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This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper OTC 28716, “Campos Basin Technologies Yard: 40 Years of Lessons Learned,” by M. Roberto, A.B. Coutinho, and A.R. Dos Santos, Petrobras, prepared for the 2018 Offshore Technology Conference, Houston, 30 April–3 May. The paper has not been peer reviewed. Copyright 2018 Offshore Technology Conference. Reproduced by permission. Over the last 40 years, the Campos Basin has been a major stage for technology development to push offshore oil and gas production to water depths (WDs) never before experienced. This paper presents a retrospective of the most-significant technologies developed and deployed in the Campos Basin for more than 80 production systems in more than 30 oil- and gas-field developments; a few of these milestones are described in this synopsis. Introduction The discovery of oil in the Campos Basin in 1974 occurred in the context of the 1973 world oil crisis and its effects on geopolitics and the global economy. In addition to the challenges associated with this period, a need existed to increase oil production while reducing costs, leading to a fast-track approach. The development of the Garoupa field, followed by the Pargo, Badejo, Namorado, Enchova, Bonito, and Pampo fields, revealed huge oil-production potential, minimizing Brazil’s need to import petroleum. The development and application of new technologies, such as early production systems (EPS), horizontal wells, tree standardization, flexible pipes, and subsea processing and boosting, allowed the necessary cost reduction and risk mitigation. Now, most of these technologies are consolidated and are used in new Brazilian discoveries, particularly in presalt areas. To speed the development of these technologies, a deep- and ultradeepwater technology program, the Technological Development Program for Deep water Production Systems (PROCAP), was initiated in 1986. PROCAP and its four versions—PROCAP 1000 (1000-m well depth), PROCAP 2000, PROCAP 3000, and PROCAP Future Vision, have since supported the development of Campos Basin technologies and the exploration of new frontiers. Technology Development Many technologies have been developed in the Campos Basin during the last 40 years in order to support the production, developing, revitalization, life extension, and decommissioning of its fields. The Campos Basin development has become successful because of a strong partnership between the operator and suppliers, academia, research centers, and other operators. Despite the challenges faced during the last 40 years, the Campos Basin served as an excellent laboratory in which technologies, methodologies, internal programs, human-resource initiatives, suppliers and subsuppliers, university resources, and engineering and spinoff companies were developed to achieve and sustain the high production of these fields. 1971 to 1974: First Exploratory Wells Drilled and First Discoveries. The first exploratory well in the Campos Basin, named 1-RJS-1, was drilled in 1971 with a jackup-type rig at a WD of 49 m, which resulted in a dry well with no indications of hydrocarbons. In the following years, additional exploratory wells were drilled in WDs of greater than 60 m. The first indications of hydrocarbons were noticed in 1973 in another exploratory well, although it had no production potential. In fact, seven dry wells were drilled since the beginning of the well-exploration campaign.
- Instructional Material > Online (0.55)
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- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Field > Macae Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Field > Lago Feia Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Garoupa Cluster > Garoupa Field (0.99)
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Campos Basin, during the last 40 years, has been the stage where the technology development has played its main game in terms of pushing the offshore oil and gas production to overcome its challenges to go deeper and deeper in WDs never experienced before. Incremental, innovative, enabler or even disruptive technologies, supported by a strong commitment to success and the capability and drive for field test new ideas have made such a difference. Structured actions based on technology programs specific created for reaching defined targets, such as Petrobras Deep and Ultra Deep Water Technology Program named PROCAP, in its four sequential "versions" for over 28 years, resulted in two OTC Awards, in 92 and 2001, and helped Petrobras to achieve an important position worldwide in offshore production. A focused projection of the future in terms of the next generation under development to overcame challenges related to revitalization of Campos Basin mature fields, such as life extension methodologies, heavy oil processing, oil and gas contaminants treatment, subsea boosting and separation systems, power distribution and transmission, that are part of Petrobras technologies "gold list" are being developed and they will be available in the next couple of years. Additionally, an internal program, named Subsea Operational Technologies, has been developed to promote a full integration among suppliers, R&D and operation teams to reduce OPEX and enhance oil and gas production in Campos Basin. Also, associated to that, a strong and efficient integrated operation control has promoted the required offshore field management drive and safety. This paper will present a retrospective of the most significant Subsea system, Well Drilling and Completion, as well as Topsides technologies developed and deployed in the Campos Basin for more than 80 production systems in more than 30 oil and gas fields development.
