Lula Alto - Strategy and Execution of a Megaproject in Deep Water Santos Basin Pre-Salt

Abstract This article presents the successful history of Lula Alto Project, one of the development modules of Lula giant field, located in Santos Basin pre-salt at southeast Brazil at a 2,120 meters water depth. The project is currently producing at its maximum oil capacity, considering operational performance, achieved only 9 months from first oil. This is the fifth module of Lula field, which modular development allowed drainage plan and subsea layout optimization. The article will present the reservoir conceptual model, drainage plan optimization, information acquisition strategy and modular development insights; the subsea layout optimization that led to a minimum flowline length per well; twin FPSO construction strategy; project development and fast ramp-up and the challenges faced during the first year of production. It will also address integrity and maintenance management, aiming a secure and sustainable operation, and well construction highlights. The leased FPSO Cidade de Maricá initiated production in February 2016, and the project strategy was to carbon copy FPSO Cidade de Ilhabela engineering (this FPSO is also producing in pre-salt), reducing design costs and schedule. Construction phase strategy was to build two identical FPSO's in parallel, FPSO's Cidade de Maricá and Cidade de Saquarema, with a planned 2 months schedule delivery gap. Suppliers and construction sites were the same, allowing cost reduction, construction risks mitigation and supply chain optimization. After one year of production, many challenges had to be surpassed, and all lessons learned were important for a solid ramp-up achievement and sustainable peak production.