The Vallourec Oil & Gas magazine N°09 / March 2017
Focus
New frontiersand powerfulsolutionsfor Africa------SolutionsOne Stop Shop: making our customer’s life easier
VAM® Engineering Services for support beyond the pipe
-------------The tech filesRevolutionary Cleanwell Dry 2: cleaner, faster, safer
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Publisher: Vallourec Oil and Gas France - 27, avenue du Général Leclerc, 92660 Boulogne Billancourt Cedex - FranceChief Editor: Rebecca Le Rouzic ([email protected]) - Phone: +33 1 49 09 36 47 - Editor, interviews and articles:Stephan Caso - Drilling section editor: Larissa Hernandez - Pipe Project section editor: Zoe Stowell - Production: Zabriskie, ParisDesign: LeGrand8, Paris - Photographs: Vallourec, Serimax, Stephan Caso, Thierry Truck, Christophe Guibbaud / CAPA, 123RFor as mentioned otherwise. All rights reserved.
VAM® is a registered trademark of Vallourec Oil and Gas France
Edito
Dear customers,partners and readers,
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.3
www.connection-mag.com www.vallourec.com
The last 2 years have been impacted by the unprecedented collapse of oil & gas
exploration and production investments. Vallourec considers this challenging context
as an opportunity to carry out a significant transformation plan with a stronger focus
on competitiveness, innovation and customer proximity.
The horizon of the oil & gas market, though fragile and unpredictable, is brightening,
supported by oil prices on the rise and the emergence of an upturn in the United States,
on the one hand, and new exploration frontiers in Africa, on the other. Vallourec is more
than ever dedicated to its customers and stakeholders, with an unwavering commitment
to develop high value solutions, reliability and sustainability.
Vallourec is bringing proximity to a new level, at the heart of its customer strategy.
We are now deployed and organized in 4 regions, each with commercial and
industrial capabilities to provide best-in-class products and services. For improved
cost-effectiveness, Vallourec has rationalized production in Brazil and Europe
while making the acquisition of Tianda, in China, to provide clients with a new highly
competitive pipe offer at Vallourec standards, with no compromise to safety, quality
and reliability. Our cost-effective measures extend to global solutions and one stop
shop capabilities in the Middle East and Asia, North and South Americas, Europe and
Africa. The Vallourec transformation plan increases proximity, with leaner and simpler
execution, aiming to lower the total cost of ownership for our customers.
Innovation, meanwhile, remains the spearhead
of Vallourec's technological frontier. Our research
and development engineers and field teams are
relentlessly working to create new solutions for
tomorrow's challenges. Our experts work with
you, from the earliest stages of your projects, to
help you optimize product and well design, for
maximum operational excellence, flow assurance
and well integrity.
Vallourec is decidedly turned to the future, ready
for the oil market revival. I am proud to intro-
duce you to a selection of our recent achieve-
ments and solutions in this issue of Connection
magazine.
Happy reading!
Didier Hornet, Senior Vice President,
Development & Innovation.
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Over 130 years ago, the Group’s founders were already pioneering innovative technologies that would revolutionize the tube industry. Since then, Vallourec continues to open new technological and geographical frontiers. Driven by passion and commitment, more than 20,000 employees o� er more than tubes: they provide cutting-edge products and tailored solutions. Always more reliable, always more competitive. Vallourec contributes to making all your projects possible, wherever you need us, whenever you need smart tubular solutions. vallourec.com
possible
Wemake the impossible
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.5
VISIT US AT…DUG Permian3-5 April 2017Fort Worth, Texas, USA
IADC World Drilling Conference28-29 June 2017Amsterdam, The Netherlands Booth #3 & 4
IADC Drilling Middle East 3-4 October 2017 - Dubai Booth #3
SPE Annual Technical Conference & Exhibition9-11 October 2017San Antonio, Texas, USABooth #1475
Deepwater Operations Conference & Exhibition7-9 November 2017Galveston, Texas, USA
NewsContents
Page 6
FocusNew frontiers and powerful solutions for Africa
Page 12-13-14
SolutionsCleverScan: the smart digital technology for welders, by SerimaxInternax: enhancing our range ofsolutions for the landline market VAM® Engineering Servicesfor support beyond the pipe
Page 15
The tech filesCLEANWELL® DRY 2 saves you time and money and protects the environment
Pages 20-23-24
Solutions Vallourec Global Solutions:making our customer’s life easierNorth America: spotlight on wellcoordination services Forged completion landing stringaddresses industry challenges
Page 26-27
On the market Advanced premium solutionsfor geothermal energy projectsA new milestone for VallourecUmbilicals
Page 28
StrategyVallourec: stronger and more competitive
Page 30
EventsStrengthened presence in China
Page 31
PeopleScott Granger, R&D engineer at Vallourec Drilling Products
3,730 WELDS TO BE PRODUCED BY SERIMAX AT THE ORKANGERSPOOLBASE
Many of today’s oil & gas
projects take place in increa-
singly complex and extreme
environments (deep and ultra-
deep offshore, high pres-
sure/high temperature), sub-
jecting materials to severe
stresses. In-depth quality
control is essential to ensure
the integrity of the pipes and
connections throughout the
project lifetime. In order to
better assist customers in their
projects, Vallourec PT Citra
Tubindo, located in Batam,
Indonesia, is now equipped
with a state-of-the-art ultra-
sound control facility.
With this new equipment,
Vallourec can offer cutting-edge testing to meet customers’ strictest specifications and
the tightest industry standards.
Alexandre Noel, Non-destructive testing manager, Indonesia explained: “Thanks to the
installation of a new ultrasonic inspection facility with phased array technology, our non-
destructive testing capabilities are increased, proving our commitment to quality, safety
and reliability.”
STATE-OF-THE-ART ULTRASOUND CONTROLFACILITY AT PT CITRA TUBINDO, INDONESIA
TechnipFMC awarded Serimax for the welding of a major pipeline project in Norway.
This constitutes a new milestone in the TechnipFMC and Serimax partnership, signed
in 2016. The two companies are combining their expertise and deploying Serimax
Welding Technology at TechnipFMC’s spoolbases and on board TechnipFMC’s S-lay
vessels. The welding campaign started in late 2016, after a welding quality testing
programme carried out in Orkanger. Production includes double-joints at TechnipFMC’s
adjacent facility, joining 12m long tubes into 24m long tubes, after which the pipes
are transferred to the mainline production workshop, where they are welded into
pipestalks, ready for spooling onto the TechnipFMC reel-lay vessel. Serimax is welding
1865 double joint welds and 1865 mainline welds, using the advanced Saturnax-
09-system.
NEW OIL & GAS ACCESSORIES FACILITY IN SINGAPORE In 2016, Vallourec Tube-Alloy opened a new plant in Singapore.
The new plant is located in northern Singapore and is specialized in threading VAM®
premium connections on wellhead and completion equipment, as well as manufacturing
turnkey OCTG accessories. “Asia Pacific is a key market for Vallourec,” stated Olivier
Mathey, Vice President of Vallourec Tube-Alloy Singapore, “We are strengthening our
presence in Singapore, an important regional hub for the Oil & Gas industry, to offer
more services and match our customer requirements as closely as possible.”
The unit is fully qualified* to undertake the series of operations required to produce
VAM® premium connections. With 50 engineers and technicians and an annual capacity
of 25,000 threads, the facility is well positioned to deliver high added-value tubular
solutions to Oil & Gas equipment manufacturers and operators based in the region.
In January 2017, Vallourec Tube-Alloy Singapore received the OHSAS 18001 and
ISO 14001 certifications for health, safety and environmental management.
NEW VAM® FIELD SERVICE SITE IN TEXAS TO SERVE THE PERMIAN BASINThe market of the Permian Basin, a major
region for oil production, is expanding quickly
in west Texas and southeast New Mexico,
in the United States. To support this deve-
lopment, Vallourec’s American subsidiary,
VAM USA, will open a new VAM® Field
Service office in the town of Odessa.
Today, the network of VAM® Field Service
offices numbers 230 engineers, located in
11 regional hubs, who can be mobilized and
sent to a platform at any moment for pro-
duction, support or optimization.
The new office will support the growing num-
ber of VAM® customers in the Permian Basin.
Eric Shuster, President of VAM USA explains:
“VAM USA provides its customers with field
services 24/7. The key to our success is
working together with our customers to supply
them with the best advice, running support,
and tooling to reduce Non-Productive-Time,
optimize running operations, and bring value
over the life of their projects". This brings the
number of VAM® Field Service offices to six
in the United States, with three in Texas, one
in Louisiana, one in Oklahoma, and one in
Pennsylvania.
