Considering demands for internal Brazilian market and international crude oil trade, PETROBRAS has taken the decision to concentrate a significantly part of the future of crude oil production from three deep-water fields; Roncador, Marlim Sul and Marlim Leste, all of which are in Campos Basin, with one off-shore terminal. The name of this project is PDET. This project comprises of a fixed central pumping station, PRA-1, a large FSO (2,1 million barrels storage capacity), and two calm buoys systems, at a depth of 100 m. The start-up of this project involves the crude oil from three producing platform; P-52, P-51 and P-53, which are all currently under advanced construction. In the future PDET will receive the production of crude oil from two additional new platforms. Each producing platform will have its own export pipeline, direct to PRA-1. The peak production of this system will achieve 600,000 bbl/day. PRA-1 will have special requirements to pump crude oil either to FSO or to the calm buoys systems. Based on a steel jacket structure the capacity of power generation will be 75 MW, up to 34 inches pigging capacity and many diverse pipings. The FSO has special specifications such as the electrical power and optical swivels, both are at a high level of technology and capacity. To achieve system's targeted reliability extensive studies were done. Integrity protection system, leak detection system, offloading time, sub-sea layout and flow rates were taken into consideration. Environmental risks were fully mitigated. The final configuration, which achieved high standard integrity assurance, produced a valuable project. This paper describes the logistics of this project focusing PRA-1 pumping, the export system through calm buyos, sub-sea facilities and the FSO. Also it will be highlighted some management programs used to implement this project. This work reviewed the major aspects of implementing this important infrastructure offshore facility to transport crude oil. Several technical and managerial challenges were surpassed through introduction of new technologies, tools and techniques. Introduction Campos Basin is the most important Brazilian E&P region, located offshore, in the southeast region of the country. As of June 2007, it has produced 1.5 million barrels of oil per day, which has accounted for 74% of PETROBRAS' total production worldwide and 82% of its domestic oil production. Campos offshore oilfields will continue to be the main source of Brazilian crude oil, in the near future. Expecting a sharp and steady increase in crude oil production, especially in deep water areas, PDET looked for the best integrated solution for Campos Basin offshore petroleum fields. In 2010 PETROBRAS domestic targets call for 2.4 million barrel of oil per day, meaning a huge increase in comparison with 2006 production. This will demand infrastructure of transport improvement to assure excellence concerning safety and operational procedures and environmental protection, which are strict requirements for Petrobras projects. PETROBRAS' strategic plan has officially achieved 2006 for one the company's greatest-ever achievements: Brazilian self-sufficiency in crude oil production. Reaching this level of production not only call for intense efforts in upstream to keep production increasing, but also perfect coordination with the downstream segment. E&P and Downstream areas conceived, approved and implemented a robust system to transport oil from the offshore deep water fields. So, PETROBRAS has now put in place its Campos Basin Oil Outflow and Treatment Plan (which goes by the Brazilian acronym of PDET), for the transport and delivery of the output's part from the Campos fields to the refineries. Three fields have been included in this approach: Marlim Sul, Roncador and Marlim Leste, all of them considered massive petroleum fields.
The oil shock of the 1970s challenged O&G operators for a step change in R&D with direct impact on investments in new production frontiers, such as the Brazilian offshore. More than 40 years after the first oil, around 14 billion barrels of oil and gas (boe) have already been produced in the Campos Basin and two OTC awards have been granted with the Campos Basin achievements in Marlim and Roncador fields. Today, Campos Basin production accounts for around 30% of all Brazilian O&G output. Moreover, there is still a lot of potential value to be extracted from those assets in association with the extension of the term of the contracts of the main Concessions for another 27 years. In the continued strategy of Active Portfolio Management, any Campos Basin assets that do not fit into the company's portfolio focus are either divested or decommissioned, but still Campos Basin is a core area with substantial reserves to be booked, low reservoir risk and the potential to further reduce lifting costs. We can name Marlim, Roncador and Jubarte fields as examples of assets prioritized due to their value generating potential. These "world class" assets have been further developed with a specific approach: the Integrated Development Plans, with investments in complementary wells in existing fields to manage risks, enhance the recovery factor, as well as a governance to support decision making process between new Production Units or Lifetime Extension of those currently operating. All this governance is managed under a formal "Campos Basin Renovation Plan", a program that challenges the teams to identify opportunities to increase reserves and add value to the company. In this context, considering the relevance of this world class oil & gas province, this paper intends to describe how the team is facing the challenge of generating extra value through investments in mature fields in the Campos Basin, considering its decision-making process, the increase in the recovery factor, reduction of costs, strategic alliances, and articulation with Regulatory Agencies.
The Giant field of Roncador was by far the largest discovery made in Brazil in the 90´s. Its approved Development Plan relies on its separation in four modules, due to significant reserves involved and difference among oil characteristics found. The field is already producing with SS P-52 and FPSO P-54 since 2007, for modules IA and II respectively. Soon the field will also count with SS P-55, which will start operations for Module III in 2013 and FPSO P-62, which will have its first oil for Module IV at the first quarter of 2014, and represents the focus of this work.The Roncador Module IV is located at the center of the block, placed on the northeast of Campos Basin, 125 KM far away from the Brazilian coast. Currently, its reserves are over 500 MM boe, saturated with 18 º API heavy oil. The wells are being constructed in ultra deep waters, with variations depths between 1650 and 1750 meters of water column. This paper presents an overview of the project, including strategic drivers adopted on its design, which sought to mitigate risks and reduce deployment costs, as well as its scope and the journey since the selection of alternatives through the current status, with the FPSO P-62 under final phase of construction and assembling at the Estaleiro Atlântico Sul Shipyard in Recife and near the beginning of its operation in the Roncador field. The operation in advance of four wells (three producers and an injector one) using the already installed infrastructure of the field, will also be presented in this work.
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