the marlim field development: strategies and...

The Marlim FieldDevelopment: Strategies and

Challenges

Ricardo Juiniti Bernardo -Petrobras

Presentation Summary

Campos Basin Overview

Marlim Field Development Strategies

Evolution of Driling and Completion

Techniques

Challenges to Be Overcome

Conclusions

Campos Basin Overview

Marlim Field Development Strategies

Evolution of Driling and Completion

Techniques

Challenges to Be Overcome

Conclusions

The Campos Basin

Title SlideShallow reservoir(~ 3,000 m total depth)

Mild environmental conditions( presence of high currents)

Steep slope seabed profile(including even canyons)

Unconsolidated sandstone indeepwater

The Campos BasinThe Campos Basin

• 1971 - Jack-ups - WD 50 m– TD from 1,500 m to 3,500

m. – OBS Systems

• 1972 - Drillships - WD > 80 m– Different Wellhead

Systems (SG- 1 and HB 3 - 16 3/4”)VinegarronVinegarron

The Campos Basin The Campos Basin • December 1974 – Well 1 RJS 9A - Garoupa Field

– WD: 124 m – TD at 3,750 m

Drillship Petrobras IIDrillship Petrobras II

The Campos Basin The Campos Basin

• August 13, 1977 – Well 3 EN 1 RJS –Early Production System of Enchova Field

– One vertical well producing through the BOP (10,000 bopd)

– TD: 2,520 meters

The Campos Basin The Campos Basin • 1979: Garoupa - Namorado Project

– Drilling:–Directional Wells ( max. deviation 35

degrees ) – Completion:

–7 gas lift valves + 1 kill valve–Permanent Downhole Gauge

The Campos Basin

1979: Garoupa - Namorado

The Campos Basin The Campos Basin

• 1979 : Subsea Completion in Bonito Field – Well 4 RJS 38

• 4 casing strings + 7” liner

• TD at 2,800 meters

• First sand control installation from a floating rig

The Campos Basin The Campos Basin

• 1979 – 1983 Implementation of Other Early Production Systems and Floating Production Units

– Standardization of the wellhead systems (18 ¾”).

– Drilling design: 30” / 20” / 13 3/8”/ 9 5/8” production casing or 7” production liner.

– Poor Performance of Permanent Downhole Gauges

– Use of Subsea Trees and gas lifting

Corvina EPSCorvina EPS

The Campos Basin The Campos Basin

• 1981 - 1984 Installation of Fixed Platforms from 108 to 170 m

– Wells drilled after platform installation

– 4 casing strings plus a 7” liner when required.

– Directional drilling : max. deviation 45 degrees.

– Sand control was not mandatory

Garoupa PlatformGaroupa Platform

The Campos Basin The Campos Basin

• 1989 - Installation of Fixed Platforms in “Polo Nordeste”

– Wells drilled from semis and drillships during the jackets construction.

– 4 casing strings plus a 7” liner– Use of Electrical Submersible

Pumps

Garoupa PlatformGaroupa Platform

The move towards deeper watersThe move towards deeper waters

1982 - Exploratory drilling in WD > 400 m

1984 - Dynamic Positioning Rigs

• Exploratory drilling in WD > 500 m

• Workovers in shallow and cluttered areas

1982 - Exploratory drilling in WD > 400 m

1984 - Dynamic Positioning Rigs

• Exploratory drilling in WD > 500 m

• Workovers in shallow and cluttered areas

The Campos Basin

The Marlim Field

Discovered in 1985

Total Area: 132 square Km.

WD: 650 to 1,050 m

Oil Gravity: 19 to 24 API

High Productivity Index

Poorly Consolidated Sandstone

Dependent on water injection

First Oil in 1991

The Challenges

Technological

Capital Expenditure

Period: 1986 to 1991

Portfolio: 109 projectsPetrobras 13

Marlim Field Development Strategies

Subsea Completions with Floating Production Units

Early Production System guided the Definitive development plan

Phased Development with the incorporation of the lessons learned in the previous phases

Marlim Field Development - 1989

• 135 production wells

• 20 water injection wells

• 9 FPU’s

• Peak Production : 430,000 bopd

Present Situation

Unit Type WD (m)Processing

Capacity (m³/day)

Start up

P-20 SEMI 620 10.350 June/92P-18 SEMI 910 15.900 June/94P-19 SEMI 770 15.900 Dec/97P-26 SEMI 990 20.000 March/98P-32 FSO 160 18.480 June/98P-33 FPSO 780 10.000 Dec/98P-35 FPSO 850 20.700 Aug/99P-37 FPSO 905 28.800 July/00

