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Copyright 2001, Offshore Technology Conference This paper was prepared for presentation at the 2001 Offshore Technology Conference held in Houston, Texas, 30 April–3 May 2001. This paper was selected for presentation by the OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Offshore Technology Conference or its officers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Abstract The development of deeper water fields by Petrobras has required continuous improvements with respect to their riser systems. The recent efforts for SCR development were not an isolated action. Besides this program, that involved the installation of a prototype at P-18 (Marlim Field), the studies for SCR utilization in an FPSO unit at the Barracuda/Caratinga Field, and the installation of two more SCRs in another SS unit (P-36, Roncador Field) using the hybrid installation method (i.e. reel + J-lay), other actions are being conducted, such as: search for new designs for flexible riser structures and configurations, the Hybrid Riser System with Subsurface Buoy Concept, and the riser system for the Floating Production and Workover Unit (FPWU). More recently, Petrobras has been considering Conceptual Studies for Alternative Riser Systems, which will comprise the evaluation of concepts, different from the ones previously mentioned, for Albacora Leste Field. Albacora Leste is the next relevant deep water field to be developed and operated by Petrobras. It is the first scenario considered for riser studies and development under PROCAP 3000, the new version of the Petrobras Deep Water R&D Program. The traditional flexible riser concept, the SCR, the Hybrid Riser System with Subsurface Buoy, and some Alternative Riser System (mainly riser tower type solution) concepts are being evaluated for this field. The learning from these studies will give the basis for the future deeper fields that Petrobras will be challenged to develop. This paper will bring the Petrobras experience on riser systems and views on future possibilities for deep and ultra- deep water fields. Introduction Since the beginning of the exploitation of Campos Basin offshore fields, Petrobras has been facing new challenges to produce in deeper and deeper waters. The option for the use of Floating Production Systems (FPSs), in the majority of the cases, had a strong impact on the kind of risers employed. The historical evolution of the riser systems of Campos Basin is described in this paper. Some good reasons for the emphasis given to flexibles are explained, and the main steps related to the technological advances of this technology is documented. Other technical options for riser systems, either actually used, or just investigated, are presented. Alternative Riser Systems, presently considered for the Albacora Leste Field development, are focused. Finally, some thoughts about possibilities for the future, that may be included in the PROCAP 3000, are added. It is important to mention that, although Petrobras has no deep water system based in dry completion (TLP, Spar, etc.) in operation, such option is always considered in a comparison basis with the wet completion (subsea) system, which has always been selected. Thus, to be able to properly evaluate the dry completion systems, Petrobras has performed several conceptual studies, that included the riser systems in a quite detailed level. Nevertheless, risers for dry completion systems are out of the scope of this paper. Historical Background Ref. 1 brings a summarized history of the production systems and risers used in Campos Basin. An interesting comparison between the two first systems is given. The first one, used to produce the Enchova Field since Aug/77, was a very simple system based on a drilling semi-submersible (SS) unit. This was the basis for the Early Production Systems (EPSs), as latterly called some simplified production systems employed to anticipate production in other fields. The other system mentioned in the referred paper is the one used to produce the Garoupa Field (Fig. 1) in 1979. This was a much more complex one, as it included the application of static flexible flowlines, atmospheric subsea equipment, one processing tower, and one loading tower. A fatigue failure in the processing tower probably determined the option for more compliant riser systems in the next Petrobras developments further on. OTC 13185 Riser Systems for Deep and Ultra-Deepwaters Otávio B. Sertã , Carlos E. V. Longo and Francisco E. Roveri, Petrobras

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  • Copyright 2001, Offshore Technology Conference

    This paper was prepared for presentation at the 2001 Offshore Technology Conference held inHouston, Texas, 30 April3 May 2001.

    This paper was selected for presentation by the OTC Program Committee following review ofinformation contained in an abstract submitted by the author(s). Contents of the paper, aspresented, have not been reviewed by the Offshore Technology Conference and are subject tocorrection by the author(s). The material, as presented, does not necessarily reflect anyposition of the Offshore Technology Conference or its officers. Electronic reproduction,distribution, or storage of any part of this paper for commercial purposes without the writtenconsent of the Offshore Technology Conference is prohibited. Permission to reproduce in printis restricted to an abstract of not more than 300 words; illustrations may not be copied. Theabstract must contain conspicuous acknowledgment of where and by whom the paper waspresented.

