05PA_CP_1_1.pdf

Campos Basin Deepwater Production Development An Overview César Luiz Palagi Petrobras

Rio de Janeiro - Brazil Introduction Petrobras has successfully concluded the development of Albacora and Marlim fields in water depths ranging from 230 to 1040 meters in Campos Basin (Figure 1), offshore Rio de Janeiro State, Brazil. In Albacora, there are 57 production wells and 6 water injection wells connected to two floating and production units: P-25, which is a semi-submersible unit (SS), and P-31, which is a floating, production and offloading unit (FPSO). In Marlim, there are 83 production wells and 46 water injection wells connected to eigth FPU, four SS (P-18, P-19, P-20 and P-26), three FPSO (P-33, P-35 and P-37) and one floating, storage and offloading unit (FSO P-32). These fields are producing 680 thousands barrels per day of oil and 10.6 million cubic meters of gas. Currently, there are six large fields been developed by Petrobras in Campos Basin: Roncador, Albacora Leste, Marlim Sul, Marlim Leste, Barracuda and Caratinga, which have a combined 4.2 billion barrels of proved reserves. These fields are producing through pilot-projects to existing platforms located in Marlim and Albacora fields as wells as to two other FPU: P-34 and Seillean. Two FPU (P-38 and P-40) are already in production in Marlim Sul. Three FPSOs are under construction: P43 for Barracuda, P-48 for Caratinga and FPSO-BRASIL (chartered unit) for Roncador. Eleven rigs are drilling and completing wells in Marlim Sul, Barracuda. Caratinga, Albacora Leste and Roncador. The development of some parts of these fields are still in early stages of design, however, it is possible to estimate that their full development will require the installation of eleven FPU and the connection of 150 production and 100 injection wells, which will require additional investments of over US$ 10 billion. The peak of production of these projects should reach more than 1 million barrels per day. This paper is an overall description of current and future development of Roncador, Albacora Leste, Marlim Sul, Marlim Leste, Barracuda and Caratinga fields and the main technical challenges that will be faced in years to come.

Roncador

Albacora Leste

Barracuda

Caratinga

Figure 1 – Campos Basin Location Map

Marlim Leste Marlim Sul

Marlim Sul Module 2

2000 In Partnership

P51

bpd)) Oil Production (thousand bpd

1900

Marlim Leste

1,900

Albacora Leste P50

1800 Roncador Module 1A Phase 1

1700

FPSO BRASIL

1600 1500

Marlim Sul Module 1 Barracuda Caratinga

P40 and P38

1,490 1400 1300 1200

P43 and P48

Roncador Module 1A Phase 2

Roncador Module 2

P52

1,336

2001

2002

2003

2004

2005

Figure 2 – Main Production Development Projects in Brazil

Marlim Sul Field The Marlim Sul field was discovered in 1987 by well RJS-382, in water depth ranging from 800 to 2,600 meters in Campos Basin, 120 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through a series of pilot and full-scale projects. Figure 3 and Table 1 depict a general representation and data of the entire development plan. Total proved reserves of Marlim Sul, according to the Society of Petroleum Engineers (SPE) criteria, is 1,045 million barrels of oil equivalent. There is a potential for a significant increase in this figures. The first well was connected in 1994 to FPU P-20, which is located in Marlim field. Three other wells were tied in between 1997 and 2001 to FPU P26 and P37, also located in Marlim field, and FPSO-II, located in Marlim Sul field. Two world records of deepwater production were established during the this pilot phase: the production of well MRL-4, at water depth of 1027 meters, to FPU P-20 in 1994 and the production of well MLS-3B, at water depth of 1709 meters, to FPSO-II in 1997. The first full-scale project of this field was put on stream in December 2001 when FPUs P-38 and P-40 started operation in water depths of 1,080 meters and 1,009 meters, respectively. The drilling and completion campaign for this project was initiated in 1994 and it will be concluded by 2003. All production and water-injection wells are individually tied in to its corresponding FPU. Gas is exported through a pipeline between FPU P-40 and a fixed platform PNA-1, which is located in Namorado field. Oil is offloaded from P-38 to shore terminals through shuttle tankers. Future projects for Marlim Sul include the drilling and completion of 35 production wells and 29 waterinjection wells and the installation of three new FPU as described in Figure3 and Table 1. A 726 kilometers pipeline will also be constructed to transport oil of this and other fields from Campos Basin to refineries in São Paulo state. These new projects have already been started and they are scheduled to be completed by 2009.

