-!HANDBOOK
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SAFETY
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1.1
Section
SWITCHBOARD
SAFETY TIPS
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2.
3.
5.
6.
is the
key
some
to
monitored:
da1:a
be
to
efficient
ESP
opera
tions.
Usted
below
are
..
Daily Monitorina
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..., ua "UlIUId~t:U.
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EQUIPMENT
TI,e ESP system can be divided Into subsurface and surface
components. rhe major downhole components Include an electric
motor. seal section. muill-siage cenlrifugalpump wilh an Intake and
discharge. and power cable. Optional downhole equipment may
Illclude a bottomhole pressure/temperature sensor. check and drain
valves. motor shroud. and a gas separator. The surface components
illclude a 'unction box. switchboard. and transformers. A typical ESP
Illstalialion Is shown in Figure A. A description of each component
I~ given below ,beginning downhole and moving up the well.
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Subsur1ace EoulDment
Motor
ESP motors
are two-pole.
threEt-phase,
squirrel
cage
Induction motors which operate at fl nominal speed of 3500
rpm at 60 Hz. Voltages range from 480 to 4,125 volts, whOe
amperages range from 14 to 143 amps.
Horsepower
Is
Increased by Increasing motor length for a given diameter
size or motor series. Large horsepclwer requirements usually
require two or more motors, commonly
referred to as
tandem motors.
Molors.. are lilled with a nonconductlve
oil with a high
dieleclr!c strength which provkJes lubrication
lor bearings
and good thermal conductIvity. Produced fluid moving past
the outside 01 the motor carries heat away; cooling the motor
(minimum recommended fluid velocity Is I ft/sec). lIthe fluid
veloclty'\s nor sufllclenllo
coollhe
motor, or if Ihe motor Is
located below the per1orations, 0 shroud should be placed
around'the motor.
Seal~Pro'ec'or, Equalizer
The seal section (also known a!i a protector or equalizer) Is
located between the motor and lIuld Intake 01 the pump. The
seal sery~s live main junctions: ;"
/(,
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and
underload
relays
protect
the
ml)tor
trom
Drive
(Optional)
:;: ..,
L.z
..." :,"".,",;C
Wax can
tubing as
remedied
down the
point to consider:
Pump hot oil or water down t; ! tubing if possible.
Excessively
hot fluids down the nnulus could exceed
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Scale
It well bore scale problems are presen
in your field. you
likely have scale build up in your ESP. Frequently
you
treat the pump for scale by pumping t e recommended
tor your type ot scale through the pu p. The following
some
points
annulus.
Try
ratin
and
will
can
acid
are
to consider:
to
pump
the
acid
This
the
will
oHers
acid
bener
down
nol
contact
co
Irol
tubing
,armored
th
over
instead
the
treatment of
the
cable.
ed to acid treatments
ound the cable.
(Be
r\ cause emulsions that
tion)
Not to mention
eleased from scale.
Asphaltenes
and pump.
If asphaltenes
cut material
analyzed.
If It proves to be asphaltenes. the propl!r treatment
can be applied
before
the pump becomes
Irreversibly
plugged.
Hat all
If a check
I.
valve
exists
above
the cable's
temperature
rating.
awe:
When pumping down the tubing, use two tubing
volumes at 80% to 100% 01 the lormatlon tlemperature.
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volumes
at 80% to 100%
\
Hlot Watering
? 1~~~~=~:==:=~~~!!I~~
:.
...L
of the formation
temperature.
:;~::...:;:.:::.:.,-,_c~ ,.:,.: ,.
;;1;:::;;~~;;~~~:::.~~.;:.:~~:;:
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appropri"te
chemical additives.
Rules 01 thumb
I:atering
lare the same as lor hot oiling.
~Cid
lor
hot
Selection
Ihumb are:
I.
acid
with
good
8r,eatlng
! The
T
al:idizing procedure lor a seized ESP Involves a lined
Ifpressllre
truck with a lined or nonreactive pump. The acid
shoul(]1 be thoroUGhly mixed orior to pumping
down the
Itubin~11;'~
suggested acid procedure is as lollows:
Rate
Description
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Volume
(bbls/mln)
11ublng
volume
acid
of
'h tubing
volume
of
acid
3. Allow a 15 minutelor
soak lime
the acid
10 work.
