In high H2S and high pressure/temperature fields, the average run life of ESPs is still limited to 3 years. Dismantle Inspection Failure Analysis (DIFA) results show that around 50% of ESP failures are directly or indirectly related to electrical delivery problems concentrated in about 200 ft between the packer and the motor. This paper presents a collaborative R&D effort to develop and trial test a Reliable Power Delivery System (RPDS) with the goal of extending the average ESP run life from the current 3 years to 10 years.

The development focuses on improving reliabilities of key power delivery components including packer penetrator, Motor-Lead-Extension (MLE) cable, and cable connection with the motor. The design integrates learnings from advanced completion and subsea technology, and includes new concepts, features and materials. Field pressure-testable connections are implemented to ensure proper field connections makeup. Factory testing incorporated a robust Highly Accelerated Life Test (HALT) methodology to simulate a ten-year service life.

Prototype components were designed, fabricated and tested. These components were integrated and subjected to a rigorous system integration test. After the comprehensive factory tests, a field prototype system was built and installed in an offshore well. The system has been operated and exceeds the trial test successful criteria of minimum 180 days run-life.

For years, engineers and companies have battled with ESP reliability, with electrical problems at the center of many failure causes. This paper shows the development and field trial of a new generation ESP power delivery technology with the potential of extended run life.

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