In Depth Edition
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Pre-salt
Production on A commercial scale begins
Cascade and Chinook Petrobras takes innovations to the Gulf of Mexico
Offshore intelligence center Brazil has an advanced technology park in the sector
On the way to the future Petrobras researches and develops innovations that promise to revolutionize oil production petrobras magazine 1
In Depth Edition
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Published by Petrobras
COORDINATOR AND EDITOR_ Estephani Beiler Zavarise Texts_ Cláudia Gisele Peres Martins, Eduardo Gutterres Villela, Larissa Asfora, Taísa Maciel Fortes, Telmo Wambier and Vinícius Bastiani Translation_ John Waggoner Revision_ Pamela Mills Cover Photo_ Rogério Reis/Petrobras Image Bank production
Publisher_ Flavio Rozemblatt Operations Director_ Gustavo Guimarães Contact_ Clara Botelho Director of Graphic Design_ Cynthia Homsi Designer_ Luise Krause Project Coordinator_ Carla Uyara Petrobras Magazine is not sold. To request subscriptions, photographs, additional information, please contact us: Address: Petrobras – Av. Chile, 65 – sala 1001, Rio de Janeiro – RJ CEP: 20031-912 – Brasil E-mail: petromag@petrobras.com.br web: www.petrobras.com/magazine © Copyright 04/2011
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Juliana Brum Dresjan and Matheus Alvarenga Cardeal de Miranda
Roberto Rosa / Petrobras Image Bank
Geraldo Falcão / Petrobras Image Bank
6
_the first fruits
Petrobras and its partners have already begun commercial production from the Brazilian pre-salt region
12
_Pioneering in the Gulf
Petrobras innovates by taking its expertise to the Gulf of Mexico
18
_constructing the future
Multidisciplinary teams are working to build the Petrobras of tomorrow
a center 28 _Brazil, of offshore intelligence
Cooperation among Petrobras, suppliers, and academia to develop Brazil’s oil industry has led to the rise of one of the most advanced technological complexes for the energy sector in the world
34
_a jump into the future
Petrobras incorporates new technology for constructing pre-salt wells
_time dimension 38 Petrobras deploys permanent 4-D seismic for an ultra-deepwater reservoir
42 _stepping on the gas
Petrobras invests to develop suppliers of goods and services for the domestic oil industry
46
Geraldo Falcão / Petrobras Image Bank
_training for the future
Petrobras supports training new professionals to speed up Brazil’s projects
Geraldo Falcão / Petrobras Image Bank
A commitment to the future The International Energy Agency defines “Energy Security” as the physical availability and uninterrupted supply of energy at acceptable costs, generated according to the best environmental practices. The same organization estimates that more than 60% of the oil and natural gas to be consumed by the world’s population in the 2020s and 2030s will be produced from currently undiscovered fields. The term E&P, an old and familiar phrase for the oil industry, can also be translated, in a larger sense, as energy security. Toward this domestic and global need, Petrobras is directing all the expertise of its professional teams. Energy consumption is a reflection of the quality of life of people, of their societies, and of their nations. It is a parameter that exposes unjust differences among the peoples of the world, measures the level of dignity in their lives, and guarantees their rights as citizens. Those of us in the energy industry, especially within our segment, should keep in mind that it is not enough merely to find and produce oil and natural gas. We also need to make the political decisions necessary to ensure that the fruits of our labor will be of benefit to all Brazilians and that what we do will mean continual improvement in the quality of life for our fellow citizens. The discovery of what are estimated to be extraordinary volumes of oil and natural gas in the pre-salt deposits has tremendous social and geopolitical significance for Brazil. With this in mind, the Brazilian Congress passed a new regulatory mark on December 2, 2010, which was ratified by President Luis Inácio Lula da Silva on December 22. These rules established a new regulatory structure for exploration and production activities, with the creation of a system of production sharing for the pre-salt region and other strategic areas. The guiding principle behind this decision was to ensure that the social destination of the resources from the production of this asset that belongs to the strategic national natural heritage would be crucial sectors of our society and our national development as a whole.
4 petrobras magazine
This preamble adequately sums up the socio-political contours of our strategy for developing the Brazilian pre-salt region. It also emphasizes the very great responsibility of Petrobras in this undertaking. We can guarantee that the company is ready to do its part. The expertise of our professionals ensures compliance with the company’s greater mission, which is to guarantee long term energy security throughout the 21st century. This has been the trajectory of our company throughout the almost 60 years of its history. Petrobras discovered the pre-salt deposits and put them into production in record time. To do so, it allocated heavy, increasing investments for E&P, both in seismic data acquisition and in geological interpretation, in drilling wells, in performing extended well tests, and in installing large scale projects and production systems in the Santos and Campos basins, in the southeast of the country. Within the company, there is a total commitment to guaranteeing energy security. The results achieved already demonstrate this commitment: first, there are neither technological nor operational barriers which stand in the way of pre-salt production. To this observation one may add another with utter certainty: the vast program underway to develop the Brazilian pre-salt region will not merely transpose the current successful operating model for the Campos Basin to the Santos Basin. The logistical, technological, operational, and managerial dimensions are now very different, as well as much greater. Certain aspects of these differences tend to attract more attention in a technological forum such as the OTC. As everyone knows, for example, the pre-salt reservoirs are formed by microbialites, rocks whose characteristics of porosity and permeability are still not fully understood from the geoscience point of view. This scenario provides countless opportunities to improve flow simulation models, not only to deepen the understanding of the rock itself, but also to develop new laboratory procedures. It also provides an opportunity to apply new methods and equipment to monitor the flow of fluids in the
editorial reservoir in real time. In this context, to cite another example, is the noteworthy use of 4-D seismic. Petrobras has always been driven by innovation. PROCAP, the program which guided the record-setting achievements of Petrobras in deepwater exploration and production, has been renovated with a Vision of the Future. It returns this time, once more, to come up with new and differentiated technological solutions for exploration and production, with a momentum that brings together dozens of universities, research centers, and companies. The use of nanotechnology, laser drilling technology, and subsea processing systems are just some of the themes which the technicians and scientists involved are looking into. The expected results of this new collaborative effort promise to revolutionize E&P activities in the medium and long terms, and they will be absolutely critical for the most advanced phases of developing the pre-salt fields. Given the requirements of operational safety and an environment of elevated costs, especially in the pre-salt region, well construction is another part of this work receiving special attention. In this direction, Petrobras has stepped up its field tests by incorporating unprecedented equipment and latest generation drilling systems, in joint undertakings with suppliers and renowned academic institutions which can help to improve the process, always focused on the need for operational safety.
No less important is the great need to ensure the availability of qualified human resources, so that we can meet our obligations as the primary operator of the existing blocks and concession areas, and, principally, as the future exclusive operator of the areas included in the production sharing framework. This rising demand has been met with a sizeable increase in the hiring of new geologists, engineers, and support professionals, with a strong emphasis on qualification and training. These talented young professionals have rejuvenated the company and brought to the organization an admirable internal dynamism. Official programs which have been successful, such as the Program to Mobilize the National Oil and Natural Gas Industry (PROMINP) and the National Professional Qualification Plan, have provided training for hundreds of thousands of new professionals. In addition, the integration of Petrobras with the Brazilian university system and with the official programs of the Science and Technology Ministry has guaranteed the availability of personnel with undergraduate and graduate degrees, resulting in waves of employees of excellent quality. The great game of the pre-salt region has begun in Brazil. It is by no means a gamble. On the contrary, victory will be ensured with the tools that Petrobras has counted on throughout its long history, with excellent results: technical and scientific competence, operational excellence, total dedication, respect for people, and a commitment to Brazil. Guilherme Estrella Director of Exploration and Production Petróleo Brasileiro S.A.
