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Technological Challenges and Solutions for Well Construction in Pre-Salt Fields
Rosana Lomba (PETROBRAS/CENPES)
PRESENTATION TOPICS
• The Pre-salt Province
• Technology strategy of the Company
• Pre-salt Technological challenges in well construction and stimulation
• Well construction
• R&D initiatives
• Final remarks
The Pre-salt Province
Total area: 149.000 km²
• Already under concession: 41.750 km² (28%)
• Petrobras interest: 35.750 km² (24%)
• Without Petrobras interest: 6.000 km² (4%)
• Not under concession : 107.228 km² (72%)
The Pre-salt Province
Pre-salt Cluster of Santos Basin
• Discovery at 2006 (Parati and Tupi/Lula)
• Then discovered Iara, Guará, Cernambi, Carioca,
Jupiter, Franco, Libra...
The Pre-salt Province
709m709m
1977
Enchova
EN-1-RJS
124m
1977
Enchova
EN-1-RJS
124m
1983
Piraúna
RJS-232
293m
1983
Piraúna
RJS-232
293m
1985
Marimbá
RJS-284
383m
1985
Marimbá
RJS-284
383m 1988
Marimbá
RJS-376D
492m
1988
Marimbá
RJS-376D
492m
1994
Marlim
MRL-4
1027m
1994
Marlim
MRL-4
1027m 1997
Marlim Sul
MLS-3
1709m
1997
Marlim Sul
MLS-3
1709m
1999
Roncador
RJS-436
1853m
1999
Roncador
RJS-436
1853m
2000
Roncador
RO-8
1877m
2000
Roncador
RO-8
1877m2003
Roncador
RO-21
1886m
2003
Roncador
RO-21
1886m
2009
Lula (Tupi)
RJS - 646
2172m
2009
Lula (Tupi)
RJS - 646
2172m
1979
Bonito
RJS-38
189m
1979
Bonito
RJS-38
189m
1992
Marlim
MRL-9
781m
1992
Marlim
MRL-9
781m
70`s
Reservoir:
< 2300 m
Reservoir:
< 2300 m80`s
Reservoir:
< 3200 m
Reservoir:
< 3200 m
90`s
Reservoir:
< 3500 m
Reservoir:
< 3500 m
00`s
Reservoir:
< 4300 m
Reservoir:
< 4300 m
Technology Strategy of the Company
Directions for Technology Development
• Develop a technological pole in Oil & Gas in Brazil.
• Develop infrastructure in Brazil to physically simulate the relevant Pre-salt phenomena.
Technological Challenges in Well Construction and Stimulation
• Drilling horizontal wells through salt
• Increase penetration rate (salt and carbonate)
• Long term wellbore integrity (including cementation)
• Strategy for well stimulation
• Well geometries to provide high productivity
• Interval selectivity
Vertical?
Horizontal / Slant / ERW?
Bilateral?
Radial? Dendritic Multilateral? Horizontal Multifractured?
Open hole or cased hole?
• Ideal well geometry for the Pre-salt? Well Construction
Base of the Salt
Top of the Salt
Top of the Albian Top of the K Sea bed
5 10 15 20 km 0
Basement
W E
Drilling wells in deep salt layers
Geosteering in build up, in Onshore Sergipe-Alagoas Basin
Geosteering in drop off, Offshore Campos Basin
Geosteering in build up, Offshore Campos Basin: first horizontal well in salt, 85o
Halita Fm Muribeca Halita Tupi
Salt cores and geomechanical experiments
B
Modeling in situ stress in salt and host rock
Deviating wells in deep salt layers
Rotating Drive
Shaft
Non RotatingSteerable Stabiliser
Sleeve Steering RibsHydraulic
Control Valves
Direction
Side force
• AutoTrak – RCLS
Geosteering in build up, Onshore Sergipe-Alagoas Basin
Learning curve
1) Tempo zero 2) Após 1 minuto circulando
BR-MUL
3) Após 2 horas de circulação
com BR-MUL
4) + 18 horas em contato
estático com BR-MUL
5) + 6 horas de circulação
com BR-MUL
6) + 16 horas em contato
estático com BR-MUL
7) + 1 hora de circulação
com BR-MUL
8) + 1 hora de circulação
com BR-MUL
Radiografia Radiografia
após 18h estático após 16h estático
ROCK / FLUID INTERACTION
LAB RESULTS – FLOW LOOP WITH
REAL TIME CT SCAN
100% NON AQUEOUS DRILLING
FLUID FORMULATION
To minimize caliper enlargement
and guarantee good quality salt
cores
DRILLING FLUID DESIGN
• To estimate borehole enlargement during salt layers drilling
− Drilling fluid design
− To avoid excessive localized hole enlargement
− To guarantee wellbore stability
− To guarantee good cementing job
• To estimate the amount of salt incorporation in cement slurries during salt layers cementing jobs
− To help the development of suitable cement slurries
− Compressive strength and thickening time are considered
− Actual downhole concentrations are evaluated
4SAL – SOFTWARE FOR SALT DISSOLUTION SIMULATION
TAXA DE DISSOLUÇÃO DOS TESTEMUNHOS -PASTA 5% BWOW
KCL
00,3
0,5
11,2
1,4 1,5
0
0,5
1
1,5
1,92,2
2,5
0