Vallourec received a certificate
from Total in recognition of its
participation in the ultra deep
water drilling record of the
RAYA-1 well, with a total
water depth of 11,168 feet
(3404 meters). Total began
drilling operations for this off-
shore well in Uruguay in
March 2016 and highlighted
the contribution and profes-
sionalism of Vallourec teams
throughout the process.
Congratulations to all !
WORLD RECORD FOR ULTRA-DEEP WATERDRILLING IN URUGUAY
From left to right: Olivier Mathey, Didier Hornet, Pascal Braquehais, William Gamisans.
TechnipFMC spoolbase at Orkanger, Norway.
p.4 / The Vallourec Oil & Gas Magazine N°09 / March 2017
*according to main industry standards: ISO 9001, API Q1, API 5CT
Focus
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.7p.6 / The Vallourec Oil & Gas Magazine N°09 / March 2017
New frontiers and powerful solutions for Africa
A continent of discovery,diversity and new opportunities for oil & gas
Africa has always been exciting, complex and diverse, amost fascinating land of exploration, adventure and dis-covery. It is no doubt the continent offering the greatestvariety of identities, with scores of different countries, anamazing multiplicity of peoples, languages, religions andcultures. Africa is a world of contrasts, of ever changingenvironments and climates, with extraordinary landscapesand oceans, where ancient traditional societies live along-side booming ultra-modern cities and business hubs. Lastbut not least, Africa is thriving with amazing natural resour-ces to the extent that it is believed most of Africa's naturalwealth and reserves are yet to be discovered. The recentfindings of formidable oil and gas fields in Uganda andTanzania, as well as off the coasts of Egypt, Ghana andMozambique prove this to be true. The lands and waters of North Africa and Sub-SaharanAfrica abound with massive reserves of oil and gas, many
of which at great depths, in the toughest environmentsimaginable. Whether onshore or offshore, in drilling or pro-duction, African markets require a full spectrum of productsand services to answer all requirements and configurations.You can find easy oil and gas calling for simple, low costanswers on the one hand, or the hardest to get oil in oceansand seas surrounding Africa, requiring the most advancedtechnologies and solutions, on the other hand. Vallourecis relentlessly seeking to provide the most efficient andpowerful solutions for its customers and partners in Africa.
Historical partners for long termdevelopmentVallourec has always been committed to supportingprojects and development throughout Africa. Webelieve in long term and long-lasting partnerships, inshared expertise, in meaningful local content and
development. Vallourec is present throughout thecontinent with sales offices, threading facilities, supporthubs, yard management and VAM® Field Service nearevery key market. Beyond local regulations and requi-rements, Vallourec supports local operators, stockdistribution networks and businesses, offering in-depth training to local engineers for product designand utilization, manufacturing and maintenance, weldingtechnologies and project management. ThroughoutAfrica, Vallourec can deliver its full scope of productsfor OCTG, drilling, offshore and onshore line-pipe andhydrocarbon processing together with a broad rangeof global solutions. With technical support and training, well coordination and accessories, stockmanagement, procurement and delivery solutions,VAM® Field Service maintenance and repair, Valloureccontributes to making all your projects possible.
Amidst the turmoil of the oilprice crisis, Africa is thrivingwith formidable naturalresources, opening new frontiers, challenges andopportunities for the oil & gasindustry for the years anddecades to come. Vallourecis proud to provide powerfulsolutions to its customers and partners throughout thecontinent, with a commitmentto innovation, proximity andcost-efficiency.
The port of CapeTown is located alongone of the busiestshipping corridors in the world.
Operators have focused on streamlining the morecomplex projects to lower the break-even point aswell as on developing new straightforward projectswith fast returns. Vallourec has sought to developcost-efficient answers to these new market cons-traints, supporting every project with competitiveoffers with no compromise on quality and safety.Being close to the market, establishing customer inti-macy and building partnerships to offer innovativesolutions, is more crucial than ever.
North African markets vibrant with exciting prospects North Africa offers great prospects for the Oil & Gasindustry, driven by the recent discovery of extraordinary
natural gas fields off the coast of Egypt, as well aswith Algeria’s strategic program to boost productionand processing and the potential revival of Libyan oilproduction. Beyond the great fields of Zohr, revealedby ENI in 2015, North Africa is truly vibrant with exci-ting prospects for drilling, OCTG, line pipe projectsand hydrocarbon processing. Vallourec is strengthe-ning its footprint with a new sales and service officein Algiers, in addition to the office established in Egypt,in 2009. Philippe Laurent, Regional Sales Managerfor Onshore Line Pipe said: "The qualification processto tender for projects in this area can be lengthy anddemanding, but success is all the more rewarding!We work very closely with our customers and haveestablished fruitful long-term relationships based onunderstanding, trust and reactivity. The new office inAlgeria will reinforce this proximity and help us servethe growing demand."
A wealth of opportunities in Westand in Sub-Saharan Africa Although new deep and ultradeep projects havebeen postponed in West Africa, Vallourec is stillbusy delivering offshore projects, like those ofExxonMobil in Angola, or Total in Nigeria and Congo.Vallourec remains close to all its partners, workingwith NOCs, IOCs, and independent operators toredesign projects, optimize potential and lower coststo make these projects profitable at a 50-60 $ oilbarrel. With the perspective of higher oil prices, itis clear that most offshore projects, including thehuge offshore potential in Mozambique, will graduallybecome viable and be re-activated, requiring theexpertise, innovation and global solutions thatVallourec can offer. Meanwhile, simple onshore and lower cost offshore projects are providing opportunities in Senegal andIvory Coast, in Mauritania, Sierra Leone and Gabon.Vallourec is actively developing lower cost supply routesby associating pipes from Tianda in China with VAM®
connections to provide high quality, competitive solutions.In Uganda, Kenya and Tanzania, where hundreds ofwells are planned for the coming years, Vallourec isstrengthening its presence, ready to serve the marketwith best-in-class drilling and OCTG products and services.
p.8 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
South Africa has become a major business hub fornumerous oil and gas companies operating in theSub-Saharan region, with easy access to the hugemarkets of West & East Africa. Henri de Fonvielle,Director of Vallourec South Africa, testifies: "Theadvantage of being in Johannesburg is obvious:numerous headquarters covering Sub-Saharan pro-jects are based here, the city is buzzing with peoplefrom all over the world. Business in Africa impliesbeing close to all the players, where new projectsand challenges are discussed daily. You have to behere, where the action is, just a phone call away fromyour counterparts. We are in regular contact withSasol, the largest South African chemical and energycompany, whose managers, engineers, operationalsales departments are all based in Johannesburg.Travelling to all the surrounding countries and areasis very easy from Johannesburg, which means wecan meet people every day, building the strong relationswe need with local industry players from internationaloperators through to the smallest distributors."Since opening the Johannesburg office in SouthAfrica, Vallourec has received strong interest fromthe market and has secured quality orders for a whole array of projects. Awards include OCTG inMozambique for onshore wells, OCTG in South Africafor a future offshore exploration project, drill pipes toequip offshore and onshore projects through rental
companies; together with line pipe and fittings toSouth African distributors for the hydrocarbon pro-cessing market. In short, Vallourec is working andgrowing enthusiastically with allthe key clients and partners inSouth Africa, developing businessand prospects for Uganda,Tanzania, Kenya, Angola, Gabon,Congo, Nigeria, Ghana, with moreto come.Thanks to its globally acknowled-ged expertise, Vallourec has alre-ady participated in major complexprojects throughout Africa suchas Kaombo and CLOV in Angola,Egina in Nigeria, Tullow TEN inGhana, and Moho Nord in Congo,providing a full range of products,services, solutions and projectmanagement. “There are definitelysigns that activity will be pickingup in the coming months. With thefantastic potential of Mozambique,for example, International Oil Companies are settingup future bases for development in the area. Our pre-sence in Johannesburg will prove essential by pro-viding competitive and innovative solutions for allincoming requests.” concludes Henri de Fonvielle.
The essence of customer intimacy is proximity, which is why, in 2015, Vallourecset up a new office in Johannesburg. After little more than a year, Vallourec hasdeepened relations with its customers, as well as with local operators, distributorsand industry players, particularly for the Sub-Saharan oil & gas markets.
At the heart of the African Oil & Gas industry in Johannesburg
Algiers - Algeria Sales Office
Lagos - Nigeria Sales & Services
Luanda - Angola Sales & Services
Johannesburg - South Africa Sales & Services
Port Gentil - GabonSales & Services
Cairo - Egypt Sales & Services
Tanzania)
Nairobi - Kenya(Uganda and
Sales & Services
Takoradi - GhanaSales & Services
Port Harcourt - Nigeria Threading Plant
Oil Gas
A quick overview of African markets and projects shows that although the mostchallenging offshore projects have been put on hold since the collapse of oil prices,the projects that were sanctioned prior to the crisis are still ongoing.
