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Learn how one RCI Failure Scene Investigation team used the PROACT RCA Methodology and Software to analyze the root causes of one of their significant down hole oil well failures at their producing field. This short movie will carry you through the cause-and-effect logic the team used to arrive at their conclusions. Click this URL to view: http://www.reliability.com/demos/pres/proact_series/dhoil/dhoil1.html Failure Scene Investigation training is available on-site at your facility. Click this URL to learn more: http://www.reliability.com/industry/training/failure_scene_investigation.html
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© 2009 Reliability Center, Inc..
PROACT®
Root Cause Analysis
Oil Well Logic Tree ExampleOil Well Logic Tree Example
Reliability Center, Inc.www.Reliability.com
© 2009 Reliability Center, Inc..
Surface Equipment
Coupling Joint
Cement
Downhole
Strings
PerforationsPack
© 2009 Reliability Center, Inc..
Failure Definition Producing Field
An interruption of production at one or more wells
© 2009 Reliability Center, Inc..
Producing Field Opportunity Analysis (OA) Results
0
100
200
300
400
500
600
700
800
1 3 5 7 9 11 13 15 17 19 21 23 25 27
Failure Mode Number
% o
f Lo
ss in 000's o
f US
$
Significant Few Annual CostsLead Line Ruptures $777,852Hole in Tubing $279,938Lead Line Leaks $203,739Pumping Unit Belts $169.231Pumping Unit Brakes $165,337Downhole Pump Failures $127,050Electrical Contractors $124,438Electrical Fuses $113,250Motor Bearings $105,422Pumping Unit Slings $64,218
© 2009 Reliability Center, Inc..
RecurringNon-Producing Well
RecurringNon-Producing Well
Power Failure
Power Failure
Tubing Fails
Tubing Fails
Pumping Unit Failure
Pumping Unit Failure
Rod Fails
Rod Fails
Motor Fails
Motor Fails
Sub-SurfacePump Fails
Sub-SurfacePump Fails
80%
Non-Producing Well
TOP BOX
© 2009 Reliability Center, Inc..
Non-Producing Well
RecurringNon-Producing Well
RecurringNon-Producing Well
Power Failure
Power Failure
Tubing Fails
Tubing Fails
Pumping Unit Failure
Pumping Unit Failure
RodFails
RodFails
MotorFails
MotorFails
Sub-SurfacePump Fails
Sub-SurfacePump Fails
Above GroundAbove GroundBelow GroundBelow GroundHOW CAN?HOW CAN?
© 2009 Reliability Center, Inc..
Non-Producing Well
Below GroundBelow Ground
Operationally Induced
Operationally Induced
Mechanically Induced
Mechanically Induced
HOW CAN?HOW CAN?
© 2009 Reliability Center, Inc..
Non-Producing Well
Below GroundBelow Ground
Operationally Induced
Operationally Induced
Mechanical Induced
Mechanical Induced
Body BreakBody Break Box BreakBox BreakPin BreakPin Break
HOW CAN?HOW CAN?
HOW CAN?HOW CAN?
© 2009 Reliability Center, Inc..
Body BreakBody Break
Erosion Corrosion
Erosion CorrosionFatigueFatigueScaleScaleCorrosionCorrosion Erosion Erosion Rod WearRod Wear
HOW CAN?HOW CAN?
Non-Producing Well
© 2009 Reliability Center, Inc..
Body BreakBody Break
Erosion Corrosion
Erosion CorrosionFatigueFatigueScaleScaleCorrosionCorrosion
Erosion Erosion Rod WearRod Wear
Normal Wearand Tear
Normal Wearand Tear
PrematureFailure
PrematureFailure
PhysicalRoot
PhysicalRoot
HOW CAN?HOW CAN?
HOW CAN?HOW CAN?
Non-Producing Well
© 2009 Reliability Center, Inc..
Incorrect partsfor Service
Incorrect partsfor Service
PrematureFailure
PrematureFailure
Part is Correctfor Service
Part is Correctfor Service
ImproperOperation
ImproperOperation
HOW CAN?HOW CAN?
HOW CAN?HOW CAN?
Non-Producing Well
© 2009 Reliability Center, Inc..
Stretch RodsStretch Rods Bumping BottomBumping Bottom
Pump SticksPump Sticks Pounding Fluid
Pounding Fluid
Parafin Buildup
Parafin Buildup
Pumping TooLong at a Time
Pumping TooLong at a Time
Human RootsHuman Roots
HOW CAN?HOW CAN?
HOW CAN?HOW CAN?
Speed Too Fast
Improper Speed
Improper Operation
Overstress
Non-Producing Well
© 2009 Reliability Center, Inc..
Pump TooBig
Pump TooBig
Latent Roots
ParadigmSpeed Too Fast
Eng. SaidTo Run
Maximize Production
Need To Lower Fluid
Level
Lack ofTime to Change Speed
That’s the Way We
Do It
WHY?WHY?
Non-Producing Well
