABLE 3—CONTROL PANEL
t250 Cross link nitrile
Size Amp Size Amp
t280 EP rubber nitrile
2 45 4 135
3 90 5 270 u280 EP rubber EPR & barrier

SPE Production & Facilities, May 1996 103

 TABLE 6—DC TEST LEVELS, KV
Rating Cable Connector
AC Factory Accept Maintain Accept Maintain
3 27 22 11 18 11
5 35 28 14 24 14
Seldom is a single cable available from the vent box to the motor.
A splice makes the transition between two cables while a connector
makes the transition to a packer or motor. The successful application
of a splice relies on art and skill.
The following discussion uses experience and publications. Long
flat cables are subject to impedance unbalance between the phases.
The result can be a difference in voltage drop between the legs. The
imbalance causes a negative sequence heating of the cable and mo-
tor.
A small voltage imbalance creates a much larger current imbal-
ance. The ratio of these effects is the square of the voltage. The max-
imum allowable voltage imbalance should be 5%. This develops a
current imbalance of approximately 25% and the horsepower rating
should be reduced by 25%. Small imbalance can often be corrected
by rotating all three of the phase wires. Rotating two will cause the
motor to turn in the opposite direction.
Testing of Cable Systems
API Recommended Practice 11S615 describes available techniques
for field testing cables. Factory testing assures performance of fin-
ished products. Factory tests are discussed in IEEE Std 1017, 1018,
and 1019.12,13,16
The basis of testing in the next paragraphs has been thoroughly
discussed in a technical paper.17 In general, voltage is applied and
current is measured during a test. The current may be read directly
as leakage current (IL). Conductance (G) represents the leakage cur-
rent divided by the applied voltage. Alternately, the ratio of applied
voltage to leakage current is displayed as insulation resistance (IR).
For a consistent electrical field stress on the insulation (kilovolt
(kV)/in.), more voltage is applied to thicker insulation.
Insulation properties and resulting electrical characteristics
change with materials. Polypropylene is more homogeneous and
has a resistance factor value two and one-half times greater than
EPDM. Therefore, it will have much less leakage current.
Size, shape, material, and configuration influence the insulation
resistance. An approximate conductance for new materials can be
estimated from bulk properties. Polypropylene will be 0.10 micro-
amps (ua)/kV/1,000 ft while EPDM rubber will be 0.25 ua/
kV/1,000 ft.
The conductance value will increase with exposure to moisture,
well fluids, pressure, mechanical stress, and temperature. An exam-
ple illustrates the impact of voltage, current, and temperature on the
conductance.
1. Conductance reading=0.5 ua/kV.
2. Cable temperature=100°F.
3. Correction factor=3.26.
4. Temperature corrected=0.5/3.26+0.153 ua/kV.
5. Length=5,000 ft.
6. Corrected conductance=0.153/5+0.031 ua/kV/51,000 ft.
Type of Testing. Four situations influence the type of testing: accep-
tance, maintenance (proof), in-situ, and diagnostic (fault).
Methods of Testing. Four methods are described: insulation resis-
tance, direct current (DC) high potential, alternating current (AC)
high potential, and fault location.
TABLE 8—MATERIAL TEMPERATURE
Nitrile 250°F
Highly saturated nitrile, HSN 275°F
Fluoroelastomers 325°F
Tetrafluoroethylene/propylene, TFE/P 350°F
104
TABLE 7—AC TEST LEVELS
Cable rating Factory
3,000 9,000
4,000 11,500
5,000 13,000
Present industry accepted values are shown in Table 6. The table
is extracted from IEEE RP 1017,16 which provides detailed proce-
dures for step testing using DC high potential. Because of reduced
spacing and insulation levels, connectors should be tested at slightly
reduced upper limits.15
AC high potential testing is not performed in the field. The meth-
od does not polarize the insulation like DC. However, the equipment
is larger with additional safety risks. Extended periods of high volt-
age may weaken polypropylene insulation. If a failure occurs, it will
cause arcing, resulting in damage to the cable. The standard values
are listed in Table 7.