Vallourec addresses the vast array of markets in Africa
Vallourec delivered beyond the pipe for the Tullow TENproject, off the coast of Ghana, in 2015 and 2016. We co-designed and tailored all the solutions withSubsea 7, seeking end-to-end integrity to guaranteemaximum flow assurance. For TEN, we helped optimizethe pipe-in-pipe design, provided fully integrated solutions that included non-standard pipe dimensions,pipe in pipe, coating as well as double-joints. We moni-tored the whole process from the mill to delivery, withinnovative integrated planning and project manage-ment, all the way to J-lay welding on the barge.
Global solutions with Tullow TEN
Vallourec locationsin Africa
The landmarkHillbrow Tower inJohannesburg.
Identifiedreserves
• Pipe-in-pipe
• Coating
• Sleeves
• Welding
• Double-jointing
• J-Lay
• Project
management
• Fully integrated
planning
• Logistics
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.9
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.11p.10 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
“Africa's hydrocarbon potential continues to grow atan incredible pace, a development slowed but unde-terred by the oil price crisis,” says Hubert Paris,Regional Director for Europe & Africa. "The new gasdiscoveries in Mozambique and Tanzania, as well asrising exploration in Kenya and Uganda, are changingthe game and making East Africa a future big playerin the global industry.”
Already in the fieldAfrica holds an estimated 8-10% of world reservesin both oil and gas, and a large share of these futurereserves are to be found off the coast of Mozambique.Nonetheless, with most of these fields in ultra deepwaters, the price tag to first oil is steep. In addition tochallenging market conditions, operators will have toinvest in considerable infrastructures that are lackingin the eastern regions, as well as rely on trustworthypartners to overcome the technical and logistical barriers of such projects. "This is where Vallourec proves one of the most reliable and solid partnersfor East African developments," Hubert Paris says,"Our experience and innovation track record in deepand ultra deep offshore solutions speak for themsel-ves. We have the expertise in premium pipe designfor drilling, OCTG and line pipe, together with advan-ced welding technologies. Furthermore, our teamsare seasoned in large project management and fieldservice. Our track record includes major achievementslike CLOV, Egina and Tullow TEN, amongst manyothers, bolstered by the worldwide reputation of ourVAM® service network." "Vallourec is already in the field, on these new
markets, helping operators conquer new frontiers,"confirms Damien de Montlebert, OCTG CommercialDirector for Europe & Africa. "Vallourec is strengthe-ning its regional footprint in Nigeria, Gabon, Angola,for West Africa, in Algeria and Egyptfor North Africa, as well as Kenya andSouth Africa. Even in Mozambique,we already have an onshore rig equip-ped with Vallourec products, and havedelivered OCTG casing and tubing toSasol."
Sustainable value for the customer"For every future development,Vallourec must demonstrate bothsuperior technical efficiency and costeffectiveness. We seek to bring sus-tainable value to the customer, andnot just a promise. Good solutionstranslate into saved costs, increased quality andsafety, greater field support and field efficiency, mea-sured by time saved and well integrity. Vallourec isproud to bring powerful solutions to Africa and enthu-siastic to help sustain the growth of its new frontiers!"concludes Hubert Paris.
As the world seeks new fossil fuel reserves, all eyes are turned towards Africa’s east coast. Vallourec is supporting its customers with innovative, cost efficient solutions.
Ready for the future, ready for new frontiers!
Setting up a threading mill in NigeriaVallourec's Augustin Irabor, OCTG CommercialDirector, Nigeria, explains: “Local content is essentialand mandatory in Nigeria. It involves producing orsubcontracting a certain portion of every projectlocally to support and develop local human resourcesand skills. Vallourec set up sales and services asearly as 2007, followed by a threading mill in PortHarcourt in 2009, creating jobs, developing localknow-how and stimulating training. It has helped usconsolidate relations with our customers, understandtheir needs and demands and participate in the deve-lopment of the country. Concerning customer benefit,however it's maybe too early to tell, because this levelof investment in local content comes at a cost foroperators and companies and can prove an expen-sive policy. For Vallourec, it's clearly a positive expe-rience and constitutes a major asset. Our challengein the future, however, is to make this kind of localcontent more cost efficient and appealing for ope-rators as well as local contractors and engineers.”
Working with local players and training young engineersKarsten Walz, Area Sales Manager for OffshoreLinepipe recalls two aspects of Egina's local content:
“Egina was a major offshore project with a lot of tech-nical barriers which called for Vallourec’s expertise.My first task in Nigeria was to find the best local partnerto work with us. Bell Oil and Gas, proved to be a veryserious and dedicated partner, for a very challengingproject, and together we successfully delivered theflowline and riser package of the project. One of themost original aspects of our partnership was certainlyour training program for 10 young Nigerian engineers.The training began with a focus on safety, followedby a comprehensive technical program to explain themanufacturing process, from steel production throughto the finished seamless pipes. The training encom-passed testing protocols, yield strength calculation,steel mechanical properties. The program also inclu-ded a visit to several R&D facilities in Europe, a visitto coating suppliers and to the harbor of Antwerp,to see how Vallourec manages and organizes trans-port to Nigeria. It was completed with a visit toSerimax, with demonstrations to understand how thepipes are welded and what technologies are usedfor pipe fabrication for subsea applications.”
Operating a local spoolbase and training local workers in weldingtechniquesJulien Blondeel, Commercial Director at Serimax, tes-tifies: “For the Pazflor project in Angola, we workedwith TechnipFMC, operating from the spoolbase inDande, assuring that 65% of the business was localcontent. All of the welding, inspection and field-jointcoating activities were under Serimax's responsibility.Our training plan carried out with TechnipFMC, invol-ved the selection of 30-40 local workers as well as5-6 high-potential leaders. The latter followed an inten-sive 6-week training program in Europe, so they would in turn become the trainers of the workers in Angola.At the end of the day, 60-70% of the staff working on the spoolbase were local. The training includedwelding and spoolbase operations together with highlyqualified project management positions.”
Vallourec's commitment to local content in Africa is historical and long lasting. For decades, Vallourec has sought to support local companies, train a newgeneration of engineers and technicians, and set up facilities near project locations.Local content comes at a cost, but is in its essence a true added value in thedevelopment of countries and populations, building bonds and relationshipsbeyond projects. Here are a few testimonies to our most successful ventures.
Meeting the challenges of local content in Africa
Hubert Paris,Regional Directorfor Europe & Africa.
Malcom Watt(center), RegionalHSEQ ManagerEurope, with Serimax trainees.
We can provide the best solutions for
the most complexprojects with thecapacity to setup
local Global Solutionsand One Stop Shop
capabilities, right next to future
prospects.
‘‘
‘‘
Internax is the new internal welding clamp for 48” linepipes*, capable of correcting out-of-roundness andparticularly suited for cross-country landlines.Unmatched on the market, the device includes eightfully automatic welding heads that perform root passesfrom inside the pipe. This is especially important wherecustomer specifications forbid welding on copperbacking. A wireless remote control system enhancesoperator safety; in addition, pipe re-rounding capabilitiesreduce hi-lo and fit-up time as well as improve weldquality. All these attributes make Internax one of the hig-hest productivity welding solutions.
High productivity in cross-countrylocations“Internax is the fruit of customer needs, market analysisand technological expertise. Taking Maxiluc, our highpower internal line-up clamp for mountainous terrains, asa starting point, we developed a tool specifically designedfor regions with flat, plain terrain profiles. In cross-countrylocations, especially in flatlands, with a low number ofcrossings, productivity will be exceptionally high. This newtool completes our range of landline welding solutions,giving us powerful answers for a greater number of tiers, with very high performance,” said Frédéric Lepla,responsible for Landline Project Development.
Complete range of welding solutionsThanks to the addition of Internax to the company’s port-folio, Serimax now offers an even more complete rangeof welding gears, with or without copper backing shoes,at all productivity rates for more terrain and topographytypes than ever.By combining Internax for internal root passes andSaturnax, our automatic orbital welding torch (bug-and-bandsystem) for external filling, we can propose the most completeand efficient welding solution on the market.
p.12 / The Vallourec Oil & Gas Magazine N°09 / March 2017 The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.13
Enhancing our range of solutions for the landline market
InternaxCleverScan
Ensuring the correct line up of pipes for installation can be challenging, time consumingand costly. To help customers face this very specific challenge.Serimax, designed a new welding clamp that facilitates the welding procedureand improves installation productivity, whatever the terrain and topography of the pipeline.