4. Pump a Iresh,
unspent Y. tubing
volume 01 acid Into
the ESP.
y. lubing
volume 01
acid
5. Let soak
approximately six
hours.
6. Turn on the ESP and
produce the spent
acid down the
flowline.
'h
Acldlzlng Asphaltenes
Asphaltic crudes are sensitive to the presence ollerric iron
during acidizing operations.
The iron acts to crosslink the
asphallene
molecules,
lormlng added.oil
sludges.
Iron
..r
Treallng
The asphaltene removal procedure lor a seized ESP Involves
a pressure truck with a pump containing tenon seals. The
solvent Is thoroughly
mixed prior to pumping
It Is then
pumped down the tubing
A typical asphallene removal
program is as follows:
Description
1
Volume
RIle
(bbls/mln)
1 tubing
volume 01
solvent
tubing
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-4
5.
six hours.
6.
~ tubing
volume 01
solvent
'I. tubing
volume
of
solvent
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Solvent-Rubber Reaction
Solvent Is usually pumped down the tubing and rarely down
the annulus. II solvent Is pumped down the annulus at lull
strength, h will come in contact with the cable and destroy
the Integrity 01 Its nuld jacket.
Most fluid jackets are
nltr~e-based and most solvents will swell nitrite 25 '0 50%. II
this happens the cable armor may burst and/or an electrical
short will occur.
Check with the ESP manufacturer
before pumping
any
solvents through an ESP. Some manufacturers
use nitrite
bushings in the pump. and these will swell and seize the ESP
if they are contacted by a solvent.
Solvent Selection
The Iwo most common and eHective aromatic solvents are
xytene and toluene. Both are equally eHectlve at repetizing
asphaltenes. The various chemical manufacturers have
sur1actants and dispersants which will Improve the performance 01these aromatic solvents. Chemical companies will
test a sample 01 asphaltene and determine which Is the best
lormula lor the sample given. This Is usually done quickly,
but the testing Is extremely biased. For complete. unbiased
testing, send a sample to COFRC. The testing time Is longer
but the recommendations will be nonbiased.
The volume
asphallene
present. A good
bbls/ I 000 feel of tubing.
rule
by the quantity
of thumb
of
Is IIC) use 2
clown the
program
Treatment
described
below.
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Check Valve VI. No Check Valve
PUMP OFF
~roblems
.Unit
100 large
Solutions
.Redesign
.Stimulate
",c,.
.~7
'..i;..~~~:::::::::
FALSE STARTS
Problem~
.Auto
restart delay not of sufficient
fluid build-up.
SolutIOQ~
.Increase
.Redesign
restart delay
ESP
Transformers
Transformers
are used to convert primary line volta'ge to
motor voltage requirements. Three types of transformers used
In conjunction
with ESPs are: banks 01 three single-phase
transformers.
three-phase
sta~ard
transformers.
arKi
three-phase auto transformers. The transformers are oill-filled
and self-cooling.
For oHshore platiorms where oil-filled
transformers
might be prohibited. dry type transformelrs are
available. The transformers are equipped with taps to provide
maximum flexibility In voltage outPut.
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TROUBLE SHOOTING
Section 3
3.1
or over1oad.
:1
Check the amp chart 10 see if any unusual lines or blips are
present. For help in Inlerpreling amp charts see Trouble
Shoaling Amp Charts.
3.
4.
5.
10 see Ii
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6.
Visually
inspect transformer
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!! .
f.
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,j
hookups.
the
unit downhole
I:rom the
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t.;a
Problem #2:
Possible Causes
Low well productivity
pumped-oN
Corrective
Actlcinl
.Check
amperage downhole
condition
.Shoot
fluid level. Pump water down
backside II no fluid levEllls
available. \I there Is lIullj In the
well, consider pump ctllange.
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Possible
Plugging
of pump Intake
.Check
fluid.
.Pump acid down tubin!) and
through pump II tubing Is open to
pump discharge. (see 13ectlon2,
Treating)
.Pump
acid down backside and
spot around pump Intake.
