First Worldwide ESP Well Test in Ultra Deep Water

Artificial Lift Services

V. M. Oliveira - Schlumberger

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Abstract
With analysts predicting that todays high oil prices will be
with us for the next year (WEC/WEA report Nov 2005), the
time is right to exploit these reserves. However, cost
efficiency and risk reduction are key concerns in this
environment, requiring special processes and advanced
technologies to bring these reserves on line in budget and to
plan. Given this context, efficient testing and reservoir
characterization procedures assume increasing importance
to meet bottom line production targets.
In Brazil, it is estimated that the heavy oil reserves sitting
offshore in shallow, deep and ultradeep waters would make
the country a self-sufficient oil producer and, recently
announced, an exporter. The technical challenges of
producing and lifting heavy oil are compounded, however, by
the demands and expense of offshore production.
Following a brief understand of Brazilian scenario, this paper
shows how Schlumberger performed to accomplish with
Petrobras and partners objectives related to Xerelete Field
and the operational process made to reach a worldwide
record by using Electrical Submersible Pump as artificial lift
method to test a heavy oil well in ultra deep water.

Objectives

Conclusive evaluation of Xerelete field and reservoir

characterization
Contribute to the evolution of the Offshore Well Test
concept

Optimize Time and Cost Operation

Continuity of the operation

Optimize the information and analysis
Open new prospects to the Exploratory ESP Well Test
operations in Ultra Deep Water
Consolidate SLB as the leader in Exploratory Well Test
for Heavy Oil Wells

Introduction
In March 2007, Petrobras Oil Company and partners (Devon
and Total) requested an unscheduled test with ESP-DST to
evaluate the feasibility of a subsea well. It should be a
standard well testing for heavy oil in Brazil if the water depth
was not about 2500m and the pump was not set just above
the seafloor.
To achieve well test objectives for deepwater, heavy oil
reservoirs requires a detailed, integrated testing-design
process. To design and select the most effective production
lifting and surface flow equipment and workflow requires a
thorough reservoir understanding. Obtaining a thorough
reservoir understanding also enables valid procedures to be
designed for safe, environmentally compliant effluent
disposal. This is only possible with accurate downhole data;
therefore, suitability of the downhole and surface well
testing equipment and processes relative to the heavy and
viscous fluids to be tested must be considered.
The Schlumberger full package consisted of all available
equipment and services from downhole to surface, including:

From downhole

DST tools as following

Quantum packer

TFTV (Tubing fill test valve)

SCAR (Sampler Carrier)

DGA (Digital Gauge Adapter)

IRDV (Intelligent Remote Dual Valve)

TSR (Tubing Separation Tool)

SenTREE

RSM (Riser Sealing Mandrel)

ESP into pod with

PumpWatcher Sensor 4C Saphire

Dominator Motor 450HP

Modular Tandem Protectors BPBSL

AGH (Advanced Gas Handler)

Abrasion Resistant Pump GN4000
(mixed flow , 177stg)

Sliding Sleeve

Electrical connector QCI P5000

First Worldwide ESP Well Test in Ultra Deep Water

From surface

Artificial lift

SWD (Sinewave Drive) Cabin with
step-up transformer (600kVA) and
sensor surface panel

Surface well test plant

Surface flowhead

Vx multiphase flow meter

Steam exchanger

Separator

Tanks

Transfer pumps

Evergreen burner

PVT Express

STAC (Surface Test Data Acquisition
Cabin)
gathered
to
InterACT
connection

well 3-RJS-648 (3-BRSA-481-RJS), where flows up to 2500

barrels of oil per day were registered. A new water depth
world record (2,460 m) was set at this well with the use of the
Submerged Submarine Centrifugal Pump.
Based on conclusive results from ESP well test, on
th
September 10 2007, Petrobras announced to investors that it
has declared XERELETE field commercial to the National
Petroleum Agency (NPA).
This accumulation was discovered in an asset operated by
PETROBRAS, in partnership with TOTAL and DEVON.

Figure 2: Xerelete field location.

