Research for Ultra-Deepwater Production Research for Ultra-Deepwater Production
Opening SeminarMarintek do BrasilRio de Janeiro, Apr 19, 2007
Mauricio WerneckPROCAP 3000 Coordinator
Opening SeminarMarintek do BrasilRio de Janeiro, Apr 19, 2007
Mauricio WerneckPROCAP 3000 Coordinator
2
E&PRefining & TransportGas & EnergyPetrochemicalDistributionCorporate
9%4%
3% 26%
56%
3%
US$ 87,1 bilhões
49,3
23,07,5
3,32,31,8
PN 2007-11
Petrobras Investment PlanPetrobras Investment Plan
3
1,6841,530
1,358
1,176
987
786
570
1,684
1,8801,979
2,0612,195
2,368 2,374
-
500
1,000
1,500
2,000
2,500
2005 2006 2007 2008 2009 2010 2011
1,00
0 bp
d 1.804
1.114
690Liquid
Increase
Natural Decrease
1,6841,530
1,358
1,176
987
786
570
1,684
1,8801,979
2,0612,195
2,368 2,374
-
500
1,000
1,500
2,000
2,500
2005 2006 2007 2008 2009 2010 2011
1,00
0 bp
d 1.804
1.114
690Liquid
Increase
Natural Decrease
Oil + LNG Production (Brazil)Oil + LNG Production (Brazil)
4
Oil + LNG Production and Support ProjectsOil + LNG Production and Support Projects
2,374
2,195
2,0611,979
1,880
1,684
2,368
1,400
1,600
1,800
2,000
2,200
2,400
2,600
2004 2005 2006 2007 2008 2009 2010 2011 2012
Parque das Conchas
100.000 bpd
Albacora LesteP-50
180.000 bpd
JubarteFase 1P-34
60.000 bpd
Marlim LesteP-53
180.000 bpd
FPSO CapixabaGolfinho Módulo I
100.000 bpd Frade100.000 bpd
RoncadorP-52
180.000 bpd
RoncadorP-54
180.000 bpd
Marlim SulMódulo II
P-51180.000 bpd
Piranema20.000 bpd
JubarteFase 2P-57
180.000 bpd
Rio de janeiroEspadarteMódulo II
100,000 bpd
ESS-130Golfinho Mód. III
(FPSO)100.000 bpd
Cidade de VitóriaGolfinho Mod. II
100.000 bpd
RoncadorP-55
180.000 bpd
5
2001 2002 2003 2004 2005 20060
200
400
600
800
1000
1200
1400
1600 R$ Millions (Base 2005)
R&D InvestmentR&D Investment
499598
662730
916
1.420
6
R&D RefiningR&D RefiningR&D Gas Energy &
Sustainable Dev.
R&D Gas Energy &
Sustainable Dev.
