OTC 14003 VASPS Installation and Operation at Campos Basin

O.R. do Vale and J. E. Garcia, PETROBRAS, and M. Villa, ENI S.p.A. - Agip Exploration and Production Division

Copyright 2002, Offshore Technology Conference This paper was prepared for presentation at the 2002 Offshore Technology Conference held in Houston, Texas, 6-9 May 2002. 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 VASPS (Vertical Annular Separation and Pumping System) is an innovative concept for two-phase subsea separation and pumping. The paper illustrates the installation, commissioning, and start-up of the 9,000 BBLD VASPS subsea unit, which was successfully brought on-stream in July 2001 in the Marimb Field (Campos Basin, Brazil). Introduction A large fraction of the exploration investment in all major oil companies is dedicated to deep and ultra-deepwater reservoirs. Even if the exploration is technically successful, the high production costs associated with conventional development schemes often makes such fields non-profitable. As a consequence, since the 1990s, many of the operators have been involved in the development of profitable and competitive subsea processing technologies to maximize production rates and recoverable reserves. VASPS (Vertical Annular Separation and Pumping System) is an innovative two-phase subsea separation and pumping system concept, which allows high capacity integrated separation and pumping equipment to be installed within a 30 to 36-inch conductor in a dummy well (Fig. 1). Installation and maintenance of the unit were conceived to be accomplished by using conventional subsea drilling and completion technology and equipment. VASPS technology has been developed in a phased approach [Ref. 1-10] addressing the various issues in a hierarchical manner. Phase 1 (1990-91) consisted of laboratory tests, Phase 2 (1993-95) in-land field tests at AGIP site in Trecate-Italy, Pre-subsea Phase (1995-97) in-land field tests at PETROBRAS site in Atalaia-Brazil, and the Subsea Demonstration Phase (1998 2002) in Campos Basin-Brazil.

From a mechanical point of view the VASPS is based on standard subsea tree, casing and wellhead components. With reference to the stack-up arrangement (see Fig. 2), the VASPS Subsea Hardware designed for Marimb 1 is based on the following main components: Foundation Flowbase Multi-bore and single-bore flowline connectors Separator composed of the pressure housing (6 joints, each 12 m long and 26-inch diameter), and the helix (6 joints, 12 -inch diameter) Head assembly and top plug ESP and liquid discharge tubing Running tool The control system is composed of a hydraulic power unit, subsea control module, master control station, subsea choke valve and level sensors. The electrical system includes the ESP with the shroud connected to the liquid discharge tubing, multisensor, power cable and wet-mateable connector, and variable speed drive. Detailed information is available in [Ref. 1] The system was totally assembled and tested in Aberdeen (Site Integration Test) before being transported to Brazil. Part of the hardware was re-assembled inland and tested at Maca-Brazil (Site Receiving Test) before the offshore installation. Pre-commissioning at Aberdeen The main objective of the Site Integration Tests (SIT), performed in Aberdeen during February 2000, was to check the feasibility of the proposed handling, assembly and installation procedures. Particular attention was given to the novel parts of the system or to those that had any sort of criticality during the offshore installation. In this respect the following operations were of paramount importance: Installation of the flowbase onto the 36-inch conductor housing, including the following operations: Latching the flowbase onto the 36-inch conductor with the flowbase running tool Check of the flowbase orientation and alignment Over-pull tests

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Handling and assembly of the separator with the liquid discharge tubing and the still wells. The following operations were performed: Make-up sequence of the separator and helix joints using the dedicated handling equipment Align the helix joints inside the separator Installation of the separator into the 36-inch conductor Check the connection of the 18 -inch connector with the head assembly Handling, make-up and installation of the ESP Handling and assembling of the liquid discharge tubing, still wells and the pump into the separator. Still well, ESP cable and clamps installation and termination into the top plug Installation of the head assembly onto the flowbase. The following operations were checked: Re-entry of the head assembly on the flowbase, checking the alignment of the flowbase connectors and the high pressure housing Locking of the high pressure housing onto the flow base and over-pull tests Installation and retrieval of the level sensors with the level sensor running tool In addition all the hydraulic functions of the main components, including handling and running tools were checked. Once the VASPS unit was assembled and leak tested with water, the separator was pressurized with air. The control system and the ESP were energized and the VASPS system was operated in such a way to simulate as closely as possible the subsea operating conditions. The main scope of the functional test was: Prove the communications between the different parts of the system Verify the correct response of control system and ESP to any major variation of the VASPS operating conditions (e.g. if the VASPS Level increases above the Dead Band, then the pump is operated at an higher frequency and the Choke tends to open). Pre-commissioning at Maca (Site Receiving Tests) After completion of the SIT at Aberdeen, the VASPS was dismantled, refurbished and then transported to Brazil. After the Custom Operations were completed, the various parts were transported to Maca for the Site Receiving Tests (SRT). The scope of the Site Receiving Tests performed in Maca included: Verify the status of the various items and equipment, to identify and repair any damage which might have occurred during transportation Assure that all of the equipment, including spare parts and other consumables, had been delivered/received