Geraldo Falcão / Petrobras Image Bank
Another important strategy in this integration of operators, universities, and suppliers is to ensure the continued increase of local content in our activities. We want to take advantage of this historic opportunity offered by the scale of demand represented by the development of the pre-salt fields to constantly enhance Brazil’s industrial production system. We have already seen impressive results in this area. The tangible benefits have not been limited solely to the creation of new job opportunities in Brazil. They reflect the support of a genuinely Brazilian company which is taking part, in expanding ways, in the extraordinary period of
industrial development the country has seen in recent years. The 21st century is already known as the “Century of the Knowledge Economy,” which requires of us total commitment to making Brazilian engineering the greatest beneficiary of the massive investments Petrobras will make in the decades to come.
petrobras magazine 5
f
THE FIRST
ruits
Petrobras and its partners have already begun commercial production from the Brazilian pre-salt region
A
t the end of last year, Petrobras and its partners celebrated the start of commercial production from Brazilian pre-salt accumulations. Today, close to 100,000 barrels per day (bpd) are being produced in Brazil from the oil-rich Santos Basin Pre-Salt Cluster, as well as from the pre-salt region of the Campos Basin, both located off the southeastern coast of the country. In the Santos Basin alone, by 2017, production will increase to the range of some 1 million bpd, once other units planned for the region enter into operation. 6 petrobras magazine
Two FPSOs, the Cidade de SĂŁo Vicente and Dynamic Producer, are currently installed in the Santos Basin to carry out Extended Well Tests (EWTs), in the Lula Nordeste and GuarĂĄ fields, respectively. These units are gathering technical data considered vital for the future development of the reserves found in their regions. The data obtained will be used to subsidize planning for the pre-salt activities, under the coordination of PLANSAL, the Executive Plan for Integrated Development of the Santos Basin Pre-Salt Cluster. The pilot underway in the Lula field in the Santos Basin (which originates from the Tupi accumulation), is being
Roberto Rosa / Petrobras Image Bank
The FPSO P-34 in the Jubarte Field in the Campos Basin, where the extraction of oil from the pre-salt layer began in 2008
petrobras magazine 7
performed by the FPSO Angra dos Reis, installed there since the end of 2010. This is the first production facility planned for commercial operations in the area, with capacity to produce some 100,000 bpd and 5 million m³ of gas. This platformvessel is moored about 300 km from the coastline, at a water depth of 2,149m. While the gas outflow systems to the continent are not fully operational, the facility is producing close to 15,000 bpd of oil. At peak production, Angra dos Reis will be connected to six production wells, a gas injection well, a water injection well, and ultimately will be able to alternate between water and gas injection. Just as with the FPSOs Cidade de São Vicente and Dynamic Producer, the pilot in Lula will collect data about the reservoir and production, providing fundamental knowledge for the conceptualization of future production facilities to be installed in the pre-salt regions of Brazil.
Platforms in series In November 2010, contracts were signed for the construction of eight hulls for future platforms destined for the first phase of production development from the Santos Basin Pre-Salt Cluster. These units, which have been dubbed “replicants,” will incorporate the latest generation of technology for production facilities, and are conceptualized along parameters of project simplification and standardization of equipment. The production in series of identical hulls will permit the fastest possible construction and economies of scale, with corresponding optimization of costs. Each of these Floating Production, Storage, and Offloading Facilities 8 petrobras magazine
(FPSOs) will have capacity to produce 150,000 bpd of oil and 6 million m³ of gas per day. The hulls are being built at the Rio Grande Shipyard Complex in Rio Grande do Sul state, located in southern Brazil. They were designed to guarantee that 70% of their components will be manufactured and supplied from within the country.
production in these areas, given that initial flow tests from the reservoirs have indicated excellent results.
Logistics and off taking Off taking of oil from the Santos Basin Pre-Salt Cluster projects will be carried out initially by shuttle tankers. The gas will be transported by pipeline to the Monteiro Lobato
The proven reserves of Petrobras add up, today, to some 15.986 billion boe under the criteria of the Society of Petroleum Engineers (SPE). This volume should practically double over the coming years
In all, there are 13 production units planned to start operations in the Santos Basin Pre-Salt Cluster by 2017, including the Lula pilot undertaken by the FPSO Cidade de Angra dos Reis. Each of the eight “replicants” will go into operation in blocks BM-S-9 and 11. In addition, two other pilot projects are planned nearby for the Lula Nordeste and Guará fields, both with capacity to produce 150,000 bpd of oil and 6 million m³ of gas per day, which is the same capacity as the replicants. Finally, Petrobras and its partners, at the end of 2010, approved the initial procurement of two other production facilities for projects in the Guará-Norte region and in the Cernambi field. These will be FPSOs with capacity to produce up to 150,000 bpd of oil and up to 8 million m3 of gas per day. The consortia decided to anticipate
Treatment Unit (UTCGA), in Caraguatatuba, São Paulo, and to the treatment station at Cabiúnas, in Rio de Janeiro. Studies are also being carried out for the installation in the region of a floating liquefied natural gas (FLNG) facility. Currently, the transport of personnel will be handled from the airports at Jacarepaguá and Cabo Frio, both in Rio de Janeiro state. To attend to cargo shipments, besides the ports that Petrobras currently operates, a new contract has been signed with the port of Rio de Janeiro. In the long term, two new multimodal ports are planned in Itaguaí, in Rio de Janeiro, and in Santos. Another possibility is the construction of up to three offshore cargo centers for liquid cargo and
volta ao mundo
Guilherme Costa / Petrobras Image Bank
Men on board the FPSO Cidade de Angra dos Reis
Oil and gas production targets 2010-2020 (Thous. boe/day)
7.1 % p.y.
5,382
Oil Production – Brazil
120 203 1,109
Gas Production – Brazil Oil Production – International Gas Production – International 9.4 % p.y.
3,907
128 176 623
4.9 % p.y.
2,037
11 252
85 161 251
1,500
1,540
1,810 22
2,020
2,217
2,297 2,301
96 163 274
94 168 265
1,493
101 142 277
110 126 273
1,778
1,792
2,400 2,525 97
3,950
2,723
93 146
100 124 321
141 316
384
1,855
1,971
2,100
2,980 pre-salt
1,078
1,684 pre-salt 241
2002
2003
2004
2005
2006
2007
2008
2009
2010
2014
2020
petrobras magazine 9
Geraldo Falcão / Petrobras Image Bank
Geraldo Falcão / Petrobras Image Bank
A sample of rocks from the pre-salt reservoir in the Rock Physics Laboratory at Petrobras’ Research Center (CENPES)
The FPSO Cidade de São Vicente operating in the Lula field in the Santos Basin
another for passengers to optimize logistical efficiency and to support the offshore activity.
Campos Basin Pre-Salt were also added, in this case located further north along the coast of Brazil.
Declaration of Commerciality
The proven reserves of Petrobras add up, today, to some 15.986 billion boe under the criteria of the Society of Petroleum Engineers (SPE). This volume should practically double over the coming years, if the estimated recoverable volumes in the pre-salt leasing areas are confirmed. These estimations are calculated to be between 13.3 billion and 16.3 billion boe, taking into account the declaration of commerciality of reserves in Tupi. It is important to keep in mind that this volume does not include the 5 billion boe that Petrobras acquired from the Federal Government through an act of government for the transfer of these reserves, which will add significantly to currently declared reserves.