Today, Serimax has one of the largest portfolios of specialised pipeline welding equipment in the world, with over 500 dual headSaturnax welding bugs, 135 pipe-facing machines (PFMs) and 180 internal line-up clamps (ILUCs). The company offers welding services and guarantees the highest quality in the world. Over the past five years, Serimax has managed eight global projectssimultaneously each month and performed in excess of 187,700welds annually with a repair rate of less than 2 per cent.
The largest portfolio of specialised equipment
* In response to customer needs,Serimax intends to extend its rangeto cover 36” and56” diameter pipe.
[email protected] - www.serimax.com
Improving productivity and minimizing non-qualityrelated costs is a key focus in the Oil & Gas industry:repeated processes must be optimized, fast and reli-able to speed up execution and reduce the overallcost of a project. Pipeline welding is typically a repe-titive process, in which pipe sorting and pipe-endpreparation can be time consuming and a source ofproblems, flaws, repairs or slowdowns.Introduced in 2015, CleverScan was specifically desi-gned to help customers solve recurring problemsduring pipeline installation related to out-of-roundnessat pipe ends (weld cut outs, poor quality welds, rejec-ted welds, production stopped in the bead stall...).It is an optimal, accurate and quick measurementtool, with state-of-the-art software, all packed in asimple tablet and a user-friendly interface. CleverScanchecks pipe-end dimensions with advanced analysisto propose solutions that include quality control, line-pipe sorting and pipe end-to-end fit-up, based ondigital measurements and simulations. Whether a project has large tolerance levels, with
low-specification pipe or aproject has the most strin-gent specifications forgroundbreaking offshoreapplication, welding ope-rations impact the execu-tion-time and cost of theproject. Minimizing risk and
improving welding flow are key: by integrating addi-tional measurement services, CleverScan helps anti-cipate project planning and improve welding opera-tions. In 2015 and 2016, CleverScan has a proven recordof increasing welding productivity and supportingon-time delivery of projects in vastly different appli-cations around the world, in Texas, the North Sea,Kazakhstan and Asia Pacific.
Turnkey solutions evolving in 2017 In late April 2017, the CleverScan family will be gearingup a level, to provide a bevel measurement solutionfor the most challenging projects. This new edition ofCleverScan features 360° bevel measurement withlaser profilometry, which is ideal for onsite welding,providing customers with optimal fit-up and guaran-teeing that all bevels are approved before welding.This new solution reinforces the reliability and accuracyof quality controls for the most demanding requests,namely Clad Pipelines and Steel Catenary Risers,where root pass welding is highly impacted by thequality of the bevel itself.
News Focus The tech files Solutions On the market Events People
CleverScan is a laser profiling and user-friendly software solution, designed by Serimax to ensure a trouble free sorting and fit-up of your pipes, providingthe best welding results, whatever the application.
The smart digital technologyfor welders, by Serimax
#09
/...
�News Focus The tech files Solutions On the market Events People
saves you time and money andprotects the environment
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.15
First developed in 2000, to comply with OSPAR1 recommendations for the North Sea,CLEANWELL® was designed to replace the most commonly used thread compound, APImodified dope, which contains heavy metals. Regularly upgraded and improved,Vallourec’s latest development of CLEANWELL® DRY 2 goes well beyond the replacementof thread compounds. CLEANWELL® DRY 2 is applied directly at the mill after machining the threads: it reducespipe handling operations, rig running time, the environmental impact and improves rigsafety. Whatever the conditions - offshore and onshore, in low temperatures of the arcticor high temperatures of the desert - CLEANWELL® DRY 2 is leaner, faster, cleaner andsafer than traditional thread compounds.
CLEANWELL® DRY 2 multi-functional coating technology
is specifically developed for VAM® connections to replace
both storage and running compounds (dope). Applied
directly in Vallourec mills on the surface of pin and box
threads of VAM® connections CLEANWELL® DRY features:
• Anti-corrosion and anti-galling metal plating on pin and
box to protect the steel from corrosion along the product
life and improve its anti-galling performances
• A soft wax-type lubricant coating on the box for increased
running performances.
Metal
BOX
PIN
Metal Metal Aloy PlatingAnti-Galing & Anti-Corrosion
PassivationAnti-Corrosion
Special Solid CoatingLubricating Layer
1 - OSPAR Commission to protect the North East Atlantic and its resources www.ospar.org/work-areas/oic
For over ten years, Mr. HELP has been supportedby technicians and R&D specialists, who have ans-wered thousands of technical inquiries related tocommon topics, from make-up to running, from pipematerials to connection performance. Vallourec'splatform has grown immensely popular amongst cus-tomers, both end-users and OFS, around the world.In some instances, however, questions go beyondthe common, requiring preliminary studies, designoptimization or analysis to assess and reinforce wellintegrity. In response to customer expectations forsupport in more complex and challenging projects,Vallourec launched ‘VAM® Engineering Services’.While ‘Mr. HELP’ remains focused on routine inquiries,‘VAM® Engineering Services’ can provide made tomeasure engineering studies. Access to both plat-forms is seamless and VAM® users can find a gate-way to VAM® Engineering Services through Mr. HELP.
To improve well integrity and optimize performanceOil & Gas operations have grown increasingly complexover the years, as well as more demanding with strin-gent quality assurance requirements. Questions byVAM® users now call for deeper expertise by VAM®
engineers, from design(accessory design vali-
dation, performancecalculation, well opti-mization) to post-ope-
rations analysis (destructive or non-destructive testingfor used parts). Renaud de Lapeyrière, VallourecGlobal Solutions, Development Director, explains:"You see, each well design is unique, involving a greatnumber of items, casings, connections and acces-sories that don’t just need to fit together, they needto be 100% compatible, offer perfect sealing, andshare the same mechanical properties". Vallourec hasbrought together resources from its R&D centers andtesting facilities, into this innovative VAM® EngineeringServices platform. This Premium technical supportsolution provides a quick, comprehensive range ofexpertise at cost-effective rates.Charles Dubourg, Services Business DevelopmentManager, continues: "Accessories, for instance, arenot traditionally manufactured by Vallourec but theymust have the same performance levels and technicalproperties as the OCTG items. Our engineers havethe competency to review well and accessory designsand assist in optimizing dimensions or parameters,especially for threads and interfaces."
To save time and moneyRenaud de Lapeyrière adds: “In particular cases, cus-tomers need to evaluate the lifespan of a well, or assessrisks linked to ageing. In an old well, which has beenproducing for decades, the customer may want toknow if they can extend the well life and safely producefor an additional period of time with the existing infra-structure. Based on data collected in the well, VAM®
experts can generate FEA (finite element analysis) simulations of mechanical constraints, with tests anddrawings, to assess the actual levels of mechanicalresistance following corrosion or deterioration of VAM®
connections and associated pipes.” Charles Dubourg emphasizes: “When we work toge-ther from a project's earliest stages, well optimizationcan allow the customer to save time and money.”With already over 100 advanced studies handled byVAM® Engineering Services, Vallourec is ready to helpyou reduce installation time, increase safety, enhancequality and improve well integrity.
www.vamservices.com/support/help.aspx
p.14 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
Antoine Deroubaixand Maurin Duquenne,R&D engineers basedin Aulnoye-Aymeries(France), provide customer support andproduct design for VAM®
Engineering Services.
In the past decade, operators with general questions about VAM® connectionsand Vallourec pipes have grown fond of ‘Mr. HELP’, relying on the free web-basedtechnical support platform for quick answers. Today, Vallourec is going one stepfurther, with VAM® Engineering Services, designed to bring in-depth, answers tomore specific questions and issues, at the heart of engineering and design.
VAM® Engineering Servicesfor support beyond the pipe
News Focus The tech files Solutions On the market Events People
p.16 / The Vallourec Oil & Gas Magazine N°09 / March 2017 The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.17
ling operations and associated risks are reduced. The
pipe thread and seal is clean and easy to inspect.
Reduced environmental impactAPI modified dope contains heavy metals which are
hazardous to health and the environment. Whilst alternative
compounds are available they present two major draw-
backs:
• higher galling sensitivity on grades such as 13Cr, Super
13Cr and corrosion resistant alloys.
• poor sealability performance of the connections at tem-
peratures above 170°C.
Unlike other thread compounds, CLEANWELL® DRY 2 is
a corrosion-resistant, anti-galling metal plating which is
applied at the mill. There is no discharge and no environ-
mentally hazardous material. It is fully compliant with the
latest recommendations of the OSPAR commission, sui-
table for use in environmentally sensitive areas.
