Dual-Level Electric Submersible Pump (ESP) Failure Classification: A Novel Comprehensive Classification Bridging Failure Modes and Root Cause Analysis

Electric submersible pumps (ESPs) are critical for artificial lift operations; however, they are prone to frequent failures, often resulting in high operational costs and production downtime. Traditional ESP failure classifications are limited by lack of standardization and the conflation of failure modes with root causes. To address these limitations, this study proposes a new two-step integrated failure modes and root cause (IFMRC) classification system. The new framework clearly distinguishes between failure modes and root causes, providing a systematic, structured approach that enhances fault diagnosis and failure analysis and can lead to better failure prevention strategies. This methodology was validated using a case study of over 4000 ESP installations. The data came from Egypt’s Western Desert, covering a decade of operational data. The sources included ESP databases, workover records, and detailed failure investigation (DIFA) reports. The failure modes were categorized into electrical, mechanical, hydraulic, chemical, and operational types, while root causes were linked to environmental, design, operational, and equipment factors. Statistical analysis, in this case study, revealed that motor short circuits, low flow conditions, and cable short circuits were the most frequent failure modes, with excessive heat, scale deposition, and electrical grounding faults being the dominant root causes. This study underscores the importance of accurate root cause failure classification, robust data acquisition, and expanded failure diagnostics to improve ESP reliability. The proposed IFMRC framework addresses limitations in conventional taxonomies and facilitates ongoing enhancement of ESP design, operation, and maintenance in complex field conditions.