Marlim Sul Field: An Ultra-Deepwater Development

J.E. Mendona S. Petrobras Rio de janeiro, Brazil

Abstract
The Petrobras Poster highlights the Marlim Sul Field development, its deepwater production achievements, and the associated technological key issues. Discovered in November 1987, by the wildcat well RJS-382, the Marlim Sul Field is located in ultra deep waters, ranging from 800 to 2,600 meters, in Campos Basin, with 820 million barrels of oil equivalent proven reserves. Marlim Sul, has been producing with Pilot systems since 1994, from MRL-4 well on Module 1 (1,027 m water depth), MLS-3 on Module 4, in 1997/98 (1,709 m water depth) and more recently (up to December 2001) from MLS-2 (1,228m) and RJS-442 (1,290 m) on Module 2. The development plan comprises two phases, each one with two Modules. Phase I - Module 1, has started production in December 2001 and has already achieved 149,000 bopd. Details of this Production System, of the technologies associated with this phase, as well as an overview of Marlim Sul Field Development will be displayed along the paper.

Introduction
Marlim Sul field was discovered in November 1987 by the wildcat RJS-382. This 600-km2 field lies 120 kilometers off the coast of Rio de Janeiro, in water depths from 800 to 2,600 meters. The reservoir is composed of turbiditic Oligocenic and Eocenic sandstones containing oil with API ranging from 26.7 to 16.3 in the deepest areas.

Figure 1 Marlim Sul in Campos Basin For Marlim Sul, Petrobras has adopted production anticipation by means of pilot systems and a phased field development. This approach has the combined benefits of earlier production and relevant data collection, thus reducing the economic risks of further field development. The following figure gives an idea of the areas and schedule of Marlim Sul Modules.

Figure 2 Marlim Sul Field Development

Early Production Systems

In April/1994, MRL-4 well, in 1,027 m water depth, has established a deepwater production record, by starting production from Module 1 to P20 platform. Another record was established with the production starting in August/1997 from Module 4, through MLS-3 well, in 1,709 m water depth. MLS-3 well produced to the FPSO-2, located in 1430 m water depth. This system, with capacity to process and store 30,000 bopd, operated up to October 1998, when data collection was finalized. FPSO-2 was then repositioned in 1,230 m water depth for a new pilot system, this time for Module 2. The new pilot was composed of two wells: MLS-2 and RJS-442. Production started in November 1999 with MLS-2, in 1,228 m water depth, that was followed in December 2000 by RJS-442 production, in 1,290 m water depth, and was finalized in December 2001, after completion of data collection and in accordance to Plans approved by the Governmental Regulatory Agencies.

Phase 1 Module 1 Development System

The Phase 1 Module 1 of Marlim Sul Field Development considers a total of 28 wells, 17 producers and 11 water injectors. All these wells are subsea direct satellites, linked through individual bundles to the Semi-Submersible P40, anchored in 1,080 meters water depth. P40 has capacity to produce and process up to 150,000 bopd. After the processing and treatment operation, oil production is transferred and stored in the FSO P38, nearly 5 km away from P40, in 1,020 m water depth. P38 is equipped with 1.8 million barrels of oil storage capacity and transfer facilities, including cargo pumps and offloading system for shuttle tankers, which carry the crude to shore. Oil, Electric Power and Telecommunications are transferred from P-40 to P-38 via a turret system. The compressed gas is exported, through a 12- inch rigid gas pipeline to an existing fixed platform (PNA-1). The riser from P40 to the pipeline is flexible and connected by means of a Vertical Connection Module, equipped with a Subsea Hydraulic Operated Ball Valve for Safety Purposes. On PNA-1, the gas pipeline is connected to the existing gas to shore pipeline network. Phase I - Module 1, has started production in December 2001 and has already achieved 149,000 bopd. Marlim Sul has presently the main producer in Brazil: MLS-42 well, with 32,700 bopd. Located in 1,220m water depth, this well is equipped with a 7-inch production string and interconnected to P40, at a distance of 3.6 km, by 8-inch flexible production flowline and riser. These flexible flowlines were specially qualified for this application, being subjected to offshore laying simulation (DIP tests). Also for qualification purposes, the flexible 12-inch riser for the gas pipeline has passed under fatigue tests simulating the entire operational life. Some other technologies applied in Module 1 may be mentioned, like the extensive use of the Vertical Connection System for the interface from Flowlines with Subsea Trees and from the Oil

and Gas Export Risers with the subsea PLETs; the use of Horizontal Trees developed for 2,500m water depth and the application of Taut leg anchoring systems with polyester ropes and Vertically Loaded Anchors (VLAs), in order to reduce the anchoring radius.

Figure 3 Phase 1 Module 1 Schematics Due to the good results from Module 1 operation, new Evaluation Studies are being performed, which may result in alternatives to increase production.

Phase 1 Module 2 Development System

Phase I - Module 2 is under Technical and Economical Evaluation and present plans consider a system for 180,000 bopd, comprising 15 oil producers and 10 water injectors in up to 1,500 m water depth. As well as in Module 1, all these wells tend to be subsea direct satellites, interconnected to a Production Floating Unit that may either be a Semi-submersible or an FPSO. Due to the similar water depth envelope, when compared to Module 1, the same level of technological solutions will be considered, thus reducing enormously the risk of the Enterprise. A main aspect to mention is the strong tendency to export oil via a deepwater rigid pipeline of, possibly, 18-inch diameter. This pipeline will require a Steel Catenary Riser or a Free Standing Riser for the interconnection to the Production Platform, in nearly 1,250 m water depth. Important aspects to consider are the installation and fatigue loads, as well as the maintenance facilities. In ahead of the structural aspects, due to the length of such pipeline, that may reach nearly 60 km, flow assurance is a must, as well as inspection techniques for the life of the system. Another point to mention is that a pilot well from Modules 3 and 4 is also planned for Phase I Module 2. This pilot system may consider a combination of boosting and flow assurance technologies, serving as a real test site for the technologies that will allow production from the deepest areas of the reservoir, where lower temperatures and high viscosity oil are found. Some other technologies are to be adopted in Module 2 in order to optimize production, like the Gas Lift Automation, and in order to increase Reservoir Management Control, like Multiphase Metering. Gas lift automation is part of the development work under one of the PROCAP 3000 projects. More recent technologies like Subsea Separation and Discharge of Produced Water are also under study but its application may only take place in the development of Modules 3 and 4, presently scheduled for 2006 and 2008, respectively.

Acknowledgements
The author wishes to thank Petrobras for permission to prepare and submit this summary and to make the associated poster presentation.

Bibliography 1. Diehl Filho, R. P. et alii - Marlim Sul Development Plan