To surpass the main challenges established by deep water, high gas-oil flowratios, flow assurance and constant increases in produced water, Petrobras is developing, within PROCAP Technology Program - Future Vision, several projects in the subsea processing area, such as: Compact Oil-Water and Gas-Liquid Separation Systems, Multiphase Pump with High Differential Pressure and Gas Compression System. The main applications of these projects are in fields with high fraction of gas and water, in fields/discoveries located far away from Production Units and to increase the reservoir recovery factor. Furthermore, the application of these technologies may have great benefits, such as: production anticipation, reduction of process system footprint on the Production Unit, decrease in CAPEX/OPEX and especially an increase of the topside oil processing capacity. This paper aims to present an overview of those technologies being developed in PROCAP - Future Vision. Also, this article shows the main motivations of these developments, the main benefits of using each technology, the technological challenges and gaps, typical application scenarios and results of the evaluations performed so far. Major petroleum companies are searching for new technical solutions that fulfill their needs of reducing both CAPEX and OPEX while increasing oil and gas production. The development of new subsea processing technologies, as stated above, will enable, and in some cases reinforce, the use of these technologies for deepwater and/or subsea to shore scenarios. Introduction Subsea processing is a key enabler for challenging field developments, and their benefits increase with water depth, flowrates and step-out. Regarding subsea separation, these advantages are maximized when employing subsea compact separation technologies. Also, subsea processing brings HSE benefits related to reduction of waste disposal to sea, an environmental contribution of subsea oil-water separation systems, and the possibility of using smaller platforms - or none at all - due to the use of processing equipment on the seabed instead of topside, reducing operational risks. In terms of compact separation technology development, Petrobras has been conducting several R&D initiatives for the last ten years. Firstly, these R&D initiatives were developed for topside and onshore applications, but always keeping on mind the subsea employment. In order to evaluate these technologies several tests have been performed. More recently, the Marlim SSAO 3-Phase Subsea Separation System is a very significative example of compact subsea technology employment, for a single producer well application. Multiphase boosting is always considered as a good alternative to develop oilfields, mainly for remote areas. Petrobras invested a lot on the development of twin screw and helicoaxial concepts for multiphase pumps, targeting applications with required differential pressures up to 60 bar. Recently, analysis has indicated that High Differential Pressure Subsea Boosting (up to 150 bar) is economically and technically attractive to various Petrobras scenarios and, because of that, many R&D efforts are being done to develop such technology.
Over the last 20 years subsea processing and boosting (P&B) technologies have supported and pushed forward the offshore oil and gas production, maximizing field production and recovery factor. Although those technologies achieved remarkable success, P&B is still not a heavy-weight business, despite Operators considering it adds great value. Therefore, to enhance and maximize P&B applications, a task force was created to identify the main hurdles, showstoppers and barriers, as well as to establish a robust process, methods and procedures related, including O&G Operators and Suppliers point of views, internal standards and international codes analysis. Afterwards, a critical analysis was made, more than ten initiatives were prioritized, and a Program named Bosting to Boosting (B2B) was structured. This paper will present all initiatives have been carried out in B2B and the main results for subsea projects.
Subsea processing and boosting can be key enablers or optimization alternatives for challenging field developments and their benefits increase with water depth, flowrates and step-out. Petrobras has invested a lot on the development of such technologies, supported, among other pillars, on an aggressive R&D policy through its technological programs like PROCAP, and several subsea processing and boosting systems have successfully operated in Petrobras fields. Considering that, these technologies are being considered for application in potential Petrobras' scenarios including mature and green fields. This paper aims to give an overview of the systems developed and applied in Petrobras prospects during the last twenty years, such as the Vertical Annular Separation and Pumping System (VASPS), Boosting Systems with Electrical Submersible Pumps (Mudline ESP and MOBO), Subsea Multiphase Pumps, Subsea Raw Water Injection and Subsea Oil-Water Separation (SSAO). It also reports the new R&D initiatives related to subsea processing and boosting that are being developed within PROCAP - Future Vision technology program, showing the main motivations of these developments, the main benefits of using each technology, the technological challenges and typical application scenarios. Also, this paper illustrates the analysis and evaluations performed so far, for all of the new developments presented. Introduction Petrobras has developed and applied several technologies during the last 20 years, forming a very useful " toolbox" for subsea processing and boosting applications. After successful implementation of several technology-projects, on subsea boosting and processing, Petrobras and other operators have demonstrated that such technologies are definitely a very important field development tool, as predicted decades ago. In the beginning of the exploitation of oil&gas offshore fields, the main concern is related to the initial investment to construct the production units, to drill the wells and to install all the equipment necessary for the production. During this phase, there is a lack of information regarding the field, mainly about the reservoir behavior. Normally, the reservoir behavior is calibrated during the productive life of the field. Due to this, the operators usually adopt a conventional solution, not considering the use of new technologies as the first alternative. These are considered most when they are vital for a specific field development. For most fields in Campos Basin, Brazil, the main recovery mechanism for reservoirs, since the beginning of the production, is waterflooding. A typical curve of produced fluids starts with the predominance of oil, rising to the production plateau, until the water breakthrough occurs. At this point, the production presents increasing water content in the liquid stream. So, as it is necessary a massive water injection to keep the pressure of the reservoir, after a few years the watercut of the production increases a lot. Additionally to the two aspects described above, there is also a need to overcome the constraints of existing platforms. These motivations led Petrobras to start in the early 90's the development of subsea processing and boosting solutions. Technological Programs were created to support these developments. Several processing and boosting projects were installed since year 2001, when the VASPS was deployed in the Marimba Field (Campos Basin, Brazil). These projects will be described in a brief way in this paper, focusing their main technological aspects.
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