A series of papers on operation problems and their solutions
shows results of using some of these procedures.18
Application and Testing of Seal Chamber
API Recommended Practice 11S719 lists considerations and tech-
niques for testing the seal chamber section between the motor and
the pump. The seal chamber provides five major functions: oil ex-
pansion volume, pressure equalization, exclusion of well fluids,
thrust compensation, and torque transmittal.
The chamber section is designed to operate at near-zero differen-
tial pressure between the well pressure and the pressure in the motor.
Therefore, the walls are thin and little fluid movement should exist
between the well and the internal part of the seal section.
The well fluid contains gas, oil, water, brine, and well-treatment
chemicals. These fluids attack the wetted surfaces of the section.
The housing is often carbon steel or high chrome alloys. The shafts
are high nickel materials, such as monel, inconel, or stainless. Rub-
bing metal surfaces are typically bronze. Metals should be selected
and mated to prevent galvanic corrosion. The mechanical seals are
usually carbon on ceramic. Where abrasive fluids exist, seal faces
are silicon carbide or tungsten carbide. Well-treatment chemicals in
particular may attack elastomers. The material is also influenced by
temperature limits, shown in Table 8.
Because motor oil viscosity decreases with increasing tempera-
ture, the oil type should be considered. Oil will be drained if the seal
chamber is other than vertical. Wells with any section deviated more
than 30° should have bladder-type seals to prevent loss of oil.
The section provides isolation and expansion by labyrinth (ma-
nometer) sections or elastomer bladders. Multiple sections improve
the life expectancy. Where two thrust bearings are in tandem sec-
tions, the upper will carry the pump load unless spacing adjustments
are incorporated.
The seal chamber section makes the transition from the motor to
the pump. Interchangeability of equipment from different manufac-
turers depends on seal-section characteristics. These include flange
alignment, shaft size and strength, thrust requirements, and compat-
ibility of oil in the motor and seal.
The temperature rise and fluid expansion in the seal chamber is
determined by outside functions. Variable frequency drives, voltage
TABLE 9—VIBRATION ANALYSIS
Parts F x RPM Cause
Rotor and shaft 1 or 2 x bent shaft
All rotating 1x unbalance
Coupling, bearings 1 to 2 x, or 3x misalignment
Sleeve bearings t½ x lightly loaded
Anti-friction bearing u5 x excessive friction
Mechanical rub 1/ or ½ x periodic contact
3
Journal bearing ½x bearing rotating
Motor 1x eccentric arm.
SPE Production & Facilities, May 1996
 TABLE 10—VIBRATION SEVERITY Machinery with High Direct Voltage,25 IEEE Test Procedure for
Polyphase Induction Motors Having Liquid in the Magnetic Gap,26
Peak velocity Peak-to-Peak @3600 IEEE Standard Test Procedure for Polyphase Motors and Genera-
in/sec cm/sec Severity mils mm tors,27 and NEMA Motors and Generators28 are the fundamental
t0.014 t0.036 extreme smooth t0.074 t0.0019 documents.
0.028 0.071 very smooth 0.148 0.0038 Although submersible systems use three-phase induction motors,
0.042 0.107 smooth 0.233 0.0057 they are unlike conventional equipment. First, the unit is extremely
0.057 0.145 very good 0.302 0.0077 long compared to the diameter. Second, the rotor/stator air gap is
0.099 0.251 good 0.525 0.0133 filled with oil. Third, the systems are not designed to standard volt-
0.156 0.396 fair 0.828 0.0210 ages. Finally, the heat is transferred from the motor to a hot, moving
0.255 0.628 slightly rough 1.353 0.0344 liquid rather than to ambient air. Evaluation of these differences are
0.396 1.006 rough 2.101 0.0534 critical to the successful performance of the submersible motor.
