Electric Submersible Pump Reliability Improvement Lean Six Sigma (LSS) Study

Abstract Electric Submersible Pumping (ESP) is a common artificial lift method when technically viable for high flow rate application. ESP reliability, on the other hand, is sensitive to multiple factors during its life cycle from contracting all the way to failure analysis. This paper summarizes the Lean Six Sigma (LSS) methodology that was followed to assess ESP run life performance and to enhance ESP reliability. The study scope covered the ESP downhole equipment full life cycle which includes the design, manufacturing, storage and handling, installation, commissioning and operation. Subject matter experts and LSS consultants teamed to assess ESP performance. The approach included visiting key ESP supplier manufacturing facilities to walkthrough their processes, brainstorming ESP failure potential causes, analyzing historic data, identifying root causes, and developing and implementing recommendations to prolong ESP run life. The study allowed developing recommendations that impact ESP design and manufacturing, well conditions, vendor's field technical competencies and operational compliance. Following that, an implementation plan was developed. Additionally, a quarterly report is being issued to ensure all stakeholders are well updated on the implementation status and any changes. Other key milestones accomplished included ESP performance benchmarking with other regions, and development of an ESP performance management portal to enable ESP engineers to better monitor and control the end-to-end ESP performance. After completing the LSS study and implementing its recommendations, ESP replacement jobs due to ESP failures were significantly reduced resulting in a major cost avoidance. Further improvements are also expected in the coming years.