Summary

ALS provided regular inspections of ESP equipment on behalf of an Operator located in Qatar. The inspections were performed at the primary ESP manufacturing facility, as well as the facility of the subcontractor that is used for packaging and shipping the ESP equipment. The support that ALS provided served to ensure the ESP components were assembled and tested according to procedure, and procedures were regularly updated in accordance with best practices. Furthermore, the ALS inspections ensured a strict adherence to the Operator’s specific packaging and shipping requirements to minimize risk of damage during the transportation of the equipment from the point of Manufacturing to Qatar. Along with the inspections, ALS provides the Operator with daily and final reports including pictures and release notifications.

Audited Items

  • Assembly and testing of all ESP equipment including pumps, seals / protectors, intakes, and motors as per Manufacturing procedures.

  • Procedural updates in accordance with industry best practices

  • Packaging and preparation for shipment of all assembled equipment, in accordance with Operator-specific procedures.

Inspection Summary

A summary of the equipment quantities and types inspected over the course of the project is included in the below charts.
Equipment Inspection Summary
Component Quantity Inspected Quantity Released
Motor 42 37
Pump 103 87
Protector / Seal 69 53
Gas Separator / Intake 24 24
Total 238 201
Equipment Inspected
Year Inspected Released
2016 3 3
2017 24 21
2018 151 133
2019 60 44

Findings and Recommendations

The inspections regularly identified procedural errors that were addressed immediately. When necessary updates to procedures were identified, the request for changes were communicated with both Supplier and Operator, and agreed upon before implementation. Additionally, recurring issues such as leaking mechanical shaft seals or check valves failing to open or close in the protector/seal sections were addressed directly, and new processes were developed in order to remedy the issues. Equipment that failed tests or did not meet specifications was rejected and either re-tested, or disassembled. The cause for rejection was identified, corrected, and the equipment was re-assembled and re-tested to confirm it met specifications. Once approved, ALS ensured the equipment was placed in secure shipping boxes with the required supports for shock absorption, along with sensors to identify if excessive shock forces are encountered during transportation

The Operator, Supplier, and ALS worked together in the above efforts to ensure the highest quality equipment was being installed, and all are in agreement that these methods have contributed to increased runlivesand mitigation of infant failures.