0,5
1
1,5
2
2,5
3
0 20 40 60 80
TEMPO (min)%
m/m HALITA
CARNALITA
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
12 12,5 13 13,5 14 14,5 15
Open hole diameter (pol)
TV
D (
m)
10 m/h
15 m/h
20 m/h
25 m/h
30 m/h
12 12,5 13 13,5 14 14,5 15
Open hole diameter (pol)
1000 gpm
800 gpm
600 gpm
400 gpm
200 gpm
12 12,5 13 13,5 14 14,5 15
Open hole diameter (pol)
0%
20%
40%
60%
80%
Salt 1
Salt 2
Salt 3
ROP Flow Rate Different salts
4SAL – SOFTWARE FOR SALT DISSOLUTION SIMULATION
• Borehole caliper - 250 m drilled with non saturated WBM
• Cement job - 100 m salt layer and 8.5% NaCl slurry
Flow Loop to evaluate borehole enlargement (P = 5000 psi / T = 70º C)
Aluminum Cell for X-Ray CT Scanning
Cylinder plugs Ø 1 ½ and 2” (L= 150 and 250 mm), Ø 3 ½ and 4” (L= 250 mm)
Flow rates: 100 ml/min to 3500 ml/min
SIRF – ROCK FLUID INTERACTION DOWNHOLE SIMULATION CELL
UFRRJ
Physical
simulator Halliburton
ESSS
PUC Drilling Fluids
Lab
CT Scan
TCA Cementing in
CO2 and Salt
scenarios
TCA Fluid flow and
salt diffusion studies
Cuttings
dissolution
kinetics
Software
Development
In house
development
– Sistema Hydrolift
SOLUBLE SALT CORING and PRESERVATION
Cabo
Gamma Ray
Módulo de Bombeio
Packer
Packer
~1 m
MICROFRACTURING (MDT) AND IMAGE LOGGING – IN SITU STRESSES
Fluency test to calibrate in house developed 3D model ANVEC 3D
3D NUMERICAL SIMULATOR – WELLBORE STABILITY DURING SALT DRILLING
OFFSHORE DRILLING OF DEVIATED AND HORIZONTAL WELLS
• 1º offshore well with build up in the salt
• 1º Pre Salt horizontal well
• Water depth ~2000 m
0
1500
3000
4500
6000
-20
0 0
20
0
40
0
60
0
80
0
VSEC
TV
D
Realizado Limite Superior
Limite Inferior Projetado
Learning curve (drilling performance)
Wells in Chronological Sequence
Drilli
ng R
ate
Th
rou
gh
Sa
lt (
m/h
)
Drilling bits and downhole equipments
Drilling fluids
• High costs associated to deep and ultradeep water operations
• Massive offshore campaigns
• Necessity of new methodologies:
– Enhance process safety
– Reduce process variability
– Increase ROP
– Reduce NPT
Automation techniques applied to well construction
Motivation
• The Society of Petroleum Engineers created a technical section dedicated to the issue of drilling automation (DSATS – Drilling systems automation technical section)
• Other relevant achievements are
• WITSML protocol
• Wired pipe data tranfer
• Improvement of drilling tools
• Development of real time troubleshooting software tools
DRILLING PROCESS CONTROL
Schematics of the control loop:
•ROP is the dependent or controlled
variable
•WOB and RPM are the manipulated
variables
Feedback control where P, I and D
actions can be applied. The logics was
implemented using a DELPHI platform
which allows the simulation to take
delays, noises and disturbs into
account.
50 national R&D technological networks (redes temáticas)
129 institutions in 21 States + DF
Networks for Technological Integration with Brazilian Institutions
Networks
R&D initiatives
Expanding the capacity of Brazilian R&D
Networks infrastructure in Brazil: 4 times the original
building area of CENPES
Partnership with suppliers
Technological Park
(Rio de Janeiro)
Partnerships with Universities +
R&D Instituts
Final Remarks
• Pre-salt development has posed many technological challenges which have been properly identified and addressed by PETROBRAS and partners.
• The experience accumulated during the history of success built by Petrobras in ultradeep water will largely support the Pre-salt production development. In addition, PETROBRAS has a culture of developing production by steps, including extended well test and production pilot before the definitive system, which is important for acquiring data in unusual reservoir types.
• Technological development is being made with the support of Brazilian Academia, goods and service companies, and foreign entities whenever needed.
• Pre-salt challenges are impacting and pushing the technological development in Brazil, resulting in a fast expansion of the research facilities.
• Petrobras and its partners in the Pre-salt areas are committed to sustainable development principles and best HSE practices during exploration, appraisal and production phases of the pre-salt areas.
