Predictive Maintenance · ESP
ESP failures. Caught days early.
One unplanned ESP failure on a 500 BO/d well costs $200K-1M+ all-in. Per-well ML on motor amps, intake pressure, and vibration catches bearing wear, motor-temp drift, and gas locking days before fixed-threshold SCADA would. One deferred failure pays for the annual license.
Four ESP signatures.
Signature
Bearing wear
ML detects
Vibration creeping above per-unit historical envelope
Root cause
Sand, gas slug, alignment, mechanical wear
Action
Schedule pull at 7-14 day window; not after motor seizure
Signature
Motor temperature drift
ML detects
Motor temp creeping above historical envelope
Root cause
Coolant flow loss, intake gas, downhole motor cavity gas
Action
Investigate intake first; motor pull only if downhole cooling confirmed lost
Signature
Gas locking
ML detects
Intake pressure spiking + discharge pressure falling
Root cause
GOR increase, packer leak, formation gas breakthrough
Action
Cycle VSD; investigate gas source; consider gas separator
Signature
Motor amp drift
ML detects
Amps rising at constant frequency
Root cause
Scale, bearing wear, increased fluid viscosity
Action
Chemical or pull window depends on root cause; ML attribution narrows it
Continue the cluster
ESP is one equipment class. The platform covers them all.
Other equipment classes
Predictive maintenance
The work it triggers
When ESP flags
Frequently asked
What production foremen ask about ESP ML.
What ESP failures does WorkSync detect?
Bearing wear (vibration), motor temp drift, gas locking (intake-pressure spike + discharge fall), motor-amp drift at constant frequency. Each flagged days before fixed SCADA thresholds.
Cost of an ESP failure?
Replacement $50-200K + emergency rig premium. Deferred production $20-80K/day. Total exposure on unplanned failure $200K-1M+.
Lead time vs SCADA?
Vibration: 3-14 days advance. Motor-temp drift: 1-7 days. Gas locking catches event before well stops producing.
What data?
Motor amps, intake/discharge pressure, motor temperature, vibration. From Schlumberger Lift IQ, Baker Centrilift, Borets, standard ESP VSD telemetry.
ROI math?
One ESP failure caught 7 days early on a 500 BO/d well saves ~$280K deferred production + $100K+ rig premium. Annual license pays for itself on a single deferred failure.
See ESP ML on your wells.
4-week pilot at no license cost. We surface at-risk units by Day 14.