Enhancing ESP Performance Through Integrated Hydraulic and Electrical Analytics: Lessons Learned from a Multi-Well Deployment

Abstract

This paper presents results from a field trial that evaluated an integrated electro-hydraulic surveillance framework to improve Electric Submersible Pump (ESP) performance in unconventional operations. ESPs in the Permian Basin are frequently challenged by unstable inflow conditions, gas interference, and impactful startup transients, which can lead to certain operational challenges such as pump-off behavior, elevated electrical stress, unplanned downtime, and reduced run life. The objective of this work was to evaluate whether combining hydraulic analytics, electrical signature analysis, and autonomous event detection could support earlier identification of developing instability, improve root-cause clarity, and inform targeted operational interventions. The pilot included 13 ESP wells monitored over a 12-month period using hydraulic surveillance and electrical signature analytics. Hydraulic inputs included surface and downhole pressure, temperature, and flow-related parameters. Electrical analytics evaluated three-phase voltage and current waveforms, total harmonic distortion, sequence components, phasor angles, and indicators of shaft stability. A machine-learning workflow was used to detect and classify low-flow operating states and was supplemented by weekly remote operational reviews. The integrated workflow delivered distinct value across its components. Among electrically instrumented wells, 10 of 11 exhibited power quality or electrical anomalies related to maintenance, operations, and/or utility power-supply conditions, prompting targeted inspections and operating adjustments. Across the pilot population, at least 8 wells were identified with clear opportunities for electrical or surface equipment intervention, representing the subset in which the observed anomalies were sufficiently specific to support a defined intervention path. Electrical signature analysis and historized telemetry provided the strongest diagnostic contribution, whereas the autonomous alerting layer showed mixed performance in this operating context because of false positives. Where actions were implemented, measurable improvements were observed, including reduced recurrence of low-flow events, improved power stability, and faster recovery from startup. Overall, the trial demonstrated that integrated electro-hydraulic surveillance can enhance ESP performance by improving early detection of instability, strengthening diagnostic clarity, and enabling more targeted operational interventions. The results confirm that combining hydraulic and electrical analytics provides meaningful technical insight and operational value beyond conventional ESP monitoring approaches.