Okay, you've got a potentially dangerous situation, and you're right to proceed carefully. Here's a breakdown of how to tackle this, considering your electrical background

Safety First!
TURN OFF THE BREAKER supplying power to the well pump BEFORE DOING ANYTHING. Double-check with a multimeter to ensure it's dead. Assume it's live until you prove otherwise. Lockout/Tagout

If others have access to the panel, use a lockout/tagout procedure to ensure the breaker stays off.

Understanding the Problem Arcing Wire

The arcing is a HUGE red flag. It's a fire hazard, and it's likely caused by insulation failure on the wire due to age and/or moisture.

Ground Wire in Casing

The bare ground wire hanging in the well casing is completely wrong. It's ineffective as a ground, and it could even contribute to corrosion of the casing.

Tight Wires

The tension on the wires is also a problem. It stresses the connections and makes future repairs difficult.

The Correct Approach1. Assess the Situation (Before Pulling Anything)



Pump Type

If you know the manufacturer and model of your pump, you can potentially access documentation that specifies wire type, connection methods, and hanging procedures.

Well Depth

If possible, try to determine the approximate well depth. This will help you estimate the amount of wire you'll need.

Casing Integrity

Inspect the well casing itself. Any cracks, corrosion, or other damage could be a sign of larger problems.

Electrical Components

Note the location and type of any electrical components near the wellhead, such as a pressure switch or control box.

Wire Size

Determine the existing wire size. You will need to replace with the same or larger AWG.

Wire Type

Most submersible pumps use submersible well pump cable. It is designed for constant submersion.2.

Pulling the Pump (The Right Way)



Support

Before disconnecting anything at the top, you must have a way to support the pump and its wiring. The weight of the pump and water-filled column of pipe can be significant. If the pump is suspended on a hanging device on the side of the well casing (typical), make sure that this device is in good condition and can support the weight. Have a rope or chain hoist handy as a backup, should the device on the side of the casing fail.

Disconnect

With the pump supported, disconnect the wiring at the top.

Slow and Steady

Carefully and slowly pull the pump up.

Marking

As you pull the pump up, mark the PVC pipe (or whatever pipe material is used) at regular intervals (e.g., every 5 feet) so you know how much pipe you've pulled. This will be crucial when you put it back in.

Support the Pipe

As you pull the pipe up, support it to avoid putting strain on the casing or the wires. You might need a helper for this.

Inspect the Pipe

Check the pipe for cracks, leaks, or damage. If you find anything, replace it.3.

Addressing the Tight Wire



Yes, pull the pump

You're right; you need slack. Pulling the pump is the only way to get it.

Possible Causes of Tightness



Pipe Stretch

PVC can stretch over time, but that's less likely than the wire slipping in the connections at the pump.

Improper Installation

The most likely culprit is that the wire wasn't installed with enough slack originally.

Sagging Pipe

The pipe could have bowed in the well.4.

Splicing and Wiring Submersible Pump Cable

Absolutely use only submersible pump cable for any new wiring inside the well. This is specially designed for constant submersion and won't degrade like standard electrical wire.

Proper Splices

Use submersible-rated splices (typically epoxy-filled or heat-shrink with sealant). These create a waterproof seal.

Do NOT use wire nuts or standard electrical tape. These will fail quickly in a well environment. Some people prefer epoxy-filled splices because they are very reliable. Others like heat-shrink because they are easier to install. Choose the type you are most comfortable with, but make sure they are rated for submersible pumps. Stagger Splices

Stagger your splices so that the bulk of the connections isn't all in one spot. This helps with flexibility.

Ground Wire



DO NOT just leave the ground wire hanging in the casing. That does nothing. Connect the ground wire from the pump cable to the ground lug in the control box (if there is one) or to a proper grounding point in the electrical panel that feeds the pump circuit. Securing Wires

Secure the submersible cable to the pipe at intervals using waterproof cable ties. This prevents the weight of the cable from pulling on the splices.

Slack

Leave plenty of slack at the pump connection. You want the wire to have some give so that it's not constantly under tension.5.

Lowering the Pump Slowly

Lower the pump slowly and carefully.

Keep Wire Straight

Make sure the wires don't get tangled or pinched as you lower the pump.

Use the Marks

Use the marks you made on the pipe to ensure you lower the pump to the same depth it was before.

Secure at Top

Reconnect the wiring at the top, making sure all connections are tight and properly insulated.

Important Considerations Local Codes

Check your local electrical codes for any specific requirements regarding well pump wiring and grounding.

Professional Help

If you're not comfortable with any part of this process, don't hesitate to call a licensed electrician or a qualified well pump technician. Water and electricity are a dangerous combination.

Pump Age

If the pump is 30 years old, it might be nearing the end of its lifespan anyway. Consider replacing the pump while you have it out. It could save you a lot of trouble in the long run.*

Well Inspection

Consider having a professional well inspection done. This can identify any other potential problems with the well, such as low water flow or contamination.

In Summary

You're right to be cautious. Follow these steps carefully, use the right materials, and don't hesitate to seek professional help if needed. Addressing the arcing wire and improper grounding is crucial for safety and the longevity of your well system. Good luck! Flag for review