Brazil

Landmark: World’s First Early Production Drill Pipe Riser Rated for 2,000 m (6,600ft)

Project Overview

• Contract Award: 1998 (Pilot Project) 1998 (Manifold) 2000-2003 (Mod I, Ph A)
• Sales: Rio de Janeiro, Brazil
• Fabrication: Rio de Janeiro, Brazil
• Service Base: Macaé, Brazil
• Host Type: Semi
• Contract Type: EPC

Project Characteristics

• No. Trees: 2 (Pilot Project) 11 Mod I, Ph A (8 by FMC CBV)
• Water Depth: 1,500 to 2,000 m (4,900 to 6,600 ft)
• Tree Type: Vertical, Horizontal
• Tree Pressure: 5,000 psi
• Tree Bore size: 4"x2", 5"x1"
• Hydrocarbon: Oil/Gas

Project Ownership

• Petrobras 100%

Scope of Work

• Five (5) vertical 4"x2" 5,000 psi subsea trees
  • Three (3) GLL-VI-2000
  • Two (2) GLL-VII
    
• Three (3) horizontal 5"x1" 5,000 psi subsea trees
• One (1) Early Production Riser (EPR 2000)
  • 6-5/8" monobore riser
  • Electro-hydraulic umbilical with 1" annulus line
  • Subsea multiplexed control system
  • Two (2) GLL-2000 tree
    
•  Two (2) Drill Pipe Risers (DPRs)
  • Installation and workover risers
  • Control system
    
•  One (1) multiplexed subsea gas-injection manifold
• Four (4) subsea control modules
• Nineteen (19) Pipeline End Terminations (PLETs)
• One (1) Y-Pipeline End Module (Y-PLEM)
• Fifty (50) vertical connection modules (manifold flowline and tree connection systems)
• System integration testing, offshore installation support and technical assistance

Comments

The Roncador Field was discovered in 1996 at water depths ranging from 1,500 to 2,000 m (4,900 to 6,600 ft) in the Campos Basin. It is 125 km (80 miles) from the coast. The Roncador Field was a major breakthrough for many reasons, including the world’s first drill pipe riser, subsea tree and early production riser (EPR) rated for 2,000 m (6,600 ft). The first well, RJS-436, produced to the FPSO Seillean from 1999 to 2001 using the EPR at a world water-depth record of 1,853 m (6,077 ft) with the GLL TLD 2000 subsea tree.

The first phase of this full-scale project was put on stream in May 2000 when the semi and FSO P-47 began operation. An accident caused P-36 to sink in March 2001, when six (6) wells were in production. After the accident, Petrobras chartered a production unit called FPSO Brasil to temporarily substitute the P-36 platform. For a period of 5-1/2 years, eight (8) production and three (3) injection wells will be connected to the chartered FPSO.

In 2006, the second phase of Module IA will start operating twenty (20) production wells and ten (10) injection wells, including those that had been connected to FPSO Brasil. These wells will be tied to P-52, a brand new semisubmersible with capacity to produce 180,000 bopd. This unit will be one of the largest in the world, with a total displacement of 80,000 metric tons. The feasibility studies for the other three (3) modules of Roncador are currently under way.