    AbstractThe development of deeper water fields by Petrobras hasrequired continuous improvements with respect to their risersystems. The recent efforts for SCR development were not anisolated action. Besides this program, that involved theinstallation of a prototype at P-18 (Marlim Field), the studiesfor SCR utilization in an FPSO unit at theBarracuda/Caratinga Field, and the installation of two moreSCRs in another SS unit (P-36, Roncador Field) using thehybrid installation method (i.e. reel + J-lay), other actions arebeing conducted, such as: search for new designs for flexibleriser structures and configurations, the Hybrid Riser Systemwith Subsurface Buoy Concept, and the riser system for theFloating Production and Workover Unit (FPWU). Morerecently, Petrobras has been considering Conceptual Studiesfor Alternative Riser Systems, which will comprise theevaluation of concepts, different from the ones previouslymentioned, for Albacora Leste Field.

    Albacora Leste is the next relevant deep water field to bedeveloped and operated by Petrobras. It is the first scenarioconsidered for riser studies and development under PROCAP3000, the new version of the Petrobras Deep Water R&DProgram. The traditional flexible riser concept, the SCR, theHybrid Riser System with Subsurface Buoy, and someAlternative Riser System (mainly riser tower type solution)concepts are being evaluated for this field. The learning fromthese studies will give the basis for the future deeper fieldsthat Petrobras will be challenged to develop.

    This paper will bring the Petrobras experience on risersystems and views on future possibilities for deep and ultra-deep water fields.

    IntroductionSince the beginning of the exploitation of Campos Basinoffshore fields, Petrobras has been facing new challenges toproduce in deeper and deeper waters. The option for the use ofFloating Production Systems (FPSs), in the majority of thecases, had a strong impact on the kind of risers employed.

    The historical evolution of the riser systems of CamposBasin is described in this paper. Some good reasons for theemphasis given to flexibles are explained, and the main stepsrelated to the technological advances of this technology isdocumented. Other technical options for riser systems, eitheractually used, or just investigated, are presented. AlternativeRiser Systems, presently considered for the Albacora LesteField development, are focused. Finally, some thoughts aboutpossibilities for the future, that may be included in thePROCAP 3000, are added.

    It is important to mention that, although Petrobras has nodeep water system based in dry completion (TLP, Spar, etc.)in operation, such option is always considered in a comparisonbasis with the wet completion (subsea) system, which hasalways been selected. Thus, to be able to properly evaluate thedry completion systems, Petrobras has performed severalconceptual studies, that included the riser systems in a quitedetailed level. Nevertheless, risers for dry completion systemsare out of the scope of this paper.

    Historical BackgroundRef. 1 brings a summarized history of the production systemsand risers used in Campos Basin. An interesting comparisonbetween the two first systems is given. The first one, used toproduce the Enchova Field since Aug/77, was a very simplesystem based on a drilling semi-submersible (SS) unit. Thiswas the basis for the Early Production Systems (EPSs), aslatterly called some simplified production systems employedto anticipate production in other fields. The other systemmentioned in the referred paper is the one used to produce theGaroupa Field (Fig. 1) in 1979. This was a much morecomplex one, as it included the application of static flexibleflowlines, atmospheric subsea equipment, one processingtower, and one loading tower. A fatigue failure in theprocessing tower probably determined the option for morecompliant riser systems in the next Petrobras developmentsfurther on.

    OTC 13185

    Riser Systems for Deep and Ultra-DeepwatersOtvio B. Sert , Carlos E. V. Longo and Francisco E. Roveri, Petrobras

  • 2 O.B. SERT, C.E.V. LONGO, F.E. ROVERI OTC 13185

    Although some fixed units (total of 13) are employed forproducing shallow water depth fields, the majority of theproduction is based on floating systems, which were, in thebeginning, the EPSs, that have been gradually substituted bymore permanent systems, first based on SS, and more recentlyon ship units (FPSOs). These systems are normally based onsatellite wells with wet completion, and the natural choice fortheir risers are the flexible pipes. Additionally, the oil export isfrequently based on monobuoys (CALM systems) and, morerecently, on FSOs. Again, risers based on flexible pipes are thefirst choice for such systems.

    The continuos increase on the water depth of the fieldsprogressively discovered in Campos Basin has determined thepermanent necessity of technological efforts to develop risersfor such applications. Accordingly, risers have been one of themain issues of the three versions of PROCAP R&D Program.More details on that will be given on the following topics ofthe paper.