At the end of last year, the consortium responsible for the Tupi and Iracema areas declared these accumulations had commercial volumes. Consequently, the fields called Lula and Cernambi, respectively, were designated at these areas. In the Lula field, the recoverable volume declared was of some 6.5 billion barrels of oil equivalent (boe), with 28º API. In Cernambi, the recoverable volume declared was 1.8 billion boe, with oil of 30º API. Of the total for both fields, 800 million barrels were already added to Petrobras proven reserves in January of this year. Reserves of some 100 million boe in the 10 petrobras magazine
negĂłcio Transfer of Rights
Paulo Cabral / Petrobras Image Bank
Last year, Petrobras acquired, onerously, the right to survey, explore, and produce up to 5 billion boe in areas of drainage contiguous with blocks already leased by the National Oil, Gas, and Biofuels Agency (ANP). According to the text of the bill approved by the Brazilian Congress, the company will add some 5 billion boe to its reserves, or in other words, an amount equivalent to about one third of its current declared reserves. Within these regions, which had been previously delineated by law, Petrobras will obtain 100% of exploratory rights. These concession areas must
be developed with high levels of required local content and be integrated with the areas already leased. The goal is to promote the optimization of logistical resources, to improve the overall results of the Santos Basin Pre-Salt Cluster. In additional, the Brazilian Congress approved a new legal framework for exploration and production in pre-salt and other strategic areas. Under this new structure, which adopts a production sharing system, Petrobras will be guaranteed a minimum stake of 30% in every block which has not yet been leased. For areas which have
already been leased, or which are located in geographic areas outside of the pre-salt or other strategic areas, the industry will continue to be regulated by an exploratory concession framework which has until now been in effect for all E&P activities in the country.
Producing Knowledge In 2010, Petrobras and its partners drilled eight wells in the Santos Basin Pre-Salt Cluster. Since these accumulations were discovered, a total of 20 wells have already been drilled in the region. In 2011, the commencement of drilling operations for 24 more wells is planned in the area. Data collected by drilling operations so far have made it possible to significantly reduce the uncertainties about the pre-salt reservoirs, which are formed by microbial carbonate rock, a type of formation that until now has been relatively unknown by the industry. The data from the Lula and Cernambi fields are being processed and interpreted. The collation of this information with the results obtained in the production tests has already provided a better understanding of the dynamic behavior of the new reservoirs. This has provided greater reliability for determining future production and the nature of these reserves. As new wells continue to be drilled throughout the pre-salt region of the Santos Basin, the data profiles and well tests will be used not only to better understand each field where a well is drilled, but also to provide insight into the future development of the entire pre-salt region. 
petrobras magazine 11
12 petrobras magazine
Harald Hohentha
The FPSO BW Pioneer, the first vessel of this type to operate in the U.S. sector of the Gulf of MĂŠxico
Pioneering in the
Gulf Petrobras innovates by taking its expertise to the Gulf of Mexico
T
he development of the Cascade and Chinook fields in the Gulf of Mexico represents a milestone for Petrobras and its offshore segment. In many ways it is a pioneering effort, since it is one of the first projects to focus on the production of oil and gas from the Lower Tertiary geologic formations, a region considered a major challenge by the oil industry. Due to their location in ultradeep water, the Cascade and Chinook wells are among the deepest in the world. The FPSO BW Pioneer, which will carry out development of the fields during phases 1 and 2, is the first vessel of
this type to operate in the U.S. section of the Gulf. The platform-vessel is moored in water 2,500m deep, the greatest depth achieved by the industry to date. Technologies associated with the production systems, such as its disconnectable turret buoy, free-standing hybrid risers, subsea multiphase pumping systems, pipe-in-pipe flow lines, and offloading of oil by means of shuttle tankers are all brand new for the region. Together, they completely change the way operations are performed in the locale. Even the deployment of the FPSO itself represents a landmark, given the new regulatory and environmental licensing developed specifically for this project.
petrobras magazine 13
“Each one of these achievements consolidates the expertise of Petrobras. The company is the largest FPSO operator in the world, having installed 29 units in Brazilian and international waters. This effort contributes toward the greater use worldwide of floating production, storage, and offloading systems,” says Orlando Azevedo, president of Petrobras America. The FPSO BW Pioneer, deployed for the simultaneous development of the two fields, is 241m long, 42m wide, and 20.4m high. It is capable of processing close to 80,000 barrels of oil and 500,000 cubic meters of gas per day, and can store approximately 500,000 barrels of oil. It is moored 260km to the south of the Louisiana coast, in the Walker Ridge quadrant of the Gulf of Mexico. In phase 1, currently underway, the two wells in Cascade and the one in Chinook will remain connected, in order to enable the evaluation of the performance of the reservoirs and to optimize the next
14 petrobras magazine
Captain Ezra
Braulio Perdigao
The internal mooring system of the vessel has a disconnectable turret buoy, to which risers, umbilicals, and monitoring systems are connected
phase. During phase 2, the FPSO will be connected to up to 16 wells in the two fields, when it should reach its full production capacity. Petrobras is the operator of the project, owning 66.67% of the Chinook field, in partnership with Total, and 100% of Cascade. Petrobras developed the FPSO project specifically to operate in the Gulf, with an eye on the region’s seasonal storms. The internal mooring system of the vessel has a disconnectable turret buoy, which is coupled to risers, umbilicals, and monitoring systems. This arrangement allows the vessel to rotate for better positioning under the effects of wind and currents. In the event of a hurricane, the FPSO can be disconnected from the wells and sail away to a safer location with calmer water. The rest of the structure remains below water, protected from the harsh conditions at the surface. As soon as the risk subsides, the vessel is free to return to its previous location and resume
production. “This feature means safety for the offshore personnel and greater protection for the environment, as well as protecting equipment and reducing operational downtime,” explains vicepresident for Upstream at Petrobras America, Gustavo Amaral.
Petrobras America
The technologies Petrobras took to the Gulf for this project had never before been employed in the region. According to Cesar Palagi, manager of the Walker Ridge Department at Petrobras America, “the freestanding hybrid risers used in the development of the Cascade and Chinook fields, for example, are the deepest in the world. The umbilicals are also the longest and deepest ever installed – in their composition, carbon fiber is used with a variety of polymers, in order to optimize mechanical and electrical performance
to ensure the supply of high voltage electricity to the 1,500 HP pumps situated on the sea bed. The subsea submersible pumps are the first of their kind, and are part of the multiphase pumping system installed at the greatest depth the offshore industry has ever achieved. Because they are placed outside the wells, they offer the advantage of facilitating repairs and replacement without well intervention and lengthy interruptions in production. The pipe-in-pipe flow lines for the Chinook field are also situated at depths never before achieved, and extend 14 km over the wavy surface of the seabed. The thermal insulation between the pipes is made with special material that employs nanotechnology. In addition to these innovations, the use of shuttle tankers to transport oil from the FPSO to the coast is new to the region. As for the natural
petrobras magazine 15
Brian Riordan
gas produced, it will be transported to the local Discovery pipeline system through an export pipeline,� finishes Mr. Palagi. Petrobras America worked nearly five years with the Bureau of Ocean Energy Management, Regulation and Enforcement (BOEMRE) and U.S. government agencies in order to create a regulatory framework for the project that would make it possible to inaugurate operations from an FPSO in the U.S. section of the Gulf. A series of precautions taken by Petrobras to ensure Health, Safety, and Environment (HSE) compliance contributed to the first environmental permit for an FPSO in this section of the Gulf. Some of the most notable measures include rigid criteria for selecting suppliers
16 petrobras magazine
and service providers; the adoption of the Integrated Anomaly Management System in wide use by Petrobras to prevent and evaluate incidents; a zero rate of accidents requiring leave during the installation, tests, and start of FPSO operations (including all offshore equipment involved); as well as use of an Atmospheric Emissions Management System to provide information to U.S. environmental organizations. To reinforce these precautions, the shuttle tanker Overseas Cascade was equipped with a Bow Loading System (BLS) to prevent oil emissions, and bow thrusters to provide greater stability for the vessel during mooring of the tanker to the FPSO. Drilling and completion operations for the two producer wells, one in the Cascade field and the other in Chinook,
Were it not for the
pioneering spirit of
Petrobras, the Cascade and Chinook project would never have become a reality
Braulio Perdigao
Technologies associated with the production system, such as free-standing hybrid risers, are also new in the region
took close to six months each, and were accomplished without any HSE incident. The first producer well at Cascade was the deepest ever drilled in the history of Petrobras. Drilled at a water depth of some 2,600 meters, the total depth achieved surpassed 8,000 meters. Preparation for these operations required the specification and intensive use of technologies that were not fully mature, plus additional items to reduce the risks. It also required the development of a rigid inspection system at the factory during manufacturing and to guarantee the quality of the many services rendered. Project management, in turn, was focused on the challenge of extending the limits of application for these technologies beyond conditions already encountered in former operations. Were it not for the pioneering spirit of Petrobras, always motivated by challenges, the Cascade and Chinook project would never have become a reality. From the beginning, this enterprise by Petrobras in the Gulf has generated synergies, an exchange of know-how, and greater understanding for everyone involved. Looking ahead, the focus will be to ensure the operational excellence and safe operating environment that characterize Petrobras in Brazil and around the world. The Cascade and Chinook operations will follow the best practices for the safety of personnel and preservation of the environment, adhering to the Petrobras HSE Policy and the 15 Corporate Guidelines for HSE based on the best practices in the global industry. This is nothing extraordinary for an organization which views profitability as permanently linked to social and environmental responsibility, and knows that to remain sustainable, it is unthinkable to proceed in any other way. 
