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Integrated Supply and Maintenance Services of ESP Wells Power Station Systems

Field-wide operate-and-maintain contract covering 428 generator sets across 258 ESP well locations in the Zubair field — maintenance, integrated spares supply, workshop overhaul and control systems, run on purpose-built CMMS, ERP and HR systems.

Boabat Alnoor holds the integrated supply and maintenance contract for the electrical submersible pump (ESP) well power station systems across the Zubair oil field. It is the company’s largest and longest-running operation: a continuous, field-wide service covering every generator that keeps an ESP well producing.

Scope

The contract is a full operate-and-maintain scope rather than a discrete build. Boabat Alnoor is responsible for keeping the well power stations available around the clock, which covers:

  • Preventive and corrective maintenance of the diesel generator fleet serving the ESP wells, including scheduled servicing, overhauls and unplanned breakdown response.
  • Synchronisation panels, control systems, and the electrical distribution between the generator and the wellhead.
  • Integrated supply — sourcing, holding and issuing the spare parts, consumables and lubricants the fleet consumes, with stock managed against demand rather than against a fixed list.
  • Generator overhaul and refurbishment through the company’s own workshop, so units are rebuilt in-country instead of being sent away.
  • Daily readings, fault logging, lifting operations and well status reporting to the client.

The fleet

The maintained fleet covers 428 generator sets spread across 258 well locations. Ratings run from 380 kVA to 1,250 kVA, with 500 kVA the most common unit. The fleet is mixed: Perkins, Doosan, Volvo Penta and Cummins engines all sit within the same maintenance programme, which means the crews and the spare-parts operation have to carry competence across four engine makes at once.

How it is delivered

Delivery is organised into ten site teams plus a dedicated ZFOD-IR team, each holding a defined set of wells, supported by the central workshop and a field stores operation. The workforce on the contract is approximately 200 people — local staff and expatriate specialists working a rotation.

Safety is run as a daily practice rather than a document: toolbox talks before work starts, permit-controlled activities, and hazard identification briefed to every crew on site.

Managed on purpose-built systems

Boabat Alnoor runs the contract on three in-house systems it built and operates itself, rather than on spreadsheets:

  • CMMS — the maintenance backbone. Generator and well registry, weekly planned activity schedules, daily readings, fault logs, backlog tracking, workshop throughput and well status history.
  • Procurement ERP — purchase requests through a role-based approval workflow, RFQs, goods receipt, invoicing and stock control across thousands of stock lines.
  • HR system — personnel records, attendance, rotation planning, payroll input and document/visa expiry tracking for local and expatriate staff.

The result is that fleet availability, spares consumption and manpower are reported from live data, and the client sees the same numbers the crews work from.

Project photos (16)

Generator overhaul bay — units are rebuilt in the company’s own workshop. Site team at an ESP well power station. Toolbox talk before shift — hazard identification briefed to every crew. The operations base supporting the field teams. Operations base supporting the field teams. Central workshop and stores. Central workshop and stores. Central workshop and stores. Central workshop and stores. Central workshop and stores. Central workshop and stores. Central workshop and stores. Central workshop and stores. Fuel storage at the operations base. Fuel storage at the operations base. Fuel storage at the operations base.