0.622 1.580 very rough 3.300 0.0838
extremely rough Mechanical. The three types of mechanical tests are shaft toler-
u0.622 u1.580 u3.300 u0.0838
ances, housing pressure, and coast test for friction. The shaft is
checked for end play. In addition, the movement in the extended
imbalance, and low-voltage conditions cause increased motor tem- length of the shaft is measured at the top and the bottom. Approxi-
perature. Low fluid flow restricts transfer of heat from the housing. mately 10 psi is applied to the housing to check for leakage. No pres-
Testing of the seal involves acceptance during manufacturing, sure change is permissible. After assembly, the motor is installed in
analysis before reuse, and teardown analysis after use. Because tear- a test well for the coast test and electrical checks.
down includes most of the other features, it will be used as a guide-
line. A successful analysis requires gathering operating and well- Winding Resistance. The size and length of wire will change the
condition information, accurate assembly of pull and run records,
resistance of the copper in a winding. A simple check can verify the
and prompt completion of a teardown report, such as API RP 11S1.2
proper motor is under investigation. An ohmmeter measures the re-
sistance of the copper in one winding. Compare the value to the
System Vibrations specification for that motor.
API Recommended Practice 11S820 discusses vibration in submers-
ible pumping systems. Vibration is simply oscillation in a mechani- Insulation Resistance. The first electrical check is insulation resis-
cal system described by a frequency and amplitude. Forced (or ex- tance. The phase wires must be disconnected to perform this test.
cited) vibrations continue in steady-state conditions, while free The test is conducted between each pair of phase wires and between
vibrations eventually die out after the initial disturbance. each wire and the ground. Typically, a 1,000 to 5,000 V source is ap-
The vibration depends on the relationship of the forcing function plied. A megohm reading is taken after 1 minute. The megohm val-
to the mechanical properties of mass, spring (stiffness), and damp- ues will decrease with the moisture in the air, the terminations, con-
er.21,22 The frequency is calculated from the square root of the mass tamination, temperature, and material. The same electrical safety
times spring product. The amplitude is attenuated by the damper. precautions used for cable are applicable for motors.
Potential sources of vibration are mass imbalance of materials, IEEE Std 4324 recommends minimum insulation resistance (R) in
misalignment of rotating components, flow disturbance from turbu- megohm given the relationship where the rated terminal voltage is
lence and cavitation, bearings from rotation or oil whirl, and me- in thousands of volts, kV. However, for submersibles, the insulation
chanical rubbing. Table 9 relates frequency of vibration to probable resistance values should exceed 100 megohms.
causes. The frequency is a multiple of the rotating speed.
Vibration causes can be reduced during manufacturing. However, R+kV)1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7)
once the equipment is fabricated, there are options to reduce the im-
pact of vibration. The first is isolation from external sources such as
other pumps. Next, avoid the structure’s natural frequency by Polarization Index. The measured insulation resistance of a wind-
"25%. ing will typically increase with duration of the applied voltage. A
Resonance occurs when the vibration frequency matches the nat- greater increase indicates the winding is dry and clean, while a rela-
ural frequency of the support system. The natural frequency can be tively flat megohm reading points to contamination. The polariza-
changed by modifying the mass and stiffness. Alternately, a variable tion index (PI) is the ratio of the megohms measured at 10 minutes
frequency drive can modify the frequency of the pump system. to the value measured at 1 minute. The ratio should be two or more.
Vibration potential is inherent in any mechanical equipment with The insulation resistance and polarization index rise dramatically as
a long length/diameter ratio. There are three modes of vibration. a motor is dried.
Torsional vibration occurs when changing speed. Axial vibration
occurs along the thrust bearings. Lateral (transverse) vibration High Potential. DC high potential is the predominant method of as-
occurs from alignment and load on the shaft. Both torsional and lat- certaining problems. A voltage of two times the rated voltage plus
eral modes have critical speeds to be avoided. 1,000 V is recommended. Because submersibles use basically a
Velocity measurements can be made with three types of transduc- 5,000 V insulation system, the motor should be tested at 11,000 V
ers. Accelerometers measure acceleration and can be integrated to or greater. A go/no-go test is conducted by steadily raising the volt-
provide velocity and displacement at frequencies of 15 to 10,000 age to the level. Maintain the voltage for at least 5 minutes before
Hz. Velocity probes measure directly in ranges of 10 to 3,000 Hz. reducing to zero. If the current remains constant or decreases, the in-
Proximity probes measure displacement directly but are seldom sulation is good. Conduct the test between each conductor and
used because of mounting problems. ground.