R&D ProductionR&D ProductionR&D Exploration
R&D Exploration
Basic Engineering
Basic Engineering
Technology ManagementTechnology Management
Executive Manager
Executive Manager
12 Technological Programs1000 R&D Projects50 Basic Engineering Projects500 Production R&D Projects4000 People
12 Technological Programs1000 R&D Projects50 Basic Engineering Projects500 Production R&D Projects4000 People
R&D Center – CENPESR&D Center – CENPES
Present area: 122,000 m2137 labs30 pilot units
New Construction: 180,000 m2
Present area: 122,000 m2137 labs30 pilot units
New Construction: 180,000 m2
7
Technological ChallengesTechnological Challenges
• Ultra-Deep Water– Risers and Pipelines– Mooring Systems– HPHT Wells and Equipment– Flow Assurance– Subsea Boosting and Processing
• Ultra-Deep Water– Risers and Pipelines– Mooring Systems– HPHT Wells and Equipment– Flow Assurance– Subsea Boosting and Processing
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2005 Production
13,23 billion boe
Offshore (0-300m)Offshore (0-300m)OnshoreOnshore Offshore (300-1500m)Offshore (300-1500m) Offshore (> 1500m)Offshore (> 1500m)
2005 Proven Reserves (SPE)
1.958.000 boed
10% 10%
55%
25%19%
16%
60%
5%
Exploratory Area160,500 km2
24%
12%
26%
38%
Production and Reserves vs. Water DepthProduction and Reserves vs. Water Depth
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1,000m (3,300ft)
2,000m (6,600ft)
3,000m (10,000ft)
1986 – 1991
1992 - 1999
2000 - 2006
Marlim and Albacora Production Technological Support
Roncador and Marlim Sul Production Technological Support
Production Technological Support for Ultra Deep Phases of Marlim Sul and Roncador, Exploratory Prospects, GoM and WoAAssets
PROCAPPROCAP
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Installed EquipmentInstalled EquipmentCompletion RecordsCompletion RecordsEquipment Installed
Jan/2005Planned
2005/2006Wet Trees 548 106
Subsea Manifolds 58 02
Subsea FlexibleLines (Km)
2.534 765
Umbilicals (Km) 2.229 622
Rigid Lines (Km) 1.964 305
PETROBRAS ActivityPETROBRAS Activity
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Drilling and CompletionSubsea EquipmentArtificial Lift and BoostingFlow AssuranceRiser and Flowline SystemsFloating Units and Anchor SystemsEnvironmental Database
Drilling and CompletionSubsea EquipmentArtificial Lift and BoostingFlow AssuranceRiser and Flowline SystemsFloating Units and Anchor SystemsEnvironmental Database
PROCAP-3000 Main AreasPROCAP-3000 Main Areas
12
Drilling Equipment for Deepwater►Torpedo Wellhead►Slender Wellhead►Casing Drilling►Surface Drilling BOP System
Deep Horizon Drilling►HPHT Drilling and Completion►Hard Formation Drilling Optimization
Drilling Equipment for Deepwater►Torpedo Wellhead►Slender Wellhead►Casing Drilling►Surface Drilling BOP System
Deep Horizon Drilling►HPHT Drilling and Completion►Hard Formation Drilling Optimization
PROCAP-3000Drilling and CompletionPROCAP-3000Drilling and Completion
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Deepwater – Problem: narrow
margin between pore and fracture pressures
– Theoretical Solution: Dual Gradient Drilling
– Many Practical Alternatives
Deepwater – Problem: narrow
margin between pore and fracture pressures
– Theoretical Solution: Dual Gradient Drilling
– Many Practical Alternatives
00
500500
10001000
15001500
20002000
25002500
30003000
00 60006000
Hydrostatic Pressure (psi)Hydrostatic Pressure (psi)
Dep
th (m
)D
epth
(m)
00
500500
10001000
15001500
20002000
25002500
30003000
Equivalent Mud Weight (ppg)Equivalent Mud Weight (ppg)
88 1010 1212
Mud SG 11 ppgMud SG 11 ppg
Mud DG 14 ppgMud DG 14 ppg
Light FluidsGas-Lifted RiserLight FluidsGas-Lifted Riser
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Torpedo WellheadTorpedo Wellhead
