Application of Six Sigma Statistical Methodology to Reduce ESP Failures in Central Arabia Fields

This reference is for an abstract only. A full paper was not submitted for this conference. This paper presents the application of Six Sigma statistical methodologies to diagnose, measure, improve, and control the root causes of electrical submersible pump (ESP) failures in Central Arabian (CA) fields. The word six sigma is a statistical term that measures how far a given process deviates from perfection. The main objective of this study is to increase the run life of ESPs in six Central Arabian fields of Saudi Arabia to at least three years or more using Six Sigma tool. In the last ten years 241 ESPs have experienced downhole equipment failure and were subsequently replaced at Central Arabia fields. This has a huge impact on over all fields' performance and economic resources which would be utilized elsewhere otherwise. This study was initiated and focused to diagnose the major causes of 23 ESP failures occurred in the year 2005 only. However, the scope of work will be extended to the previous failures as well. It was found that 22% of the total failures were caused by sand accumulation inside the pump stages. Scale, downthrust, and seal problems caused 51% failures with 17% each. Underestimated water cut forecasts in successive years and poor installation practices were responsible for 18% failures with 9% each. Lastly, upthrust and cable problems together caused 8% ESP failures with 4% each. This paper is divided into four sections: Effective data collection methodologies are outlined,ESP run life analysis is discussed in detail,findings and root causes of ESP failures are listed,finally, based on the findings, solutions and quality control procedures are recommended. Some of these solutions and procedures have been implemented since March 2006 and have resulted in significant reduction in the number of premature ESP failures as compared to the previous year.