Responsive
Same Day Service
Incomparable
#1 in Customer Satisfaction
Certified
ISO 9001:2008

Rapid Root Cause Analysis of Failures Saves Producers Money in Lost Production

Rapid Root Cause Analysis of Failures Saves Producers Money in Lost Production

If you’ve ever had a breaker trip at your house, you know that simply resetting it won’t work. If you don’t find out what the problem is, you’ll just have to keep resetting the breaker over and over again. It’s trying to tell you that there’s a short or an overload somewhere that must be fixed.

It’s the same with pumps in the oil field. If one breaks, we want to find out why.

When difficult well conditions lead to downtime, no one wants to wait long for a teardown to determine the cause of the failure. Delays in reporting cost thousands of dollars in deferred production and lead to repetitive failure modes. Many ESP providers take up to four weeks to tear the pump down and deliver a diagnosis—so that, in many cases, the old ESP is back on the well with no changes, waiting for another similar failure.

It’s not enough to just replace a failed pump, at least not for us. Root Cause Failure Analysis is a key factor in increasing equipment reliability, improving well performance and positively impacting the bottom lines of operators and ESP manufacturers.

To do the analysis right we need some important data from the operator and the ESP provider. Yes, we do offer failure analysis on competitors’ equipment on a timely basis.

We start with install and pull tickets, operational data, production data, well bore construction and well history. This helps the failure analysis engineer get to the root cause. The ESP sizing, drive setup sheets, drive history, serialized equipment tracking and assembly logs are very important as well.

The common perception is that gathering all this data would take too long to get the report back in time. That’s not the case in an efficiently run ESP company.   It should take no longer to send this data to the failure analysis engineer than it does to pull the pump and send it to the shop. In our case it is instant—our reliability engineers and our customers can access this data immediately in our web-based Summit Knowledge system.

To do the analysis right we need some important data from the operator and the ESP provider. Yes, we do offer failure analysis on competitors’ equipment on a timely basis.

So why do others take weeks to return these reports to the operator? If they take that long, are the reports worth the trouble?

I guess we’re a little different here at Summit ESP. From the start, we based our company on service, technology and reliability. Our goal has always been to be #1. We knew that meant we had to give customers timely root cause failure analysis.  We also leveraged that data in the continuous improvement process that relentlessly drives to quality of our product.

Years later we still think that way. So much so that EVERY service center includes dedicated reliability engineering centers. While other ESP providers rob Peter to pay Paul by using the same tooling to assemble and tear down their equipment, we have dedicated tooling because we want our reliability centers focused ONLY on testing, so we can get reports back as quickly as possible, sometimes within hours.

This dedication to speed and accuracy has caught the attention of many new customers.

For example, one customer found themselves waiting up to four weeks for reports on some of our competitors’ equipment. They asked us if we would do those reports, even though the pumps were not ours.

We jumped at the opportunity! We’re getting those failure analysis reports to them in just a week or so now—often before they return the well to production. We’re saving them an average of $10,000 per instance in deferred production.

Even better, they’ve now made us their SOLE ESP equipment and services provider. No doubt, providing great service is a win for everyone.

Archives

Joe Stewart - Eastern Sales Manager

Mr. Stewart has more than 10 years of domestic and international experience in the electrical submersible pump industry related to applications engineering, technical support, sales and management.