    Traditional Riser System FlexiblesThe flexible pipes can be considered the traditional risersystem of the floating production units of Campos Basin.Besides the historical reasons given for that in the previoustopic, it should be added that the physical flexibility inherentof such structures determines its flexibility in terms ofmanagement, lay-out adaptations, and installation, as well aspossibility of reuse. Such characteristics explain the policyadopted by Petrobras of having a long term contracted fleet forflexible pipe installation and related operations.

    Before we look at the technical aspects related to theflexible risers for deep waters, it is important to mention thatthe competitiveness of the supply market for flexibles hasbeen a constant will. Petrobras has been trying to achieve thatby several measures such as direct investment in this market(Pag-o-Flex acquisition), or, using its position of mainconsumer, by developing new suppliers, like Wellstream,Furukawa (Ref. 2), and, more recently, NKT. Thosedevelopments have been done under TechnologicalCooperation Agreements (TCAs), which are instruments thatplay an important role on the evolution process of suchmaterials.

    The need of continuous improvements due to increase ofwater depth and due to new supplier developments hasdetermined Petrobras efforts for developing its owncapabilities. This was reflected on the gradual improvementsof the purchasing specifications, that were consolidated in theN-2409 (Ref. 3), which was one of the main sources for theAPI Spec 17 J and API RP 17 B (2nd edition). Besides, the in-house development of the soft packages ANFLEX (Ref. 4), forglobal analyses, and FRAES (Ref. 5), for local analyses,deserves mention. Such programs have been continuouslyimproved.

    In fact, deeper waters represent, for the risers, increase ontop tension, in external pressure (bottom), in applied tensionercrushing, and in compression on touch down point region (bydynamics and by end cap effect). To resist such loads, riserstructural design has been improved by use of new materials,

    new profiles, optimized armor lay angles, and new layers.Those developments were normally done under TCAs.Similarly, design improvements have been incorporated inriser accessories like bending stiffeners, outerwraps andfloater modules. Operational feedback information has beenused in new projects, making the evolution possible.

    Connection systems constitute a topic that deservesattention. The top connection systems have evolved from theQCDC (Quick Connection/Disconnection Coupler) to thesimpler hang-off systems, due to the increase in FPSpositioning system reliability. Riser/flowline connection ismade at surface (installation vessel) when both are flexibles.When the riser is connected to a rigid pipe, diver assistedconnection used to be the only alternative. With the necessityof connections in water depths beyond the diving limits,alternatives were searched. The hybrid method (Ref. 6), whichconsists of retrieval to surface of the pre-laid rigid pipe forconnection with the flexible riser, was applied before thedevelopment of the Vertical Connection System. The VerticalConnection System (Ref. 7) made possible the subsea lowerconnection of the flexible risers to rigid pipes pre-laid with aPLET (Pipeline End Termination).

    Nowadays, although there is a general feeling that flexiblerisers have reached its limit in terms of water depth ofapplication, Petrobras has not yet gone beyond this threshold.We have qualified flexible flowlines of up to 6 for 2000mand risers up to 9 for 1500 water depths. These pipes havebeen installed and are operating in the Roncador Field (P-36SS).

    Steel Catenary Risers SCRsThe technical limitations and high costs of the large diameterflexible risers (mainly used for export purposes) motivatedPetrobras to invest in alternative choices. The first identifiedoption were the SCRs (Ref. 8).

    In 1993 Petrobras started a R&D project, under PROCAP,to investigate deeply the use of SCRs as an option forutilization in the SS units that, at that time, were programmedto be installed as part of the production systems to beexploited. This work was quite extensive and involved theUniversity of S. Paulo (USP), the Instituto de PesquisasTecnolgicas (IPT), some consultant companies,Petrobras/R&D, and Petrobras/ E&P (in coordination). Severalaspects were investigated, and many reports generated, assummarized in Ref. 9. The main conclusion was that theconcept was feasible for the intended application.

    To consolidate the SCR technology, it was considerednecessary to install a prototype. P-18 SS, in the Marlim Field,was identified as the appropriate scenario (Fig. 2). The SCRwould be part of an import gas line from P-26, which was abackup export line of this last platform. A flexjoint order wasplaced with Oil States, together with the design of the riser, forwhich they sub-contracted MCS (Ref. 10). The installationwas performed in Sep/1998 with the Amethyst SS, which wasprovided with a modular J-lay tower sub-contracted by theoperator of the vessel with Oil States (Ref. 11).

