A new high-temperature electric submersible pump (ESP) system was introduced in 2017 that is designed to address documented failure mechanisms and improve system reliability for steam-assisted gravity drainage (SAGD) operations at 250°C. A closed-loop product improvement workflow based on equipment dismantle, inspection and failure analysis (DIFA) has significantly driven high-temperature ESP technology development and reliability. In this paper, the authors discuss the unique closed-loop design workflow, present the new engineering features to address the identified failure modes, review field results and demonstrate the positive effects of the design modifications by comparing reliability trends based on nearly 150 field installations of the new generation equipment.

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