ESP WELL TEST - The Integrated Appraisal Process

Figure 1: Components used in an integrated well test.

XERELETE PROJECT
The well 3-RJS-648, evaluation plan PA-1-EPB-RJS, is
located in territorial waters of Campos Basin. The Xerelete
field is located partially in the old BC-2 and partially in the
BM-C-14, 155 km southeast of the city from Cabo Frio and 42
km east of the Papa Terra field.
Preliminary geological studies indicate the accumulations
total area may reach more than 26 km, holding an estimated
in-place volume of some 1.4 billion barrels of oil equivalent.
Additional studies are being carried out to define this new
fields production development project.
The Xerelete discoverer well, the 1-EPB-1-RJS, drilled at a
water depth of 2,483 meters, reached sandy 17.5 API oilbearing reservoirs at a depth of 3,478 meters. This
accumulations productivity was confirmed via delimitation

Vivianne de Oliveira

Page 2 of 5

In order to determine the rock-fluid system characteristics,

evaluate the well potential and quantify the reserves, with
the consignment to be as most accurate as possible, and
based in the high probability that this well will not flow
naturally at 2460m water depth; it was required to perform a
pressure - production well testing with the use of an Artificial
Lift method.
Few alternatives were analyzed to perform the well testing.
The ESP (Electrical Submersible Pump) DST (Drill Stem
Test) system was concluded to be the best option that will
warranty the flow to the surface (as function of the reservoir
outflow), the data acquisition and then accomplish the whole
test objectives. Several analyses were evaluated to define
the pump set depth. The ESP string placed just above the
BOP required a contingency plan with Coil Tubing for diesel
injection. The choice was based on software PipeSim and
DesingPro simulation and results.
Normal preparation work for this type of offshore well would
take on average 2-3 months. This job was expedited in 2
November, 2007

First Worldwide ESP Well Test in Ultra Deep Water

weeks with full commitment and resources to ensure that
proper procedures and guidelines were followed as per
normal standard operating procedures which included
QHSE, ESP design, equipment selection and preparation,
transport, rig up and a contingency plan to re-start ESP after
static period.
MAIN CHALLENGES

Heavy and viscous oil

Low reservoir temperature, 160F @Datum
Water depth, 2460 m (8100ft)
Deep Water Off Shore Environment

Low temperature at sea bed riser, 4C

Heave/stability
Non-consolidated formations
Short notice given, 2-weeks campaign

The rig type was a semi submersible, SS-53, Noble Paul

Wolff (Figure 3).

Figure 3: SS-53 Platform

As mentioned, the downhole well testing, production lifting
and surface components used in heavy oil operations are
similar to those used in conventional oil production, with
some special modifications. The completion diagram,
including completions, oilphase, DST and ESP tools is
described in Figure 4.

Figure 4: Downhole String Diagram.

Vivianne de Oliveira

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November, 2007

First Worldwide ESP Well Test in Ultra Deep Water

To optimize the testing phase, consideration was given to the
volume of drilling fluid lost to the formation while drilling, the
ESPs range of operation, and the flow rate desired while
testing.

Graphic 3: Third Flow Period.

For the ESP equipment design used in this exploratory well, it

was used the information from the Carapebus formation
which the lithology is Santoniano, a frail sandstone. The fluid
produced in the reservoir explored and tested has
overridden the specific gravity parameters and mainly high
viscosity were expected when flowing at sea depth due to
low temperature (4 degC), in such way the ESP equipment
was working under critical conditions of operation. Three
flows were performed at different downhole motor
frequencies and wellhead choke, lifting successfully oil
around 16 API and 40 cp at reservoir conditions, without any
downtime (see graphics).
TECHNICAL RECCOMENDATIONS
Graphic 1: Clean-up and First Flow Period.
Experience has shown that a mobile multiphase flowmeter is
fundamental equipment in these operations. The multiphase
meter used in conjunction with the artificial lift diagnostic
process enables ESP optimization during operations. High
frequency monitoring of the separation process in real-time:
oil, gas, water vessel level, densities, flow rates, oil content
in the water line, as well as the aperture of the oil, water and
gas line control valves when analyzed with the ESP
downhole sensor data helps to identify variations in flow
before issues occur.

