Marine Technology Reporter Blogs - fmc

Today, much emphasis is given to working with real-time production data, real-time pipeline monitoring, leak detection and equipment condition monitoring. ROV/ AUV operations are used to support all sorts of deepwater seafloor construction processes, allowing operators to continuously monitor their subsea systems and intervene when necessary. Basically all equipment being installed on the seafloor has real-time communication systems, which allow operators on the surface to monitor the equipment’s performance and even control much of the equipment from the surface. Equipment that can be monitored from the surface but which cannot be manipulated remotely…

With the experience Petrobras has gained in deepwater field construction, the national operator has learned the best ways to get the job done and who to work with. Much of Petrobras’ deepwater seafloor construction work has been done by DOF, Technip, Subsea 7, FMC and Aker. Large deepwater post-salt fields such as Roncador, Frade and Marlim amongst others have been the main testing grounds of many construction techniques and much of the equipment being installed. Obviously, experience in deepwater seafloor construction has also been gained by Petrobras and service providers in locations such as the GoM and West Africa. Most of the pre-salt subsea trees will be built and installed by FMC, OneSubsea and Aker. FMC has a total order worth $1,5 billion, which was announced in March of 2012.

Subsea oil fields are dependent on a large amount of connections between various kinds of subsea equipment in order to function. They allow umbilicals, flowlines, risers and rigid jumpers to connect to manifolds, x-mas trees, BOPs, pipelines and riser bases. These connections need to be absolutely safe and reliable as connection problems can cause a series of problems in operating subsea equipment which may affect exploration and production only a little or cause these to partially or completely stop. On top of that subsea connection failures may also cause oil spills or gas leakage in the environment in small or large amounts, driving operators and subsea service and equipment providers to invest heavily in research regarding ideal connection manufacture…

The Brazilian ROV pilot training company RRC Robotica Submarina, has recently acquired two work class ROVs from majorn U.S. ROV manufacturer Schilling Robotics. RRC Robotics also offers specialized services such as; Consulting and Auditing ROV systems; 3D modeling of subsea operations; Subsea engineering; ROV operations and rental, sales and maintenance of ROVs and tools from its base in the City of Macaé, located northeast of the city of Rio de Janeiro. Macaé is also the main hub for all offshore O&G companies and service providers in Brazil. Schilling Robotics was founded in 1985. Schilling is headquartered in California U.S.A. and has regional offices in Texas U.S.A., Aberdeen, Scotland, and Singapore. Schilling Robotics also operates a service and support station in Brazil.

The advent of reliable subsea processing has taken a considerable time to develop. For a few years now, it has been looked at as a vital solution for deepwater O&G development. Subsea processing technology was first developed to overcome challenges posed by extremely deep wells but in time it has become a proven solution in mature fields by decreasing the amount of equipment on the surface, therefore lowering operational costs and of course by boost diminishing production from mature wells, normally through re-injection of fluids, such as water, into the wells to increase the pressure inside the well. It is also an important solution in locations where harsh surface weather conditions make it extremely risky to have an anchored production plant.

The Marlim Field in the Campos Basin is the host for the world´s first operational system for deepwater subsea separation of heavy oil and water including the vital water reinjection to boost production in this mature Brazilian oil field and may be a key factor in expanding the production life of other mature fields in Brazil. Marlim is located in the north-eastern part of the Campos Basin, about 110km offshore of Rio de Janeiro, in water depths ranging from 650m to 2,600m (2,100 to 8,500ft). It has some 102 production wells, 50 injection well and 8 floating production units (FPU), devoted to the extraction of O&G. Marlim as a mature field approaching 20 years in operation…

Subsea gas-liquid separation coupled with liquid boosting can be an effective means of oil reservoir exploitation. Despite advances, multiphase pumping technology remains limited in its capabilities. Dynamic (centrifugal and helico-axial) pumps function with reasonable efficiency for single-phase, low-viscosity liquids. However, they become very inefficient when a high-viscosity liquid is combined with high percentages of free gas. While use of multiphase pumps is in many instances an effective solution, special consideration must be taken when challenging conditions exist such as are found in deeper water or with long tieback distances, or when heavy-oil production is involved. More effective oil reservoir exploitation can be achieved using subsea separation coupled with liquid boosting.