Rehearse for the offshore operations, including the stack-up test and check-out of the rig-specific installation hardware and interfaces rain Contractor and PETROBRAS personnel involved in the installation, commissioning, and operation of the system In order to comply with this scope the following activities were performed: All flushing operations Level sensor response test in the final configuration by using the control system and the actual control umbilical Install and retrieve the level sensors and carry out function checks on the level sensor running tool Continuity tests and check electrical isolation on the top plug high voltage system Land the flowbase onto the stack up and test base Pressurize the flowbase Install the control pod into the head assembly Install the head assembly onto the flowbase Install and latch the monobore vertical connector Install and latch the single bore vertical connector Install the power cable anchor Install the top plug into the head assembly Connect all the jumpers Connect and commission the control system Perform full system leak tests (3000 psi) Operate the choke valve and conduct functional checks Carry out ROV interface tests to confirm the functionality by matching all the interfaces Checks on HPU (pressurization tests, checks on pumps and instrumentation) Level sensor lens cleaning test Communication tests with the level sensors Operate the flowbase valves Electrical continuity tests on all electrical jumpers Pressure test the hydraulic jumper Test all the parking positions Offshore Installation of VASPS in Campos Basin After completion of the SRT in Maca, the VASPS system was ready for installation, which was performed by the SEDCO 710 (Petrobras SS-43). Due to rig crane lift limitations, it was necessary to keelhaul the Flowbase and the Head Assembly. This was conducted in 6 hours by using a service barge carefully positioned under the moonpool using tugs. After the keelhauling, the installation sequence was: The SEDCO 710 traveled to the Marimba Field Site and a site survey was conducted The 42-inch conductor temporary guide base was run and the 42-inch conductor jetted-in

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The hole for the 36/30-inch casing was drilled The 36/30-inch casing was run, landed in the temporary guide base, and cemented The flowbase was lowered to the seabed and landed on the 36-inch conductor housing The VASPS separator (high-pressure housing and helix) was assembled and hung-off in a special support structure at the moonpool level The VASPS head assembly was connected to the separator and the complete assembly was supported by the head assembly hang-off beams The ESP, still wells, liquid discharge tubing and top plug assemblies were made up and installed in the head assembly/separator The VASPS was pressure and leak tested before running subsea The head assembly and the separator were run to the seabed, oriented, landed and locked onto the flowbase. This completed the SEDCO 710 VASPS activities.

All the activities performed on the rig as well as at the mudline were monitored and recorded. The installation of the VASPS subsea hardware was carried out in 7 days, including the drilling of the dummy well. After the installation of the VASPS subsea hardware, the Seaway Condor was used to lay and connect the flowlines, control umbilical and power cable. The main marine operations performed were: Lay down and connection of the 6-inch flexible gas flowline and relevant riser, the electro-hydraulic umbilical and the 6-inch flexible oil flowline with a first end vertical connection at the VASPS and a second end pull-in at the P-8 (Marimb Platform) Recover, cut, re-terminate and pressure test the existing 6inch flexible flowline from MA-01 to the P-8. Install to the input of the VASPS using a second end vertical connection Connection of the electrical power cable as first end connection at the VASPS and pull-in at P-8 The VASPS was installed in 395 m water depth, 550 m away from the MA-01 well subsea tree and 1050 m from the P-8, where the gas and oil streams are sent. Commissioning of VASPS Surface equipment VASPS separates the gas and liquid phases, delivering both the streams independently to the P-8. The oil line is connected to both the production and the test manifolds with flow controlled by the surface choke valve. The gas stream arrives at the P-8 under pressure control and is delivered to a gas scrubber and ultimately to the suction of the main compressor system. Flow rate, pressure, and temperature measurements are taken on both the oil and gas lines on the

