Ken Saveth is a graduate of Oklahoma State University with a Bachelor of Science Degree in Petroleum Engineering Technology with 35 years of experience in the oil & gas industry in the field of artificial lift; primarily in the area of Progressing Cavity Pumping and Electric Submersible Pumping Systems. Ken has provided global technical support in the areas of training, design, application, deployment & troubleshooting of the progressing cavity pumping as well as electric submersible pumping systems to the industry at large. He has worked for many of the major Progressing Cavity & Electric Submersible pump manufacturers. Ken is also an Instructor or PetroSkills for their Fundamental Progressing Cavity as well as their Fundamental Electric Submersible Pump courses. He has chaired & co-chaired numerous SPE conferences & workshops as well as served on dozens of SPE committees internationally as well as authored several SPE technical papers. Currently Ken is Engineering Manager for Progressing Cavity Pumps, Gas Lift & HPUs for Baker Hughes, a GE Company.
The moment an Electric Submersible Progressing Cavity Pump (ESPCP) has been installed, the possibility exists that it could fail for some reason. There are a plethora of reasons not all of which are related to the ESPCP components themselves. The purpose of this work is to provide a generic guideline for writing a Dismantle, Inspection Failure Analysis (DIFA) Report for an ESPCP. The intent is to provide a guideline on how best to gather information and what data to gather to conduct a DIFA and it does not make one an expert on drawing conclusions. This work will outline the various types of data needed to be gathered so as to provide the necessary information that will allow the reliability engineer or dismantling persons the critical tools with which a solid determination of the Root Cause of Failure can be made and a comprehensive DIFA Report written. Without all of the necessary information, any cause of failure reached would be inconclusive and often nothing more than a guess.
Additionally, it will outline and suggest the information needed to be included in the report itself and suggest an information flow that will help make the DIFA report much easier to follow and ultimately be understood. Like a Forensic Scientist in a crime scene investigation, gathering the correct type and quantity of critical information, knowing important chronological sequences of events and taking proper component photographs are paramount to conducting a successful DIFA, writing an acceptable report of findings and ultimately in reaching an accurate Root Cause of Failure.
This generic DIFA outline will highlight the basic steps needed to conduct a proper dismantle, inspection & failure analysis for an Electric Submersible Progressing Cavity Pump.
This Failure Analysis Guide is intended to give a general outline of common failure modes of Progressing Cavity Pumping Systems along with their respective root causes and possible solutions. In order to properly understand some of the failure modes covered herein and their respective root causes and solutions, an understanding of progressing cavity technology is crucial. It will be done by first reviewing the basic progressing cavity pump components followed by some basic progressing cavity pump theory. This guide is not intended to give final answers on progressing cavity pump component failures but should help in evaluating whether further investigations are necessary.