Figure 3 – Marlim Sul Field

Marlim Sul (P51)

Marlim Sul Module 3 TO BE DEFINED 100,000

Marlim Sul Module 4 TO BE DEFINED 120,000

Type of Stationary SS Production Unit Processing Capacity (BPD) 180,000 Gas Compression Capacity (MM M3/D) 7.2 5.4 5.4 Water Injection Capacity (M3/D) 40,000 20,000 25,000 Number of Production Wells 15 7 13 Number of Injection Wells 10 6 13 Start of Production 2004 2007 2009 Oil Peak of Production (BPD - YEAR) 180,000 - 2006 80,000 - 2009 115,000 - 2013 Gas Peak of Production (MM M3/D - YEAR) 4.3 - 2006 1.2 – 2008 1.2 - 2013 Stationary Production Unit Water Depth (M) 1,250 1,580 1,800 Table 1 – Future Marlim Sul Projects

Barracuda Field The Barracuda field was discovered in 1989 by well RJS-381, in water depth ranging from 600 to 1100 meters in Campos Basin, 95 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through one pilot and one full-scale project. Figure 4 and Table 2 depict a general representation and data of the entire development plan. Total proved reserves of Barracuda, according to the Society of Petroleum Engineers (SPE) criteria, is 692 million barrels of oil equivalent.

The pilot project is comprised of eight production wells tied in individually to FPU P-34, which started production in 1997. It will be concluded in 2003 when the P34 will be removed from its location and the wells will be connected to the FPU of the full-scale project. The full-scale project of this field will be put on stream in 2003 through FPU P-43 in water depth of 800 meters. The drilling and completion campaign for this project was initiated in 2000 and it will be concluded by 2004. All production and water-injection wells will be individually tied in to P-43. Gas will be exported through a pipeline between P-43 and a fixed platform PNA-1, which is located in Namorado field. Oil will be offloaded from P-43 to shore terminals through shuttle tankers.

Caratinga Field The Caratinga field was discovered in 1994 by well RJS-491, in water depth ranging from 850 to 1350 meters in Campos Basin, 100 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through one pilot and one full-scale project. Figure 4 and Table 2 depict a general representation and data of the entire development plan. Total proved reserves of Caratinga, according to the Society of Petroleum Engineers (SPE) criteria, is 287 million barrels of oil equivalent. The pilot project is comprised of three production wells tied in individually to FPU P-34, which started production in 1997. It will be concluded in 2003 when the P-34 will be removed from its location and the wells will be connected to the FPU of the full-scale project. The full-scale project of this field will be put on stream in 2003 through FPU P-48 in water depth of 1,040 meters. The drilling and completion campaign for this project was initiated in 2000 and it will be concluded by 2003. All production and water-injection wells will be individually tied in to P-48. Gas will be exported through a pipeline between P-48 and a fixed platform PNA-1, which is located in Namorado field. Oil will be offloaded from P-48 to shore terminals through shuttle tankers.

Figure 4 – Barracuda and Caratinga Fields

Barracuda (P43)

Caratinga (P48)

Type of Stationary Production Unit FPSO FPSO Processing Capacity (BPD) 150,000 150,000 Storage Capacity (MM BBL) 1,7 1,7 Gas Compression Capacity (MM M3/D) 6.0 6.0 Water Injection Capacity (M3/D) 40,000 32,000 Number of Production Wells 20 13 Number of Injection Wells 14 8 Start of Production 2003 2003 Oil Peak of Production (BPD - YEAR) 130,900 - 2005 117,500 - 2005 Gas Peak of Production (MM M3/D - YEAR) 1.75 - 2005 1.68 - 2005 Stationary Production Unit Water Depth (M) 800 1,040 Table 2 – Future Barracuda and Caratinga Projects

Marlim Leste Field The Marlim Leste field was discovered in 1987 by well RJS-359, in water depths ranging from 1,000 to 2,000 meters in Campos Basin, 120 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through one pilot and one full-scale project. Figure 5 and Table 3 depict a general representation and data of the entire development plan. Total proved reserves of Marlim Leste, according to the Society of Petroleum Engineers (SPE) criteria, is 14 million barrels of oil equivalent. The pilot project is comprised of one production well which was tied in 2000 to FPU P-26, located in Marlim field. This pilot will be concluded in 2002. There is a potential for a significant increase in these figures. The full-scale project of this field will be put on stream in 2005 through an FPU in water depth of 1,200 meters. The drilling and completion campaign for this project will initiate in 2004 and it will be concluded by 2007. All production and water-injection wells will be individually tied in to the FPU. Gas will be exported through a pipeline between the FPU and FPU P-26, which is located in Marlim field. Oil from this and other fields in Campos Basin will be transported to refineries in São Paulo state through a 726 kilometers long pipeline which will be constructed between 2002 and 2004.

Figure 5 – Marlim Leste Field

Marlim Leste (P53) Type of Stationary Production Unit TO BE DEFINED Processing Capacity (BPD) 120,000 Gas Compression Capacity (MM M3/D) 3.5 Water Injection Capacity (M3/D) 15,000 Number of Production We 13 Number of Injection Wells 7 Start of Production 2005 Oil Production Peak (BPD - YEAR) 85,000 - 2008 Gas Production Peak (MM M3/D - YEAR) 2.2 - 2006 Stationary Production Unit Water Depth (M) 1,200 M Table 3 – Future Marlim Leste Project

Albacora Leste Field The Albacora Leste field was discovered in 1986 by well RJS-342, in water depths ranging from 800 to 2000 meters in Campos Basin, 120 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through one pilot and one full-scale project. Figure 6 and Table 4 depict a general representation and data of the entire development plan.