  • OTC 13185 RISER SYSTEMS FOR DEEP AND ULTRA-DEEPWATERS 3

    The technology related to SCRs evolved, more recently, bythe installation of two others in SS P-36 (Roncador Field, lastyear). In this case, hybrid installation method, combining ReelLay with J-Lay (this last used for the fatigue most criticalsections) was employed (Ref. 12).

    For application of SCRs in ship based units (FPSOs),Petrobras has promoted a study involving ReverseEngineering, Tecnomare and Marin (Ref. 13). This study hasindicated the feasibility of the concept for typical PetrobrasFPSOs, and the lazy-wave configuration as therecommended one. Field application has not yet occurred dueto the absence of an appropriate scenario.

    Alternative Riser SystemsAlthough the large majority of the risers of the FPSs ofCampos Basin are flexibles, except for the three mentionedSCRs and the Seillan production system (which employs adrill pipe riser for production in 1850 m water depth),Petrobras has always considered other alternatives, as will beshown in this section of the paper. The Cameron concept,considered by some authors as the first generation of hybridrisers (Ref. 14), has been deeply evaluated and considered forprevious scenarios. Another option, considered a promisingone, is the Hybrid Riser System with Subsurface Buoy.Finally, the riser towers, such as the ones presently consideredfor the West Coast of Africa, are been focused in some workcurrently in progress.

    The Cameron Concept. This hybrid riser concept wasdeveloped by Cameron Offshore Engineering in the late1980s. It was installed by Placid Oil Company in the Gulf ofMexico at Green Canyon Block 29 (GC29) in 465 m waterdepth (Refs. 15 and 16). The FPS accommodatedsimultaneous production and either drilling or workover(while experiencing a 1-year storm) from the same SS.

    The hybrid riser concept consists of a rigid riser and aflexible riser. The rigid riser extends upward from the top ofthe riser base and terminates about 45 meters below mean sealevel. There, the flexible flowlines (the flexible portion of thehybrid riser) are attached to the upper riser connector package.They transfer the production to the permanently mooredfloating SS. From top to bottom, the rigid riser is composed ofan upper riser connector package (URCP), a series of riserjoints, and a stress joint/bottom connector assembly.

    The hybrid riser is self-supporting with positive buoyancyprovided by fixed (i.e., syntactic foam) and/or variable (i.e.,air in open bottom containers) methods. The riser can includeindividual non-integral production and annulus lines for eachwell within fiberglass guide tubes through syntactic foammodules that surround the riser joints, separate oil exportline(s), and separate gas export line(s).

    Of particular importance is the stress joint, which permitscantilevering the rigid riser from its base while keeping thestresses in the riser within acceptable levels. The riser base isintegrated to the foundation structure.

    In 1989 Petrobras contracted Cameron for the study of thehybrid riser concept considering the situations: (a) rigidimport/export risers for the central floating productionplatform for big diameter lines, and (b) rigid export orimport/export risers for the individual floating productionplatforms. Three different rigid riser concepts were consideredas candidates for the central platform whereas four candidateproduction riser configurations were investigated. Thepreferred configurations for both the central and productionplatforms were fully covered up to a basic design level.

    The concepts for the central platform riser constituted asubstantial extrapolation of prior riser designs that combinestechnology from the hybrid riser and compliant towerstructures because of the large size of the export oil and gaslines. To accommodate the heavy, large diameter export lines,all central platform riser concepts are truss structures that arebuoyantly supported by submerged air tanks and an airchamber inside a central caisson.

    The outcome of the study was a rigid riser concept for thecentral platform in 700 m water depth for freestanding 22-inchand 38-inch diameter gas and oil respectively. The option ofmanifolding the incoming 16-inch oil line from sevenproduction platforms was investigated. The investigation ofrigid production risers was for designs that terminates toflexible flowlines attached to the production platform, for 12production and 8 injection wells, in 980 m water depth. Fig. 3shows the preferred configuration for the central platform,whereas Fig. 4 shows the selected configuration for theproduction platform.

