Unit Inspection
Transcript of Unit Inspection
WELCOMEWELCOME
LUFKIN INDUSTRIES, INC.
BEAM PUMPING UNIT
INSPECTION
AND
PREVENTIVE MAINTENANCE
Beware of Cookbooking –Beware of Cookbooking –The Same Recipe Does Not The Same Recipe Does Not
Necessarily Work ForNecessarily Work ForEach Well!!Each Well!!
A Good Way to Start but Wells A Good Way to Start but Wells Should be Fine TunedShould be Fine Tuned
TrackingTracking
Tracking All Failures – both to Tracking All Failures – both to Surface Equipment and Surface Equipment and Downhole Equipment Will Downhole Equipment Will Ultimately Lead to The Right Ultimately Lead to The Right Decision on What Corrective Decision on What Corrective Action to TakeAction to Take
RememberRemember
Including Downtime and Including Downtime and Deferred Oil Costs in the Deferred Oil Costs in the Tracking Process will Tracking Process will Ultimately Reveal the True Ultimately Reveal the True Cost of Equipment FailuresCost of Equipment Failures
The Sucker Rod SystemThe Sucker Rod System
Pump
Rod String
Tubing String
PumpingUnit
Surface Equipment Failure ModesSurface Equipment Failure Modes
Surface Equipment FailuresSurface Equipment Failures
Can be, but are not Always, Related Can be, but are not Always, Related to Downhole Problemsto Downhole Problems
A Good Maintenance Program will A Good Maintenance Program will Eliminate Failures from Neglect – Eliminate Failures from Neglect – Failed Equipment Must Then have a Failed Equipment Must Then have a Source , Which Should be Source , Which Should be InvestigatedInvestigated
PUMPING UNIT PUMPING UNIT INSPECTION INSPECTION
WIRE LINE ASSEMBLYWIRE LINE ASSEMBLY
Look for corrosionLook for corrosion Check for broken wiresCheck for broken wires Check for kinksCheck for kinks Measure size of wire ropeMeasure size of wire rope Check condition of carrier bar Check condition of carrier bar Look at alignment with well Look at alignment with well
headhead
Surface Equipment FailuresSurface Equipment Failures
FOUNDATION
• CHECK LEVEL IN BOTH DIRECTIONS
• LOOK FOR WASHOUT AROUND THE EDGES
• LOOK FOR MOVEMENT AS THE UNIT RUNS
• CHECK TIEDOWN BOLTS FOR TIGHTENESS
• CHECK CONDITION OF CONCRETE SURFACE
• LOOK FOR CRACKS
STRUCTURE AND FASTENERSSTRUCTURE AND FASTENERS Listen for unusual noises such as creaks, Listen for unusual noises such as creaks,
pops, squeals, etc.pops, squeals, etc. Check for cracksCheck for cracks Look for bent or twisted partsLook for bent or twisted parts Look for signs of prior repairsLook for signs of prior repairs Look for excessive corrosionLook for excessive corrosion Check for loose joints – rust stainsCheck for loose joints – rust stains Check for broken or missing bolts Check for broken or missing bolts Check condition of ladderCheck condition of ladder
STRUCTURAL BEARING STRUCTURAL BEARING ASSEMBLIESASSEMBLIES
Visually inspect housings, caps and retainers for Visually inspect housings, caps and retainers for cracks and/or signs of movement (rust stains)cracks and/or signs of movement (rust stains)
Look for metal shavings, pieces of bearings, seals, Look for metal shavings, pieces of bearings, seals, snap rings, etc. on the ground beneath the snap rings, etc. on the ground beneath the bearing assembliesbearing assemblies
Listen for popping, creaking or groaning noisesListen for popping, creaking or groaning noises Collect sample of old grease from the relief fitting Collect sample of old grease from the relief fitting
and look for metal particles in grease as well as and look for metal particles in grease as well as other contaminationother contamination
STRUCTURAL BEARING STRUCTURAL BEARING ASSEMBLIES - CONTINUEDASSEMBLIES - CONTINUED
Check crank pin to crank joint for signs of Check crank pin to crank joint for signs of poor fitpoor fit
Check for signs of endplay in crank pin Check for signs of endplay in crank pin bearingsbearings
Check hinge pin bore for movement in the Check hinge pin bore for movement in the housinghousing
Check for signs of misalignment of walking Check for signs of misalignment of walking beam and equalizer/pitman assembly.beam and equalizer/pitman assembly.
