An Operating Condition Diagnosis Method for Electric Submersible Screw Pumps Based on CNN-ResNet-RF

Abstract

Electric submersible progressive-cavity pumps (ESPCPs) deliver high lifting efficiency but are prone to failure in the high-temperature, high-pressure, and multiphase down-hole environment, leading to production losses and elevated maintenance costs. To achieve reliable condition recognition under these noisy and highly imbalanced data constraints, we fuse deep residual feature learning, ensemble decision-making, and generative augmentation into a unified diagnosis pipeline. A class-aware TimeGAN first synthesizes realistic minority-fault sequences, enlarging the training pool derived from 360 field records. The augmented data are then fed to a CNN backbone equipped with ResNet blocks, and its deep features are classified by a Random-Forest head (CNN-ResNet-RF). Across five benchmark architectures—including plain CNN, CNN-ResNet, GRU-based, and hybrid baselines—the proposed model attains the highest overall validation accuracy (≈97%) and the best Macro-F1, while the confusion-matrix diagonal confirms marked reductions in the previously dominant misclassification between tubing-leakage and low-parameter states. These results demonstrate that residual encoding, ensemble voting, and realistic data augmentation are complementary in coping with sparse, noisy, and class-imbalanced ESPCP signals. The approach therefore offers a practical and robust solution for the real-time down-hole monitoring and preventive maintenance of ESPCP systems.