Corrosion resistanceA large number of tests were performed to measure the cor-
rosion resistance of CLEANWELL® DRY 2 in the most severe
environments. These accelerated lab test in critical condition
validated temperature range from -60°C up to +70°C.
• The VDA 233-102 testing method alternates salt spray,
humid and freezing phases with high moisture and
thermal cycling during 8 one-week cycles. It generates
high corrosivity and high internal stresses at the sub-
strate/coating interface.
u VAM® 21 CLEANWELL® DRY 2 performance was
excellent, with no sign of corrosion after 8 weeks
of accelerated corrosion
VAM® 21 CLEANWELL® DRY 2
after VDA 233-102 testing
• The Gazprom test involves testing connections to thermal
shocks (down to -60°C) and to high temperature/pressure
water-jets to simulate behavior of frozen connections
u Climatic tests confirm that CLEANWELL® DRY 2 is
not affected by cold and can be used in extreme
low temperatures, down to -60°C.
storage lifetime Two sites were selected to replicate field exposure and
long time storage in the worst case conditions.
• Dunkerque was selected due to its corrosive urban
marine atmosphere and temperate climate (category
C3 according to the ISO 9223:2012 standard).
• Dubai was selected for its dry and very hot climate.
VAM® 21 CLEANWELL® DRY 2 pin
after 24 months storage in Dunkerque
u After more than 2 years exposure, the threads are
in excellent condition. The storage test is still on-
going to determine the full product lifetime.
u CLEANWELL® DRY 2 can be stored for more than
2 years whatever the conditions without deterio-
ration. It proves that CLEANWELL® DRY 2 is totally
rig ready and does not require any maintenance
during storage.
#09OpERAtiONAL sAviNgs iN thE YARD
CLEANWELL® DRY 2 has been designed to totally replace
storage and running compounds, simplifying the storage
operations even in challenging climatic conditions. Thanks
to its proven corrosion resistance properties, the con-
nection can be stored for more than 2 years on a yard
without specific maintenance requirements.
1. Remove thread protectors and
storage compound
2. Inspect connection thread
3. Re-apply storage compound
and thread protectors
1. Remove thread protectors and
storage compound
2. Inspect connection thread
3. Re-apply storage compound
and thread protectors
1. Remove thread protectors and
storage compound
2. Apply running compound and
re-apply thread connectors
1. Remove running compound
2. Inspect connection thread
3. Reapply storage compound
and thread connectors
Thread inspection
at pipe delivery
(≈ 10% of
delivered pipes)
Periodic thread
inspection
(≈ 10% of pipes
every 6 months)
Thread
preparation
before sending
to rig
Rig returns
storage yard
operationsOperational Savings
& BenefitsCLEANWELL® DRY 2Standard Compounds
Remove thread
protectors and inspect
connection thread
Remove thread protectors
and inspect connection
thread
Can be stored for up to 3 years
without specific maintenance
Rig ready
Rig ready
l No need for storage and
running compounds
l Reduced
water treatment,
waste management
and disposal costs
l Faster make-up
l Less manual pipe
handling
l More consistent
and reliable
l Cleaner
l Environmentally friendly:
Classified GREEN by
OSPAR
l Easier management
of rig re-turns
OpERAtiONAL sAviNgs ON thE Rig
By replacing the need for running compounds, CLEAN-
WELL® DRY 2 delivers significant operational advan-
tages to reduce rig time and generates important cost
savings. We estimate that running time can be reduced
by 20% compared to standard VAM® connections.
Reduced reject and back-out rate With CLEANWELL® DRY 2 make-up operations are more
consistent, improving the make-up rate at first attempt
from a typical 97% to 99% (including back-out and rejects).
Non productive time related to failed make-up is reduced.
• By applying CLEANWELL® DRY 2 at the mill, Vallourec
is able to standardize the process and ensure the quality
of the product
• CLEANWELL® DRY 2 metal plating has very strong resi-
stance to galling, whatever the steel grade
Make-up graphs are much more repeatable: no risk
related to application of too much or too little dope (too
little dope leads to lack of lubrification and risk of galling,
too much leads to dope pressure and unacceptable
make-up graph). With CLEANWELL® DRY 2 the connec-
tion can be used even if contaminated with mud, water
or dope.
Faster make-up Casing connections with CLEANWELL® DRY 2 can be
made up at up to 30 RPM compared to 10 to 20 RPM
for conventional connections. “This outstanding perfor-
mance is achieved thanks to the unique engineering of
the CLEANWELL®
DRY 2 coating which protects the
metal surface of the connection to prevent galling wha-
tever the grade” says Thibault Mathon, R&D leader in
charge of CLEANWELL® DRY 2 development.
improved well productivityRemoving the use of running compounds eliminates pro-
blems such as equipment plugging and formation damage
caused by using too much or too little dope, thereby
improving the overall productivity of the well. This is par-
ticularly important for highly deviated wells and wells using
ICD (Inflow Control Devices).
improved safetyWith CLEANWELL® DRY 2, operators provide safer and
cleaner workplaces for the rig crew. By removing the need
for storage and running compounds, CLEANWELL® DRY
2 ensures that the rig site is cleaner and safer. Pipe hand-
CLEANWELL® DRY 2 is available on vAM® 21
All grades: Carbon steel, 13Cr, Super13Cr and CRA
Same sealability performance as VAM® 21 standard:
- API RP 5C5 2017 CAL IV
- Connection performance envelope same as the pipe - 100% VME
Full compatibility with standard connections for all sizes
Pin Box
With thread protector
Without thread protector
tEstiNg
p.18 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People #09sealability testsIn order to validate the sealability performance of a
connection, the reference standard is API RP 5C5 4th
edition - 2017 - Procedure for testing casing and tubing
connections. It is currently the most demanding qualifi-
cation available, certifying premium connection perfor-
mance. This protocol guarantees the sealing of the
connections by testing complex combinations of loads
to simulate extreme downhole situations. This revised
edition requires most of the tests to be carried out at high
temperature.
The VAM® 21 full product line with CLEANWELL®
DRY 2 is qualified to API RP 5C5 2017 CAL IV:
• First, the most critical sizes for sealability were
identified by FEA (Finite Element Analysis): this
was done by comparing computed sealability
criterion on each product line OD / thickness /
grade.
• Second, a series of physical tests as per API
RP 5C5 2017 CAL IV protocol were performed
on the most critical sizes of VAM® 21 with
CLEANWELL® DRY 2.
u All validation tests were successful and
demonstrated that CLEANWELL® DRY 2
does not alter the product sealability perfor-
mance, even at high temperature. Technical
reports are available upon request.
Make-up and break-out tests In accordance with API RP 5C5 to evaluate the anti-galling
performance of connections under lab conditions, a mini-
mum of 3 make-up and break-out (M&B) are required on
casing without reject, and 10 M&B for tubing. CLEAN-
WELL® DRY 2 was tested up to 5 M&B for casing and 15
M&B for tubing.
No dope or lubricant was added, and even after 15 M&B
the connections were still acceptable for further make-
up. The threads were in perfect condition.
u CLEANWELL® DRY 2 showed make and break perfor-
mance far above API RP 5C5 requirements demon-
strating its capacity for faster and more reliable make
up.
Rig tests and field testsRepresentatives from major and local oil and gas com-
panies were invited to attend rig tests in Stavanger, Norway
to witness the performances and the benefits of the new
CLEANWELL® DRY 2 coating optimized for VAM® 21 con-
nections.
During the operations at the rig, VAM® Field Service tech-
nicians conducted a series of trials pushing the limits of
the VAM® 21 with CLEANWELL® DRY 2 demonstrating
the excellent make-and-break performances and the
robustness of the solution in different configurations.
Most participants agreed that the combination of CLEAN-
WELL® DRY 2 with VAM® 21 will reduce the environmental
impact, improve the running efficiency by avoiding cleaning
and doping operations and will in addition solve various
dope related issues.
More rig demonstrations are scheduled for 2017. Please
contact your Vallourec sales representative if you wish to
attend.
CLEANWELL® DRY 2 usage on the fieldOver 4 million feet of CLEANWELL® DRY have been run
since 2005. Onshore or offshore, in freezing cold or un
bearably hot operating environments, the running per-
formance has always exceeded customer expectations.
u Field proven benefits
According to VAM® Field Services, the back-out and
reject rates of VAM® 21 CLEANWELL® DRY 2 are divi-
ded by 2 when compared to VAM® 21 standard (dope
version).
