Integrated Evaluation of Electric Submersible Pump Failures under Diverse Field Operating Conditions

Electrical submersible pumps (ESPs) are an efficient and reliable artificial lift method for lifting large volumes of fluids from wellbores at flexible rates. Despite their advantages, including high flow rates and real-time downhole telemetry, ESPs are prone to frequent and unforeseen failures under harsh reservoir conditions, resulting in costly production delays and interventions. This paper presents an integrated evaluation of ESP failure mechanisms based on an analysis of run and pull reports, dismantle inspection failure investigation (DIFA) records, and operational data from 47 wells in two oil fields across the Murzuq and Sirte Basins, Libya. The study identifies and classifies failure modes across electrical, mechanical, and operational/system-level categories, quantifying their relative frequencies and root causes. Results indicate that mechanical failures dominate, accounting for 44.1% of incidents, driven primarily by sand production, corrosion, and seal degradation. Electrical failures represent 27.7%, largely due to insulation breakdown and moisture ingress, while operational and system-level issues account for 25.4%. A comparative analysis with global benchmarks reveals a higher incidence of mechanical failures in the fields studied than in typical industry profiles, attributed to aggressive downhole environments. The study further illustrates failure evolution pathways and recommends integrated mitigation strategies, including improved material selection, real-time monitoring, chemical treatment, and robust system design to extend ESP run life and enhance operational reliability.