P-8. The instrumentation for both subsea and surface are depicted in the operator console screens in Figure 3 and Figure 4. In order to control and monitor the operation and the performance of the VASPS system, a dedicated master control station was installed on the P-8. The master control station controls and monitors the hydraulic power unit, the variable speed drive and the subsea control module. After the subsea installation all systems were full of seawater. During the commissioning the sea water in the VASPS and the oil and gas flowlines was replaced by diesel oil, pumped into the system from the P-8. The diesel oil from the gas flowline was removed by pigging prior to the start-up. The hydraulic power unit was put in operation, the subsea hydraulic umbilical pressure tested and functional tests of the subsea valves performed. Functional and integration tests between the variable speed drive, master control station, ESP, multisensor, hydraulic power unit and surface instrumentation were extensively performed. The surface piping circuits and the associated equipment was purged, pressure tested and pressurized with gas during commissioning. The MA-01 well was opened and initially put on-stream with gas lift assistance and the VASPS in by-pass mode, reference FIGURE 4. The multiphase fluid arriving to the P8 manifold system was diverted to the production separator. After all these operations the VASPS was considered ready to start-up. Start-up and operation of VASPS First start-up The VASPS separator was filled with diesel oil during the commissioning. Gas was back flowed from the P-8 to the VASPS prior to start-up to remove liquid from the separator (sending it to the liquid line). This reduced the VASPS liquid level to 40% as foreseen in the start-up procedures. The VASPS was put into production mode (subsea and surface choke valves were partially open; the VASPS liquid inlet, oil and gas outlet valves were opened; the by-pass valve closed) and the level control was put in MANUAL mode using the ESP speed to control the level. The VASPS was pressurized from the P-8 via the gas line up to 36 kgf/cm2. The VASPS pressure was gradually decreased, consequently the level started to increase and at this moment the ESP was started with 45 Hz. Figure 8 represents the behavior of the main ESP process variables during a typical start-up. Several minor problems were encountered during the initial start-up period, most of which can be attributed to operator error or lack of experience with the system. These conditions were quickly overcome and system operation in MANUAL mode became routine but did require full time attention by the start-up team operators. The answer to full time operator attention was addressed by the operation of the system in the AUTOMATIC mode.

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This mode of operation is highly dependent on the level sensors. Level Sensors The VASPS control system utilizes level sensors to monitor the liquid level within the separator housing for the following reasons: Maintain liquid level at an optimum point to maximize separator efficiency Maintain liquid level above the ESP intake to prevent pump damage Maintain liquid level below the gas outlet to prevent liquid carry over into the gas flow line The measurement of the liquid level inside the separator is fundamental for the correct operation of the VASPS system. Therefore a redundant system was designed which includes two level sensors both located in the top plug, one operational and the other in hot standby. The devices are radar types. A transmitter emits a signal through an antenna and after target surface reflection the echo signal is received. The measurement principle of level radar is based on the time detection of the reflected microwave signal. Still wells were added to act as wave-guides to enhance the range of the measurement system. The system may be operated in one of two modes, MANUAL or AUTOMATIC. In MANUAL mode the operator is completely responsible for level control. The operator may adjust several system parameters such as pump speed, subsea or surface choke opening, or the backpressure on the surface proportional valve on the gas line to maintain liquid level. In AUTOMATIC mode the system software becomes responsible for level control. Three (3) modes of operation are selectable: ESP pump only mode (only the pump speed will be changed, CHOKE only mode (only the subsea choke position will be changed) or, COMBINED mode (both ESP pump speed and subsea choke position will be changed with the priority given to the ESP pump speed). The system was specified to maintain level within a +/3-meter band around the operator selectable set point. Testing to date has proved that the VASPS control system can keep the separator level within a +/- 1.5-meter dead band in the AUTOMATIC ESP pump mode. Level control in MANUAL mode is highly dependent on operator training; however, the operators have easily maintained levels within the +/- 3-meter design basis. As with all control systems, it is more desirable to have the system function in AUTOMATIC mode as this frees the operator to do other specialized platform related tasks.