Vibration measurements should be taken at the midpoint, top ra- A step test can be used to determine the quality of the insulation.
dial bearing, and bottom radial bearing for each housing in the sub- The details are outlined under the cable section for IEEE RP 1017.16
mersible system. The recommended maximum vibration is 0.156
in./sec. Table 10 indicates vibration severity. Idle Power. After assembly, the motor is placed in a test well. Ener-
gize the motor at rated voltage. Measure or calculate the current,
Motor Testing power factor, power, efficiency, speed, noise level (decibels), and
API Recommended Practice 11S923 for testing motors is being de- temperature. The no-load test reflects conditions independent of the
veloped. Until that document is established, other procedures are pump and seal section. The motor should be run to establish break-in
necessary. IEEE RP for Testing Insulation Resistance of Rotating and detect infantile problems. Typically, the motor is run until the
Machinery,24 IEEE RP for Insulation Testing of Large AC Rotating oil reaches a nominal temperature of 145°F.

SPE Production & Facilities, May 1996 105

 TABLE 11—PHYSICAL CHARACTERISTICS bearings, thrust bearings, and rotor bearings for wear or improper
spinning. Review all surfaces for rubbing. If the stator checks elec-
Awg Area Weight Diameter mil Bare Coated trically, it can be dried for reuse.
Size cmil lbm/ 1 str 7str 1,000 ft 1,000 ft
1,000 ft
Field Testing
6 26240 79.4 162 0.419 0.431
4 41740 126.0 205 232 0.263 0.271 IEEE Recommended Practice Std 101716 gives procedures for test-
2 66360 206.0 258 292 0.169 0.175 ing of submersible cable. The earlier section identified the funda-
mentals of testing and the voltages from the IEEE RP 1017. As a re-
1 83690 260.0 289 328 0.134 0.139
sult, this portion will only address DC high potential step testing and
interpretation.
TABLE 12—INSULATION PHYSICAL REQUIREMENTS If the step method of voltage increase is employed, a minimum
EP Rubber Poly of five steps are suggested. Duration at each step is long enough for
Unaged
the current to stabilize before taking a leakage current reading. One
minute is suggested. The maximum test voltage should be main-
tensile strength, min, psi 900 3,000
tained for 5 minutes. The current is noted at 1 and 5 minutes after
elongation at rupture, min, % 1,000 250
the maximum is reached.
Aged in air at 250°F for 7 days After completion of the test, voltage should be gradually reduced
tensile strength, min, % of unaged 75 75 to zero. Then the phase wire must be grounded to discharge any re-
elongation, min, % retention 75 75 maining charge in the insulation.
The most difficult portion of the test is interpretation of the leak-
TABLE 13—NITRILE PHYSICAL REQUIREMENTS age current level. Reasonable levels were developed in a previous
paper.17,29 In general, if the current in each phase remains steady or
Unaged decreases, the cable is acceptable. If the current starts increasing, the
tensile strength, min, psi 1800 cable is unusable.
elongation at rupture, min, % 300
Aged in air at 212°F for 7 days Specifying Rubber Insulation
tensile strength, min, % of unaged 50
elongation, min, % retention 50
IEEE Recommended Practice Std 101812 describes the perfor-
mance of material used in the manufacture of cable with ethylene-
Aged in ASTM2 at 250°F for 18 hours
propylene rubber (EPR) insulation. Table 11 lists the physical char-
tensile strength, min, % of unaged 60
acteristics of copper conductor. The properties of EPR insulation are
elongation, min, % retention 60 given in Table 12. The properties of nitrile rubber jacket are listed
in Table 13. Galvanized steel strip properties are noted in Table 14.
TABLE 14—GALVANIZED STEEL REQUIREMENTS Voltage ratings of cables are based on thickness of insulation. The
relationships are shown in Table 15. Cable ampacity ratings are lim-
bare steel nominal width t0.75 in ited by ambient temperature, liquid/gas environment, heat rise ow-
thickness for round u+22 mil ing to resistance, heat distortion properties of insulation, and ability
thickness for flat to dissipate heat.
u+17 mil
The maximum copper conductor temperature for EPDM insula-
tensile strength u40,000 psi tion with nitrile jacket is 284°F. Numerous curves are developed to
elongation u10% in 10 in correlate these properties with well temperature, current capacity,
weight of zinc wire size, and cable shape. The methods of developing these curves
u0.35 oz/ft
are described in a technical paper.30
zinc coated thickness t120% of bare
Specifying Polypropylene Insulation
TABLE 15—VOLTAGE RATINGS IEEE Recommended Practice Std 101913 describes the perfor-
Rating Thickness kV Test mance of material used in the manufacture of cable with polypropy-
kV mil AC DC lene insulation.