petrobras magazine 17
constructing the
future Multidisciplinary teams are working to build the Petrobras of tomorrow
18 petrobras magazine
petrobras magazine 19
Juliana Brum Dresjan and Matheus Alvarenga Cardeal de Miranda
I
magine a scenario in which the majority of operations performed today from offshore platforms are transferred instead to the sea bed, at a depth of more than 2,000 meters, where they are controlled by remote from an operations room on dry land. A scenario in which oil and gas produced from petroleum fields are separated right at the ocean depths and then delivered to their destination. Imagine as well specialty molecules developed in a laboratory able to detect where the oil or water are accumulated in a petroleum reservoir. Or molecules that instantly repair damage to the surface of equipment during production. Or beyond: wells drilled with laser beams and rigs on the sea floor. These and other innovations which promise to revolutionize oil
production in Brazil are currently being devised and developed by Petrobras, in partnership with universities, research centers, and suppliers. The focus of these technological efforts is to facilitate the many projects the company is planning to develop the vast amount of oil resources discovered in recent years along the Brazilian coast, particularly those of the pre-salt layer. These and other projects aimed at bringing about such revolutionary technologies are being developed under the umbrella of the PROCAP Future Vision Program. This program is considered the next step in the company’s long history of creating new technology for extreme challenges. PROCAP Future Vision encompasses five distinct areas: new concepts for production systems; well construction; logistics; reservoirs; and sustainability.
Each of these technological initiatives shares a common goal of pushing the limits of knowledge and gathering the greatest number of good ideas. The focus is on obtaining the best possible results in the least amount of time, never losing sight of the common ground among the various areas and disciplines involved. The guiding principle is to think of the future of Petrobras as an integrated scenario. A scenario in which best use is made of each link or connection among the different technologies which chart the course for the future of the company. It is like a complex puzzle, whose parts are moved about at the same time as they are pieced together. In this direction, the technicians and researchers will continue to work giving more emphasis to a concept of open innovation, with teams of Petrobras professionals working
agradecimentos: JonnySize, Addict
Geraldo FalcĂŁo / Petrobras Image Bank
20 petrobras magazine
volta tecnologia ao mundo
Juliana Brum Dresjan and Matheus Alvarenga Cardeal de Miranda
together in a network with research institutions and suppliers around the world. Future Vision will emphasize local content in its projects. The objective, in this case, is to promote the development of technological expertise and Brazilian engineering on a competitive basis. The idea is to stimulate Brazilian technological know-how, as well as to contribute to the development of the country and make it easier for Petrobras to supply its needs from the Brazilian market in future tasks such as the development of new products and efficient local support for maintenance and replacement of parts and equipment.
A sea of history PROCAP Future Vision is the next generation of Petrobras’ technological programs. These began in the 1980s with an emphasis on bold solutions for the extreme challenges of exploration
Petrobras will use specially designed molecules to get more oil out of the reservoirs, and robots to perform maintenance tasks offshore
The idea is to stimulate Brazilian technological know-how, as well as to contribute to the development of the country and make it easier for Petrobras to supply its needs from the Brazilian market today and in future tasks
Men working in the core laboratory at Petrobras’ Research Center (CENPES)
petrobras magazine 21
Bruno Veiga / Petrobras Image Bank
Today, Petrobras already uses virtual operation rooms and integrated teams to get better results
and production in deep water. These challenges having been overcome, the focus of the new version is on an integrated view of major technological breakthroughs. At the end of the 1980s, Petrobras made history by discovering the Marlim and Albacora oil fields, located below more than 1,000 meters of ocean. At the time, technology needed to be developed to reach such depths. That gave rise to the first Program for Technological Qualification in Deep Water, known by its Portuguese acronym PROCAP. The goal was to adapt existing technologies for petroleum production at depths of 400 meters, in the Campos Basin (the deepest well Petrobras had at the time), to make it possible to bring the recently discovered deepwater fields into production.
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Of the funds mobilized by PROCAP (U$S 730 million), 80% was invested in the extension of existing technologies, and 20% was dedicated to breaking new ground, or, in other words, starting from scratch. The first PROCAP reached its goals. The focus of PROCAP 2000, which came next, was on qualifying the company to produce oil and gas at up to 2,000 meters of water depth, an entirely new challenge. It contributed, among other things, toward bringing about something entirely new for the industry of the day: the subsea centrifugal pumping system for subsea wells, which would facilitate lifting fluids from wells found at such great ocean depths. In 1991, the company began to develop new technologies for subsea processing:
among them, multiphase pumping systems (which sought to pump oil, water, and gas to the platform, all at the same time). The vast natural laboratory where these new technologies were tried out was the Campos Basin, which accounted then, as it does now, for the majority of Brazilian oil output. The scenario for PROCAP 3000 unfolded in the fields of Marlim Sul and Roncador. In the latter field, Petrobras set one of its most important world records for ultra-deepwater oil production.
award bestowed by the global offshore petroleum industry: the Distinguished Achievement Award, given at the Offshore Technology Conference (OTC). With PROCAP Future Vision, the goal is to cultivate a wide variety of projects, with a longer term horizon, in order to develop new ways of producing petroleum from the fields recently discovered by the company. In addition, it seeks to optimize production from existing fields by use of the technological innovations that will be developed.
A new concept for platforms
With PROCAP Future Vision, the goal is to cultivate a wide variety of projects, with a longer term horizon, in order to develop new ways of producing petroleum from the fields recently discovered by the company It reached 1,886 meters of water depth. An array of challenges was met and overcome, with new technologies for the day such as bold concepts for risers, subsea intervention, and other aspects of ultra-deepwater operations. One such example was the patent filed by Petrobras for mooring production facilities by means of torpedo piles, which are released 100 meters from the ocean floor and penetrate the sea bed with their own weight, using only the effect of gravity. Thanks to such successes, Petrobras twice (in 1992 and 2001) was honored with the most prestigious
The flagship of this program is a new concept for production systems, which encompasses a series of technological innovations. New equipment, for example, is being developed for primary processing, almost ten times smaller than conventional technology. Using resources such as centrifugal force or electrostatic fields, this equipment, in the form of compact tubes, can be installed below the sea at extreme depths. It can also be used topsides, facilitating operations and saving space on the platforms. These technologies being studied also include compact fluid separators (oil, water, and gas) that use various alternatives such as ceramic membranes, molecular compounds derived from ammonia, and microwaves. These technologies permit gains through increased energy efficiency, lower cost, and an increase in the capacity of production and storage on the platform, as well as a reduction in the use of chemical products for this purpose.
petrobras magazine 23
One form of compact separator has already been tested to process heavy oil from the Jubarte field, in the north of the Campos Basin, as well as onshore. By the end of the year, it will be used in other projects, and then be made available to all the company’s projects.
the automation of operations that are now carried out step by step, such as running a well test, or performing a pigging operation to clear obstructions from pipelines. These innovations should reduce logistical costs as well as limit the number of personnel offshore.