ECONOMICAL IMPACT

For PETROBRAS and Partners:
This ESP-DST test helped Petrobras and its partners to
successfully test an exploratory well in ultra deep water.
This job allowed a conclusive evaluation in three flows; it
was conducted in 18 days without incidents nor downtime,
meeting all the objectives and client's expectations.
Current offshore development strategies incorporate an
extensive use of wells that provide access to sub-sea deep
or ultra-deep resources. Many concepts or technologies
have been discussed to improve the recovery and the
economics of these assets to produce them in the most
efficient manner. Today, projects have been integrated from
produce to float facilities, through subsea production
systems as a way for reducing the development and
operating costs.
Also, subsea boosting is seen as fundamental for providing
access to deepwater reserves. This concept is rapidly
growing and has gained Customer thanks letter to the proven

Graphic 2: Second Flow Period.

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November, 2007

First Worldwide ESP Well Test in Ultra Deep Water

performance
applications.

and

reliability

of

similar

artificial

lift

MARKET OPPORTUNITIES

For Schlumberger:
Every job brings approximately 1.5 MUSD of revenue for SLB.
More over, the successful implementation of a job like this
with tight schedule increases the chance to perform more
jobs in the near future. Petrobras drilling campaign for
exploratory wells is likely to include more of this type of well
tests in their planning for 2008.

For Artificial Lift Brazil:
In 2006, the Well Test Contract with Petrobras was
responsible for 27% of total annual revenue.
Year to date, the total receives with the contract is 4.3 million
USD, with 31% Net Income BT (with operation).

BUSINESS ANALYSIS
MARKET SHARE
The Brazilian market for Heavy Oil and Deep Water Well Test
is recent and has been explored mainly for the major
company, Petrobras.
Since 2002, when Petrobras performed the first well test with
Schlumberger Artificial Lift, some of technologies have
changed, operational procedures have been improved and
people trained. The recognized growth and quality reached
after years gave to Schlumberger ALS an exclusivity
contract with Petrobras to test all Heavy Oil wells with
Electrical Submersible Pumps in Brazil.
Year to date were performed 21 Heavy Oil and Deep Water
well test, where 14 were carried out by Schlumberger and
one by Baker Centrilift, for a well test to Shell.
Graphic 4: Current Brazilian market for HO&DW well tests.

Auto Flow Sub Flow Check

Combined ESP and natural flow test

No well intervention

No control lines or hydraulic systems

Prevents pulling at wet string
Phoenix Saphire Select

More variables monitored

Pressure operational limit up to 10000 psi

Excellent long-term stability

Excellent accuracy

Highest temperature range
espWatcher

Real time Build-up and drawdown

Faster decision concerning flows time and
period

espWatcher & PhaseWatcher integration
allows

Matching well flow pressure and
surface flow rates

Confirming reservoir evaluation

CONCLUSIONS

Petrobras and partners test objectives were

accomplished with success
Conclusive evaluation of Xerelete field with investors
announcement
Worldwide record for Exploratory Well Test with ESP in
ultra deep water
Quality Recognition by Petrobras HQ
Quality Recognition by SLB ALS LAM
Increase Service Revenue for AL
Opportunities identified for 3 NT5 (Auto Flow Sub,
Phoenix Downhole Sensor and espWatcher)

20

REFERENCES
REFERENCE S

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SLB ALS
Competitors

Vivianne de Oliveira

Resources to Reserves, OECD / IEA, 2005.

Heavy oil testing in deepwater wells - How can the
latest technologies and processes be best applied
for testing success?, www.heavyoilinfo.com, 2007.
New discovered in Xerelete Field, Petrobras
Investor Relations, 2007.
Artificial Lift NT5 Products, www.sail.slb.com, 2007.

SLB ALS & PBR

SLB ALS & Others

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November, 2007