ESP Downhole Reliability Engineer

EMNR30 - Sr. Technical Professional Maintenance & Reliability Engineer

KBR Sustainable Technology Solutions (STS) provides holistic and value-added solutions across the entire asset life cycle. These include world-class licensed process technologies, differentiated advisory services, deep technical domain expertise, energy transition solutions, high-end design capabilities, and smart solutions to optimize planned and operating assets.

The ESP Reliability Engineer is responsible for improving the reliability, performance, and integrity of all Electrical Submersible Pump (ESP) systems throughout their operating life. The main focus is to extend ESP run life, reduce unplanned failures, and support production goals by applying sound reliability engineering practices and data driven analysis.

As the number of ESP operated wells in the field continues to grow, the reliability function becomes increasingly critical to sustaining performance and managing operational complexity. The ESP Reliability Engineer ensures that every system performs to design expectations and that lessons from the field are systematically turned into improvements in design, operation, and maintenance.

The role involves working closely with operations, maintenance, subsurface, and vendors to understand equipment behaviour, identify reliability risks, and recommend practical solutions. Typical responsibilities include analysing ESP performance trends, leading Dismantle and Inspection (DIFA) and Root Cause Failure Analysis (RCFA) activities, maintaining failure records, and tracking reliability KPIs to measure performance improvements over time.

Based on findings from field investigations and lessons learned, the ESP Reliability Engineer works with vendors and field teams to raise alerts and document any manufacturing, quality, or procedural issues, recommending design or process changes to prevent similar problems in the future. This helps close the feedback loop between field operations, engineering, and manufacturers, ensuring lessons are turned into lasting improvements.

Performance data from PI Vision and other monitoring tools is used to spot anomalies early and support evidence-based investigations during DIFA and reliability reviews. The ESP Reliability

Engineer also works closely with the Data Scientist and Reliability Advisor in designing, maintaining, and continuously improving ESP reliability dashboards in Power BI, ensuring data is effectively transformed into actionable insights that drive better decisions and field performance.

The ESP Reliability Engineer in close coordination with the Reliability Advisor, ensures alignment on reliability priorities, shares technical findings, and jointly drives improvement actions to enhance ESP performance across the field. Both roles collaborate as partners within the reliability function, combining field insight and analytical expertise to achieve safer, more efficient, and more reliable operations.

Responsibilities

Reliability & Technical Assurance

Lead and coordinate ESP failure investigations, including Dismantle and Inspection (DIFA) and Root Cause Failure Analysis (RCFA).
Analyze operating parameters, well histories, and performance trends to identify emerging reliability issues.
Maintain and update the ESP failure database, ensuring data integrity, traceability, and proper documentation of all incidents.
Review and validate contractor failure reports and warranty cases, ensuring corrective actions are effectively implemented.
Provide technical recommendations to enhance ESP system design, installation practices, and operational standards.
Develop and maintain reliability dashboards and reports to track KPIs such as MTBF, run life, recurring failure modes, and reliability trends.
Analyze ESP failure data and historical performance to identify patterns, risks, and opportunities for reliability improvement.
Conduct preliminary assessments of reported anomalies or incidents and recommend further investigation or corrective actions.
Support RCFA and DIFA investigations by verifying technical findings and ensuring appropriate follow-up actions.
Review reliability metrics and maintenance reports to provide actionable recommendations to improve ESP life and reduce failures.
Advise on reliability risks associated with planned changes or maintenance activities, ensuring alignment with design limits and safety standards.
Document findings, lessons learned, and recommendations in formal reliability reports and databases.

Operational Support

Provide technical expertise on ESP systems to identify, analyze, and resolve performance deviations or anomalies highlighted through DIFA findings.
Support site teams in assessing and managing reliability risks to minimize potential production impacts.
Review operational data and DIFA insights to recommend improvements in ESP performance, efficiency, and longevity.
Collaborate with Operations and Maintenance teams to ensure ESP systems operate within safe and design parameters.
Lead investigations into recurring equipment failures identified through DIFA or operational performance trends and recommend preventive actions.
Contribute to reliability-centered maintenance strategies and continuous improvement efforts based on failure analysis findings.