    Later, in 1990, Petrobras contracted Cameron for thefeasibility study of the hybrid riser concept for the MarlimPilot System, to be installed in 600 m water depth. The systemconsisted of 10 wells and 3 export lines (1 line for gas and2x8-5/8 for oil). The hybrid riser concept was one of thealternatives for exploitation of the field, however the flexiblerisers in free hanging catenary were the selected option, due totechnical and economical considerations.

    Hybrid Riser System with Subsurface Buoy. This conceptconsists in one large subsurface buoy (emerged approximately100 m) moored by means of at least four tendons (chain +wire rope + chain), which are connected individually tosuction piles or similar foundation device. The subsurfacebuoy hangs the steel catenary risers (SCRs) coming from anysubsea equipment or used for exporting. Flexible jumpers areused for upper connection to the FPS.

    The main advantages of this concept are as follows:i. The vessel motions are directly transferred to the jumpers

    and not to the main catenary (SCR), which will not besubjected to significant dynamic direct wave loads either.Consequently the SCR design is optimized;

    ii. Risers catenary loads are substantially reduced on theFloating Production Unit;

    iii. The installation schedule is improved, making it moreflexible, as it does not depend on the production unitarrival at the field site;

  • 4 O.B. SERT, C.E.V. LONGO, F.E. ROVERI OTC 13185

    iv. This concept will improve market competitiveness(flexibles x steel pipes).The advantages listed above led Petrobras to start the

    development of this concept together with the FederalUniversity of Rio de Janeiro (UFRJ) and the Instituto dePesquisas Tecnolgicas (IPT).

    The scenario selected as a reference for the developmentstudy was the Marlim Sul Field, P-38 unit. The linesconsidered were: 2 x 10 inches oil import pipes, 1 x 6 inchesfuel gas, and 1 control umbilical, for a water depth of 1000 m.The concept was developed in two phases as follows:

    Phase I: Consisted of parametric studies, model tests,buoy/tendons system analysis, SCRs and jumpers dynamicanalysis;

    Phase II: Consisted in developing the buoy installationprocedures based on the results of the model test for buoytowing and installation, risers clashing analysis, pile design,interference analysis, evaluation of different buoy/tendonsystem pattern and different buoys geometry, model tests fortendons failure and buoy damaged condition, evaluation ofSCRs connectors at the buoy (flex joints x stress joints).

    The results so far obtained are very satisfactory, and afterthe end of phase II, it was concluded that one more model test,now with the presence of current, should take place. The mainobjective of this model test will be to investigate the buoy trimand heel, identified as relevant technical parameters that, if arekept under certain limits, will guarantee the efficiency of thisconcept and turn it into a consolidated technology.

    Once the results of the final model tests are satisfactory,Petrobras will consider this concept ready to compete with anyother technology available in the market for development ofthe Albacora Leste Field. As this concept is easily extendableto depths greater than 1000 m (original design), Petrobrasconsiders it a very promising option for further developments.Besides, the system was conceived considering that all theequipment required to do the installation job should be withinPetrobras resources (under long term contracts). This premisereinforces the economical attractiveness of the concept.

    Albacora Leste Field Case. Petrobras is presently contractingwith three companies the development of Conceptual Studiesof Alternative Riser Systems (ARS) to be applied in theAlbacora Leste field scenario. The new system will becompared with the evaluation of a Base Case, to be alsoincluded in the study. Engineering, design and analysis will beperformed to the extent that a budgetary cost and schedule isgenerated. The analysis will address all aspects of the conceptto the point of confirming the feasibility of the system.

    The Albacora Leste field is the next field of Campos Basinto be put in production (Fig. 5). Its production system willencompass eight manifolds to be connected to a turret mooredFPSO in 1290 m water depth. Five production and three waterinjection manifolds are considered, amounting to 32 wells. A10-inch gas export line is also planned. The oil export will beperformed by a shuttle tanker.

    The Base Case riser system is a SCR in a lazy-waveconfiguration, which has been demonstrated to be feasible inother similar scenarios (Refs. 13 and 17). Fig. 6 showsschematically the riser system configuration for that case. Theenvironmental loading direction to be considered in theanalyses is also shown. The results of the Base Case RiserSystem evaluation will be used as a reference for comparisonwith the proposed ARS and as an auxiliary instrument forcomparison/equalization of different proposals.