Surface Equipment FailuresSurface Equipment Failures
Broken Crank Pin Caused by Continuously Pounding Fluid
Surface Equipment FailuresSurface Equipment Failures
CRANK ARMS AND COUNTER CRANK ARMS AND COUNTER WEIGHTSWEIGHTS
Visually inspect the slow speed shaft’s fit in the Visually inspect the slow speed shaft’s fit in the bore of the crank especially if clamp on crankbore of the crank especially if clamp on crank
Check key and key wayCheck key and key way Look for cracks in crank around slow speed bore Look for cracks in crank around slow speed bore
and around counter weightsand around counter weights For clamped on crank type units check the ears at For clamped on crank type units check the ears at
the splitthe split Look for cracks between crank pin holesLook for cracks between crank pin holes Visually inspect counter weights for cracksVisually inspect counter weights for cracks Check weight boltsCheck weight bolts
BELT COVER AND WEIGHT BELT COVER AND WEIGHT GUARDSGUARDS
Check for areas of excessive rubbingCheck for areas of excessive rubbing Check attachment flanges and bracketsCheck attachment flanges and brackets Check to insure that they meet the requirements Check to insure that they meet the requirements
of API 11E for unit guardingof API 11E for unit guarding Check all joints for proper weldingCheck all joints for proper welding Check all pins and attachment devices for proper Check all pins and attachment devices for proper
functionfunction Check for the presence of all safety signageCheck for the presence of all safety signage
GEAR REDUCERGEAR REDUCER Check for cracks in the gear case, bearing carriers, Check for cracks in the gear case, bearing carriers,
etc.etc. Inspect the slow speed shaft and sealsInspect the slow speed shaft and seals Visually inspect gear oil, look for signs of Visually inspect gear oil, look for signs of
contaminationcontamination Inspect the slow speed gearInspect the slow speed gear Inspect the intermediate assyInspect the intermediate assy Inspect high speed pinionInspect high speed pinion
GEAR REDUCER - CONTINUEDGEAR REDUCER - CONTINUED
Look for signs of loose bearings (in the Look for signs of loose bearings (in the bearing carriers)bearing carriers)
Inspect the brake assembly and adjust brake Inspect the brake assembly and adjust brake if requiredif required
Check condition of beltsCheck condition of belts Check the gear reducer sheave Check the gear reducer sheave Check prime mover sheaveCheck prime mover sheave
Robust HousingRobust Housing
Well Supported Well Supported Crank ShaftCrank Shaft
Long Life Crank Shaft Long Life Crank Shaft BearingsBearings
Bearing CarriersBearing Carriers
Gear ReducerGear Reducer
Proper Wiper Operation
Adequate Lubrication is necessary for long reducer life.
