SHAFT PREMATURE FAILURE ANALYSIS IN ELECTRICAL SUBMERSIBLE PUMP SYSTEM: A CASE STUDY FROM MUARA ENIM, SOUTH SUMATERA, INDONESIA

Abstract

The shaft is a critical component in ESP. In many cases, dismantle analyses cannot identify a definitive root cause for shaft failure. Several hypotheses have been studied to explain shaft failure. This paper will review typical shaft failure modes; more specifically, the power source and the consequence of shaft failure will be discussed. An analysis of the premature failure of the shaft used in an electrical submersible pump (ESP) for lifting oil has been carried out. During shaft failure root-cause analysis, mechanical components have been the primary focus. Chemical analysis, microstructure characterization, fractography, and hardness test were used. In addition, the shaft running stress and the possibility condition (the condition of the possible broken shaft has been approached analysis using finite element analysis). It was concluded that the material defects were the prime cause of the shafts' premature failure.