    The use of flexible risers (pipes and umbilicals) isconsidered by Petrobras as a traditional solution for FPSOssystems. Therefore that option will not be considered as theARS. The use of other catenary configurations rather than lazywave (free hanging, steep wave, laze S, etc.) may beconsidered for each of the risers as the ARS concept. Otherriser concepts are seen to better represent the ARS concept.Those are the various types of hybrid risers considered by theindustry, such as the ones described in Refs. 14 and 18. Theproposed ARS concept may be based on single line risers,bundled risers or on a combination of them. The selectedconcept may differ from one application to another, whichmeans that the Alternative Riser Concept may be differentfrom the production risers, the injection risers and the gasexport riser.

    Fig. 7 shows schematically the ARS and the environmentalloading direction to be considered in the analyses. The figureshows a general riser configuration consisted of (a) line(s)linking the near vertical section top to the FPSO internalturret, (b) a buoyancy tank at the top providing up rightingmomentum for the riser system vertical section and (c) aseabed interface of the near vertical portion of the risersystem.

    The conceptual study will address relevant aspects of boththe Base Case and ARS, such as dynamic global analysis,installation analysis, interference analysis, fatigue due towaves, fatigue due to vortex induced vibrations (VIV), andloads at the interface riser/turret. Of particular importance forthe system is the thermal analysis and thermal insulation, todemonstrate that the produced mixture reaches the FPSseparator with the minimum required temperature.

    The presence of CO2 in the produced oil will require ajudicious selection of materials. Appropriate material selectionand/or corrosion inhibitor injection are acceptable measuresfor internal corrosion protection. For external protection, theuse of cathodic protection and coating is envisaged.

    Special modifications on turret arrangement that may berequired to make feasible the proposed Base Case or ARS willbe identified. All special components of the system, such asflexible jumpers, flexjoints, buoys/floatation elements, VIVsuppressor devices, riser base, and connectionsystem/elements will be indicated and assessed in theconceptual study.

    The installation is a very sensitive part of the project, as itis possibly the most demanding service in terms of economicalresources, involves the highest risks and the great majority ofthe interface issues with elements and factors that are outside

  • OTC 13185 RISER SYSTEMS FOR DEEP AND ULTRA-DEEPWATERS 5

    of the scope of the project. Because of that, alternatives toconventional installation methods are sought, if those bringoverall cost reduction or increase system/operations reliability.Sometimes, these alternative options may imply inmodifications on the conventional arrangement of turret or insome other Petrobras specified requirement.

    The economical evaluation of both Base Case RiserSystem and ARS, including all production, injection, control,and export lines, will be addressed in this Conceptual Study.Tables with materials and services costs will be presented,containing all relevant items. Associated with the economicalevaluation, a schedule of the work will be presented. Theschedule will cover all project relevant phases, which include,but are not limited to, detailing design/engineering,procurement, fabrication, assembly, construction, installation,testing, and commissioning.

    Riser System for the FPWULast year Petrobras requested FMC to provide engineeringservices for a conceptual/feasibility study of a FloatingProduction and Workover Unit (FPWU). It will be based on amoored SS vessel converted to a production unit with a tautleg mooring system. The FPWU will have several productionand injection wells clustered underneath it, and could also beconfigured with satellite injection wells. The production fromthese wells will be commingled through subsea manifoldsystems and then conveyed to the surface FPWU through aseries of vertical, top-tensioned steel risers. All subsea wellswill be pre-drilled using a mobile offshore drilling unit(MODU) prior to the arrival of the FPWU. Once moored onstation, the FPWU will complete the wells and conduct allsubsequent workover operations.

    The direct well intervention capability makes the FPWUconcept a good solution for fields where the oil is somewhatheavy and serious or frequent intervention problems are likelyto occur.

    Subsea completed wells will be linked to subsea manifoldriser bases. For each manifold there will be flowline risersextended upwards to the floating platform. Some of the riserswill carry produced fluids up from the riser base, while otherswill be used for gas or water injection. Gas and oil export willbe done through risers connected to export base(s). The riserswill be a single casing design and their terminations aresurface flow heads, which connect to the FPWU via flexiblejumpers.

    A tensioner assembly is required for supporting each riserand for allowing relative motions between the FPWU and theriser. All risers with exception of the catenary umbilical arethe vertical top-tension type. Buoyancy modules aredistributed over the upper portion of the risers and support themajority of the riser and contents weight. The study wasconducted for 1250 and 3000 m water depths.

