• Class and Course

    Electric Submersible Pumps - Practical Equipment Training with Manufacturing Plant Tour

    In this class, the participants will be introduced to the different types of Artificial Lift (AL) applications and then will focus on the practical background and hands-on exercises on the Electric Submersible Pumps (ESP) equipment.

    The class includes comprehensive visits to the ESP Manufacturing Plant in Singapore (Plant Tour) so the participants can get practical experience working with the actual equipment related to ESP.

    Day 1 - Introduction

    • Introduction / HSE Orientation / Welcome: The class will start with an informal introduction session.  This will include a brief outline of the history of the course and the main areas/topics that will be reviewed.  An overview of the training will be discussed with participants to determine if the agenda meets the needs of those attending the training. The goals and objectives of each client will be recorded to ensure the training meets expectations. If there are some requests not covered in the agenda, where possible, the agenda will be adjusted to accommodate additional requests.
    • HSE: Safety for the class will be of the upmost importance. Sections of the training that require PPE or special attention will be reviewed.  This will also include who to contact if any concerns arise.
    • Artificial Lift Review: This section focuses on the fundamentals of Artificial Lift and how fluid moves through a reservoir, how it behaves in a well and what characteristics of the well have the biggest impact on Artificial Lift. This may be a review from some, but ensuring the basics are correct is essential for the understanding of the balance of the training. Each form of Artificial Lift has advantages and disadvantages – it is important that the five main forms of Artificial Lift, including Rod Pump, PCP, Jet Pump, Gas Lift and ESP be reviewed to determine which form of lift is best suited for various reservoir conditions.
    • Plant Tour:
    Quality Control (QC):  one of the key differences between an ESP running a short or long time is the quality control implemented during the construction and assembly of the ESP components. During this tour the quality control practices and equipment used to ensure confirm specifications will be demonstrated.
    • Quiz

    • Pump: There are 8 elements of the pump that need to be designed including Stage Type, Number  of Stages, Stage Material,  Bearing Material,  Bearing Spacing, Shaft Material, Housing Material  and Construction Configuration. Each of these will be reviewed in detail to determine the best design for specific environments.
    • Plant Tour:

    Foundry  & Finishing: (PPE Required – Safety Shoes, Safety Glasses, Fume Mask and Headset with Communication). First part of this tour is a review of the foundry area which starts in the Green Sand Lab; where the quality  of the cast parts are controlled including metallurgy, hardness, finish, etc. The foundry area will be toured where raw materials such as iron, zinc, nickel, chromium, etc. are melted and formed into impellers and diffusers.  It will include a review and observation of the casting process from start to finish.

    • Quiz

    • Intake and Protector/Seal: Intake - the intake portion will include standard intakes, gas separation devices and gas handling devices. This section will also include why gas is such a problem for ESP’s, how gas behaves in the well bore and true efficiency of gas separators. Protector - The 5 main functions of a protector will be reviewed including Pressure Equalization, Barrier Protection, Thrust, Torque and Oil Reservoir for the motor.  The three types of protectors will be reviewed including Positive Seal, Labyrinth and Bellows.
    • Plant Tour:

    Head and Base Machining - two of the most complicated parts to manufacture for any ESP component is the head and base - this process will be observed. Pump assembly will be observed as to what steps are required to build the pump, including observing the impeller/diffusers installed in the housing.

    • Quiz

    • Motor and Gauge: How the motor works will be reviewed from the basic principles of electricity. Without this understanding how downhole gauges/sensors operate, which is discussed in the following section will not be possible. Motor insulation, rating and temperature limitations will be reviewed. Gauge - how data is transmitted without the use of a separate cable will be reviewed including common issues that can be experienced with a gauge.
    • Plant Tour:

    Protector Assemble will include a review of the parts used to manufacture a protector followed but observation of one section of the protector constructed and tested. Motor - stator winding will be followed by motor assembly. Included in this step will be the witnessing of the auto shaft straightening process. Gauge - will include a review of how the electronic parts are first tested/vetted for selection followed by the assembly and final test of the gauge.

    • Quiz

    • Power Cable, Connectors and Surface Equipment: Worldwide failure rates indicate that approximately half of all ESP failures occur in the cable string. In this section each of the components of the cable including conductor, insulation, barrier, jacket and armour will be reviewed. Connectors are considered part of the cable string and are often the most susceptible to shorting. The reasons for that and what can be done will be reviewed. Surface Equipment- there are usually only 4 main components to the surface equipment including the Transformer, Switchboard, VSD and Motor Controller. Each of these will be reviewed in detail, but extra time will be spent on the VSD. The issue of Harmonics, both back onto the power system and down to the ESP, is often not well understood – this section of the training will remove any mystery surrounding harmonics. Also, the benefits and drawbacks of different types of VSD’s will be reviewed.
    • Plant Tour:

    Gauge - will include a review of how the electronic parts are first tested/vetted for selection followed by the assembly and final test of the gauge. A VSD will be reviewed including the controller, components and step up transformer.

    • Quiz

    Production/Artificial Lift Engineers

    Production Operations Engineers

    Production Optimization Engineers

    Production Technologists

    Knowledge of Artificial Lift (AL) and Electric Submersible Pump (ESP) is a plus.

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