Monitor your complete ESP health from the surface-level motor control cabinet.
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The average electric submersible pump (ESP) runs to failure in just 2-3 years, due to harsh operating conditions. Failure is often unexpected, making it difficult to replace the ESP in a short time frame. What’s more, efforts to prolong ESP run-life often center around data from downhole sensors, which can fail themselves due to the harsh conditions down the well.
Non-productive time can stretch from 16 days to 7 months.
Downhole sensors frequently stop working before the ESP itself.
Samotics’ Electrical Signature Analysis technology is in the best position to detect electrical failures. Our sensors continue to function after a downhole sensor breaks down, because you install the sensors safely inside the surface motor control cabinet.
Electrical failure modes | Detection lead time | Detectable by Samotics | Detectable by downhole sensor | Detectable by Ammeter chart* |
---|---|---|---|---|
Phase unbalance | Real time on indicators, failure in hours to days. | |||
Under- and over voltage | Real time on indicators, failure in hours to days. | |||
Sine wave filter failure | Real time on indicators, failure in hours to days. | |||
Overcurrent | Real time on indicators, failure in hours to days. |
* Samotics also provides an Ammeter chart.
What if you could see ESP failure coming days to weeks in advance? That would allow mobilizing a workover rig, getting replacement parts and scheduling a crew even before failure happens. For typical oil field operations, this saves days to weeks of suspended production.
At the same time, having a reliable source of ESP operational insights allows operators to adjust their operating settings to extend ESP runlife.
Solve above-ground electrical issues to extent ESP lifetime or be warned for imminent motor failure, enabling timely overhaul preparations.
SAM4 detected a severe increase and imbalance in the main harmonics, indicating electrical component failure—likely in the sine wave filter.
The customer investigated and was able to repair the sine wave filter in time, preventing a ‘dirty’ power supply to the ESP and reducing the risk of early failure.
Accurately predict upcoming ESP failure. Enabling operators to prepare for an overhaul, reducing lost production time.
SAM4 detected increased energy around the 2nd and 4th harmonics, indicating mechanical wear on one of the rotors within the ESP. The customer was able to prepare for ESP replacement, reducing turnaround time.
Enabling operators to take action, increasing production and extending the ESPs lifetime.
SAM4 identified gas-locking through a combination of excessive cycling combined with spikes and inconsistent power consumption, indicating unexpected changes in the process or pumped medium.
Safely install the condition monitoring sensor inside the surface motor control cabinet to monitor the most important parts of the drivetrain at hard-to-reach places.
Book a demo to see how SAM4 detects early signs of ESP degradation using sensors in the motor control cabinet. Get clear, real-time insights into pump and motor health – so you can act before production is disrupted.
SAM4 is built in The Netherlands
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