SPE 165004

Tracking System, Failure Analysis and Reuse Program To Optimize Usage

of Power Cable in Electrical Submersible Pumping Systems
E. Rubiano, H. Vargas, J. L. Martin, OXY
Copyright 2013, Society of Petroleum Engineers
This paper was prepared for presentation at the SPE Artificial Lift Conference-Americas held in Cartagena, Colombia, 21-22 May 2013.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
In an electrical submersible pumping system, power cable has a big impact in cost and performance; reuse
procedures are established based on electrical test only, not based either on run life of the cable or number of
running of the system. In Llanos Norte field in Colombia, OXY started a process to reuse power cable as an
optimization cost process with good results, having in mind motor amperage, electrical test results, number of
runnings, conductor size, and some other important variables which affect power cable performance.
As a second phase of optimization, failure analysis of cable presented a main issue to solve, because it is not
easy to track power cable failures due to sometimes the cable used becomes spliced in many parts. Also, if the
cable is reused adds an additional difficulty to the process; so, tracking is a key factor for success.
This paper contains successful story of tracking system, failure analysis and reuse program in Cao Limn as an
optimization process to improve cost without affecting electrical submersible pumping systems run life and
performance, including lessons learned and good practices.
Introduction
Oil production in Llanos Norte field started in the early 80s in Cao Limn field with high flow rates in sandy wells,
average run life of Electrical Submersible Pumping Systems was very low; different practices were applied
increasing the run life with the time, and different suppliers were used. Also, for power cable, different suppliers,
different cable types were used. Some of them achieved good performance decreasing continuous failures due to
power cable issues.
Electrical Submersible Pumping Systems are the most common artificial lift method in the field because flow rates
are normally above 3,000 BFPD. Due to lack of experience, reuse protocols and contract warranties, after an ESP
failure, the power cable was changed for a brand new one. This situation created two scenarios: First, high
average ESP cost per installation, mainly because of the power cable cost, and, second, storage of power cable
with short run lives and useful for operation.
The process for cost optimization includes different phases, as described below:
- First step for optimization of this process was the installation of Power Cable workshop in the field for power
cable inspection, test and repair. Including API recommended practices for testing of power cables either
new or used. At this point, reuse of power cable with short run lives with good electrical and mechanical
condition began. At this point, it was necessary to change contractual warranties to include power cable
reuse.
- Failure analysis of power cables to determine best power cable to use under Cao Limn field conditions.
Similar technique used for the tear downs of ESP was implemented. Collection of samples for tear down and
some analysis in manufacturing plants were required.
- Performance analysis of used cable was required in order to extend the run life of cables to be reused.
- Implementation of a tracking system to have proper information of run life of power cables, to optimize
following up of installations, number of times power cable has been reused and to improve failure analysis
and performance of different suppliers or cable types.
With the implementation of this program the average cost per ESP system used was tremendously reduced and
run lives of power cables to be reused increased with the time from 150 days up to 2,500 days in some cases in a

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safe way with good performance. Actually, reuse protocols are established and continuous optimization of cost
takes place in the field.
Power Cable Types Used in Llanos Norte Field
With the continuous operation in the field, round cable is used instead of flat cable because of its technical
properties and capabilities to support mechanical handling and reuse.
For field conditions, AWG1 and AWG2 power cables are currently used, mainly because of the horsepower
requirements and consequently high amperage of these motors. Additionally, these types of cables give flexibility
to use them in the wide range of motors used in the field. Table 01 shows current distribution of cable usage in
Llanos Norte field:
# Wells

Length [Ft]

AWG #1

302

1,540,000

AWG #2

104

605,000

Total
406
2,145,000
Table 01. Power cable distribution in Llanos Norte
Both cable types have solid conductors due to its higher breaking strength, bending stiffness, and lower voltage
stress and cost. Insulation selected under Llanos Norte field conditions is EPDM rubber for 300F and 5kV
resistances. Based on its higher original tensile strength and elongation, Nitrile rubber was selected for jacket
taking into account that reservoir temperature in Llanos Norte is maximum 210 F. Galvanized steel armor round
interlocked is used with 0.020 thickness.
Power Cable Testing
Recommended Practice API RP 11S61 reaffirmed on April 2008 is used for power cable testing to check electrical
and mechanical integrity of cables to be reused.
- Visual Inspection: Spooling the cable from one reel to another one in the workshop facilities in order to detect
physical damage or deterioration to takes corrective actions. After the inspection, cable shall be re-spooled in
its original armor direction.
- Diagnostic Testing: performed to locate faults, determine the cause of failure, and evaluate the condition of
used cable.
- Insulation Resistance Test: Used as a quality check on the insulation of the power cable by using a DC
Megohmmeter.
- DC High Potential Tests: Used for quality assurance on cables to be reused by measuring the micro amp
leakage current value.
Determination of Power Cable Useful Time
The process started as an optimization cost initiative in the late 90s, collecting data of power cable consumption,
cable types and run life (no reuse at this point). With this analysis the first attempt of reuse criteria was developed
based on the following table:
- Motor Amperage
- Cable testing results
- Run Life of previous installation
However, with the time, copper price started to increase and reuse of cable was challenged, the selection criteria
was extended and some cables were reused with run lives up to 3,000 days in some cases. Some premature
failures (less than 365 days) occurred.