Early Operations During the initial start-up, VASPS was in MANUAL mode and MA-01 was producing with gas lift assistance. The early experiences during the initial start-ups of the VASPS system in production mode provided valuable lessons that eventually lead to a dramatic reduction in the time to take the system from by-pass mode to production mode where the level is actually maintained within limits. Figure 6 shows a typical start-up system response in AUTOMATIC mode while Figure 7 shows a typical system response in MANUAL mode. Note that in AUTOMATIC mode the level is maintained within the system limits in less than 1 hour while the MANUAL mode is considerably longer. After the initial experiences with production of the system several tests were conducted to evaluate the system performance and reaction to various operating conditions. The first tests conducted were to evaluate the production of MA-01 with and without gas lift assistance while the VASPS was in production mode. The results of the tests showed only a slight increase in production rate using gas lift. Therefore, the decision was made to stop gas lift assistance to the MA-01 well and continue production with VASPS only. Before the start-up of VASPS, well MA-01 was producing 750 m3/d with gas-lift assistance of 100,000 m3/d and with a flowing pressure of 36 kgf/cm2 when the VASPS was in bypass mode (inlet valve closed and the VASPS by-pass valve open). Post start-up production in AUTOMATIC mode has averaged approximately 1,000 m3/d without gas lift assistance to MA-01. Figure 9 clearly shows the dramatic effects the VASPS has had on MA-01s production rate and the reduction in gas lift volume. During normal operations with the system stabilized the following conditions typically exist: VASPS pressure 11 kgf/ cm2 ESP discharge pressure 64 kgf/ cm2 Gas pressure at P-8 = 6 kgf/ cm2 Frequency = 50 Hz Gas lift flow rate = zero Oil flow rate = 1000 m3/d Figure 4 shows the main screen of the Data Acquisition System with the values of the process variables when the well MA-01 is producing via VASPS in by-pass. Figure 3 shows the process variables after the start-up and VASPS in production mode. Figure 5 shows the ESP monitoring screen. Additional tests carried out to evaluate the performance of the system and the ability of the control system to respond to unique situations included intentional level upsets from the operator selected level set point. Examples of the tests conducted were to force the level to a Low Low condition and HighHigh condition to verify that the system responded by returning the level to the setpoint without significant over shoot. Other level related tests included taking the VASPS from production mode to by-pass mode with the separator level

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at the extremes (HighHigh and LowLow levels). This allowed the start-up procedures for these conditions to be adjusted and verified for future operations. Various production rate tests are underway to evaluate the performance of the system at different separator levels and flow rates. While the tests are far from complete all the early results indicate performance well within the expected targets. During the first months of production with VASPS some platform ESDs occurred which provided the opportunity to test the operators performance and validate their understanding of the system operation and start-up procedures. The operators without fail performed accurately and with very little coaching, which speaks to the quality of personnel as well as the ease of VASPS operations. Conclusion At the time of compilation of this paper the VASPS had more than four months of operation at the average production rate of 1000 m3/d. During this period the separator has operated at various levels in order to assess its performance in terms of separation of the liquid and gas phases. Broad ranges of transient conditions have also been explored in order to verify the ability of the control system to manage any sort of operative conditions. The production of MA-01 well, via VASPS, has been demonstrated to be straightforward with respect to production from similar wells with gas lift. The start-up and the operation of the VASPS at the Marimb Field in the Campos Basin beginning July 2001, has proved and demonstrated the separator and pump concept. The MA-01 well experienced an incremental production rate of about 250 m3/d, equal to one-third of the original daily production (Fig. 9). The reduced flowing pressure (11 kgf/cm2 instead of 36 kgf/cm2) allowed the MA-01 to produce at a higher rate without the gas-lift, providing a positive impact on the dayby-day operations. The feasibility of the installation and the controllability of the system (Fig. 6 & 7) have been demonstrated. Oil companies can consider VASPS technology as a viable alternative when analyzing the production options for an offshore field.

Acknowledgments We wish to thank: - The Commission of European Communities DG XVII for their support in all phases of the development. - The Partners (ENI-Agip, ExxonMobil and Petrobras) in having supported the project. - All contractors involved in the project: Cameron, Reda, Kongsberg Offshore, Sonsub, and Tecnomare. - Mr. Ted DuBose, VASPS project technical coordinator from 2000 to present, for his dedication and contribution to the project. - Mr. Massimo Benetti, coordinator of the VASPS Project from 1993 to 2000, who demonstrated valuable leadership during the Project. References
1. Benetti M., Villa M., Vale O.R., Carvalho P., Williams J.D. Installation of the VASPS subsea gas-liquid separation and pumping system in Marimb field paper presented at the 12th D.O.T. Conference, New Orleans, Nov. 2000. 2. Vale O. R. et al.: Pre-subsea Phase Development; High Viscosity Field Test and outlook for Subsea Prototype, paper OTC 8864 presented at 1998, Houston, May 1998 3. Assayag, M. et al.: Subsea boosting systems: Advances, trends and challenges, World Oil (Nov. 1997) 61. 4. Benetti, M. and Villa, M.: Field tests on VASPS separation and pumping system, paper OTC 8449 presented at the 1997 Offshore Technology Conference (OTC), Houston, May 1997. 5. Pagot, P. R. et al.: Subsea separation systems: Petrobras effort, paper OTC 8060 presented at the 1996, Houston, May 1996 6. Frana, F.A. et al.: Hydrodynamic studies on a cyclonic separator, paper OTC 8059 presented at the 1996 Offshore Technology Conference (OTC), Houston, May 1996. 7. M. Benetti, G. M. Bozzo, N. Villa: VASPS Subsea Separation and Pumping concept ready for subsea trials, 5th International Symposium, Edinburgh, Oct. 1996. 8. Pagot, P.R. and Carvalho, P.M.: Subsea separation - A promising technology to increase profits in offshore petroleum production, paper presented at the 8th D.O.T. Conference, Rio de Janeiro, Oct. 1995. 9. Ribeiro, O.J.S. and Paulo, C.A.S.: The impact of subsea boosting on deepwater field development, paper presented at the 8th D.O.T. Conference, Rio de Janeiro, Oct. 1995. 10. Benetti, M. Gohil, M. Villa, O. R. do Vale: VASPS Stage II Development Functional field tests on an innovative separation system, DOT Conference, Rio de Janeiro, Oct. 1995

