ESP Troubleshooting & Failure Analysis -

Intermediate
0 Total Enrolled
12 hours Duration
February 19, 2026 Last Updated
Enrollment validity: Lifetime
Certificate of completion

About Course

Instructor led classes scheduled from 14 April to 23 April 2026.

This professional course provides engineers and technicians with structured methodology to diagnose ESP performance issues using surface data and controller history. Participants learn to interpret operational parameters, identify shutdown types, analyze failure mechanisms, and apply a clear decision matrix—Restart, Adjust, Flush, Reverse, or Pull .

The program emphasizes practical troubleshooting logic to reduce unnecessary pulls, minimize downtime, and optimize ESP system performance.

Interpret ESP surface parameters (amps, voltage, frequency, dynamic level, pressures) for accurate diagnosis
Identify and analyze shutdown types: overload, under-load, insulation trips, and blackout events
Apply structured troubleshooting logic to decide: Restart, Adjust, Flush, Reverse, or Pull
Diagnose gas lock, pump wear, shaft failure, voltage imbalance, and cable faults
Use pump curves (Q–H) and shut-off pressure tests in performance evaluation
Conduct safe restart procedures and controlled flushing operations
Correlate surface symptoms with downhole failure findings after pulling
Extract and analyze controller (VSD) history for informed decision-making

Course Content

Module 1: Understanding ESP Behavior During Operation

Relationship between amps, voltage, frequency, flowrate, dynamic level, and pressures
Reading VSD, amp chart , and insulation unit together
Recognizing normal operating behavior before failures

Modul 2: ESP Shutdown Types – What the Trip Tells You

Module 3: Overload Trip – Deep Diagnosis

Module 4: Under load Trip or Flowrate Drop – Deep Diagnosis

Module 5: Insulation Trip – Failure Path Analysis

Module 6: Restart After Blackout

Module 7: Reading the Well to Diagnose the ESP

Module 8: Freeing a Stuck ESP (Flushing & Reverse)

Module 9: Using Pump Curve (Q-H) in Troubleshooting

Module 10: Failure Patterns Seen After Pulling ESP

Module 11: Decision Matrix – Restart, Adjust, Flush, or Pull

Module 12: Documentation & Controller History

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About Course

What Will You Learn?

Course Content

Module 1: Understanding ESP Behavior During Operation

Relationship between amps, voltage, frequency, flowrate, dynamic level, and pressures

Reading VSD, amp chart , and insulation unit together

Recognizing normal operating behavior before failures

Modul 2: ESP Shutdown Types – What the Trip Tells You

Overload trip: Pump cannot rotate freely

No-load trip: Pump rotating but not moving fluid

Insulation trip: Electrical path to ground

Blackout/power loss: Hydraulic and thermal instability after restart

Module 3: Overload Trip – Deep Diagnosis

Causes: Pump seizure, wrong tap, fluid in motor, VSD setup error

Megger cable-motor and VSD-JB, check WYE connection

Voltage and current unbalance limits: 5% and 15%

Controlled restart cycles: max 3 with 30 min cooling

Decision logic from current value

Module 4: Under load Trip or Flowrate Drop – Deep Diagnosis

Causes: Gas lock, tubing leak, wax, clogged choke, pump wear, broken shaft

Check DFL dynamic level for 1 hour

Check shut-off pressure vs pump curve

Back flush and hot water (<80°C)

Module 5: Insulation Trip – Failure Path Analysis

Sources: Motor fluid ingress, cable damage, feedthrough failure, unit fault

Megger both sections and visual cable inspection

Criteria to safely restart (>1 MΩ)

Module 6: Restart After Blackout

Start at minimum frequency

Adjust under-load setpoint

Gradual return to previous frequency

Optimize motor voltage via base frequency

Module 7: Reading the Well to Diagnose the ESP

Rising amps + falling rate = restriction

Falling amps + no rate = gas or broken shaft

High amps + stable rate = voltage problem

Unbalanced phases = cable issue

Module 8: Freeing a Stuck ESP (Flushing & Reverse)

Direct vs back flushing decision

Increase tap 3–5 steps, inject 10–15 m³

Reverse rotation start, then normal

Max 3 cycles with 1 hr cooling

Module 9: Using Pump Curve (Q-H) in Troubleshooting

Shut-off pressure test

Matching field data to pump curve

Detecting worn stages vs blockage

Module 10: Failure Patterns Seen After Pulling ESP

Cut O-ring, air in protector, splice on collar, pothead stress, bad banding

Linking surface symptoms to downhole findings

Module 11: Decision Matrix – Restart, Adjust, Flush, or Pull

High amps after restart: Flush or reverse

No amps and no rate: Check shaft or coupling

Insulation <1 MΩ: Locate cable fault

Gas symptoms: Reduce frequency and stabilize level

Wax symptoms: Hot oil and gauge tubing

Module 12: Documentation & Controller History

Extracting useful data from VSD logs

Importance of history before pulling

Reporting standards after trips

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