Field Validation of High-Frequency Electrical Signal-Based Diagnostics for Electrical Submersible Pump Condition Monitoring

Summary This study presents results from a field validation of high-frequency electrical signal-based diagnostics for condition monitoring of Electrical Submersible Pumps (ESPs) in a SAGD operation at Firebag, Canada. The monitoring system utilizes three-phase current and voltage data from the variable frequency drive (VFD) panel to detect mechanical, electrical, and flow regime anomalies in ESPs. Five wells with unique operational challenges were instrumented, building on prior foundational work in ESP signal analysis. The approach demonstrated a direct correlation between periodic mechanical vibrations and distinct frequency components in electrical signals, enabling early fault detection. Field trials showed that this technology provided actionable insights even on legacy drive systems, improving well availability and production stability. The diagnostic tool supplemented conventional troubleshooting, offering clarity in cases where standard methods were inconclusive. Recommendations based on monitoring data led to corrective actions that reduced drive harmonics and enhanced ESP reliability. The results support a proactive maintenance strategy, reducing lost flow events and operational costs. This work contributes novel insights into ESP reliability and performance in SAGD environments. Overall, the findings advance predictive maintenance practices and reliability-centered approaches for ESPs in thermal production operations.