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TABLE 1 - Operational & Design Data for VASPS in Well 7-MA-1D-RJS- Marimb Field Design liquid flowrate & gas flowrate Separation temperature Typical VASPS separation pressure Design pressure Pump head & power Platform arrival pressure Level control (*) Well fluid properties Oil Density Dead oil viscosity up to 1,500 m3/d & up to 190,000 m3/d (200 C, 1 atm) 40 to 70C 8 to 12 bar 3000 psi up 70 bar & 150 kW 7 bar via one subsea control valve and Variable Speed Drive on the ESP motor supply API = 29 @ 38 C = 14,3 cP - @ 60 C = 7,6 cP

Fig. 1 - VASPS Concept

Liquid outlet
Separator Head
(gas expansion chamber)

Gas outlet Fluid Inlet

Pressure Housing
(external casing)

Helix Joint
(intermediate casing)

Gas Annulus SEPARATED GAS SEPARATED LIQUID MULTIPHASE FLOW ESP

(internal casing)

Liquid Discharge Tubing

(internal casing)

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Fig. 2 VASPS STACK UP

VASPS SEPARATOR (VASPS down-hole) BASE - TGB FLOWBASE

VASPS HEAD ASSEMBLY

VASPS INSTALLATION AND OPERATION AT CAMPOS BASIN

VASPS SUBSEA HARDWARE

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Fig. 3 VASPS operation screen

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Fig. 4 VASPS by-passed screen

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Fig. 5 ESP monitoring screen

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11

Fig. 6 VASPS level response during start-up in AUTOMATIC mode control

Automatic Mode
70.0

60.0

50.0

40.0

Frequency (hz) Level (m) Flow (m3/hr)

30.0

20.0

10.0

0.0 16:22:21 16:35:20 16:48:20 17:01:21 17:14:21 17:27:20 17:40:20 17:53:21 18:06:20 18:19:20 18:32:20 18:45:20 18:58:20 19:11:20 19:24:20 19:37:20 19:50:21 20:03:21 20:16:20 20:29:20 20:42:20

Time

Fig. 7 VASPS level response during start-up in MANUAL mode control

Manual Mode Operation

60.0

50.0

40.0

Frequency (Hz) Level (m) Flow (m3/hr)

30.0

20.0

10.0

0.0 1:00:42 1:13:42 1:26:42 1:39:42 1:52:42 2:05:42 2:18:42 2:31:42 2:44:41 2:57:42 3:10:42 3:23:42 3:36:41 3:49:42 4:02:42 4:15:42 4:28:42 4:41:42 4:54:42 5:07:41 5:20:41 5:33:41 5:46:42 5:59:42 6:12:42 6:25:42 6:38:42 6:51:42

Time

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Fig. 8 VASPS Pump start-up conditions

Pump Start Up Conditions 180 160 140 120 100 80 60 40 20 0 16:23:00 16:23:16 16:23:31 16:23:47 16:24:03 16:24:18 16:24:34 16:24:49 16:25:05 16:25:20 16:25:36 16:25:52 Flow (m3/hr) Pump Intake Press (bar) Pump Discharge Press (bar) Motor Temp (C) Frequency (Hz) Torques (%) Output Power (Kw)

Time

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13

Fig. 9 Well Production before and after VASPS

Produced fluid Gas Lift Sep Gas 50 45 40

MA-1 Production History

10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Pre VASPS Post VASPS

35 30 25 20 15 10 5 0

Time

Gas Lift & Sep Gas rates (m /hr)

Produced Fluid Rate (m /hr)