Recommended Practice for Electrical Submersible Pump Teardown Report

# Understanding the API Recommended Practice for Electrical Submersible Pump Teardown Report

Electrical Submersible Pumps (ESPs) are critical components in many oil and gas production operations, often operating in harsh downhole environments. When these complex systems fail, a thorough understanding of the root cause is paramount for efficient repair, replacement, and future reliability improvements. The American Petroleum Institute's (API) Recommended Practice (RP) for Electrical Submersible Pump Teardown Report (API RP 11S1) provides a standardized framework to ensure this critical post-failure analysis is conducted comprehensively and consistently. This practice bridges the gap between raw field data and actionable engineering insights, transforming a potentially chaotic teardown process into a structured, data-driven investigation.

Purpose & Problem Solved

Traditional ESP failure analysis can often be inconsistent, relying on anecdotal evidence or varied reporting methods. This leads to difficulties in accurately diagnosing failure modes, identifying recurring issues, and implementing effective preventative measures. API RP 11S1 addresses this by establishing a standardized procedure for documenting the teardown of ESPs. It provides a structured format and essential data points to capture during the teardown process, enabling engineers to precisely identify the cause of failure, guide subsequent repair or replacement decisions, and contribute to a growing knowledge base for improving ESP reliability across the industry. The benefit lies in moving from generalized assumptions to specific, verifiable findings, ultimately reducing downtime and operational costs.

When to Apply This Practice

• • Required Situations:
• • Mandatory for all ESP failures where a detailed root cause analysis is required by company policy or regulatory compliance.
• • When a significant capital investment is being considered for ESP repair or replacement, necessitating a robust justification based on failure data.

• • Recommended Situations:
• • For any ESP failure, regardless of severity, to build a comprehensive historical database of performance and failure modes.
• • When troubleshooting recurring ESP issues to identify subtle trends or patterns that might otherwise be missed.
• • As part of a continuous improvement program aimed at enhancing ESP system design and operational parameters.

• • Not Applicable When:
• • The equipment is being decommissioned and will not be returned to service.
• • The failure is clearly attributable to external factors not related to the ESP's internal components (e.g., surface power failure with no downhole impact).
• • A simpler, less detailed inspection is sufficient for minor cosmetic issues with no impact on performance.

Implementation Framework

Phase 1: Preparation & Planning

Before commencing the teardown, ensure all necessary personnel are trained on API RP 11S1 guidelines. Gather all relevant historical data, including equipment specifications, previous run reports, production data, and any information regarding abnormal operating conditions prior to the failure.

Phase 2: Execution & Implementation

Systematically disassemble the ESP components, meticulously documenting observations at each stage according to the recommended practice. This includes detailed visual inspections, photographic evidence, and recording any anomalies, damage, or wear patterns.

Phase 3: Verification & Validation

Compare the observed findings against expected performance and failure modes. Corroborate observations with any available diagnostic data or test results. Ensure the collected data accurately reflects the condition of the components and the likely sequence of events leading to failure.

Phase 4: Documentation & Closure

Compile a comprehensive