The introduction of this compact subsea technology, allied with multiphase pumping systems (oil, water, and gas together) and subsea electrical distribution, opens the real possibility of developing flow systems for production that can operate without a platform. These are systems known as “subsea to shore,” which would export production from a well directly to the shore, or to remote platforms, between 50km and 100km away. To achieve a viable electrical transmission system from land to the Santos Basin pre-salt region, about 300km from the coast, the time frame is estimated for completion by 2020.
More kinds of remote and automated technology will also be tested in the coming years. One such possibility includes industrial robots with built-in, three-dimensional cameras to assist with platform maintenance. For mobility, these could be placed on an overhead bridge crane above the facility, which itself would have a smaller footprint because of the compact processing technology. Operation could be controlled by three-dimensional visualization centers at Petrobras units or at other locations on land. Equipped with a special helmet, the operator would activate a robot with the camera and accompany its movement for inspections.
Remote operations Petrobras currently already operates some unmanned platforms by means of land-based remote control stations. With PROCAP Future Vision, the goal is to go even further. One such possibility being studied is
Laser drilling In downhole technology, the first prototype for laser drilling should be deployed for tests on land in 2013. With the increase in the use of industrial lasers, the cost
of this technology has decreased significantly in recent years. This technology operates by emitting a laser pulse which weakens the rock ahead of the bit, making drilling easier. With this technique, a rate of penetration (ROP) can be achieved from 4 to 10 times faster than conventional systems, making drilling operations both cheaper and safer. Yet another project being considered, which should soon be included in the Future Vision portfolio, is the placement of a drilling rig on the sea bed. Surface activities which today are controlled by a joystick would be transferred to the ocean floor, where they would be tracked and controlled by cameras, and operated remotely with the help of remotely operated vehicles (ROVs). In the concept of Future Vision, the sea bed becomes a locale of abundant activity, operated remotely from shore or from the surface. Following this philosophy, Petrobras has already deployed state-of-theart equipment in the Jubarte field. Last year in Jubarte, the company installed geophones at record depths – achieving the benchmark of 1,260 meters of ocean depth, compared to a previous record of
Another field of science which can provide huge material benefits for managing underground resources is nanotechnology
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Raphael Augusto Mello Vieira / Petrobras
Engineered molecules will release more oil from the reservoir rocks
only 70 meters in the North Sea. This equipment monitors the oil reservoir in real time, from the moment oil is produced. The data are transmitted via fiber optics to a 4-D seismic room on the P-57 platform, and from there are sent to the company’s seismic processing centers on land. Based on this data, it can be shown to what extent water is penetrating the reservoir, and algorithms assimilate this information and suggest with greater precision where oil or water might be located within the porous formation. This makes it possible to define exactly where new production wells or water injection
wells should be drilled to facilitate the production of oil.
Personalized molecules Still another field of science which can provide huge material benefits for managing underground resources is nanotechnology. Advancements in this area already make it possible to think of creating molecules in a laboratory to perform specific functions in a petroleum reservoir. Just as with the 4-D technology deployed in Jubarte, one of the goals is to better manage the infiltration of water into the reservoir. Nanobubbles of air injected into the reservoir
petrobras magazine 25
make it possible to enhance seismic data in order to “see” where water is located. This occurs due to the differences in the behavior of sound waves in water or in air. Some prototypes of this kind will be tested in the coming years. Another kind of nanoparticle is being developed to remove oil adhered to the rock, which can then be tapped for production. One product has already been tested successfully in the lab, and there are plans to begin using it in the Carioca accumulation, part of the Santos Basin pre-salt cluster.
Multidisciplinary teams are building today the oil industry of the future in Brazil
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Rogério Reis / Petrobras Image Bank
In the area of materials, certain molecules created in a laboratory provide a regenerative function. A very intriguing concept is selfrepairing coatings. This involves using two carbon nanotubes, the first being a hardening substance on the inside, and the second an adhesive substance. These can be mixed with the coatings for subsea equipment, for example. When the material suffers abrasion or some other damage, the nanotubes break and the two substances, the hardener and the adhesive, mix together and instantly reconstitute the coating. A good application for this technology is anticorrosive coatings for pipelines. This project is still being conceptualized, with a number of companies working toward its development with Petrobras.
petrobras magazine 27
Petrobras Image Bank
The Technology Park at the Federal University of Rio de Janeiro (UFRJ)
Brazil, a center of
offshore intelligence
Cooperation among Petrobras, suppliers,
and academia to develop Brazil’s oil industry has led to the rise of one of the most advanced technological complexes for the energy sector in the world
R
ising investments in Brazil’s oil and gas industry are helping to develop, in Rio de Janeiro, one of the most advanced research centers for the energy sector anywhere in the world. Spurred by demand from Petrobras, which plans to invest $212.3 billion in Brazilian projects by 2014, multinational companies are setting up research facilities for the latest technologies geared toward the development of exploration and production projects for oil and gas. At the same time, they are establishing long term partnerships to supply goods and services to Petrobras. The Technology Park at the Federal University of Rio de Janeiro (UFRJ) is currently at the hub of this process.
Following the example of Silicon Valley, in California, this location brings together cutting-edge companies and the academic community, enhancing integration and the exchange of knowledge. Close to the park is located the Petrobras Research Center (CENPES), one of the largest applied research complexes in the world, which in 2010 was expanded to meet Petrobras’ rising demand for new technologies. These partnerships – among suppliers, scientific institutions, and Petrobras – are creating jobs and training highly qualified personnel for the sector in Brazil. If before, Brazilian scientists left the country in order to find work abroad, today it is the multinationals which are coming to Brazil for access to the academic and research community as well as for the qualified professionals. petrobras magazine 29
Petrobras today is the single most important investor in research and development in Brazil. Between 2008 and 2010, the company spent US$2.6 billion in search of technological solutions for the challenges of its business plan
With over 350,000 square meters of campus, set aside primarily for companies in the energy, environment, and information technology areas, the UFRJ Technology Park has a commitment from at least six major equipment and service suppliers from the oil and gas industry to set up new research facilities on site. The first was Schlumberger, which, in 2010, opened its Brazil Research and Geoengineering Center, for which it has already hired 50 Brazilian researchers. Other companies in the process of installation are Halliburton, Baker Hughes, FMC Technologies, Tenaris Confab, and the Brazilian firm Usiminas. These companies are market leaders for their activities and will invest millions of dollars in facilities and research, primarily directed toward offshore exploration and production. It is estimated that over 200 different firms will eventually establish facilities in the park, which is currently 80% occupied, and will create more than five thousand highly skilled jobs. Besides the companies setting up centers at the Technology Park, BG Group and General Electric (GE) have also announced they will 30 petrobras magazine
build research facilities in Rio de Janeiro. The BG Group alone plans to invest some US$ 1.5 billion in its Global Technology Center by 2021. The demand is so great that other cities have already started to be sought out by companies hoping to build their own centers, confirming Brazil’s status as a major hub of technology for the energy sector. In February, Petrobras and Cameron – the U.S. based supplier of flow equipment products and systems for the oil and gas industry – signed a Letter of Intent to cooperate on R&D projects directed toward subsea equipment. The signing of the agreement is one of the steps Cameron is taking toward building a technology center on the campus of the State University of Campinas (Unicamp), in São Paulo.