    Considerations about the futurePetrobras has some promising reserves beyond the frontier of2000 m water depth. The PROCAP 3000 version is focused inthese scenarios, but it is still difficult to guess how riser

    technology will evolve for application in such areas. However,if we consider, based on what have happened in the majorityof the cases before, that the new technologies will be anextension of the available ones, we can risk some thoughts.

    The technology applied to flexible risers has beencontinuously improved since its first application in CamposBasin, more than 20 years ago, and it is premature to affirmthat it has reached its limit, as already commented. New wireprofiles and materials has been proposed for the structural pipelayers. Manufacturing methods and machines have beenimproved and upgraded. Such trends may continue in thefuture. Installation is a very important constraint to deeperapplications. Although laying equipment has beensubstantially increased, alternative methods, such as towingfrom land or shallower areas, may be one type of innovationnecessary to go further with flexible risers.

    SCRs are potentially applicable in waters deeper than thepresently considered. Nevertheless, limitations of imposedloads to FPS and geometric constraints (excessive spacedemanded, excessive angles on top) may be a restriction for itsuse for a large number of lines, except for export systems.Riser towers and hybrid risers are already a reality, as alreadyshown in the paper, and tend to be good options for deeperwater locations. They present the advantage of anticipatingproduction because they can be installed independently of theFPS, requiring a relatively simple tie up of the top jumperswhen production unit is available.

    The exploitation of fields in deeper and deeper waters andthe limitations inherent to systems composed by carbon steeland flexibles, will require that other types of materials areconsidered by the industry for the development of newconcepts of riser systems. Materials such as aluminum,composites and titanium, which are being considered only forvery special scenarios nowadays, mainly due to cost reasons,may play an important role in the future. Materials forfloatation and thermal insulation will also be demanded inlarger amounts, and their costs and availability will be keyaspects for future projects. Additionally, before they can beconsidered for ultra-deep waters, some technological effortswill probably be required.

    ConclusionPetrobras has been working in conjunction with the product/service supply market over the years to fulfill its increasingdemand for providing cost-effective alternatives forproduction/export lines of deepwater fields.

    Technical and/or economical limitations sometimespresented by a particular concept through the years has causedeither an improvement of the concept or its replacement by anew one, such as to overcome the momentary situation.

    Considering that the same Petrobras policy of cooperationwith the supply market will be kept, now in a better situation,as more operators are going to deep waters, it is likely that ourneeds for the future will continue to be made available by themarket in the form of cost-effective solutions.

  • 6 O.B. SERT, C.E.V. LONGO, F.E. ROVERI OTC 13185

    AcknowledgementsThe authors would like to thank Petrobras management for theincentives and approval for publication of this paper.References1. Sert , O. B. , Selection of the Best Production Riser for Campos

    Basin Deep Water Risers , paper presented at the Mooring andRiser Systems Technical Forum IIR, Aberdeen, Nov/1996.

    2. Sert , O. B., de Almeida, M.C., Cooperao Tecnolgica entrePetrobras e Furukawa Para Desenvolvimento de Tubos Flexveispara guas Profundas , paper presented at the I SEMINRIO DETECNOLOGIA DE PRODUO (Petrobras/Nov/93).

    3. Flexible Pipe Specification N-2409 Petrobras, Aug/944. Mourelle, M. M., Gonzales, E. C., Jacob, B. P. , ANFLEX -

    Computational System for Flexible and Rigid Riser Analysis,paper presented at the Brazil Offshore 95 - X InternationalSymposium on Offshore Engineering, Rio de Janeiro.

    5. Troina, L.M.B., Rocha, D.M., Sert, O.B. (Petrobras); Geymayr,J.A.B. (COPPE/UFRJ), Expert System for Strength Prediction ofFlexible Risers, paper presented at the Offshore Mechanics andArtic Engineering (OMAE 1998) - ASME 1998.

    6. Scherer , I.M.Q., Teixeira , M.J.B. (Petrobras); Espinasse, P.(Coflexip), Recovery and Laying Hybrid Pipelines in DeepWaters - OTC 7296, Houston, May/1993.

    7. Nagle, F.J.M., Moreira, J.E.F., Cerqueira, M.B., PrototypeTesting of an Innovative Diverless Guideliness FlowlineConnection System, paper presented at the Deep OffshoreTechnology (DOT) Conference, Rio de Jameiro, 30 October/ 1November 1995.