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- Instructional Material > Online (0.86)
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- Government > Regional Government > South America Government > Brazil Government (0.67)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlin Field (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Sul Field > Macae Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Sul Field > Lago Feia Formation (0.99)
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- Well Drilling > Pressure Management (1.00)
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Abstract Since the first subsea well started producing in Campos Basin, this province has turned into a big laboratory where innovations and different concepts have been tested, ranging from one-atmosphere chambers to diverless guidelineless deepwater subsea trees and manifolds. The need to produce successive discoveries in increasing deepwaters imposed the challenge that sparked the continuous technology development in the past 25 years. The subsea trees evolution in the world is very much associated with the developments tested in this province. It starts with the dry subsea trees in wellhead-cellars in Garoupa field, passing through the shallow waters diver operated trees, the development of the lay-away technique and, furthermore, development of the diverless vertical connection system and the guidelineless deepwater subsea trees. The strategic effort on standardization of subsea tree interfaces provided operational flexibility and increased rationalization to deal with wellheads, trees, tools and completion risers of different manufacturers for hundreds of wells. Evolution of subsea manifold architecture and modularization concept has been present along the development of several fields as Garoupa, Bonito, Linguado, Albacora, Marlim and Roncador. The same for subsea controls, including direct hydraulic and electro-hydraulic multiplexed systems. Subsea flowlines, umbilicals and risers were also developed for a variety of conditions of water depth, production facility (semi-submersible, FPSO, monobuoy), fluid characteristics and thermal insulation requirements. These developments included an extensive use of flexible tubes, steel pipelines and the pioneer Steel Catenary Riser connected to a semi-submersible production unit in deepwater. Adding new components to the toolbox of subsea engineers, boosting systems have also been developed, as the first in the world subsea completion with an Electric Submersible Pump (ESP) in Carapeba Field and the Marimbá Subsea Separation System. Supported by the operational experience acquired throughout the years and motivated by the challenge to develop the ultra deepwater discoveries, other technological developments are being conducted by Petrobras. This paper presents the evolution of subsea equipment so far, the development efforts being carried out and the next steps to meet the future demands. Introduction Campos Basin initial production development was based in the widely use of Early Production Systems (EPS), from Enchova field at 120 m water depth (WD) up till now in Roncador field at almost 2,000 m WD. The use of EPS confirmed to be a reliable and cost effective solution being extended for the definitive offshore fields developments. This concept implementation required an intensive use of subsea trees, manifolds and flexible pipes for static and dynamic applications, leading Petrobras to focus in the subsea hardware technology development to overcome the big challenges of producing in shallow, deep and ultra deep waters, as highlighted bellow: The use of drilling equipment for the first Petrobras EPS in 1977, with a test tree (EZ tree) suspended by a drilling rig inside the Blow-Out Preventer (BOP) stack to produce the well 3-ENO-1-RJS at 120 m WD.