• Totally dry and non sticky
• Clean: no plugging, no discharge
• No galling
• Corrosion resistant
• Excellent lubrication properties in hot or cold environments
• Ensures perfect sealability of VAM® Connections
• Reduces handling, improves safety
• Environmentally friendly
In summary, the main advantages of CLEANWELL® DRY 2 are:
p.20 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
In all operations, Vallourec has developed leaner management,smarter and faster solutions, simpler execution, dynamic andcost-efficient approaches. Vallourec's answers have grownto adapt to all oil & gas priorities: rig-ready products, with yardmanagement that includes all connections and accessories,as well as threading, inspection and VAM® Field Services fordrilling and OCTG. For offshore projects, Vallourec deliverscoating, reeling, on-vessel welding, field joint coating, all forreduced line pipe-laying time with record low repair rates,ensuring saved time and costs. Vallourec's Global Solutionscan meet client expectations through a vast network of facilitiesand partners worldwide. These very concrete services areadapted to the specifics of each area or project profile andinclude One Stop Shops, spoolbases, well coordination, service hubs and licensee networks that offer service capa-bilities from the mill to the well.
Customer services worldwide Vallourec has set up One Stop Shop capabilities throughoutthe world, bringing together a wealth of services in a singlespot in response to customer requirements. Every hub hasits own specialties and accommodates services for drilling,OCTG or line pipe, working in synch with customers, oftencoordinating with partners and suppliers to facilitate informationflow, simplify the supply chain, ensure the highest quality andsafety while improving efficiency. Gathering all parts andaccessories in a single location and conducting testing,inspection and shipping in a single rational way means thecustomer gets exactly the parts he needs with rig-ready orlay-ready solutions that improve execution, decrease rig orbarge time and save costs. Vallourec has One Stop Shop
capabilities from its own proprietary sites as well as throughpowerful local players. Whether in Europe and Africa, theMiddle East and Asia, in North and South America, Valloureccan deliver world class solutions.
One Stop Shop capabilities in Europe and the Middle EastVallourec has developed One Stop Shop services in theNetherlands, with partners and service providers to managethe complete drill string lifecycle for customers. Everythingessential to preparing the drill pipe for its next operation;inspection, re-hardbanding, rethreading and accessories,is available in one place at the lowest cost. With over 50years of experience in the Netherlands, Vallourec can offerthe highest standards of quality and fast delivery, constitutingone of the most reliable options in Europe for new and repaired equipment. Vallourec has now set up a similarbase of operations in Abu Dhabi. Abdias Alcantara, ServicesBusiness Development Director for Vallourec DrillingProducts said: “We get praise for how fast we can do thejob. Customers can send us a truck with a piece to repairand they are able to drive back to the field with the repairedpiece the same day.” In addition to our services, Vallourecoffers a variety of drilling accessories and yard managementfor inventory. The One Stop Shop is adaptable to all projectsand client orders, guaranteeing improved supplier scheduleand coordination.
One Stop Shop in Vitôria, BrazilIn Brazil, Vallourec has set up a vast One Stop Shop facilityin Vitôria, very close to the coast, which brings together
seamless pipe supply (from the Belo Horizonte - Barrieroand Jeceaba sites), large diameter welded pipe and coatingfacilities from TSA and welding expertise from Serimax, toanswer all customer needs for onshore and offshore linepipe projects.In addition to anti-corrosive pipe coating and thermal insu-lation, the Vitôria site can provide welding qualifications,double jointing and field joint coating.Hildeu Dellaretti Junior, Projects SalesDirector at Vallourec Brazil, explains:"Here's an example of value creation:we are answering client expectationsby offering 24.4-meter long pipes withdouble jointing instead of the traditional12.2-meter long pipes that the contrac-tor would have to weld and coat on thebarge or at its spoolbase. We help save50% of field joint coating (FJC), whichis a critical path of the operation, reducevessel operating time, increase qualityand inspection levels, and considerablymitigate risks. For welding, we are nowseeking a single welding qualification,at a spoolbase for instance, to furthersimplify and enhance our offer". DiegoAlmeida, Marketing Coordinator at Vallourec Brazil, continues: "By reducing spoolbase operation time and eliminating 50% of FJC, for example, we are reducing customer TCO, but, more importantly, we are deliveringsolutions with increased flow assurance and productintegrity."
Vallourec's One Stop Shop Brazil is growing to include com-plementary services, yard and pipe management, andadvanced project management.
A powerful hub in Batam, South-East Asia At the other end of the world, in Batam, just across from
Singapore, Vallourec P.T. Citra Tubindo (PTCT) hasgrown into a world-class partner of Vallourec, offeringglobal solutions throughout the Asia Pacific area. FromPTCT’s facilities in Batam, Indonesia, Vallourec canprovide heat treatment, thread VAM® premium con-nections and oil-field accessories and provide a widerange of services and logistics solutions to cover thetubular needs of Oil & Gas customers. In addition toOCTG, the scope of services has expanded vastlyto include global solutions for linepipe projects.Amongst the services offered by Vallourec and PTCT,we find a full range of non-destructive testing facilitiesincluding a new ultra-sound test bench to ensure100% quality control. Last but not least, Vallourec canhandle all the yard management logistics for optimal customer storage and shipping organization.
Serimax delivers powerful solutions around the worldAs the challenges faced by customers worldwide constantlychange, Serimax continues to innovate, developing and apply-ing new technologies and processes which meet these challenges head on. Its spoolbase operations at Evanton inthe UK, Orkanger in Norway, Mobile in the USA and Dande
Vallourec has developed a vast array of Global Solutions over the years, both tooffer high value services and to reduce operators’ total cost of ownership (TCO).Customer convenience is at the heart of these services which can include yard operations, logistics and coordination, threading, testing and inspection, coating
and welding, designed to deliver quality and time saving solutions, beyond tubular products.
Vallourec Global Solutions
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.21
Making our customer’s life easier
Globally, our One Stop Shop can speed
up onshore and offshorefabrication, providing
extra manufacturing andscores of intermediary
enhancements and inspection protocols,
reducing project executiontime for the operator,and accelerating time
to first oil.Diego Almeida
‘‘
‘‘
p.22 / The Vallourec Oil & Gas Magazine N°09 / March 2017 The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.23
News Focus The tech files Solutions On the market Events People
Oil & Gas companies are looking for the most efficient technicalsolutions to reach deeper wells, ensuring well integrity whilecutting costs. Amongst Vallourec's Global Solutions, well coor-dination involves the preparation of a complex array of tubulargoods, connections, accessories and services at a singlepoint, managing information flow to ensure timely delivery,yard logistics, quality control and synchronized schedulingacross the supply chain. Vallourec Tube Alloy delivers a full range of accessories, spe-cifically developed to meet the challenging demands of com-plex offshore Oil & Gas projects, initially in the Gulf of Mexico,and more recently in south-east Asia, with a newly openedfacility in Singapore.
From the mill to the well: quality and customer intimacyWhile VAM® connections are renowned for their reliability andperformance, they are high tech products that must be properlyhandled, transported, stored, installed and sometimes repaired."No one knows VAM® like VAM®", says Chris Hebert, SalesDirector, North America, Vallourec Tube Alloy. "That’s one ofthe reasons customers have entrusted us to integrate moreand more services upstream and downstream from the manu-facturing to the running, from the mill to the well, beyond pipesand connections." Vallourec Tube-Alloy sought a logisticssolution and partnered with Offshore Energy Services to easesome of the challenges across the entire value chain with anintegrated solution, from its strategic location in Houma,Louisiana, just an hour away from the biggest offshore basesin the Gulf of Mexico. "Vallourec has developed a new levelof customer intimacy," as Todd Davies, Account Manager atVallourec Tube Alloy, explains: "I'm communicating with all our
partners, on a daily basis, to coordinate operations: we'retalking to end users, OFS, distributors, trucking companies,supply chain groups, completion and drilling engineers, aswell as field service and technical support teams. This bringscustomer intimacy to a whole new level: in barely 7-8 years,we have really grown into well coordination specialists."
Guaranteeing well integrity and lowering costsChris Hebert continues: "We're helping our cus-tomers lower their TCO in very concrete ways.We look for hidden costs or costs associated totransportation, transactions, intermediaries, redu-cing the number of touches for a single part andany redundant operations. For transportation, forexample, we have cut down mileage, redrawnroutes, optimized truck loads; trucks are spendingless time on the road, which means increasedsafety and reduced transport liability. We've cutour carbon footprint by 30% and achieved a near50% reduction of transportation costs. For inspections, we'vegone from multiple inspections at different sites to a singlecrew, at a single location, just before final delivery. We havesimplified access to products and services, by managing thecoordination off one single desk. In addition, we've improvedthe utilization of customer inventory: this year alone we havebeen able to reduce storage goods by 75%. We're probablyat $750,000 savings using inventory goods that had beensitting around for about a year." Vallourec Tube Alloy is part ofthe Global Solutions strategy of Vallourec and is still exploringfurther possibilities to optimize time, standardize all pre-rigoperations, and reduce costs.