.Change
out pump. Have the pump
ackilzed and tested beliore sending
lor repair. This may avoid the
.Check
amperage dowrlhole on all
three phases and comlpare with
nameplate amperage 01 motor.
Reset under1oad lilt Is above 80%
01 nameplate amperage. Do nol go
below 60% 01 molar arnperage.
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.Compare
downhole amperage with
Idle load amperage (typically
45-55% 01 nameplate amps).
Reverse unit In switchboard
by
changing two downhole leads.
Check amps again; they should be
within :t 10% of lirst reading.
Reverse leads again. Pump water
down backside if available. Start
unit again. " amperage Is constant
through this procedure. a broken
shaft exists and the unit must be
pulled.
.Pump
water down backside
break gas lock.
Is gas locked
.Vent
casing to flowline
to
II possible
.Check
setting depth to see if unit
can be lowered closer to
perforations.
.Install
Faulty remole conlrols
switchboard
10
.Check
pressure control circuit or
other auxiliary that could cause
shutdown.
Flowline restrictions
~Pump
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8rOb'em
[prOblem #6: Unit will not shut down with HOA switch.
II Possible Causes
C II Controlrelaystuck
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Possible Cause.
Undercurrent shutdown
.Check
downhole
~or~al~ust
Remote controls have
opened and shut unit
down
Unit starts but shuts down
withIn 5 seconds
arTlperage. II
setting.
.Check
for open or closed contacts
on remote circuits and clean or
repair as necessary.
.Check
remote contclcts and clean
or repair as neces~lry.
.Check
lor correct phasing on
control power Irans10rmer.
Change II necessarf.
.Check
CT phasing. Change 3.5.7
10 controller If necessary.
.Check
remote circuits. Unll will nol
slart In lime-oil II relmole contacts
are open.
.Underload
underload
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FIGURE A
;,';'
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::::::::-i:"
~'::::i~i:;;,
2.
fluid.
4
5.
..
:c. .::,
-~:;; ::[;;~:.;
,;. ii,' :.:~;~~';
~~~.i.:;:;~~'
t~".::o.:-~.::
~I
protection.
Pump
The submersible pump Is a multi-stage centrifugal
pump;
each stage consisting ot a rotating Impeller and a stationary
diffuser, that produces a given amount ot head for a given
volume. Impeilers may be either floatinq or fixed. Aoating
imoellers, which are the most common, move axially along
the shaft and are tree-floating when the pump is operating
within the recommended
capacity range (see Figure B).
However. jf the pump is operating ~
(to the left of) the
recommended
capacity ~,
the impeller will be in a
downthrust condilloQ. Conversely. if the pump is operating
~
(to the right of) the recommended capaCity~
the
~Ie~
..
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;;~;;,:i';;'
',-" "';
;:~~i.~1t~
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impeller will be in an u~Ihrust condition Both downthrust and
upthrust can cause excessive wear and can be detrimental
to the pump.
f:lxed Impeller.
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fluids.
Power Cable
Electric cable strapped to the tubing Supplies power from the
switchboard
to the motor. The cable Is made up of three
copper
conductors.
either
solid or mullistrand
The
conductors are Individually Insulated: various Insulallons are
available
depending
on well fluids, temperature.
and
pressure.
A jacket
material
surrounds
the Ins~ated
conductors for protection against mechanical damage and
the environment. A metal armor Is wrapped around the/acket
lor further protection against mechanical damage. The metal
armor also helps prevent swelling when gas or liquid
permeates
at high pressures.
#8
#4
#2
#1
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-up to 37 Imps
-38-57 Imp.
.58-65 amps
-66+ amps
temperature.
should
not
Sul1ace Eaulcmenl
Junction Box
A vented
junction
box is located
arid
switchboard.
In high pressure wells, gas may permeate tile
cable and migrate to the surlace. The 'unction box allows gas
~.j~:;~;:.