The pilot project was comprised of one production well which was tied in from 1998 to 2001 to FPU P25, located in Albacora field. The full-scale project of this field will be put on stream in 2003 through the FPU P-50 in water depth of 1,240 meters. The drilling and completion campaign for this project was initiated in 2001 and it will be concluded by 2007. All production and water-injection wells will be individually tied in to P-50. Gas will be exported through a pipeline between the P-50 and a fixed plataform, PNA-1, which is located in Namorado field. Oil will be offloaded from P-50 to shore terminals through shuttle tankers.

Figure 6 – Albacora Leste Field

Albacora Leste (P-50) Type of Stationary Production FPSO Unit Processing Capacity (BPD) 180,000 Storage Capacity (MM BBL) 2,0 Gas Compression Capacity (MM M3/D) 6.0 Water Injection Capacity (M3/D) 35,000 Number of Production Wells 21 Number of Injection Wells 10 Start of Production 2003 Oil Peak of Production (BPD YEAR) 170,000 – 2007 Gas Peak of Production (MM M3/D - YEAR) 2.1 - 2007 Stationary Production Unit Water Depth (M) 1,240 Table 4 – Future Albacora Leste Project

Roncador Field

The Roncador field was discovered in 1996 by well RJS-436A, in water depth ranging from 1,500 to 1,900 meters in Campos Basin, 125 kilometers from the cost of Rio de Janeiro state. The development of the field has been conducted through a series of pilot and full-scale projects. Figure 7 and Table 5 depict a general representation and data of the entire development plan. Total proved reserves of Roncador, according to the Society of Petroleum Engineers (SPE) criteria, is 1,943 billion barrels of oil equivalent. There is a potential for a significant increase in this figures. Two pilot projects were conducted in the field. First, well RJS-436 produced to FPU Seillean from 1999 to 2001, at that time a record at water depth of 1845 meters, then well RO-20 produced also to FPU Seillean from 2001 to 2002, in water depth of 1815 meters. The first full-scale project of the field was put on stream in May 2000 when FPU P-36 and P-47 started operation in water depth of 1360 meters and 815 meters, respectively. Unfortunately, an accident caused P-36 to sunk in March 2001, when six wells were in production. Gas was being exported through a pipeline between P-36 and a fixed platform PNA-1, which is located in Namorado field. Oil was being offloaded from P-47 to shore terminals through shuttle tankers. Eleven people were killed in the accident. Future projects for Roncador include the drilling and completion of 57 production wells and 31 waterinjection wells and the installation of FPSO-BRASIL and three additional new FPU as described in Figure 7 and Table 5. A 726 kilometers pipeline will also be constructed to transport oil of this and other fields from Campos Basin to refineries in São Paulo state. These new projects have already been started and they are scheduled to be completed by 2009.

Figure 7 – Roncador Field

Roncador Roncador Roncador Roncador (P52) FPSO - Brasil Module 2 East Module 2 West Type

of

Stationary

FPSO

SS

TO BE

TO BE

Production Unit DEFINED DEFINED Processing Capacity (BPD) 90,000 180,000 180,000 180,000 Storage Capacity (MM BBL) 1,5 Gas Compression Capacity (MM M3/D) 3.0 9.3 5.0 6.0 Water Injection Capacity (M3/D) 15,000 48,000 40,000 48,000 Number of Production Wells 8 20 11 18 Number of Injection Wells 3 10 8 10 Start of Production 2002 2004 2005 2007 Oil Peak of Production (BPD - YEAR) 80,000 - 2003 170,000 - 2007 160,000 - 2008 165,000 - 2011 Gas Peak of Production (MM M3/D - YEAR) 1.4 - 2003 3.4 - 2007 2.6 - 2008 2.9 – 2010 Stationary Production Unit Water Depth (M) 1,290 1,800 1,750 1,650 Table 5 – Future Roncador Projects

Technical Challenges There are several technical challenges to implement the series of deepwater development projects described previously in a safe, risk-controlled and efficient way. The first challenge is the proper characterization of the reservoir such that the entire project is designed accordingly and the wells are located and positioned correctly. Given that most reservoirs are unconsolidated sandstones and that most wells are horizontal, the next challenge is the design and installation of sand control equipment. Still at the well level, it is important to capture the high productivity/injectivity of the wells through the installation of large diameter production/injection columns. The single more challenging aspect at sub-sea level is the design and installation of large diameter risers at water depths above 1500 meters. Also the flow assurance of high viscosity oil at low seabed temperature will impose technical complexities. The main challenges to be faced during the design and construction of the FPUs are their mooring system and their interfaces with the risers. Also, all units should be operated with high safety standards.

Conclusions The development of the existing oil fields in Campos Basin will require the drilling, completion and connection of more than one hundred and fifty wells to eleven new FPU in the next seven years. These projects and the ones that have already been concluded are the basis for the achievement of the strategic goal of Petrobras, which is to produce 1.9 million barrels per day by 2005, in Brazil. The proper design and operation of these projects in a safe, risk-controlled and efficient form will require intense ingenuity in all technical disciplines: reservoir, wells, sub-sea and topside facilities.