    8. da Silva, R. M.C., Scherer, I.Q., Sert, O.B. (Petrobras); AndradeB. (USP), An Alternative for Large Diameter Flexible Riser -OTC 7597, Houston, May/1994.

    9. Sert , O.B. , Experincia Acumulada no Desenvolviemnto deRisers de Ao em Catenria, paper presented at the IISEMINRIO DE TECNOLOGIA DE PRODUO(Petrobras/Nov/97).

    10. Sert , O.B., Mourelle, M. M. (Petrobras); Grealish, F.W. (MCSInternational); Harbert, F.W. F., Souza, L.F., (OSI), SteelCatenary Riser for The Marlim Field - OTC 8069, Houston,May/1996.

    11. da Silva, R.M., Critsinelis, A.C.F., Braga, V.R., A FeasibleSolution for Large Diameter Steel Catenary Risers: FirstWorldwide Installation of 10-Inch SCR in Semi-Submersible,paper presented at the 2nd Workshop on Subsea Pipelines, Rio deJaneiro, Apr/1999.

    12. da Silva, R.M., Braga, V.R., Moraes, M.G.G., dos Santos, J.A.C.,Reel/J-lay Method - The New Technology of Petrobras for SteelCatenary Risers Installation in Deepwater, paper presented at theDeep Offshore Technology (DOT) Conference, New Orleans,Nov/2000.

    13. Summers, P., Pellizzari, L., Jacob, P., Nicolussi, F., van denBoom, H., da Silva, R.M., Moraes, M.G.G., Design and Testing ofa Steel Catenary Riser for FPSO Applications in DeepwaterOffshore Brazil, paper presented at the Advances in RiserTechnologies Conference, Aberdeen, Jun/98.

    14. Hatton, S., Lim, F., Third Generation Hybrid Risers, paperpresented at the World Wide Deepwater Technologies Conference,London, Jun/99.

    15. Filson, J.J., Henderson, A.D., Edelblum, L.S., Pickard, R.D.,Modification of the Penrod 72 for Green Canyon Block 29Development OTC 5845, Houston, May/88.

    16. Fisher, E. A., Berner, P.C., Non-Integral Production Riser forthe Green Canyon Block 29 Development OTC 5846, Houston,May/88.

    17. Nicolussi, F., Pellizzari, L., The Applicability of Steel CatenaryRisers to Floating Production Systems, paper presented atthe Deep Offshore Technology (DOT) Conference, The Hague,Nov/97.

    18. Dserts, des L., Hybrid Riser for Deepwater Offshore Africa OTC 11875, Houston, May/2000.

  • OTC 13185 RISER SYSTEMS FOR DEEP AND ULTRA-DEEPWATERS 7

    Fig.1-Garoupa Field System Artistic View

    Fig. 2-P-18 SCR Schematic View

    Fig.3-Cameron Riser Concept considered for Central Platform Fig.4-Cameron Riser Concept considered for Production Platform

  • 8 O.B. SERT, C.E.V. LONGO, F.E. ROVERI OTC 13185

    4150

    00

    4125

    00

    4175

    00

    7555000

    7555000

    7560000

    MSP-ABL-05FPSO

    MSP-ABL-01MSI -ABL-01MSI -ABL-02

    MSP-ABL-02

    MSP-ABL-03

    MSI -ABL-03

    MSP-ABL-04

    MSI-ABL-02MSI-ABL-03

    MSI-ABL-01

    MSP-ABL-02

    MSP-ABL-03

    MSP-ABL-04

    MSP-ABL-05

    MSP-ABL-01

    1500

    1400

    1200

    1100

    1300

    7560649414972 1340

    413104 7559113 1170

    413157 7557261 1160

    416099 7556079 1360

    417685 7558150 1520

    416536 7560862 1490412230 7560835 1150

    411626 7557986 1100

    415075 7557992FPSO

    COORDINATES1290

    GAS EXPORT LINE

    EQUIPMENT W A T E RD E P T H

    Fig. 5-Albacora Leste Field lay-out considered for Conceptual Study of ARS

    mud line

    current

    wave

    vessel offset

    internalturret

    vessel

    distributed buoyancy

    X

    Z

    Fig. 6-Schematic view of the Base Case Riser System

    mud line

    current

    wave

    vessel offset

    X

    Z

    internalturret

    vessel

    buoy

    riser

    jumper

    Fig. 7-Schematic view of the ARS

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