- Energy > Oil & Gas > Upstream (1.00)
- Government > Regional Government > South America Government > Brazil Government (0.72)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Field > Macae Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Field > Lago Feia Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Enchova Cluster > Enchova Field (0.99)
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- Well Completion > Completion Selection and Design > Deepwater completions design (1.00)
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- Facilities Design, Construction and Operation > Offshore Facilities and Subsea Systems > Subsea production equipment (1.00)
- Facilities Design, Construction and Operation > Offshore Facilities and Subsea Systems > Subsea processing (1.00)
With more than 100 thousand square kilometers and representing about 58% of Brazil's oil and gas daily production in 2016, Campos Basin has proved its gigantism by producing 12 billion barrels of oil equivalent since 1977, extracted from the various concessions, like the giant fields of Marlim, Roncador and Jubarte. Comprising fifty-three production units, 711 wells and 14.8 kilometers of subsea pipelines, Campos Basin can be considered one of the largest offshore oil and gas complex operated by a single company in the world. In this context, considering the relevance of this oil province, this paper aims to present the journey of Campos Basin, summarizing the main challenges overcome in the last 40 years, the technologies developed, the strategies applied and the results obtained.
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Santos Basin > Block BM-S-11 > Tupi Field > Lula Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Santos Basin > Block BM-S-11 > Tupi Field > Guaratiba Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Santos Basin > Block BM-S-11 > Tupi Field > Cernambi Formation (0.99)
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- Facilities Design, Construction and Operation > Offshore Facilities and Subsea Systems > Floating production systems (0.30)
Abstract Campos Basin, the main production province in Brazil, was discovered in 1974. It is located on the North coast of the Rio de Janeiro State and comprises an area of around 115,000 km2 (28,400 acres), as shown in Figure 1. The producing oil fields are between 70 and 150 km (43 to 93 miles) far from the seashore. It started its production on August 13th, 1977 with 10,000 bopd (barrels of oil per day) from the well 1-EN-01-RJS, which produced to a semi-submersible platform; this well has produced nearly 35 million barrels of oil until February 1998, when it was shutdown for economical reasons. Today, after more than twenty-five years of continuous operation, the overall production system comprises 13 fixed platforms and 24 Floating Systems distributed among 42 oil fields, which account for the production of 1.21 million bopd - which corresponds to more than 80% of Petrobras oil production, plus 18.9 million m3 of gas per day - or 43% of the gas production (as of December 2002). Such an evolution was supported by investments in exploration and production development, in deepwater technology developments and in continuous management improvement. This paper describes the main driving forces to exploit Campos Basin - especially its deep and ultra-deepwaters fields, the technological and production developments performed, the experience accumulated by Petrobras along these 25 years of operations as well as its contribution to the global oil industry. Introduction The 1973 world oil crisis brought a tremendous economical impact on most countries, especially on those with strong dependence on imported oil, such as Brazil. This led a worldwide increase in investments on oil and gas exploration and production, including the search of new technology for producing fields located in hostile environment. The first oil discovery in Campos Basin occurred in 1974, while Brazil was facing the economical commotion created by the crisis, worsened by the country's unbalanced external payments account. Bringing the newly discovered prolific oil province on to production, as fast and at the lowest cost as possible, became a key issue for Petrobras. The increased throughput would help reducing the burden of Brazil to manage its increasing external debts. The oil imports were responsible, at that time, for a significant portion of the Brazilian payment unbalance. The country had to simultaneously reduce its oil consumption and increase its production. The reduction would come with the introduction of alcohol-fueled vehicles, and the use of other alternative energy sources, while the increase would mainly come through the Campos Basin offshore development. The problem was to produce in conditions never experienced before. The Garoupa and Enchova Fields, the first ones in the basin, located in 120 m water depth (WD), were already considered in deep waters, at the time. The available field-proven solutions using fixed platforms were technically and economically feasible, but it would take years for its implementation, and the costs were relatively high. The country also had to limit the use of foreign services and goods to a bearable minimum, to not worsen the economical scenario.
- Energy > Oil & Gas > Upstream (1.00)
- Government > Regional Government > South America Government > Brazil Government (0.78)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Sul Field > Macae Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Sul Field > Lago Feia Formation (0.99)
- South America > Brazil > Rio de Janeiro > South Atlantic Ocean > Campos Basin > Marlim Leste Field > Macae Formation (0.99)
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