Emerging deepwater fields in the Gulf of Mexico pose significant challenges for the deployment and operation of subsea tree ESP systems, where reliability is crucial to the economic viability of the fields. Key challenges include high initial reservoir pressures (13,500 psi), 1- to 2-year natural flow startup conditions without affecting electrical integrity, 5-years mean time between failures (MTBF) for the ESP system after startup of the pump, high horsepower pumps (1,200 hp), restricted space at the tree interface, and the need for integrated power and controls to the pump system. One of the main system components is the power feedthrough connector through the wellhead. This component has to be deployed into the wellhead as part of the cable hanger assembly through a marine riser and subsequently connected to the tree cap assembly remotely in up to 10,000 ft of water depth.

For effective well control, the connector systems have to maintain pressure barrier seals for the life of the well in a 15,000-psi-rated tree. In addition, the connector system has to maintain electrical integrity under high-voltage conditions and be mated together consistently within the confines of the tree system. Increasing qualification standards by operators pose even greater challenges to the connector vendors.

This paper presents the latest connector technology developed by OneSubsea to meet the extreme challenges and needs of high-pressure (HP) ESP applications in the Gulf of Mexico.