Every ESP failure carries information. A disciplined failure analysis turns an expensive workover into a lesson that prevents the next one. This article covers the common causes of ESP failure and how to work back from symptom to root cause.
Why failure analysis matters
Without root-cause analysis, operators tend to replace like-for-like and repeat the same failure. A structured dismantle inspection and failure analysis (DIFA) identifies not just what broke, but why — so the next design can be improved.
The usual suspects
Most ESP failures trace back to a handful of causes: electrical failures in the motor or cable, mechanical wear from sand and vibration, scaling and plugging, gas interference, and thermal degradation. Often several act together — sand accelerates wear, which increases vibration, which stresses the cable.
Reading the dismantle
A methodical teardown reveals the story: erosion patterns on stages point to abrasives, discolouration points to heat, scale points to water chemistry, and burnt windings point to electrical or cooling problems. Photographing and documenting each section is essential.
From symptom to root cause
The goal is to separate the primary cause from secondary damage. A pump that failed on abrasion did not fail because the impeller wore — it failed because the well produces sand that was never adequately managed. Fixing the symptom without the cause guarantees a repeat.
Designing out repeat failures
Once the true cause is known, the fix is often in materials and protection: wear-resistant components and PTFE-based composite coatings for abrasive service, better gas handling, or a revised sizing that keeps the pump in its operating range.
Fiastar helps operators engineer out repeat failures with the right components and coatings. Send us your well conditions and failure history and we'll respond within one business day.