Adequate Lubrication
Corrective Pitting-Normal in New Reducers
Fatigue Fractures-Normally Caused by Overloading
Destructive Pitting-Poor Lubrication or Overload
American Slow Speed Shaft-Design Defect
Shaft Deflection Shaft Deflection
Surface Equipment FailuresSurface Equipment Failures
Surface Equipment FailuresSurface Equipment Failures
Sheaves and BeltsSheaves and Belts Horsepower Losses Result from Worn Out Horsepower Losses Result from Worn Out
Sheaves or if Belt Tension is Inadequate – Sheaves or if Belt Tension is Inadequate – Replace Sheaves if Worn or Damaged and Replace Sheaves if Worn or Damaged and Replace Belts if Cracked or FrayedReplace Belts if Cracked or Frayed
Sheave Alignment is Critical to Belt and Sheave Alignment is Critical to Belt and Sheave LifeSheave Life
Belts Found on the Ground Can Signify the Belts Found on the Ground Can Signify the Possibility of a Serious Downhole Problem Possibility of a Serious Downhole Problem or Sheave Misalignment Either of Which or Sheave Misalignment Either of Which Should be Investigated and Corrected Should be Investigated and Corrected BeforeBefore Putting Unit Back On-Line Putting Unit Back On-Line
Surface Equipment FailuresSurface Equipment Failures
Sheaves and BeltsSheaves and Belts Worn Out Sheaves Worn Out Sheaves
Reduce Horsepower Reduce Horsepower Transmission and Transmission and Belt LifeBelt Life
Replace Sheaves if Replace Sheaves if Found in This Found in This Condition – If Condition – If Bottom of Sheave Bottom of Sheave Groove is Shiny, Groove is Shiny, Sheave is Worn OutSheave is Worn Out
Pumping Unit MaintenancePumping Unit Maintenance The implementation of a very complete and The implementation of a very complete and
comprehensive PM Program is not an expensive comprehensive PM Program is not an expensive endeavor and the savings in major repair costs related endeavor and the savings in major repair costs related to catastrophic unit failure as well as the potential to catastrophic unit failure as well as the potential prevention of injuries and/or loss of life will more than prevention of injuries and/or loss of life will more than offset the cost of any PM program, when properly and offset the cost of any PM program, when properly and routinely performed.routinely performed.
Preventive maintenance is everyone’s job. Those who Preventive maintenance is everyone’s job. Those who are responsible for the well should perform the daily are responsible for the well should perform the daily and monthly requirements of a good PM Program. and monthly requirements of a good PM Program. Professional’s familiar with the operation and Professional’s familiar with the operation and maintenance of beam pumping units should carry out maintenance of beam pumping units should carry out the bi-annual PM work. The bi-annual PM inspection the bi-annual PM work. The bi-annual PM inspection and tasks should be documented and the reports and tasks should be documented and the reports should be kept in the well file. should be kept in the well file.
The following is the minimum recommended The following is the minimum recommended procedures for a good PM Program:procedures for a good PM Program:
Pumping Unit MaintenancePumping Unit Maintenance
DailyDaily1.1. LOOKLOOK - Really look at the unit on a daily basis to observe any - Really look at the unit on a daily basis to observe any
changes in the unit’s alignment, pitman to crank spacing, changes in the unit’s alignment, pitman to crank spacing, wireline tracking, and any thing else that has changed in the wireline tracking, and any thing else that has changed in the past 24 hours which may indicate a problem beginning to past 24 hours which may indicate a problem beginning to manifest itself. These changes should be reported and/or manifest itself. These changes should be reported and/or corrected as soon as possible or at least checked out by a corrected as soon as possible or at least checked out by a qualified service representative for confirmation of further qualified service representative for confirmation of further action to be taken.action to be taken.
2.2. LISTENLISTEN – Really listen for any noises such as gearbox or – Really listen for any noises such as gearbox or structural bearing rumbling, popping, clicking, squalling, structural bearing rumbling, popping, clicking, squalling, squeaking or any other noises that may indicate the squeaking or any other noises that may indicate the beginning of a bigger problem. Any changes in the sound of beginning of a bigger problem. Any changes in the sound of a pumping should be reported and further investigated to a pumping should be reported and further investigated to prevent a more in depth problem or possible catastrophic prevent a more in depth problem or possible catastrophic failure. failure.