Network collaboration Petrobras today is the single most important investor in research and development in Brazil. Between 2008 and 2010, the company spent US$ 2.6 billion in search of technological solutions for its challenges, in line with its business goals. This investment was spent on proprietary research and in partnerships with Brazilian and international companies and R&D institutions.
Ocean technology laboratory installed in the Technology Park at the Federal University of Rio de Janeiro
Besides developing research internally and encouraging its partners to do the same, Petrobras works in conjunction with universities and research institutions. Since 2006, Petrobras has spent close to R$ 400 million per year in partnerships with these institutions. These investments resulted from a clause found in the concession contracts for exploration and production between Petrobras and the National Oil, Gas, and Biofuels Agency (ANP), which stipulates that at least 1% of gross revenue from highly profitable fields, or those with large scale production, should be spent on research and development in Brazil. In order to make the most of these investments, in 2006, Petrobras created the Thematic Networks model. Each network includes a range of universities and research institutions working together under the coordination of Petrobras on themes defined by the company. Currently there are 50 networks, through which more than 100 R&D institutions exchange expertise, share facilities, and develop research activities together. Early on, most of the funds were spent on building or improving laboratory
petrobras magazine 31
Geraldo Falc達o / Petrobras Image Bank
JoĂŁo Luiz dos Anjos
facilities, which today rank among the finest laboratories for the energy sector anywhere in the world. With the facilities now built and fully equipped, the value of the R&D activities conducted there, as well as the qualification of the researchers, has continually increased. Through the strategy of the Thematic Networks, the total laboratory space in Brazilian universities has surpassed that of the facilities at CENPES. In addition, as a result of the partnerships with these institutions, for every researcher at CENPES, there are close to 15 others working on projects of interest to Petrobras at academic institutions in Brazil. 32 petrobras magazine
Preparing for the challenges ahead Besides promoting applied scientific production at the universities and other companies, Petrobras has recently doubled its own research center. These new facilities, built with innovative construction techniques that emphasize sustainability and environmental efficiency, were designed according to criteria established by the Leadership in Energy and Environmental Design (LEED) certification of the U.S. Green Building Council, which is awarded only to ecologically sound facilities. With this expansion, opened in October 2010, CENPES grew to occupy 300,000 m2, making it one of the largest applied research
centers in the world. A wide range of laboratories were built to better meet Petrobras’ technological needs. One of the most noteworthy is the Collaborative Visualization Nucleus (known by its Portuguese acronym NVC), where 3D environments are simulated for project development. Researchers can work via a remote connection to other locations within the company, as if they were inside the model being studied. CENPES today employs close to 1,600 of its own full time personnel. Among them, 1,300 are focused on Research and Development (R&D) activities, with 800 bachelor degree level researchers and 500 laboratory technicians. About half the researchers hold master’s degrees and one fourth
Petrobras’ R&D experimental facilities
BIO-LUBES Fotaleza (CE) BIOFUELS Guamaré (RN) FLOW ASSURANCE Aracaju (SE) CO2 TECHNOLOGY Poiuca(BA) WELL TECHNOLOGY Taquine (BA)
CENPES Rio de Janeiro (Rj) REFINING PROCESSES São Mateus do Sul (PR)
Geraldo Falcão / Petrobras Image Bank
With the expansion, the area of CENPES (to the left) was doubled in 2010. Below, the building of the Corrosion and Non-Destructive Testing Laboratory at the UFRJ, which is also part of the Thematic Networks project
have PhDs. Finally, almost 300 engineers dedicate themselves full time to basic engineering, with responsibility for the first stages of large scale projects. This serves to bring together design specialists and researchers and facilitates the use of innovative technologies in the projects at hand. Besides the facilities in Rio de Janeiro, CENPES also has six experimental nuclei at Petrobras’ operational units for tests on a semi-industrial scale, making it possible to bring research activities closer to the company’s industrial activities (see the figure above).
petrobras magazine 33
Petrobras Image Bank
34 petrobras magazine
a
jump into the future Petrobras incorporates
new technology
for constructing pre-salt wells
P
etroleum reservoirs monitored by a set of intelligent sensors able to determine the behavior of the oil during the production phase of the wells. Fiber optic sensors dedicated exclusively to the acquisition of data in real time throughout the entire service life of an oil well. These are just a few examples of the latest generation solutions that Petrobras is working on, in partnership with suppliers and universities, to be deployed for monitoring the performance of oil and gas
wells and managing production from pre-salt deposits. Currently still in the research and development phase, these technologies are being prepared for deployment by Petrobras in projects that will go into operation over the coming years. Another innovation programmed by Petrobras in this segment is the use of laser drilling during well construction. The methodology consists of using a laser during drilling, in order to weaken the resistance of rock and increase the rate of penetration (ROP) of
petrobras magazine 35
the bit. This is a technological advance that will add speed and efficiency to well construction operations. Another technology being developed is the “look ahead of the bit� technique, a kind of profiling that allows operators to predict with precision the conditions a drill bit will encounter 200 or 300 meters ahead of its position. These are solutions directed, primarily, toward enhancing the performance of well construction in pre-salt environments, which present specific challenges such as reservoirs with extremely complex, heterogeneous carbonate rock formations that are difficult to drill. Beyond this, however, these technologies face deployment in ultra-deep environments, at water depths close to 2,000 meters and total depths reaching up to 7,000 meters on average, with the added challenge of salt layers approximately 2,000 meters thick and in constant movement. These harsh conditions require customized solutions, which have yet to be deployed by the global oil industry, to reduce the investment required and improve the project costs for developing production from the reservoirs.
Cost reduction The application of new well construction processes and technologies by Petrobras has already achieved a significant reduction in the time required for drilling and in operational costs. A good example of cost reduction is in the area of equipment. During the start of the exploratory activities in the Santos Basin, for example, the company used up to four bits to drill through the salt layer. Today, these wells are drilled with a single bit, representing a huge gain in efficiency. The result is a savings of close to US$ 5 million per well in this region. The use of ever more sophisticated drilling fluid systems with specialty additives, and innovative concepts for bit design, have helped to reduce interaction with the salt and to mitigate the risk of a spontaneous well collapse.
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Currently still in the research and development phase, these technologies are being prepared for deployment by Petrobras in projects that will go into operation over the coming years
Another initiative that will increase efficiency in pre-salt formations is the use of horizontal drilling. This technology will be deployed definitively in 2011 in the Lula field, also in the Santos Basin. The idea is to increase the area of drainage in comparison with a vertical well. Expanding the area of a drainage system increases the interval of contact between the well and the reservoir, leading to higher production. Significant progress has already been achieved with the use of new technologies to increase drilling speed: with them, Petrobras has already managed to triple the ROP compared with the older technologies deployed during the start of pre-salt exploration. The know-how acquired over the past four years has made it possible for Petrobras to achieve a performance in the pre-salt formations in the Santos Basin equivalent to that achieved in the past in the Campos Basin, where the wells are less complex. 