With an eye on the lucrative subsea equipment market, suppliers are investing in technology, local workforce and expanding local facilities. New Brazilian companies specialized in subsea equipment and services also strive to compete with foreign suppliers.Today Petrobras is one of the greatest if not the greatest subsea equipment buyer in the world. With the ongoing discoveries of new deepwater and ultra-deepwater O&G plays in Brazil´s offshore, there is a sustained demand for essential subsea systems such as BOPs, Christmas trees, subsea manifolds, risers, rigid and flexible flowlines, umbilicals, subsea control and monitoring systems, ROV´s, AUS´s and all manner of subsea support systems.

The FMC research center will be located at the technology center inside the UFRJ campus, which already houses other important international research centers and CENPES research center, owned by Petrobras.FMC will be the fourth major international O&G service provider to establish itself at the UFRJ technology park, joining Schlumberger, Baker Hughes and Halliburton (still in negotiations). Expectation are high that with this great influx of researchers and investments in the UFRJ Technological Park, it will soon become the biggest O&G research center in the world, it is already acknowledged as being at the forefront of deepwater technological research.

FMC will deliver subsea manifolds and another range of subsea equipment to Petrobras. FMC Technologies has signed a four-year subsea manifold frame agreement with Petrobras. The award is expected to result in approximately $300 million in revenue to FMC Technologies if all of the subsea equipment included in the agreement is ordered. The agreement provides assurance that a minimum of 75 percent of the contracted equipment will be ordered during the contract's four-year call-off period. FMC's scope of supply includes the manufacture of up to eight subsea manifolds with subsea multiplex control systems. All equipment will be engineered and manufactured at FMC's facility in Rio de Janeiro, Brazil. Deliveries are scheduled to commence in 2012.

This new pre-salt discovery in the Campos Basin, highlights the potential for new discoveries in both the pre and post salt layers of this mature basin, which up to now has been the main O&G producer in Brazil and until recently was considered by many as not having much more to give in terms of new reservoirs.Petrobras announced the discovery of a new accumulation of light oil (29o API) in the pre-salt layer of the Campos Basin, in water depths of 648 meters at the Marlim field. Marlim is located in the north-eastern part of Campos Basin, in water depths ranging from 648m to 1,050m. It has some 102 production wells and 50 injection wells. Over 80km of rigid pipelines and 400km of flexible lines have been laid on the field.

The Petrobras oil-water subsea separator pilot project includes the qualification test, design and construction of a prototype to be installed in the Marlim Field, at the Campos Basin.During the OTC 2010 in Houston, Petrobras unveiled its subsea oil-water separation, which is being developed by FMC Technologies. This system will push the limits of the subsea three-phase separation envelope to deep waters and heavy oil. Petrobras and FMC are performing an extensive qualification test program for the key components of the separation unit. The increasing produced water rate, its respective treatment costs and limited processing capacity at the existing platforms are the main drivers for Petrobras to move towards a subsea three-phase separation and reinjection system.

FMC signs an $80 million subsea service contract with Petrobras in January and is awarded a $400 million contract for subsea trees in February.FMC Technologies signed a subsea service contract with Petrobras effective through 2012 and expected to result in an additional $80 million in revenue. FMC's scope of supply includes storage, maintenance, commissioning and offshore services for subsea and topside control systems and drill pipe riser systems. "FMC has a strong and longstanding relationship with Petrobras," said John Gremp, Executive Vice President of FMC Technologies. FMC Technologies has signed a four-year subsea tree frame agreement with Petrobras.

The partnership between Schilling Robotics and FMC is having a very positive impact on nearly all of the fifteen projects FMC operates in Brazil.Since 1985, Schilling Robotics has been engineering, manufacturing, and delivering the highest quality subsea equipment in the subsea market. Its first small, hydraulically powered underwater remote manipulator went to market in 1986, and by 1988 Schilling had become a leading supplier of high-performance subsea remote manipulator systems used in offshore oil, telecommunications, scientific, and military operations. By 1997, Schilling had developed a suite of manipulator systems and accessories to fit a variety of needs and budgets.