Current Production:490,000 bopd 129 subsea wells5 subsea manifolds

Present SituationReservoir Management

The Marlim Field

Evolution of Drilling and CompletionTechnology in Deepwater

Evaluation of Drilling and Completion Technology

• Well Design

• Sand Control Operations

Well Design

1991 / 95: Vertical and directional wells

1995: First Horizontal Well -•Water injection ( 8 MRL 38H ) 905m WD

screens with no gravel pack

2005- 27 horizontal production wells and 7 horizontal water production wells160 to 1,138 m of horizontal section

3 MRL 3 RJSDrilled in 1989

48”Conductor

30”20”

13 3/8’

9 5/8”

• Vertical well• 48” conductor pipe• 4 casing strings• 9 5/8” production casing

3 MRL 3 RJSon stream since 1991

• 20 m of perforations• Gravel pack (slurry pack)• 5 1/2” Production string• 6,000 bopd

7 MRL 150 HPdrilled in 2001

30“Condutor

13 3/8“

9 5/8“

- Jetted 30”casing- 9 5/8” casing shoe

inside the reservoir

7 MRL 150 HPdrilled in 2001

- Open hole 8 1/2”- 400 to 420 meters long

30“Condutor

13 3/8“

9 5/8“

7 MRL 150 HPon stream since 2001

- 5 1/2” OD screens- Gravel Pack- External Casing Packer- 15,000 bopd

ECP

30“Condutor

13 3/8“

9 5/8“

Sand Control OperationsVertical and Directional Wells

• 1991 - Slurry PackSignificant drop of the PI

• 1995 - Water PackImprovement over slurry pack operations

• 1998 - Frac PackSimplified sand control operationsNo significant drop of the PI

Sand Control in Deepwater Developments

Slurry Pack•Perforations in underbalance

•Flow the well to clean perforations

• Adequate casing and stringcleaning

• Significant drop of the PI

• Acid Jobs were required

Sand Control in Deepwater Developments

Water Pack•Introduced in 1995

•Improved the PI if comparedto slurry pack systems

•Nowadays is limited to 12 meters long intervals wherethe oil/water contact is present

Sand Control OperationsHorizontal Wells

• Stand Alone systems in injection and production wells

higher PI sand production above 0,01 %

• Open Hole Gravel Packsuccessfully used for sand control

Sand Control OperationsHorizontal Wells

• OHGP systems with ECP

• Expandable screens

Challenges in Sand Control Operationsin the Campos Basin ( 1 )

• Long Horizontal sections up to 2,000 meters in unconsolidated sandstone

• To improve Drill in Fluid removal in water injection wells ( time x efficiency )

Challenges in Sand Control Operationsin Campos Basin ( 2 )

• Selective Open Hole Gravel Pack Operations

• Smart Completions + Sand Control in Deviated and Horizontal Wells

Marlim Field Development Strategies

SubseaStandardization Program for the Subsea Trees

Standardization on the Flowlines ConnectionSystems

2 8 7 1731 38

58

76

102

122 127 129

31

0

20

40

60

80

100

120

140

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003

Year

Num

ber o

f Wel

ls

0

0,25

0,5

0,75

1

Rat

io o

f In

terv

entio

ns

Number of Wells % of Interventions

Present SituationNumber of Interventions

Challenges to Be Overcome

Oil Production until 2025

Water Injection

Produced Water Processing

Aging of the wells

In a profitable way…..

Oil Production until 2025

Water Injection

Produced Water Processing

Aging of the wells

In a profitable way…..

Challenges to Be Overcome

Topsides

Subsea Separation

Raw Water Injection

Topsides

Subsea Separation

Raw Water Injection

W-O SEPARATION SUBSEA SYSTEM

WATER INJECTION

OIL+GAS

PRODUCER

water

oil

gas

wellstream

Challenges to Be Overcome

Flow Assurance

Hydrates

Emulsion

Flow Assurance

Hydrates

Emulsion

Challenges to Be Overcome

Well Operations

Workovers / New Wells

Cost of the rigs

Subsea Equipment

Integrity of the subsea equipment

Flowlines and risers inspection

Well Operations

Workovers / New Wells

Cost of the rigs

Subsea Equipment

Integrity of the subsea equipment

Flowlines and risers inspection

Conclusions ( 1/2)

• Drilling and Completion projects werehighly influenced by technologicalinnovations.

• Significant evolution in spud in operations decreased drilling time.

• Use of horizontal wells allowed reduction of total number of wells.

Conclusions ( 2 / 2 )

• Evolution of Sand Control Techniquesimproved productivity indexes.

• Marlim Field: Laboratory for thedevelopment of deepwater technology.

• With the field maturation new challenges willhave to be overcome to ensure the forecasted levels of production.