,--"'---'
"-
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+-ANA
L YZE PBQ~L-.EM
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Section
'ii~~U1
,!4.1
EQUIPMENT TESTING
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When ESP equipment Is pulled from a well its disposition may vary
from running h back Into a well, to sending it to the manufacturer to
be rebuilt, to having h tested by a manufacturer or testing company.
lf the equipment was pulled for some reason other than a failure, a
well site Inspection may be adequate to determine whether it Is
suitable lor rerunning. However, if the equipment Is not going to be
rerun Immediately,
or If there is doubt as to hs condition,
It is
recommended that it be tested. Testing Is an Inexpensive means of
determining the condition of used equipment.
In the motor testing
program, expensive repair costs can also be reduced as much as
90%. Sending equipment to be tested Is of particular Importance
when equipment has been subjected to a hostile well environment
(high water cut, COl, HJS, etc.). The cleaning of equipment and
preparation for storage that Is Included In the testing procedure, is as
Important. if not more so, than the testing Itself. Pumps. in particular.
left stored on the rack without flushing can "lock down. and become
Inoperable.
PumR Tesllng
Each section 01 a pump should be Inspected lor problems,
such as a twisted shah, hole in the housing, or any problem
that would require h to be sent lor repairs rather than testing.
2.
HCL
containing
an Inhibitor
and
dispersant
should
be
.
!
.!
6.
9.
7.
8.
Molar Testlo.g
a.
b.
c.
the
phase-to-ground
(lead-to-housing)
.IROUBlE
rnalyzing
ammeler charts Is one of Ihe best ways to diagnose a
.~ulllber
of problems.
LIsted on the next few pages are examples of
ammeter charts lor various operating conditions.
These charts are
reprinted from the .Submerslble
Pump Handbook" with permission
Ilroin Centrilift.
Comparing these amp charts to your amp chart may give an
B Indication 01 the type 01 problem you have.
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NORMAL
.Under
normal conditions the ammeter should draw a smooth
symmetrical curve near nameplate current. S'plkes at start-up
are normal.
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POWER FLUCTUATIONS
Problems
.Fluctuation
of Primary Power Supply
motors Injection pumps etc.)
(Start-up
of large
SolU1lons
.Investigate
Power Fluctuations
.10
causes 01 fluctuations
(Start-up
of larget HP
Injection pumps)
.Call
power company
-::.
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"
mott
HP
Cle~n molor
Sleam clean body to within one foot of motor head.
b.
T"8 nXltor oil should be drained and checked lor bronze content
"
(Indicator
01
bearing
wear),
water
content:,
varnish/epoxy content, and melled babbit contenl (silver In oil'l.
lor
damage.
tie
on Iill valves
should always
01 nXltor problems.
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~2I STANDARDDOERATINGORDCEDURE
o"mp'
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f,
1-
GAS LOCKING
~.Lowering
.Gas
fluid 'e~el
e~oI~es In pump
.S-Q!Y1!~
.Lower
pump
.Choke
.Put
production
on \imer
.Redesign
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111
pump
back
n.
UII
(F't
v. Commt8U: 8~,
1111
m8pr roalldtnllt081
lor ~alpmtDIItIkd:
(YIN!
E.acn
Do...
Do..WOc..pIoW:
1\
WORKOVER
VII.
DATA
1\
80
BW
GV
CO1~
Ii
VIII.
DAn:
fllnD
u:vEl
lAwell
CASING
PRESS.
COMMENTS
Dale
Equip.
RUD
RUIOD
os
Up/DUp/D..
Up/D..
Up/D..
Up/D..
X. Comments:
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~~:-:.;-,7':~;~'-;~'--- -' I
!:l!;;" "
"I DESIGN!
"Capital and operating
costs, well
conditions,
reservoir
and ease of
-ESPO,
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,:':'
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DECISION
Decision analysis can help you make Ihe best economic artificial lift
decision. Merek. whict! utilizes many lools of decision analysis. Is a
good program to base your economic decisions.
TI19 foundation
01 good decisions
Is historical
data.
Please keep
go~ recordsl
!;
---
PUL1Jl':/J
G A~
TABI: UP
Ssction
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INSTALLATION/PULLING
Pre-Job Checklist
listed In this section are tips that will hopefully lead to fewer failures.