Drilling platforms operating in the Roncador field in the Campos Basin
Geraldo FalcĂŁo / Petrobras Image Bank
Specialized Rigs Due to the expansion of drilling activity in Brazil, driven by the push to develop pre-salt formations in the Santos Basin, the demand for rigs in the country is soaring. To rationalize the use of these units, which are also in demand all around the world, Petrobras is adopting the so-called “specialty rig� model. The objective is to avoid using costly megarigs equipped for all forms of drilling operations, which is currently the industry standard. The concept is to create niches for equipment with specialized functions, which can be mobilized for well-defined tasks. For example, a simplified unit with a correspondingly lower day rate can be used exclusively for initial drilling operations. Then, another more sophisticated unit can be deployed for the more robust work of drilling and completion. Finally, a third unit can carry out, for example, the installation of wet trees, well stimulation, and production tests. With this rationalization, the company expects to economize millions of dollars in well construction for pre-salt projects planned in the Santos Basin. This is possible because this strategy will result in the reduction of well construction time and will make good use of specialty rigs, providing more efficient operations at a lower cost.
petrobras magazine 37
Bruno Veiga / Petrobras Image Bank
Geophysicists, geolologists, and reservoir engineers make decisions in Petrobras’ visualization room
38 petrobras magazine
time dimension
Petrobras deploys permanent 4-D seismic for an ultra-deepwater reservoir
I
n December 2010, Petrobras started an innovative operation: the first ultra-deepwater production platform to be connected to a real-time reservoir monitoring system. Equipped with technology that permits acquisition of geophysical data in 4-D (time-lapse), the P-57 platform, which produces from the Jubarte field of the Campos Basin off the coast of Espírito Santo, is connected to an optical system installed on the sea floor at a depth of over 1,200 meters. This system, equipped with optical sensors, transmits real time data to the production facility. The 4-D Seismic / Permanent Reservoir Monitoring – 4-D PRM, installed on the platform, represents an important technological advance for production development in oil fields. “The great interest in seismic reservoir monitoring is to know precisely where to locate the oil that has not yet been produced from the various reservoirs, because this makes it possible to increase production and raise recovery factors by means of infill drilling,” says Paulo Johann, manager of E&P Reservoir Geophysics at Petrobras. The 4-D seismic is a technological leap ahead of classic 3-D seismic. First used by Petrobras in 1978, in the Cherne field of the Campos Basin, 3-D seismic makes it possible to estimate the spatial characteristics of length, width, and thickness of a given reservoir. The technology is fundamental for estimating volumes present in oil fields (the dimensions of the deposits). The use of 4-D seismic adds a fourth dimension: time. Different from conventional seismic – 2-D or 3-D -, whose purpose is to locate and characterize oil reservoirs, 4-D makes it possible to monitor various time stages of the production process in an oil field. What changes with 4-D PRM is the use of 4-D technology deployed via permanent installations that collect seismic data in real time. Besides providing data relative to the geometry of the reservoirs – which is what 3-D seismic does – 4-D PRM petrobras magazine 39
PGS
Seismic station with 4-C optical sensors: three accelerometers and one hydrophone
reveals the position of moving fluids and/or pressures, temperatures, and other dynamic phenomena within the reservoirs during the life of the field. This minimizes the time lag between the seismic data acquisition and its use for the management of the reservoirs. This improvement makes it possible to permanently analyze the physical characteristics of the reservoirs, such as the identification of unswept oil regions, and the pressure and saturation of the reservoir. With these capabilities, the technology becomes an important ally in the optimization
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of production from fields that have already reached peak production and have entered into the phase of natural decline.
A dive into P-57 The P-57 platform is equipped with a 4-D seismic data room that contains computers connected to a fiber optics system, which in turn are connected by optical cables (or risers) to the optical seismic lines installed on the sea bed. These fiber optics transmit data collected by optical seismic sensors installed on the sea floor, which are transformed into images. The optical sensors are one hydrophone
volta ao mundo The permanent 4-D seismic system enables geophysicists, geologists, and engineers to know with greater certainty exactly where the still unproduced oil is located and three accelerometers (4-C acquisition), which, for the first time in the global oil industry, are being used for seismic survey in ultra-deepwater. From the 4-D seismic room of P-57, the data is transmitted in real time to Petrobras’ seismic processing centers, where it is processed. Back at the production assets, the data is interpreted by geophysicists, geologists, and reservoir engineers, subsidizing the technical and management decisions that are necessary to fine tune production from the oil reservoirs.
Petrobras’ FPSO P-57: the first production platform with permanent seismic reservoir monitoring – 4-D PRM
Rogério Reis / Petrobras Image Bank
The permanent 4-D seismic system also makes it possible to optimize production, since it enables geophysicists, geologists, and engineers to know with greater
certainty exactly where the still unproduced oil is located. With this detailed information, it becomes possible to plan more efficiently the number of wells to drill and the best approach. “This represents an important technological breakthrough, because it becomes possible to collect data in time intervals that are necessary to better monitor the behavior of the dynamic properties of the reservoirs,” says Johann.
A record depth Permanent seismic has already been used in the North Sea since 2003, at the Valhall field operated by BP, but in shallow water (70 meters). In the Jubarte field, the water depth reaches 1,260 meters, setting a new benchmark for the technology. “For Petrobras, this project means a very important advancement for monitoring the dynamics of our oil reservoirs, improving the planning for production from our oil fields, and for the resulting improvement in project economics,” says Carlos Eugênio Melro da Resurreição, general manager of E&P Reserves and Reservoirs at Petrobras.
Ari Versiani
Stepping on the gas
Petrobras invests to develop suppliers of goods and services for the domestic oil industry
P
etrobras is betting on the sustainable growth of the Brazilian oil and gas industry to ensure the viability of its many exploration and production projects underway in the country, which are driven, in large part, by the development of pre-salt deposits. The company’s Business Plan calls for record investments of US$ 108.2 billion in exploration and production in Brazil by 2014, of which US$ 57.8 billion will be spent on domestic goods and services. This means that no less than 53% of the total amount to be spent on goods and services for E&P projects will go to Brazilian suppliers. This represents a historic opportunity to develop the entire productive chain for the oil and gas industry in Brazil. Recent statistics prove the wisdom of this strategy. During the previous year alone, Petrobras set a new record for the overall volume of orders placed with domestic suppliers of goods and services: some US$ 25.1 billion in contracts were signed with local suppliers, representing an increase of 400% compared to 2003. In addition, 42 petrobras magazine
The Brasfels shipyard, in Angra dos Reis, Rio de Janeiro
To consolidate this expansion in a sustainable way and to foster scientific and technological development, the basis of industrial growth, Petrobras is also betting on
Employees working on the conversion of the FPSO P-57 at the Mauá-Jurong shipyard
partnerships between Brazilian and foreign suppliers
the percentage of minimum local content for projects in all the company’s business segments went from 57% in 2003 to 74% in 2010. This growth contributed to the creation of 995,000 new jobs in this span of time. These results are the fruit of the company’s strategic decision, made in 2003, to progressively scale up the required domestic content for its projects. The intention is not only to help revitalize the country’s shipyards, but also to foster the growth of a wide range of companies specialized in supplying goods and services for the production of platforms, drilling rigs, valves, pipelines, pumps, risers, and countless other components. In a larger sense, the priority is to help transform Brazil into a major international competitor as a supplier of goods and services for the oil and gas industry, and, at the same time, to promote the generation of income and economic development in the country, backed by the sustainable development of the domestic industrial complex.
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Stimulating the industry The positive results of this decision can also be seen within the Exploration and Production (E&P) segment: local content for E&P projects increased from 48.5% in 2003 to 60.5% in 2010, representing additional orders worth some US$ 6 billion for the Brazilian industry. This expansion came about through great effort to strengthen the domestic industrial complex, based on the qualification of laborers, restructuring finance modalities to allow small and medium sized companies to participate, encouraging partnerships between foreign and domestic firms, and creating the conditions for new manufacturing facilities to be built in the country. In the coming years, investments in the local goods and services industry will continue full steam ahead: Petrobras will spend close to R$ 46 million in 24 projects to develop local suppliers of equipment and materials that previously were not manufactured in Brazil. In
the E&P segment alone, there are ten different projects underway, representing investments in the order of R$ 17 million. To consolidate this expansion in a sustainable way and to foster scientific and technological development, the basis of industrial growth, Petrobras is also betting on partnerships between Brazilian and foreign suppliers. The intention is for foreign suppliers to team up with companies already operating in Brazil, or to build new facilities in the country – either alone, or in association with local businesses.
