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