Reliability & Technical Assurance

Lead and coordinate ESP failure investigations, including Dismantle and Inspection (DIFA) and Root Cause Failure Analysis (RCFA).
Analyze operating parameters, well histories, and performance trends to identify emerging reliability issues.
Maintain and update the ESP failure database, ensuring data integrity, traceability, and proper documentation of all incidents.
Review and validate contractor failure reports and warranty cases, ensuring corrective actions are effectively implemented.
Provide technical recommendations to enhance ESP system design, installation practices, and operational standards.
Develop and maintain reliability dashboards and reports to track KPIs such as MTBF, run life, recurring failure modes, and reliability trends.
Analyze ESP failure data and historical performance to identify patterns, risks, and opportunities for reliability improvement.
Conduct preliminary assessments of reported anomalies or incidents and recommend further investigation or corrective actions.
Support RCFA and DIFA investigations by verifying technical findings and ensuring appropriate follow-up actions.
Review reliability metrics and maintenance reports to provide actionable recommendations to improve ESP life and reduce failures.
Advise on reliability risks associated with planned changes or maintenance activities, ensuring alignment with design limits and safety standards.
Document findings, lessons learned, and recommendations in formal reliability reports and databases.

Operational Support

Provide technical expertise on ESP systems to identify, analyze, and resolve performance deviations or anomalies highlighted through DIFA findings.
Support site teams in assessing and managing reliability risks to minimize potential production impacts.
Review operational data and DIFA insights to recommend improvements in ESP performance, efficiency, and longevity.
Collaborate with Operations and Maintenance teams to ensure ESP systems operate within safe and design parameters.
Lead investigations into recurring equipment failures identified through DIFA or operational performance trends, and recommend preventive actions.
Contribute to reliability-centered maintenance strategies and continuous improvement efforts based on failure analysis findings.

Process Safety & Risk Management

Support the identification and evaluation of reliability-related risks in ESP systems for ORA and other safety frameworks.
Analyze mechanical, electrical, and hydraulic ESP failure modes and assess their potential impact on process safety.
Review ESP design changes or modifications to ensure both reliability and process safety implications are addressed.
Recommend monitoring, control, and mitigation measures to prevent reliability failures from escalating into safety incidents.
Integrate lessons learned from ESP failures into process safety management programs to enhance risk reduction.
Maintain documentation of reliability assessments, risk analyses, and failure investigation outcomes for compliance and future reference.

Continuous Improvement

Lead or support Continuous Improvement (CI) initiatives focused on increasing ESP availability, reducing failure rates, and lowering lifecycle costs.
Analyze recurring failure trends and recommend design, operational, or process modifications to eliminate root causes.
Document and share lessons learned, reliability alerts, and best practices across internal teams and contractors.
Evaluate and support adoption of new technologies, predictive maintenance tools, and data analytics to strengthen ESP reliability monitoring.

Collaboration & Coaching (Reliability Focus)

Collaborate with vendors, engineering, operations, and maintenance teams to align reliability strategies with system design and performance objectives.
Act as a central point for sharing reliability insights, failure analyses, and technical recommendations across stakeholders.
Facilitate cross-functional discussions to prioritize reliability improvements and ensure consistent implementation of best practices.

Experience And Qualifications

Bachelor’s degree in Electrical, Mechanical, or Petroleum Engineering (or equivalent experience).
5 years of experience in ESP operations, reliability or engineering support including minimum 3 years dedicated to DIFA.
Proven experience in ESP DIFA/RCFA and understanding of ESP design, operation, and failure mechanisms.
Strong analytical and problem solving skills with a data driven approach.
Proficiency in reliability tools and methods such as 5 Whys, Fishbone, FMEA, Pareto etc.
Proficiency in English (reading, writing, and speaking).
Strong interpersonal and communication skills to interface across departments and with contractors.
Competent user of various analytical and productivity tools, such as Power BI, Maximo, PI Vision, and Microsoft Office tools.
Demonstrated ability to work independently in a rotational field environment and deliver measurable reliability improvements.

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