The tables and properties for copper, nitrile, armor, and voltage
3 75 9 27
rating are the same as EPR. The major difference is the insulation
5 90 13 35
property and the ampacity. The properties of polypropylene insula-
tion are given in Table 12.
Coast Test. When power is removed after the idle test, the time is
The maximum copper conductor temperature for polypropylene
measured until rotation stops. The coast time indicates windage (oi-
insulation is 205°F. Numerous curves are developed to correlate
lage), friction from thrust bearing, and alignment of sleeve bearings.
these properties with well temperature, current capacity, wire size,
Shorter motors and viscous oils will cause less coast time. Typically,
and cable shape.
the coast time should be greater than 5 seconds.

Oil Inspection. After the running test, take samples of the motor oil.
Inspect the oil for contaminants and discoloration. A dielectric test
may be used. With 1-in. diameter electrodes, 40°C oil should with-
stand a potential greater than 27 kV AC across a gap of 0.1 in. Oil
that has been in a motor should withstand greater than 15 kV.
Reuse. Before a motor is considered for reuse, several tests should
be conducted. These include the mechanical shaft checks, pressure
checks, and coast test. The electrical tests include insulation resis-
tance and high potential.
Teardown. Follow the first mechanical checks for a seal chamber.
Perform an insulation resistance test and inspect the oil. If the oil is
discolored or contaminated, determine the source. Analyze sleeve
Conclusions
Numerous standards, recommended practices, procedures, and pa-
pers have addressed electric submersible pumps. This paper pro-
vides a synopsis of the major documents. These address installation,
manufacturing, and reuse. The paper is a ready reference when all
the documents are not available.
References
1. American Natl. Standards Inst. (ANSI)/American Petroleum Inst. (API)
RP 11S, Recommended Practice for the Operation, Maintenance, and
Troubleshooting of Electric Submersible Pump Installations, third edi-
tion, API, Dallas (1994).
2. ANSI/API RP 11S1, Recommended Practice for Electric Submersible
Pump Teardown Report, second edition, API, Dallas (1995).

106 SPE Production & Facilities, May 1996

 3. Lea, J. et al.: “ESP Teardown Inspection,” Electric Submersible Pump 23. Recommended Practice for Electric Submersible Pump Motor Testing,
Roundtable, Houston (April 1984). ANSI/API RP 11S9, API, Dallas.
4. Lea, J. and Powers, W.: “ESP Teardown Inspection,” Petroleum Engi- 24. ANSI/IEEE Std 43, Recommended Practice for Testing Insulation Resis-
neer Intl., Houston (April-Sept. 1984). tance of Rotating Machinery, IEEE, New York City.
5. STARS: Submersible Technical Analysis and Reporting System, Theway 25. ANSI/IEEE Std 95, Recommended Practice for Insulation Testing of
Corp., Tulsa, OK (1989). Large AC Rotating Machinery with High Direct Voltage, IEEE, New
6. ANSI/API RP 11S2, Recommended Practice for Electric Submersible York City.
Pump Testing, first edition, API, Dallas (1990). 26. ANSI/IEEE Std 252, Test Procedure for Polyphase Induction Motors
7. ANSI/API RP 11S3, Recommended Practice for Electric Submersible Having Liquid in the Magnetic Gap, IEEE, New York City (1977).
Pump Installations, first edition, API, Dallas (1993). 27. ANSI/IEEE Std 112, Standard Test Procedure for Polyphase Motors and
8. ANSI/API RP 500, Recommended Practice for Classification of Loca- Generators, IEEE, New York City (1984).
tions for Electrical Installations at Petroleum Facilities, first edition, 28. Natl. Electrical Manufacturers Assoc. (NEMA) Std MG1, NEMA Mo-
API, Dallas (1991). tors and Generators, NEMA, Washington, DC (1987).
