Pumping Units

A. Vehicles should be parked upwind and a safe distance from the pumping unit. Be aware that some gas is produced in all oil operations and gas vented from casing on a rod-pumped well can be ignited by a spark, open flame, hot catalytic converter, etc.

B. Before approaching the pumping unit, visually inspect the general condition of the bridle, belts, belt guards, horsehead, carrier bar, bearings, bearing seals and guardrails. Also, look for excessive vibration.

C. The pumping unit should be stopped while it is being worked on or serviced. Electrical power should be shut off or the gas driver shut down, the clutch disengaged and the brake set before the unit stuffing box or wellhead equipment is worked on or serviced.

D. To prevent a flash and eliminate a fire hazard, the “stop” button should be pressed before using the double-throw switch on a pumping unit motor to change speeds from high to low, or from low to high.

E. When a job requires that a unit be worked on or work is to be done in close proximity to the unit, the pole (main) switch should be locked out by following lockout/tagout and testing procedures. If the unit is in operation, first turn the control panels switch to the “off” position and then throw the pole (main) safety switch. For start-up, reverse this procedure.

F. When the position of a pumping unit counterweight is being changed, the brake should be set and the crank spotted so the counterbalance will not move when it is loosened.

Counterbalances should be either in balance in the down position, tied down, or blocked.

G. When re-fusing electrified pumping wells, the following procedures may be used as a guide:

1. Turn the Hand-Off-Auto switch to the “off” position. Push the reset buttons. Check the fuses before attempting to start the unit.

2. As you approach the main safety switch on the pole, be sure to notice whether or not it is attached to a ground wire. This ground wire should be tied into a pole ground wire or a ground rod at the base of the pole. Be sure the ground wire connections are tight.

Check for burned spots, blistered paint, smoke marks around the lip of the door, or the odor of burned insulation.

3. Use a current detector to check the control box for stray current and or electrical shorts.

If feasible, an alternative may be to have a qualified electrician check for current prior to physical contact. Refer to API RP 54.

4. When opening or closing a safety switch, stand to the side of it, never in front. Open or close in one quick motion.

5. Open the door of the switch box and latch it. Requires a qualified person under the electric standard.

6. Check the inside of a switch for burned spots, blistered paint, smoke marks, and for the odor of burned insulation. Be sure the switchblades are all in the “open” position.

Requires a qualified person under the electric standard.

7. Using a fuse puller, remove all three fuses and replace them with fuses of the same rating. Make sure the fuses are tight in the fuse clips. Requires a qualified person under the electric standard.

8. Close the switchbox and latch it. When closing the safety switch, stand to the side of it, never in front.

9. Turn the “Hand-Off-Auto” switch on the motor control to the “On” position. If the unit fails to start, advise the immediate supervisor.

10. Keep fuse pullers clean and dry. If they get wet or have a buildup or grease and dirt on them, the moisture or dirt may form a conductor for electricity.

11. Never replace a fuse you remove from a switch with a fuse of a different rating. Always replace with a fuse of the same ampere rating. If a smaller fuse is used, the unit will run only a short time before the fuse blows again. Using a larger fuse may create a hazard for operating personnel or severely damage the equipment. The rating is stamped on the brass ring on the end of the fuse.

H. Low-voltage, renewable-element fuses below the 100 ampere size should be prohibited.

I. Before replacing a fuse, always make sure the disconnect is open. Only authorized persons should replace primary fuses such as transfer, disconnect and line fuses. A person should not be authorized to replace such fuses unless they have been fully instructed on the approved safety procedure for doing so. This procedure should include the use of a fuse puller.

J. Makeshift substitutes for fuses such as pennies or slugs should be absolutely prohibited.

K. When replacing belts, shift the prime mover such that belts have slack sufficient for easy removing and replacing. Belts should not be forced.

L. For oiling and greasing, as well as for other work performed around the pumping unit, on the wellhead equipment, or on a chemical pump, the prime mover should be shut down or the clutch disengaged and the brake set.

M. When stopping the unit, make sure the brake is in good operating condition. If it is not, block the unit and repair the brake before making other repairs.