For complete running and pulling directions please consult API RP
IIR.
Eaulcment ReQuired
Motor
Ogtlonal EglliPJillll!'.
.Gas Separator
.Seal
Section
.Check
Valve
.Pump
.Drain
Sub
.Cable
Motor Flat
.Motor
Shroud
.Switchboard
.Variable
Speed Driver
.Round
Power Cable
.Junction
Box
.Transformers
.ESP
Tubing Hanger with Tubing Head
.Tubing
PUP (2'-6')
Services Required
.Cable
Reel (54" or larger!
.Cable
Bands and Bander (Hand band with precut bands
or power band with reel 01stainless steel bands!
.Electrician
(lor disconnecting and connecting ESP and
testIng cable!
" Subpump SeNlce Technician (on 10catlof1lor length 01
lob)
.Chevron
Representative (coordinale Iplacement 01
equipment, timing 01 deliveries. and supeNislon 01 the
installation!.
.
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PROCEDURES
00 NOT RUSH.
Preolannina
is an investment
for success.
Wellbore PregaraliQn
Run a bit and positive scraper set to drih diameter at least
100 leet below nllmn !;Rnlnn npnlh A ~Ip~n ntillrin t)plnw IhA
If cost ellectlve.
Note
Eaulcment Handling
When unloading ESP equipment, use a spreader bar with a
chain allached near each end of the box. Never pick-up In
the middle!
If the equipment
damaged.
location.
Is dropped.
damaged.
or appears already
~gJRunnlna
Eaulomeot
of work
or concerns.
10 be
.
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2.
3.'
1 Service Technician
1 Chevron Supervisor
Handle equipmenl
technician.
as recommended
by the
subpump
Clble ReellnQ/BandinglRunnlng
Reeling
1
5.
Always
line 01
sight.
6.
to prevent
cable
from
dragging
Banding
It Is very Important
the tubing.
be run straight
up
2.
3.
side of
above
has the
the flat
splice.
4.
armor.
6.
7,
if the cable Is
damaged.
8.
Splices
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5.
Running/Pulling Cable
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(ulecllical
resistance checks).
6.
Run and pull pump between 1000' and 2000' per hour
Never pull the cable 'rom tile reel.
B.
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ESP
62
START-UP
PROCEDURES
Load tubing
2.
Set
overload
nameplate
amperage
at
110-120
percent
of
motor
amperage.
4.
5.
6.
7.
to
start,
01 30 minutes.
consult
a service
technician
to
and
or
9.
10.
b.
c.
d.
8.
8.
11,
Is within
10 percent
01 the
Use 24-hour charts for first three days alter ESP Installation
(may go to 7 -day charts alter).
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GASSY
Problems
.Gas
Is being produced
through
the pump
Solutions
.Lower
.Install
~--",~-.~~..~~,-",~~~,
:
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EXCESSIVE
CYCUNG
PrQblem~
.Detrimental
to ESP motors
.Too
large a Unit
.Plugged
TBG
.Tubing
leak
Solutions
.Obtain
.Check
,.
UNDERCURRENT
lOAD
P.!.g~
.No
/luki In hole
.Failure
of timing relay
~~
.Lower
Undercurrent
.Remedial
ackJ.
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UNDER CURRENT
BELOW NO LOAD
Problem~
.Unit
oversized
.Under
current
Actions
.Shut
well In
II
, '"
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CONTROLS
Eroblems
.Controlled
shut down
(By tank level, elc)
.Set
.Use
.Check
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OVERLOAD
Problems
.Increase
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equipment
~ctions
.Have
.Do
electrician
not restart
:.:-o:--~~
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DEBRIS
Proble~
.Debris
SolutlQll~
.Use
clean workover lIuids
.Clean
well prior to ESP installation
.See
treating
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EXCESS RESTARTS
Problems
.Power
problems
Solulions
.Have
.Do
unit ctlecked
not restart
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out by an electrician
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ERRATIC
Problems
.Mechanlcallallure
(locked pump. burn motor.
.Change
In suriace pressures
.Change
In specific gravity
Solutions
.Do
out.
blown fuses)
--he
~angeIY,
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