Today, Vallourec Tube Alloy delivers more value than ever. Well coordination guarantees saved time and lower total cost of ownership (TCO).
Spotlight on well coordination services
in Angola provide tremendous reeling capability. On-vesselwelding capabilities for J-lay and S-lay provide the most cuttingedge technologies with the lowest repair rates in the world.Serimax offers specialized welding solutions for high gradesteels which are used in some of the most challenging ultradeepwater or arctic environments. Our global welding solutionschange the game for complex offshore projects and definitelysave execution time and costs for our customers.Whilst research and development teams design and createinnovative solutions to support next-generation opportunitiesfor Oil & Gas exploration and production, our engineers andtechnicians ensure that our on barge execution and reelingcapabilities are efficient and cost-effective to meet the chal-lenges our clients face today - and tomorrow.
Ready for the future Vallourec's Global Solutions and One Stop Shop capabilitiesbring us closer to the customer. Our offer now far exceedscustomer expectations as we deliver so much more. With
projects that are particularly cost and time sensitive in today'sharsh market conditions, it is paramount to provide solutionsthat make the customer's life easy and trouble-free. Valloureccan provide answers from a very early stage, for well andaccessory design, all the way to well completion. We haveproven our proximity capacities by setting up local threadingfacilities in Africa, double-jointing bases in Europe and Brazil,for example, or by partnering with TechnipFMC and managingtheir spoolbases. We have developed lean and efficient yardmanagement by encompassing all assets within a samelocation, minimizing handling and transportation costs. Ourexpertise aims at ensuring well integrity and lower TCO: atthe heart of our products and services, you will always findquality and safety. “This is why Vallourec can best manageyour tubes, connections, and services from the mill to youryard, and all the way down your wells and strings”, says DidierHornet, Senior Vice President, Development & Innovation.“Vallourec knows how to handle, prepare and deliver so yourexecution on the rig is quick, smooth, safe and efficient.”
Global SolutionsOne Stop Shop capabilities • Yard & inventory management• Testing & Inspection• Maintenance & repairs • Rig prep & rig return • Threading & accessories • Coating & double jointing
Customer benefits• Pre-project organization and planning• Easier Project Management & Execution:
- Optimized schedules - Transport and yard sychronization - Supplier coordination - Better product integrity- Better product preparation
• Better vision • Better cost control • Risk mitigation • Lower Total Cost of Ownership• Operators can focus on core activity
Welding services • Spoolbase management • Double joints • Field Joint Coating• Reeling • J-Lay, S-Lay
VAM® Licencee network • Threading • Accessories • VAM® Field Service
Vallourec Global Solutions Footprint
North America
We've cut our carbon footprint
by 30% and achieved a near 50% reduction
of transportationcosts.
‘‘
‘‘
High tech products must beproperly handled,transported, stored, installed and sometimesrepaired.
One Stop Shop capabilities
Serimax Operated TechnipFMC Spoolbase
VAM® Field Service & Licensee network
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.25p.24 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
By combining three innovative features, Vallourechas developed a completion landing string whichoffers large drift diameter, high working pressure, andhigher gas tightness performance, thanks to the VAM®
Express-M2MTM connection.A completion landing string is generally an assemblyof seamless pipe with gas tight connections used indeep offshore wells for diverse operations, such assending instrumentation downhole, performing welltesting, and for other completion and interventionoperations at different times during the lifetime of thewell. The most important function of the landing stringis to provide a gas-tight conduit between the seabedand the platform, where tools can be lowered andfluids circulated. Using a completion landing stringalso allows operators to perform pre-analysis ofhydrocarbons, to evaluate the value of completingthe well. These operations are, by definition, complexand expensive, so operators are continuously seekingsolutions to improve their economic and operationalperformances.
Large drift diameterThe latest technical requirements for completion lan-ding strings require the drift diameter to reach a mini-mum of 6 in. to retrieve the BOP plug. Vallourec’s pre-mium forged pipe PFPTM manufacturing technologymakes it possible to produce integral shaped pipewith a variable outside diameter, preserving the metal-lurgical integrity of the pipe by getting rid of the weld.The higher tensile capacity achieved by forging allowsus to offer larger outside-diameter pipe (7 5/8 in. ver-sus 6 5/8 in.) with flush inside diameters (up to 6 1/4in.) without having to reduce the inside diameter tocompensate for the weld. This large internal diameter
reduces the pressure and hydraulic horsepower requi-rements for circulating drilling fluids, viscous pills andcement and thereby optimizes hydraulic performance.
Gas-tight connectionThe VAM® Express-M2MTM connection is a drill pipebased, double-shoulder, gas-tight connection witha metal-to-metal rotary seal technology. This dou-ble-shoulder connection distinguishes from otherdouble-shoulder connections because of its highertorque capacity, which averages 150% to 200% morethan an API connection. The VAM® Express-M2MTM
provides the highest gas-tight operating envelope inthe industry; qualified up to 30,000 PSI internal pres-sure and 25,000 PSI external pressure.
Cost benefitsDrill pipe based landing strings are more cost effectiveto run compared to alternative solutions, becausethey are compatible with conventional drill pipe hand-ling equipment. Additionally, they are faster to make-up, more resistant, resisting up to 100 make andbreaks, and they can be used for drilling if needed.The weld free design, reduces production time andcost compared to welded ormachined assemblies. The combination of these fea-tures provides operators anddrilling contractors with a costeffective and flexible solutionto use the same tubular stringfor both drilling and comple-tion operations, without com-promising performance orsafety.
To better address operator requirements for completion landing strings, Vallourecdeveloped a drill pipe based solution which offers improved performance and costbenefits when compared to existing systems.
Forged completion landing string addresses industry challenges
possible
Wemakeoptimization
the step from innovation to cost
By co-designing the pipe solutions from the start of a major o! shore oil development project in Ghana, Vallourec demonstrates its ability to anticipate its clients’ requirements and constraints. The Group not only supplies non-standard pipe dimensions to optimize pipe-in-pipe design, it also leads complex operations such as coating, double-jointing and logistics. Thanks to its unique and e" cient project management approach, Vallourec ensures smooth execution, risk mitigation, and lower cost of ownership. Vallourec contributes to making all your projects possible, wherever you need us, whenever you need smart tubular solutions. vallourec.com
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The forge in Aulnoye-Aymeries tube mill (France).
Watch an overviewof the forged drillpipe heat treatmentprocess.
VAM® Express-M2MTM connection.
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.27
A new milestone forVallourec Umbilicals
Advanced premium solutionsfor geothermal energy projects
In 2016, TechnipFMC successfully assembled umbilicals using 130km of seam-welded super duplex tubes for Total’s Glenlivet project in the North Sea.
The Glenlivet project was the first real world trial forVallourec's welded tubes for umbilicals following a four-year qualification program by Total’s E&PTechnology Department. Vallourec delivered 130km oftubes to TechnipFMC Umbilicals to be assembled toform the static Glenlivet umbilical. The innovative productis acknowledged to be a breakthrough for the SURFindustry with excellent performance in all qualificationtests: The tubes are lighter, with high performancemechanical characteristics that are particularly adaptedto deep and ultra deep waters, with a high level of fati-gue resistance.Vallourec understood that subsea systems for deepand ultra-deep offshore projects were becoming moreand more demanding and that applying the most com-mon solution, using thicker tubes, was not an optiondue to the impact on price, weight and fatigue. By providing the client with laser welded umbilical tubes,seam welded along the entire longitudinal length,Vallourec Umbilicals was able to reduce the wall thickness, thus saving considerable weight. Supportedby Serimax for the development and qualification ofboth longitudinal laser welding and butt weld orbitalGTAW welding procedures ensured that Vallourec’sseam-welded super duplex tubes for umbilicals reachedunprecedented quality.
Stringent qualification process“The qualification process was extremely stringent, morethan 11,000 tests were undertaken before qualification”,declared Stephan Chrobot, Managing Director ofVallourec Umbilicals. “As it is a totally new, innovativesolution, there is no margin for error. Total needed to be100% sure that the new product corresponded perfectlywith their requirements”. For Jean-Philippe Roques and Henri Romazzotti, engi-neers at Total, the choice of Vallourec Umbilicals wasclear: “We wanted a technology that was more pertinentin terms of mechanical properties and capacities. Thesetubes go well beyond: the tubes are finer and less rigid.Furthermore, they provide an important benefit in termsof cost. It’s an excellent product that fulfils all our expec-tations.”