9. ANSI/National Fire Protection Assoc. (NFPA) 70, National Electrical
29. Durham, M.O., Boyer, L., and Beer, R.: “Field Testing of Submersible
Code, NFPA, Batterymarch Park, Quincy, MA (1993).
Cable,” Trans., IEEE on Industry Applications, New York City (Nov./
10. ANSI/API RP 11S4, Recommended Practice for Sizing and Selection of
Dec. 1980) IA-16, No. 6, 783-786.
Electric Submersible Pump Installations, first edition, API, Dallas
30. Baker, G. and Durham, M.O.: “Correlations of Submersible Cable Per-
(1994).
11. ANSI/API RP 11S5, Recommended Practice for Application of Electric formance,” Trans., IEEE on Industry Applications (March 1992) 28,
Submersible Cable Systems, first edition, API, Dallas (1993). No. 2, 282-286.
12. ANSI/Inst. of Electrical and Electronic Engineers (IEEE) Std. 1018,
Recommended Practice for Specifying Electric Submersible Pump SI Metric Conversion Factors
Cable-Ethylene Propylene Insulation, second edition, IEEE, New York
bbl 1.589 873 E*01 +m3
City (1991).
13. ANSI/IEEE Std 1019, Recommended Practice for Specifying Electric
cycles/sec 1.0* E)00 +Hz
Submersible Pump Cable-Polypropylene Insulation, second edition, ft 3.048* E*01 +m
IEEE, New York City (1990). °F (°F*32)/1.8 +°C
14. Durham, M.O. and Boyer, Lynn: “Downhole Submersible Design—An in. 2.54* E)00 +cm
Electrical System Approach,” IEEE Petroleum and Chemical Industry mil 2.54* E*05 +m
Conference (PCIC), No. PCIC-80-33, 80CH1549-5IA, New York City psi 6.894 757 E)00 +kPa
(Sept. 1980) 105-110. rev/min 1.047 198 E*01 +rad/s
15. ANSI/API RP 11S6, Recommended Practice for Testing of Electric Sub-
mersible Cable Systems, first edition, API, Dallas (1996). *Conversion factor is exact. SPEPF
16. ANSI/IEEE Std 1017, Recommended Practice for Field Testing of Elec-
tric Submersible Pump Cable, second edition, IEEE, New York City
(1990). Marcus O. Durham is director of the Power Applications ReĆ
17. Durham, M.O. et al.: “Can Present Field Test Technology Reasonably search Center at the U. of Tulsa and is an associate professor of
Determine Cable Quality?” IEEE PCIC, No. PCIC-94, 94CH, Vancouv- electrical engineering. He is an Inst. of Electrical and Electronics
er (Sept. 1994). Engineers (IEEE) fellow. He received a PhD degree in electrical
18. Lea, J.F. and Bearden, John: “Operations Problems and Their Solu- engineering from Oklahoma State U. James F. Lea is special reĆ
tions,” Electrical Submersible Pump Roundtable, Houston (April search associate at Amoco EPTG, Tulsa, OK. He has been an SPE
1994). Distinguished Lecturer on production operations. He received
19. ANSI/API RP 11S7, Recommended Practice on Application and Testing a PhD degree in mechanical engineering from Southern MethĆ
of Electric Submersible Pump Seal Chamber Sections, first edition, API, odist U.
Dallas (1993).
20. ANSI/API RP 11S8, Recommended Practice on Electric Submersible
Pump System Vibration, first edition, API, Dallas (1993).
21. Durham, M.O., Williams, J., and Goldman, D.: “Vibration Failure of
Submersible Pumps,” JPT (Feb. 1990) 186-191.
22. Brinner, T.R., Traylor, F.T., and Stewart, R.E.: “Causes and Prevention
of Vibration Induced Failures in Submergible Oilwell Pumping Equip-
ment,” paper SPE 11043 presented at the 1982 SPE Annual Technical
Conference & Exhibition, New Orleans, Sept. 26–29. Durham Lea

SPE Production & Facilities, May 1996 107