3.3. APPLYAPPLY – Apply the brake slowly but firmly to assure it is in – Apply the brake slowly but firmly to assure it is in good working condition. Should the brake need adjustment good working condition. Should the brake need adjustment or is not working properly, it should be reported and/or or is not working properly, it should be reported and/or corrected immediatelycorrected immediately..
Pumping Unit MaintenancePumping Unit Maintenance
MonthlyMonthly
1.1. Continue with the LOOK, LISTEN, and Continue with the LOOK, LISTEN, and APPLY.APPLY.
2.2. Check the oil level in the gear reducer to Check the oil level in the gear reducer to ensure it is at the proper operational level.ensure it is at the proper operational level.
Pumping Unit MaintenancePumping Unit Maintenance
Every Six MonthsEvery Six Months1.1. Continue with the LOOK, LISTEN, and APPLY.Continue with the LOOK, LISTEN, and APPLY.2.2. Check the significant bolting for proper bolt tightness. Check the significant bolting for proper bolt tightness.
Additionally, this should also be done two weeks after any unit is Additionally, this should also be done two weeks after any unit is set and put into operation.set and put into operation.
3.3. Take a sample of the reducer oil. This should be done after the Take a sample of the reducer oil. This should be done after the unit has been shut down for a time sufficient enough to allow for unit has been shut down for a time sufficient enough to allow for oil in the bearings and the oil trough to drain back into the oil in the bearings and the oil trough to drain back into the reducer. Take a typical sample, preferably in a glass or reducer. Take a typical sample, preferably in a glass or transparent bottle and set aside for further separation. Check transparent bottle and set aside for further separation. Check the sample for possible contamination by sludge, dirt, water, the sample for possible contamination by sludge, dirt, water, metal or any other foreign material. Smell the oil for possible metal or any other foreign material. Smell the oil for possible breakdown of the additive package. An acrid odor indicates a breakdown of the additive package. An acrid odor indicates a breakdown of the extreme pressure additive. It is also good to breakdown of the extreme pressure additive. It is also good to have a sample of good new oil to compare the collected sample have a sample of good new oil to compare the collected sample to. Top off the oil before leaving and report any problems or to. Top off the oil before leaving and report any problems or leakage.leakage.
4.4. Grease the structural bearing assemblies and report any Grease the structural bearing assemblies and report any detected problems such as metal flakes in relieved grease.detected problems such as metal flakes in relieved grease.
5.5. Issue a complete pumping unit inspection sheet to the Issue a complete pumping unit inspection sheet to the designated Company representative for his determination of designated Company representative for his determination of further work required.further work required.
Pumping Unit MaintenancePumping Unit Maintenance
Preventative maintenance, by definition, is Preventative maintenance, by definition, is decisive counteraction to keep any piece of decisive counteraction to keep any piece of equipment from premature failure. By following equipment from premature failure. By following the aforementioned general procedures, one the aforementioned general procedures, one should be able to recognize telltale signs that should be able to recognize telltale signs that would indicate a problem in its most early would indicate a problem in its most early stages. The six-month in-depth inspection, stages. The six-month in-depth inspection, lubrication and bolt-tightening program, which lubrication and bolt-tightening program, which should be performed by professional pumping should be performed by professional pumping unit personnel, will complete the PM cycle, unit personnel, will complete the PM cycle, provide a detailed report of the condition of the provide a detailed report of the condition of the pumping unit and identify and problems pumping unit and identify and problems requiring immediate action to be taken. requiring immediate action to be taken.
Surface Equipment – A Geometry Surface Equipment – A Geometry or Unit for Every Wellor Unit for Every Well
Questions, Answers and Questions, Answers and DiscussionDiscussion
Sucker Rod Beam Pumping Sucker Rod Beam Pumping System MaintenanceSystem Maintenance
Thank You For Your Thank You For Your Attention!Attention!
Thanks also to:Thanks also to:
Petrobel Management and Field Personnel – for Petrobel Management and Field Personnel – for the opportunity to make this presentationthe opportunity to make this presentation