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Figure 01. Distribution of power cable failures by root cause

Figure #1 show the distribution of failures where the run life of the figure corresponds to ESP run life. Pink spots
represents failures with power cable run life over 3,000 days or ESP system run life over 900 days; which
correspond the expected run life for Llanos Norte field.
As observed in the Figure #1 in 2007 and 2008, the number of ESP failures increased due to reuse of cable with
3,000 days of Run Life. The criteria were updated having in mind the experience and technical specs of power
cables used in the field. Finally, the following criteria are being applied:
-

Insulation: Only EPDM cable for down hole.

Conductor size: AWG 2, used with motors up to 70 A. AWG 1, used with motors up to 178 A.
Insulation: < 5 GOhms scrap cable. Power cable with insulation between 5 GOhms and 7 GOhms can be
used with single motors up to 390 HP with a maximum pump setting depth of 4,500 ft. Power cable with
insulation > 9 GOhms can be used with either single and tandem motors > 390 HP.
Number of Runs: Maximum number of runs is 7 for cable to be reused.
Lengths: A minimum of 1,000 ft between splices is required; however, only one splice can be located in 500
ft. Shorter lengths of cable sections shall be scrapped. Longer cable section must be spliced with the motor
lead extension. Newer cable section must be spliced to motor lead extension.
Armor repairs: Maximum 5 armor repairs in total cable length are allowed.
Cable types: Power cable sections with different insulation rubber shall not be combined.
Splices: Maximum 5 splices in the total cable length are allowed; including motor lead extension.
Run Life: For motors with amperage up to 123 A, a maximum run life of 2,500 days is allowed. For motors
with higher amperage, a maximum of 1,500 days is allowed.

With these criteria in place, premature failures were reduced tremendously and cost optimization of cable reuse
set in place. Figure #2 shows distribution of power cable failures since 2009 to 2012. Notice in 2012, that pink
spots in short ESP run lives represents power cable used with more than 1,500 or 2,500 days.

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Figure 02. Distribution of power cable failures by root cause 2009 - 2012

Tracking System
Every power cable in the operation has a tracking assigned four digits ID number. To track it, connection to motor
lead extension correspond to the first section of cable and second, third and etcetera, moves upwards from
downhole to surface.
If the cable is cut in sections (no more than 4 are allowed), a consecutive letter is added to the end of each
section ID number; i.e. XXXX-A or XXXX-B in the case of two sections, having a maximum of D series.
Cable protocol format is prepared to send the power cable to field indicating power cable sections, splices, and
cable testing results.

Figure 03. Example of power cable protocol

Notice that in the example presented in Figure #3, run life of power cable sections #2 and #3 are higher than
3,000 days. This cable was used on December 2011 and indeed presented a failure on August 2012. In the
example above, Cable 1 is the one spliced to motor lead extension because it had the shortest run life.

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Power cable database and statistical software

Early 90s a database was created to store all power cable information; however, reporting and managing
statistics were important issues with years of information. At corporative level OXY developed an application for
an intranet web database and easy to customize based on Llanos Norte experience on power cable tracking.
A brief description of this software includes:

Figure 04. Input window

This input window allows from a dropdown list to:

- Create a new power cable: brand new cable arriving from manufacturing center.
- Assign a power cable to a well in specific installation.
- Database of power cables in standby or waiting for inspection / repair at workshop.
- Update cable information
- Update information of a cable section
Creation of new cable

Figure 05. New Cable window

ID number, cable type, length, reel number for storage, voltage insulation, date of arrival to warehouse and some
comments are updated at this point. This software avoids errors in the cable ID assignment; i.e. ID repetition.
Assignment of power cable to a specific installation in an oil well
To assign a cable to an installation in a well, is necessary to select a cable from the database, and the total length
of the cable is showed; normally not a complete length is required. In the example shown on the figure #6, 5,000
ft out of 8,000 ft is required. So, the system automatically creates a 3,000 ft section with the new ID: i.e. 0947A.
An option to choose which section goes to the well is selected and now requires the new cable reel of the
remaining or not used section.

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Figure 06. Cable assignment

Power cable in stand by database

This section contains the power cable in standby, ready to be used, waiting for inspection, etc.

Figure 07. Power cable in stand by database

The input window to upload data to repair database contains main information of the cable, and the option to
include some comments about the results of the testing, the length of cable to be scrapped.

Figure 08. Input window for cable database

Reporting
System allows creating different reports easy to customize under specific requirements, for instance, history of a
cable section and information of the assigned well with the cumulative run life of it.

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Figure 09. Example of power cable report

Conclusions

Power cable optimization process takes some time; however, economical results are excellent and
operating costs can be optimized.
Run life of power cable is based on field conditions and operating procedures in place.
Initial investment in a workshop facility at the field is not as representative as the savings obtained by
reuse of power cable.
In order to establish an estimated run life of power cables to reuse them is necessary to implement a
proper tracking system as a first step in the process.
An excellent team work is necessary to implement this process; mainly because different groups are
involved, including power cable suppliers.

Acknowledgements
Thanks to OXY for permission to publish this paper.
Thanks to Andrey Ayure who helped in the development of the tracking software for power cables.
References
1.
Recommended Practice API RP 11S6 reaffirmed on April 2008