N. The unit can be stopped with the counterweights balanced in either the 12 o’clock position or the 6 o’clock position. For most units, the brake unit should be set at the top of the stroke and the weights should be at the bottom of the rotation. Apply brakes so that the rotational movement will stop smoothly.

O. When work is to be performed inside the weight guard area or on the unit members, the unit should be locked in a positive manner to prevent movement. On units which have stop pawls installed, the stop pawls should be engaged with notches in the brake drum. On units, which do not have stop pawls, the weights should either be chained or blocked.

P. When respacing the pump, the counterweights may be stopped in positions other than 12 o’clock or 6 o’clock, provided the brake is in good operating condition.

Q. Major repair jobs involve massive weights and thus require tools of proper design and rating.

Overstressing small tools or using makeshift tools should be prohibited.

R. During repairs, the work area should be kept clean and free of oil and grease.

S. Before working on wellhead equipment, properly rated pressure gauges should be installed.

Check the casing annulus, tubing and flowline pressures. Bleed off any pressure. Then clean up any fluids around the wellhead work area according to local guidelines.

T. Stuffing boxes should be supported by clamps or another suitable method during stabbing and makeup. Hands should not be put on polished rods. When laying down a polished rod, keep the stuffing box and other loose equipment at the bottom of the rod.

U. Before a polished rod stuffing box is packed, bleeder valves should be opened. During the packing, the top half of the box should be held by clamps specifically designed to hold it.

V. A proper packing hook, not a screwdriver, should be used to remove old packing.

W. When pressuring tubing, recognize that high pressures can build up very rapidly in certain wells, especially when testing for leaks with the existing rod pump, and particularly in installations having long-stroke units longer than 64 inches.

X. Pressure testing with a long-stroke unit should be performed by two persons. One should observe the pressure, and the other should operate the motor controls and brake.

Y. To observe the pressure being placed on a well, a pressure gauge of adequate range should be used.

Z. To respace a pump, the following procedures may be used as a guide:

1. Plan the job with all personnel involved before starting work.

2. Check the condition of belts, brake, throat bolt on horsehead, bridle, latch on carrier bar, rotation of units, etc.

3. Stop the unit near the bottom of the stroke by shutting off the electrical motor or by disengaging the clutch on the gas engine and setting the brake.

4. Clean up any fluids spilled around the wellhead work area.

5. Install a pressure gage in the wellhead flowstream and bleed off any pressure.

6. Loosen liner packing and set screws. Use a loose polished rod clamp to drive the liner down to the top of the stuffing box. Use spacers or adjusting nuts to protect the stuffing box packing. Install the polished rod clamp and tighten it in position on top of the liner. If a “suitcase” (or sleeve) is used between the polished rod liner head and the stuffing box to support the rod string, be sure to use one with a positive locking device to prevent it from jumping out and dropping the rod string.

7. To position a polished rod clamp on top of the carrier bar:

a . Have all personnel move away from the wellhead area.

b . Release the brake and start up the unit.

c . Set the brake.

d . Move the polished rod clamp to the desired location.

e . Release the brake slowly to allow the carrier bar to move up to the polished rod clamp and engage the rod string load.

8. To respace the liner:

a . Remove the polished rod clamp above the liner.

b . Move the liner to the desired position. If possible, clear the stuffing box and allow space for the polished rod clamp above the liner.

c . Remove the spacers or loosen the adjusting nuts. Tighten the liner packing and set screws.

9. To resume pumping:

a . Have all personnel move away from the wellhead area.

b . Run the unit through a cycle slowly to check clearance and pump spacing.

c . If pump spacing is not satisfactory, repeat the respacing procedure.

10. To tighten or loosen the polished rod clamp:

a . Always position the clamp with its open face toward one of the bridle cables.

b . Work from ground level, when possible. If an elevated platform is required, use an appropriate structure with fall protection as needed. (Refer to Section 20)

c . Use a box-end wrench or a socket wrench with an extension. Do not use a pipe wrench or a crescent-type wrench.

d . One individual should perform the wrench work.

e . Stand to one side of the wrench, not directly in front of it.

AA. Pumping units should be checked after initial installation on a periodic basis and after major repairs are completed to ensure that nuts and bolts are properly torqued.