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PROCAP-3000 Artificial Lift and BoostingPROCAP-3000 Artificial Lift and Boosting
Boosting Systems for Deepwater► ESP for Subsea Well - BCSS► Subsea Multiphase Pumping – SBMS► Gas/Liquid Separation System – VASPS
Gas Lift for Deepwater Subsea Wells
Boosting Systems for Deepwater► ESP for Subsea Well - BCSS► Subsea Multiphase Pumping – SBMS► Gas/Liquid Separation System – VASPS
Gas Lift for Deepwater Subsea Wells
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► Benefit: production increase► Performance and endurance tests concluded at Núcleo
Experimental Eng. Baruzzi► Modules under final assembly for installation at Marlim
field (Oct 07)
► Benefit: production increase► Performance and endurance tests concluded at Núcleo
Experimental Eng. Baruzzi► Modules under final assembly for installation at Marlim
field (Oct 07)
Performance TestsSBMS-500Performance TestsSBMS-500
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Eni Agip
THERMIETHERMIE
THERMIE
► Marimbá Pilot (P-8)► Production increase: from 4.700 to
6.300 bopd► Gas lift stopped► WD : 400 m► Phase 1: Jul/2001 a Dec/2001► Phase 2: May/2004 on► New R&D project to increase flow
capacity, decrease CAPEX and installation costs
► Marimbá Pilot (P-8)► Production increase: from 4.700 to
6.300 bopd► Gas lift stopped► WD : 400 m► Phase 1: Jul/2001 a Dec/2001► Phase 2: May/2004 on► New R&D project to increase flow
capacity, decrease CAPEX and installation costs
VASPS-Vertical Annular Separation & Pumping SystemVASPS-Vertical Annular Separation & Pumping System
VASPSVASPS
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PROCAP-3000Flow AssurancePROCAP-3000Flow Assurance
Wax and Hydrate Control►Multisize Pig Development► Wax Deposit Prediction► Hydrate Blockage in na Emulsion System► Wax Deposit in Condensate System
Wax and Hydrate Control►Multisize Pig Development► Wax Deposit Prediction► Hydrate Blockage in na Emulsion System► Wax Deposit in Condensate System
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PROCAP-3000Subsea EquipmentPROCAP-3000Subsea Equipment
Subsea Equipment for 3.000m de WD
►Horizontal Tree for ESP Wells with ROV Tree Cap►Equipment Installation by Cable►Completion Riser for 3,000 m►Test Xmas Tree with ESP in the Riser►Deepstar phase VIII
Subsea Equipment for 3.000m de WD
►Horizontal Tree for ESP Wells with ROV Tree Cap►Equipment Installation by Cable►Completion Riser for 3,000 m►Test Xmas Tree with ESP in the Riser►Deepstar phase VIII
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► Benefit: short intervention time for pump changes► Prototype installed at JUB-6 well on Dec 2005► Benefit: short intervention time for pump changes► Prototype installed at JUB-6 well on Dec 2005
BCSS Horizontal Tree for 2.500 m WDBCSS Horizontal Tree for 2.500 m WD
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Gas Lift Manifold for RoncadorGas Lift Manifold for Roncador
Installation Procedures
System Modeling
Hydrodynamic Analysis
Installation Monitoring
Installation Procedures
System Modeling
Hydrodynamic Analysis
Installation Monitoring
► Cable Installation – pioneer► WD 1.886m – world record (Manifold)► 190 ton
► Cable Installation – pioneer► WD 1.886m – world record (Manifold)► 190 ton
Equipment Installationby CableEquipment Installationby Cable
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Pendular MethodPendular Method
► No use of criticalresources for equipmentup to 270 ton
► No use of criticalresources for equipmentup to 270 ton
► Tests done in smallscale (1:35) and withfield scale model (1:1)
► Roncador Gas LiftManifold installed(Dez 06)
► Tests done in smallscale (1:35) and withfield scale model (1:1)
