DF-06Foundational
SCADA/Historian Connectivity & TSDB
Gets the live sensor data out of the control system safely and stores it at full resolution, which almost nothing else on this site does.
Data FoundationIoTIT
PR-04IntermediateWave 2AIIoT
ESP Monitoring & Failure Prediction
In one sentence
Watches the downhole pump’s electrical and pressure signature to warn of gas lock, wear or burnout before the well stops.
The problem
An ESP failure costs the deferred production of the well plus a rig-based replacement. Run life varies by a factor of three across wells in the same field, and most of that variance is operating practice rather than equipment quality.
How it works
Motor current, intake and discharge pressure, motor temperature and vibration are trended against the pump’s published performance curve. Pattern detection identifies gas locking, pump wear, shaft break and progressive insulation degradation, each with a different lead time and a different recommended action.
Data required
- ESP downhole gauge data: intake pressure, discharge pressure, motor temperature, vibration
- VSD data: current, frequency, voltage imbalance
- Pump and motor specification with performance curves
- Pull reports with the failure mode found at surface
What you get
- Health index and remaining-run-life estimate per ESP
- Failure-mode-specific alerts with recommended operating change
- Field run-life benchmarking by pump type, vendor and operating practice
What it cannot do
Prediction requires downhole gauge data. On wells where the gauge has failed — common, since the gauge often fails before the pump — the capability degrades to surface-only monitoring, which detects gas lock and gross wear but gives little warning of electrical failure. Insulation breakdown in particular can progress from normal to failed within hours.
Every capability page states a real limitation. If a vendor cannot tell you where their product stops, you are not being told the truth about where it starts.
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