Research for Ultra-Deepwater Production Opening Seminar Marintek do Brasil Rio de Janeiro, Apr 19, 2007 Mauricio Mauricio Werneck Werneck PROCAP PROCAP 3000 3000 Coordinator Coordinator
Petrobras Investment Plan PN 2007-11 US$ 87,1 bilhões E&P Refining & Transport Gas & Energy Petrochemical Distribution Corporate 3% 26% 3% 4% 56% 1,8 2,3 3,3 49,3 9% 7,5 23,0 2
Oil + LNG Production (Brazil) 2,500 2,000 1,684 1,880 1,979 2,061 2,195 2,368 2,374 Liquid Increase 690 1,000 bpd 1,500 1,000 1,684 1,530 1,358 1,176 987 Natural Decrease 1.114 1.804 500 786 570-2005 2006 2007 2008 2009 2010 2011 3
Oil + LNG Production and Support Projects 2,600 2,400 2,200 2,000 1,800 1,600 Albacora Leste P-50 180.000 bpd 1,684 Jubarte Fase 1 P-34 60.000 bpd 1,880 Piranema 20.000 bpd Roncador P-52 180.000 bpd Rio de janeiro Espadarte Módulo II 100,000 bpd FPSO Capixaba Golfinho 2,195 Módulo I 100.000 bpd Frade 100.000 bpd 1,979 Roncador P-54 180.000 bpd Cidade de Vitória Golfinho Mod. II 100.000 bpd ESS-130 Golfinho Mód. III (FPSO) 100.000 bpd 2,061 Marlim Sul Módulo II P-51 180.000 bpd Marlim Leste P-53 180.000 bpd 2,368 2,374 Jubarte Fase 2 P-57 180.000 bpd Parque das Conchas 100.000 bpd Roncador P-55 180.000 bpd 1,400 2004 2005 2006 2007 2008 2009 2010 2011 2012 4
R&D Investment 1600 R$ Millions (Base 2005) 1400 1.420 1200 1000 916 800 600 499 598 662 730 400 200 0 2001 2002 2003 2004 2005 2006 5
R&D Center CENPES Executive Manager R&D Exploration R&D Production R&D Refining R&D Gas Energy & Sustainable Dev. Basic Engineering Technology Management 12 Technological Programs 1000 R&D Projects 50 Basic Engineering Projects 500 Production R&D Projects 4000 People Present area: 122,000 m2 137 labs 30 pilot units New Construction: 180,000 m2 6
Technological Challenges Ultra-Deep Water Risers and Pipelines Mooring Systems HPHT Wells and Equipment Flow Assurance Subsea Boosting and Processing 7
Production and Reserves vs. Water Depth 2005 Production 2005 Proven Reserves (SPE) 5% 19% 16% 25% 10% 10% 60% 55% 1.958.000 boed 13,23 billion boe Onshore Offshore (0-300m) Offshore (300-1500m) Offshore (> 1500m) Exploratory Area 160,500 km 2 38% 24% 26% 12% 8
PROCAP 1986 1991 Marlim and Albacora Production Technological Support 1,000m (3,300ft) 2,000m (6,600ft) 3,000m (10,000ft) 1992-1999 Roncador and Marlim Sul Production Technological Support 2000-2006 Production Technological Support for Ultra Deep Phases of Marlim Sul and Roncador, Exploratory Prospects, GoM and WoA Assets 9
PETROBRAS Activity Completion Records Installed Equipment Equipment Installed Jan/2005 Planned 2005/2006 Wet Trees 548 106 Subsea Manifolds 58 02 Subsea Flexible Lines (Km) 2.534 765 Umbilicals (Km) 2.229 622 Rigid Lines (Km) 1.964 305 10
PROCAP-3000 Main Areas Drilling and Completion Subsea Equipment Artificial Lift and Boosting Flow Assurance Riser and Flowline Systems Floating Units and Anchor Systems Environmental Database 11
PROCAP-3000 Drilling and Completion 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 12
Light Fluids Gas-Lifted Riser Deepwater Problem: narrow margin between pore and fracture pressures Theoretical Solution: Dual Gradient Drilling Many Practical Alternatives Depth (m) Hydrostatic Pressure (psi) 0 0 6000 500 1000 1500 2000 Mud SG 11 ppg 500 1000 1500 2000 Equivalent Mud Weight (ppg) 8 10 12 0 2500 3000 Mud DG 14 ppg 2500 3000 13
Torpedo Wellhead 14
PROCAP-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 15
Performance Tests SBMS-500 Benefit: production increase Performance and endurance tests concluded at Núcleo Experimental Eng. Baruzzi Modules under final assembly for installation at Marlim field (Oct 07) 16
VASPS VASPS-Vertical Annular Separation & Pumping System THERMIE Eni Agip 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 17
PROCAP-3000 Flow Assurance Wax and Hydrate Control Multisize Pig Development Wax Deposit Prediction Hydrate Blockage in na Emulsion System Wax Deposit in Condensate System 18
PROCAP-3000 Subsea 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 19
BCSS Horizontal Tree for 2.500 m WD Benefit: short intervention time for pump changes Prototype installed at JUB-6 well on Dec 2005 20
Equipment Installation by Cable Gas Lift Manifold for Roncador Installation Procedures System Modeling Hydrodynamic Analysis Installation Monitoring Cable Installation pioneer WD 1.886m world record (Manifold) 190 ton 21
Pendular Method No use of critical resources for equipment up to 270 ton Tests done in small scale (1:35) and with field scale model (1:1) Roncador Gas Lift Manifold installed (Dez 06) 22
Subsea Separation of Oil/Water SSAO Separation and reinjection of the separated water Aiming topside facilities debottlenecking Layout OIL + GAS PRODUCTION GAS SEPARATION GAS SEPARATOR GAS + OIL OIL WATER INJECTOR WELL PRODUCER WELL WATER SEPARATION SYSTEM PRODUCTION 23
PROCAP-3000 Risers 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 24
Tethered Riser Buoy 25
RHAS for P-52 Export Line Benefit: Big diameter riser for deepwater and load reduction on the floating unit FEED, Contract and Patent documents issued 26
SCRs for Roncador Project P-52 - Roncador Module 2, phase 1A 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 Semi-Submersible 80.000 tons WD 1.800m 68 risers, being 47 SCRs and 21 control lines 27
PROCAP-3000 Floating Units and Anchoring Systems Benefit: Low movement units allow deepwater risers FPSO-BR Mono-BR 28
Numerical Tank Hydrodynamic coupled movement analysis of the unit, risers and anchoring system Universities USP, IPT, UFRJ, UFAL, PUC-RIO 29
G0228 Polyester Anchoring Systems Applications of synthetic polyester 4 SS (P-19, P-26, P-27 e P-40) 6 FPSOs P-34, FPSO II, P-47, Avaré, P-38 e FPSO Brasil 2 Monobuoys IMO 1 and IMO 3 G0795 Conventional Mooring System - R = 3xWD ~ Taut-leg R = 1X WD Total Installed: 175km in 161 lines 30
Torpedo Anchors and Polyester Cables for Albacora Leste 31
Gathering and Treatment of Geological, Geotechnical and Oceanographic Data Benefit: support of production development projects (drilling, anchoring, flowlines, etc.) 32
Thank you 33