This paper is based on the subsea work performed during the design, implementation and operation of the Cascade and Chinook Field Development Project in ultra-deep waters of the U.S. Gulf of Mexico (USGoM). It describes the engineering, procurement, construction, installation, operation and integrity management phases of the subsea production system. This project required several innovative technologies and solutions that resulted in several " firsts" and records for the industry: first of a kind and deepest subsea boosting system with ESP-Electric submerged pumps installed on the seabed at 8800 ft, non-conventional power umbilicals utilizing carbon fiber rods as the principal tensile strength elements, first subsea pull-in of umbilicals utilizing a submerged winch, deepest and highest pressure rated Free Standing Hybrid Risers (FSHRs), deepest pipe-in pipe flowline and deepest gas export pipeline. This case history paper also describes the procurement strategies employed and the project management systems adopted to mitigate technical, time and cost risks. Introduction The C&C fields are located in the Walker Ridge Outer Continental Shelf (OCS) leasing area of the central USGoM. Both fields are situated near the base of the Sigsbee Escarpment on the abyssal plain of the USGoM in ultra deep water. Cascade is located about 160 miles south of the Louisiana coast in 8,200 ft water depth and Chinook is about 15 miles due south of Cascade in 8,800 ft water depth. The Cascade discovery was made in 2002 and Chinook was discovered in 2003. The C&C reservoirs are in the Lower Tertiary (Wilcox) Ultra-Deepwater trend. After appraisal work the C&C was sanctioned in late 2007 based on a phased development concept. The initial project phase, the subject of this paper, is an early production scenario based on a limited number of wells and subsea infrastructure and the purpose of this initial phase is to gain reservoir information in order to optimize future development phases. The initial phase utilizes a leased, disconnectable, floating, production, storage and offloading (FPSO) vessel located between the fields. Produced oil is transported from the field in shuttle vessels and gas is exported through an export pipeline. The main reason for selecting the FPSO was safety, primarily with respect to hurricanes. The detachable turret mooring buoy provides a mooring point for the FPSO and during the approach of a hurricane the buoy enables the FPSO to disconnect in a short period of time in order to depart the area. Future phases increase the amount of producing wells and subsea infrastructure and a definitive optimized permanent production facility is to be installed in the last phase. Decisions on the type of and design basis of a definitive facility and number of wells will be finalized in 2013 and 2014.

Since 1977, when the fust oil was produced to a floating rig through a test tree inside the BOP Stack (Enchova-01 well), around 30 Floating Production Systems were installed in Campos Basin, offshore Brazil. Due to the prolific geological conditions of this province, production ranges from shallow (100m) up to deep waters (1027m), demanding significant breakthroughs in the applied subsea and marine production equipment which were used for the exploitation of these fields. This paper presents the technical evolution of the associated hardware, as manifolds, umbilicals, flowlines, monobuoys and mooring systems, highlighting some milestones which made viable the achievement of the present water depth limits of oil and gas production. Their field performance is also shown and gives a real solid background for the extension of the water depth limits up to 2000m for future production systems under design/construction, not only in Campos Basin but also for other offshore sites around the world.

The production approach adopted for Campos Basin oil fields has been strongly based on subsea completed satellite wells, floating production units and oil offloading through oceanic terminals. Flexible flowlines, risers and umbilicals have played an important role in this scenario, gradually building an outstanding reputation of reliability and cost-effectiveness. With a background of more than 3,500km of flexible lines and umbilicals already deployed in water depths ranging from 100m up to 1853m (present world record), it is natural that the "flexible solution" has been adopted for almost the totality of Marlim giant field applications. This paper encompasses the technical evolution of flexible flowlines, risers and umbilicals, highlighting some milestones as world records and pioneer applications, installation and pull-in procedures, keeping the main focus over projects in Marlim field. The adoption of new products like protection against coral, IPU (Integrated Pipe and Umbilical), collapse resistant hoses for chemical injection, etc., is also presented. The paper reports the installation of a 10-inch gas export steel catenary riser (SCR) on platform PETROBRAS-18, as the first of its kind on a semi-submersible unit in the world. New trends under evaluation like the use of tension leg riser system and long length deepwater bundles installed through controlled depth tow method (CDTM), both considered as competitive solutions compared to flexible lines, have their scenarios presented and discussed in the paper. The paper also emphasizes the partnership between PETROBRAS and suppliers, contractors, universities and operators around the world, that made it possible to overcome challenges faced to bring Marlim field production onstream. Problems that occurred on the course of operations are also discussed.