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Publisher Offshore Technology Conference LanguageEnglish
Document ID 4980-MSDOI  More information10.4043/4980-MS
Content TypeConference Paper
TitleDesign Features of Improved Electric Submersible Pump (ESP)Cable To Withstand Installation and Service Conditions
AuthorsD.H. Neuroth, The Kerite Co.
Source

Offshore Technology Conference, 6-9 May 1985, Houston, Texas
ISBN978-1-61399-078-0
Copyright1985. Offshore Technology Conference
PreviewABSTRACT

Field studies, with oil industry assistance, identified major failure mechanisms that presently limit the service life of conventional electric submersible pump cable. A new cable, designed to address each of these failure modes, was developed and tested. Special load-bearing members placed within the cable improve crush resistance from 500 Ibs./cable in. with conventional cable to 3000 lbs./cable in., while at the same time enhancing decompression strength. The manner in which the new design increases edge protection, eases installation handling, enhances abrasion resistance, and provides greater chemical protection is also discussed. The mechanisms by which design features achieve these improvements are supported by laboratory results and actual field experience. Diagrams, photos, and graphs are included.

Oil recovery industry personnel who are interested in extending ESP cable service life will find this paper both provocative and informative.

INTRODUCTION

With the increasing use of secondary and tertiary recovery techniques resulting in high water cut production fluids, there has been a growing need to extend the run life of Electric Submersible Pumps (ESPs), which are usually the favored method of lifting high volume production fluids. As the reliability of pumps and motors has improved, there has been an increasing demand to improve the performance of ESP cables. Frequently, ESP system life has been limited by cable life causing premature pulls, excessive downtime, and production losses.

In 1978, The Kerite Company was approached by a major oil company to take a fresh look at ESP cable problems, with the goal of designing a new cable that would prevent the failure mechanisms presently limiting the service life of conventional ESP cable. To determine the scope and nature of present problems, Kerite conducted an extensive engineering and marketing research program. Discussions were held with engineering and production personnel of Shell Oil, Amerada Hess, Amoco, ARCO, Chevron, Texaco, Thums, and others.

FAILURE MODES OF ESP CABLE

Because conditions vary widely from field to field, one must be cautious when analyzing and interpreting information. However, we found that roughly 60% of all "pulls" were identified as being caused by electrical problems, and the majority of these involved failures of the power delivery system such as a fault in the cable, in the motor flat lead extension, or in the motor flat lead splice.

Opinions varied concerning the cause of the failures. Nevertheless, a general pattern emerged that allowed us to identify the following failure modes, ranked in descending order of importance:

  1. Failure of motor flat lead splice

  2. Failure resulting from mechanical during installation and/or damage service

  3. Failure due to decompression rupture

  4. Electrical failure due to high operating temperature and chemical attack
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