► Roncador Gas LiftManifold installed(Dez 06)
23
Subsea Separation of Oil/Water SSAOSubsea Separation of Oil/Water SSAO
► Separation and reinjection of the separated water
► Aiming topside facilities debottlenecking
► Separation and reinjection of the separated water
► Aiming topside facilities debottlenecking
Layout
GAS SEPARATION
GAS SEPARATION
GAS + OILGAS + OIL
SEPARATORSEPARATOR
WATERWATER
OILOIL
GASGAS
PRODUCTIONPRODUCTION
SEPARATIONSYSTEM
SEPARATIONSYSTEM
INJECTORWELL
INJECTORWELL
PRODUCERWELL
PRODUCERWELL
PRODUCTIONPRODUCTION
OIL +GASOIL +GAS
WATERWATER
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PROCAP-3000Risers and FlowlinesPROCAP-3000Risers and Flowlines
► Rigid Riser System– SCR for FPSO and SS– SCR in “Lazy Wave”
► Flexible Riser System– Sour service lines– Integrated umbilical
control-power
► Alternative Riser Systems– Tethered Riser Buoy– Self Standing Hybrid Riser
RHAS
► Rigid Riser System– SCR for FPSO and SS– SCR in “Lazy Wave”
► Flexible Riser System– Sour service lines– Integrated umbilical
control-power
► Alternative Riser Systems– Tethered Riser Buoy– Self Standing Hybrid Riser
RHAS
25
Tethered Riser BuoyTethered Riser Buoy
26
► Benefit: Big diameter riser for deepwater and load reduction on the floating unit
► FEED, Contract and Patent documents issued
► Benefit: Big diameter riser for deepwater and load reduction on the floating unit
► FEED, Contract and Patent documents issued
RHAS for P-52 Export LineRHAS for P-52 Export Line
27
SCRs for RoncadorSCRs for Roncador
Project P-52 - Roncador Module 2, phase 1A
Project P-52 - Roncador Module 2, phase 1A
► Semi-Submersible 80.000 tons► WD 1.800m► 68 risers, being 47 SCRs and 21 control lines
► Semi-Submersible 80.000 tons► WD 1.800m► 68 risers, being 47 SCRs and 21 control lines
► Limits for the SS movements► Optimized definition of the risers hanging
points► SCRs viability► Thermal Insulation thickness limits
definition► Maximum loads in support, pull-in and
anchor systems
► Limits for the SS movements► Optimized definition of the risers hanging
points► SCRs viability► Thermal Insulation thickness limits
definition► Maximum loads in support, pull-in and
anchor systems
28
► Benefit: Low movement units allow deepwater risers
► FPSO-BR► Mono-BR
► Benefit: Low movement units allow deepwater risers
► FPSO-BR► Mono-BR
PROCAP-3000 Floating Units and Anchoring SystemsPROCAP-3000 Floating Units and Anchoring Systems
29
► Hydrodynamic coupled movement analysis of theunit, risers and anchoring system
► Universities – USP, IPT, UFRJ, UFAL, PUC-RIO
► Hydrodynamic coupled movement analysis of theunit, risers and anchoring system
► Universities – USP, IPT, UFRJ, UFAL, PUC-RIO
Numerical TankNumerical Tank
30
Applications of synthetic polyester
► 4 SS (P-19, P-26, P-27 e P-40)
► 6 FPSOsP-34, FPSO II, P-47, Avaré, P-38 e FPSO Brasil
► 2 MonobuoysIMO 1 and IMO 3
► Total Installed: 175km in 161 lines
Applications of synthetic polyester
► 4 SS (P-19, P-26, P-27 e P-40)
► 6 FPSOsP-34, FPSO II, P-47, Avaré, P-38 e FPSO Brasil
► 2 MonobuoysIMO 1 and IMO 3
► Total Installed: 175km in 161 lines
Polyester AnchoringSystemsPolyester AnchoringSystems
G0228
Taut-leg R = 1X WDTaut-leg R = 1X WD
G0795
~
Conventional Mooring System - R = 3xWDConventional Mooring System - R = 3xWD
31
Torpedo Anchors and PolyesterCables for Albacora LesteTorpedo Anchors and PolyesterCables for Albacora Leste
32
► Benefit: support of production development projects (drilling, anchoring, flowlines, etc.)
► Benefit: support of production development projects (drilling, anchoring, flowlines, etc.)
Gathering and Treatment of Geological, Geotechnical and Oceanographic DataGathering and Treatment of Geological, Geotechnical and Oceanographic Data
33
Thank youThank you