Maersk Supply Service hand-picks UK firm for ‘complex’ ultra-deepwater job at Brazil’s huge oil field

UK-headquartered engineering solutions player Maritime Developments Limited (MDL) has been tasked with providing horizontal subsea umbilicals, risers, and flowlines (SURF) lay spread onto an I-class subsea support vessel to assist Denmark-headquartered Maersk Supply Service (MSS) with a solution development scope at a giant oil field in the pre-salt Santos Basin off the coast of Brazil.

The Scottish flex-lay specialist’s scope in the Libra (Mero) block in the Santos Basin encompasses the development of an integrated spread of equipment and expert personnel to support the installation of a dynamic riser assembly, which will enable connection to a grid of permanent reservoir monitoring (PRM) sensors over wells of Mero 1 and Mero 2 projects in the basin’s ultra-deep waters.

Yuri Mendes Martins, MDL do Brasil Country Manager, noted: “We are pleased that MDL has been chosen to deliver a solution for this complex installation, where we were able to assist from the early planning stages with our in-house engineering expertise. When faced with a challenging scope like this one, being able to perform feasibility studies on the most optimal approaches is invaluable in delivering a safe and successful project overall.

“This award represents the confidence that Maersk Supply Service has in MDL’s abilities to provide innovative and reliable solutions. Brazil’s ultra-deep waters require companies that can meet these complex challenges head-on and MDL is uniquely equipped to do so.”

Aside from the dynamic cable riser, complete with DUTA and pigtails, the PRM network entails backbone cables and over 650 km of seismic array cables. MDL’s horizontal SURF lay spread will be supplied onto an MSS I-Class vessel to support Maersk Supply Service with the installation campaign planned for 2025. Previously, the UK firm was hired to undertake a front-end engineering design (FEED) study to assess the feasibility of the PRM network installation, with the umbilical, DUTA, and pigtails being supplied pre-connected, thus, the five pigtail lines need to be installed simultaneously.

Alexander Wilson, MDL’s Flexlay Solutions Unit Lead, commented: “As a result of completing the FEED, MDL had an intimate knowledge of the project and the challenges faced by Maersk Supply Service, and we were therefore best placed to hit the ground running with the most achievable approaches within the client’s timescales. Having performed the study, we appreciated the substantial challenge of a parallel installation of five pigtails, a dynamic umbilical and DUTA, supplied as a continuous product from a single reel.

“Through open and in-depth technical discussions between the two companies, we were able to identify a solution, utilising our proven back-deck technology, known for its safety and integration features which will provide reassurance on such complex multi-system installation. Our experienced project engineering team will assist with the packaging of the spread on the client’s vessel while our expert field service team will ensure safe operations on board, supported with remote connectivity to the beach.”

The unitized Mero field in the pre-salt Santos Basin, which is part of the Libra consortium, is operated by Petrobras (38.6%), in partnership with Shell Brasil (19.3%), TotalEnergies (19.3%), CNPC (9.65%), CNOOC (9.65%), and Pré-Sal Petróleo SA – PPSA (3.5%), as the Brazilian government’s representative in the non-contracted area. As the third largest field in Brazil after Tupi and Búzios, Mero is home to three FPSOs: Pioneiro de Libra, Guanabara, and Sepetiba.

Moreover, the remaining additional development phases of 180,000 b/d each, Mero 3 and Mero 4, are currently under construction, with start-ups expected in 2024 and 2025, respectively. The FPSO Marechal Duque de Caxias, which arrived in Brazil in May 2024, will enter into operation in the second half of this year and is part of Mero’s third definitive production system anticipated to boost the field’s installed production capacity to 590,000 barrels of oil per day.

With the capacity to produce up to 180,000 barrels of oil daily and compress up to 12 million cubic meters of gas, the FPSO Marechal Duque de Caxias is envisioned to provide for the interconnection of 15 wells, out of which 8 are oil producers and 7 are water and gas injectors, through a subsea infrastructure made up of 80 km of rigid production and injection pipelines, 47 km of flexible service pipelines, and 44 km of control umbilicals.

Alexandre Ferraz, Country Manager for Maersk Supply Service Brazil, underlined: “The installation of the dynamic riser in conjunction with DUTA and pigtails contains technical and operational challenges that can only be overcome with an effectively designed and integrated lay system. Maersk Supply Service was able to build a collaborative partnership with MDL that gives us confidence that project will be delivered successfully.”

Since Petrobras is set on implementing the high-pressure subsea separation technology (HISEP) technology in Mero’s third definitive production system from 2028, separating oil and gas at the bottom of the ocean and reinjecting CO2-rich gas, the FPSO Marechal Duque de Caxias is equipped with technologies to curb emissions, such as carbon capture, utilization, and storage (CCUS), enabling gas rich in CO2 to be reinjected into the reservoir.

The Brazilian state-owned energy giant intends to bring online 14 FPSOs from 2024 to 2028 in line with its ‘Strategic Plan 2024-2028‘ showcasing the firm’s agenda to spend $102 billion over the next five years, with $11.5 billion earmarked for projects propelling its decarbonization journey forward.

After confirming a final investment decision (FID) for the second development phase of the Atapu and Sépia fields, Petrobras hired Seatrium on two contracts, valued at approximately S$11 billion ($8.15 billion), to construct the FPSOs P-84 and P-85, which would be deployed at these fields.

TechnipFMC recently secured two new subsea assignments with Brazil’s state-owned energy giant, enabling it to design, engineer, and manufacture subsea production systems for deployment on the Atapu 2, Sepia 2, and Roncador projects.

Meanwhile, MDL worked on a liquefied natural gas (LNG) project in Europe in 2024, handling the subsea scope of work related to the first floating storage regasification unit (FSRU) under the Greek flag, set to start operating in the Aegean Sea off the coast of Greece next month.

On the other hand, Maersk Supply Service, which is expected to become part of DOF upon the completion of the ongoing merger process, won a contract with Cenovus Energy for a field support vessel, anticipated to assist with operations at the White Rose field.

The newbuild vessel will be built by Crist in Gdynia, Poland, and delivered in 2027. The 110 m long vessel, based on the MMC Ship Design & Marine Consulting 995L SBC hull design, will be a DP3, ice-classed ship with a POB of 164 and a walk-to-work gangway.