Bruno Veiga / Petrobras Image Bank
training
for the future
Petrobras develops a human resources training program to train skilled workers for the sector and to sustain the growth rate of the Brazilian industry
46 petrobras magazine
Geraldo Falcão / Petrobras Image Bank
Petrobras supports training
new professionals
to speed up Brazil’s projects
A
true revolution is underway in Brazil’s energy industry, driven by the pre-salt discoveries. Because of the projected increase in domestic production, there are plans, for example, to construct new refineries, petrochemical facilities, and networks of pipelines. The main factor to ensure optimum efficiency in the operation of these complex systems will be people. “People are essential to the success of any organization. In the case of Petrobras, besides the efforts and contributions of each individual, there are other even more important qualities, such as commitment and the willingness to meet new challenges. These two values, present in the company’s culture, combined with the technical expertise and concern for the environment, make our workers all the more important and differentiated,” says Petrobras’ Human Resources executive manager, Diego Hernandes. With this scenario for the Brazilian energy sector in mind, in 2010, Petrobras launched its Human Resources Training Program, with the goal to join the country’s efforts to train qualified workers to sustain the fast pace of growth in the domestic industry. The program enables the training of students in the oil, gas, and biofuels field all over the country by means of scholarships. The plan includes from students in secondary technical schools to those doing doctoral studies. It also provides partner institutions with new computer equipment and software, subscriptions to periodicals, improved infrastructure, and the chance to participate in scientific and academic events. Since the program began, 1,605 scholarships have already been granted, and the company expects to provide 5,000 more by 2016, based only on current agreements. In 2010 alone, more than 30 agreements with universities and technical schools were signed, and, from 2010 to 2016, close to R$ 77 million should be distributed.
Geraldo Falcão / Petrobras Image Bank
Professions of the Future To prevent a possible shortage of qualified labor and to make the industry more attractive, another program is underway called “Professions of the Future,” the goal of which is to promote technical careers in the oil and gas industry in schools throughout Brazil, sparking the interest of students from technical schools, high schools, and the last year of middle schools in the growing professional opportunities in the segment. The project also encourages high school students to pursue careers in engineering, geology, and geophysics.
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In partnership with the Brazilian educational system and various entities associated with the oil, gas, and energy industries, the program focuses mainly on the Brazilian states where Petrobras has the most projects. At the end of 2010, during the pilot phase, program lectures were attended by 1,725 students in three states. The goal is to reach at least 40,000 students in 294 schools in 2011. Besides these presentations, a program website is being developed to gather detailed information about the many different career options in the oil, gas, and energy sectors, including the various technical schools providing training. The idea is to form a link between students, training institutions, and companies.
PROMINP
The need for new professionals is commensurate with the Petrobras Business Plan. The company’s average annual investment has grown more than seven times since 2003, expanding from US$ 5.8 billion that year to US$ 42.4 billion in 2010. “This represents both an opportunity and a challenge seven times greater for the industry. In order to meet this challenge in Brazil, with companies that are located in the country, it is fundamental to have a high level of competitivity, in order to provide the services needed for these projects,” says José Renato.
Strategic Importance According to Flávio Neves Júnior, professor and coordinator of the Human Resources program for the oil, gas, and biofuels sector at the Federal Technical University of
Paraná state (UTFPR), Petrobras’ initiatives to train personnel are strategically important. “They create a social and supportive environment at the university, where the activities are focused on the sector in which the company operates,” he explains. For the professor, this effort by Petrobras favors greater knowledge of the company, which in turn disseminates interest in the sector throughout the academic community. “In many cases, the universities already have a great deal of interaction with the company by means of research and development projects. The scholarship students who take part in these projects receive a consistent and continuous education, integrated with increasingly solid research and development.” He concludes: “This creates a virtuous cycle in training, research, and development, with a strong corporate link and with current themes and strategies. This cycle allows the universities to participate in this wave of innovation.”
Rômulo Oliveira
A program called PROMINP, endowed with R$ 260 million through the National Professional Qualification Plan (PNQP), graduated 78,000 professionals in oil and gas training courses in 15 Brazilian states by the end of 2010. According to PROMINP’s executive
coordinator, José Renato de Almeida, by 2013, the demand for qualified professionals to work on projects related to the pre-salt area will reach 207,000 people. A large number of these jobs will be linked to the shipbuilding industry.
48 petrobras magazine
Marco David Teixeira
_Diego Hernandes Petrobras’ Human Resources executive manager
A class in the Professions of the Future program, in Rio de Janeiro
The pre-salt discovery increased the need for human resources at Pertrobras in Brazil. What are the main needs? Careers in geology, geophysics and engineering, in the case of higher education, and those for operation technician, maintenance and projects, and construction and assembly, among those on the secondary level, will be extremely important. The first two higher education careers, for example, are essential for exploration activities, which involve finding where oil exists and where the wells should be drilled. Careers linked to engineering are fundamental for the entire value chain, since the activities of drilling, production, processing, and refining and transport of oil, gas, and oil products are highly complex, and this is also true for the implementation of new projects. There will also be strong demand for professionals dealing with logistics in production, distribution, and support activities, especially for facilities offshore, using support vessels or pipelines. With the anticipated growth in oil production and new refineries, activities linked to the chemical sector will also be needed to research and develop oil products that are consistent with sustainable development. There is also great concern for the
health and safety of workers and for issues related to the environment. Accordingly, professions which attend to each of these specialties will be in demand. In a high performance field such as the oil industry, what role does job experience play for the labor force? The experience of veterans makes a difference in many situations, especially in day to day operations. One of the company’s greatest concerns, in terms of the sustainability of its business, is how to manage and share knowledge. The primary goal is to establish the value of sharing knowledge among the employees, principally the most experienced ones, who should pass on to the younger employees their tacit knowledge, both technical expertise and management techniques, as well as transmitting the company’s culture and values. In the specific case of tacit knowledge, more than any technology, personal communication is the most effective means. It is often informal conversation that stimulates the creation of new ideas and the resolution of problems. One effective strategy is to mix new employees with the older ones, making possible the transfer of knowledge, and, of course, the dissemination of Petrobras culture. Depending on the activity, this mixture will be in greater or smaller degree, always based on the skills needed by the unit that will receive the transferred employee, as well as the skills present at the original unit. Why is it important for a company like Petrobras to maintain ties with the scientific and academic community? The company believes that technological mastery is a critical factor for the success of its business. From the very beginning, it has worked in partnership with Brazilian universities and research institutes, contributing to advances in domestic technology for the area of oil, gas, and energy. Is the Petrobras work force prepared to meet the challenges of the pre-salt region? I am quite certain it is, given the history of the challenges that have been overcome, and given the potential shown by the young people coming into the company since 2001, when Petrobras began recruiting again through a public selection process. Today, the company can count on a robust and highly qualified staff to reach its goals, and with the pre-salt region, it will be no different.
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Petrobras in the world
THE NETHERLANDS
UNITED KINGDOM
PORTUGAL UNITED STATES
MEXICO
LIBYA CUBA
Exploration and Production
VENEZUELA
BENIN NIGERIA
COLOMBIA Refining
ECUADOR BRAZIL
distribution
ANGOLA
PERU Lube oil plant
BOLIVIA PARAGUAY
Representation office
URUGUAY
Headquarters
CHILE Petrochemicals
Biofuels
Electrical energy
Pipeline transportation
ARGENTINA
NAMIBIA
overview
JAPAN
CHINA
IRAN
TURKEY
INDIA
SINGAPORE
TANZANIA
AUSTRALIA
NEW ZELAND
energy that moves
the world!
Petrobras joined Lomography, at www.lomography.com, to discover how people see energy around themselves and around the planet. Photographers from different continents sent thousands of pictures that together form the biggest LomoWall ever made in Latin America, exhibited at Museum of Modern Art of Rio de Janeiro, from 28th April to 15th May 2011. The exhibition marks the launch of Petrobras new global website, www.petrobras.com. Access our website and see through the lens of these photographers the result of this experience.
www.petrobras.com