Next steps Today, Vallourec Umbilicals has two production linesand 20 employees, but a second project order placedthis year calls for investment in a third production lineand additional recruitments. “We have moved from thestart-up to the growth phase of our develop-ment,” said Stephane Chrobot adding, “I amconfident for the new orders and projects forthe future”. Vallourec tubes for umbilicals are specificallydesigned to withstand the toughest environ-ments and operating conditions. Serimax wel-ding engineers are supporting the secondproject order and providing the welding qua-lification procedures. In this way, Valloureccontinues to offer innovative and cost-efficientsolutions for all SURF markets.
The Holy Grail of engineering: a product that
is lighter, stronger and more
cost efficient to fabricate…
From left to right: Henri Romazzotti (Total), Stéphane Chrobot and Eric Poupart(Vallourec Umbilicals), Jean-Philippe Roques (Total).
Umbilicals transmit power, chemicals and communications fromsurface controls to subseainstallations.
p.26 / The Vallourec Oil & Gas Magazine N°09 / March 2017
Geothermal energy projects use the thermal energygenerated and stored in the core of the earth's geo-logy to generate electricity. Using production wells toextract steam and hot water out of the ground andbring it to the surface, thermal energy is transferredeither to a domestic water network to heat homes ortransformed into electricity and transferred to thepower grid. Once the heat energy has been used,the water is reinjected into the reservoir though aninjection well.
A virtuous energy cycleHowever, geothermal well profiles are challenging.Concentrated at the edges of the earth's tectonic plates,the extremely hard and abrasive rock formations createhigh torsion levels and equipment wear, even worse thanconventional oil & gas drilling. High temperatures, highpressure and the presence of hydrogen sulfide are justsome of the challenges of geothermal wells. In 2016, Vallourec supplied premium OCTG for thegeothermal plant in Holzkirchen, Bavaria, Germany.This project involved drilling two wells to a depth ofnearly 5,000 meters, with temperatures over 180 °Cand external pressures up to 743 bars.
This year, Vallourec will assist FonrocheGéothermie, the leading French companyin high temperature geothermal energy, inthe exploration phase of the undergroundreserves in Alsace. The project will consistof two to four wells drilled in doublets (oneinjection well and one production well)requiring premium tubes and connectionsincluding VAM® 21TM, the highest perfor-ming premium connection on the market.A team of VAM® Field Service technicianswill supervise the on-site descent. The dril-ling of the first well is expected to begin inJune 2017. Geothermal plant projects are developingaround the world, confirming the rise inthis technology for producing electricityfrom green energy. Today, only 6 to 7%of global geothermal energy is in use, butthis is expected to grow fivefold for elec-tricity production and two-fold for urbanheating by 2030. Vallourec is positionedas the leading partner in this new environ-ment friendly market.
Vallourec is committed to developing technicalsolutions for renewable energy. This is clearlyillustrated through the recent awards to supplypremium tubes and connections for twoimportant geothermal energy projects in Europe.
News Focus The tech files Solutions On the market Events People
Our tubes can cope with thehighest mechanical and thermalloads, because they are made fromsteels specially developed for the
energy industry, and in additionwe use VAM® premium connec-tions for the tube strings.
Markus Renner, Sales Director OCTG Europe
‘‘ ‘‘
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.29p.28 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions Strategy Events People
Over the past two years, Vallourec has undertaken a profound
transformation plan. Through the structural reduction of its cost base,
the Group has developed into a global, leaner and more competitive
organization, with a balanced industrial footprint, close to its strategic
markets and customers.
Vallourec Stronger and more competitive
Within the framework of this transformation, innovation
remains more than ever a path to progress and suc-
cess. As a market leader, Vallourec is committed to
innovative new products, services and solutions
to support customers for all their tubular needs.
Developing sales and new growth drivers across the
entire range of Vallourec’s offer, is a key objective. The
new organization is structured around 4 regions, each
with their own commercial and industrial operations.
The global growth strategies for all product lines and
the development of the Group’s industrial footprint,
will be organized across two new central departments:
Development & Innovation (D&I) and Technology &
Innovation (T&I).
Europe and AfricaOur European production facilities offer the widest
range of tubular products in the world, including
high value added products and services. The stream-
lining of our operations preserves this expertise and
ensures competitiveness to serve both the technical
challenges of our European markets and new oppor-
tunities in Africa. You will find several examples of
our solutions in the focus article on Africa (pages
6-11).
Middle East and AsiaThe recent acquisition and integration of Tianda Oil
Pipe (detailed on page 30) gives Vallourec a highly
competitive production hub to supply the domestic
Chinese market and export worldwide, particularly
in Asia and the Middle East. With heat treatment,
threading facilities and one stop shop capabilities
across the region, Vallourec can support its customers
with a full range of Global Solutions.
North AmericaIn 2015 and 2016, Vallourec’s operations in North
America underwent significant streamlining to improve
competitiveness and adapt to the sharp fall in demand
caused by the oil price crash. As leader on the North
American market, our local production facilities are
already responding as the market recovers, providing
the flexibility and responsiveness to address customer
needs with short lead times, high value and creative
solutions.
South AmericaThe merger of its two Brazilian entities into a single
powerful unit, Vallourec Soluções Tubulares do Brasil,
provides a second highly competitive production hub
to serve domestic customers as well as worldwide
customers with high-end products and solutions.
It also highlights the strong and fruitful partnership
between Vallourec and NSSMC.
Through its bold policy and actions, Vallourec is pro-
viding new, operational and highly efficient answers
to its most demanding customers.
Hubert Paris-------------------------Senior VicePresident,Europe & Africa
EdouardGuinotte-------------------------Senior VicePresident,Middle East & Asia
Nicolasde Coignac-------------------------Senior VicePresident, North America
Alexandre Lyra-------------------------Senior VicePresident, South America
Didier Hornet-------------------------Senior VicePresident,Development & Innovation
PhilippeCarlier-------------------------Senior VicePresident,Technology & Industry
Regional, commercial & industrial management
Changzhou
Nansha
Chuzhou
Vallourec sales officeVallourec Field Services
Tianda Oil Pipe
Tianda Oil Pipe
Trading center (oil & gas)
Valinox Nucléaire (steam generator tubes for the Chinese nuclear power industry)
Beijing
Production and finishing facility of seamless pipesThreading facility of VAM® premium connections
Vallourec sales office
Shanghai Tongcheng
Zhangjiagang
Plants Sales and services
p.30 / The Vallourec Oil & Gas Magazine N°09 / March 2017
News Focus The tech files Solutions On the market Events People
The Vallourec Oil & Gas Magazine N°09 / March 2017 / p.31
Scott graduated in December of 1997 with a Bachelor’sDegree in Mechanical Engineering from Texas A&M andsoon after he joined Vallourec. Ever since, Scott hasbeen a key team member of Vallourec Drilling Products,participating in the teams that introduced the TM2, TM4and the popular VAM® Express™. His experience andexpertise have proved invaluable for product supportand ongoing projects. His exceptional problem solvingskills and his outstanding technical input to Vallourechas contributed significantly to the success of our products.Scott explains: "Eighteen years ago, I started as a product engineer at OMSCO, which was acquiredby Vallourec in 2006. I started out as a product engineer working with product drawings and docu-mentation, moved to the Vallourec Research Centerin Aulnoye, France, working on connection R&D, thendrill string optimization, and finally moved back toHouston. Throughout my eighteen years at Vallourec, I’ve beenfortunate to work with different teams and departmentsin the United States and in France, allowing me to callVallourec not only my place of work but my family. WithinVallourec, I’ve been able to improve my knowledge tobetter advise my team and our customers. Vallourechas always supported my professional career path, helping me learn more about how our product is manufactured and used. I must say I enjoy attendingconferences and being part of committees, includingthe API, which helps me develop professionally."
Growing with VallourecScott is now an R&D expert at Vallourec Drilling Products,responsible for Drill String Engineering and product andproject support since 2010. Drill String Engineering isa service which supports high performing drill string
design for specific drilling and landing program objectives. The service focuses on providing customers with the best drill stringsolution for their specific operations.This involves listening to the custo-mer to understand the details of theirproject and operations; then gene-rating simulations with different drillstring designs to eventually providethe customer with an optimizedsolution. Thanks to this service,Scott is able to understand the customer’s challenges, spot trends,compare products, and proposethe best customized solution. Scottproves how client intimacy and trust are crucial to deli-vering value, making Vallourec a true solution providerbeyond the pipe.Drill string engineering includes tests and field trials ofmany of Vallourec’s products, including Hydroclean,Shale Drill pipe, and landing string projects. It also contributes to finding the best solutions to customerclaims. With over 150 studies made for clientsthroughout the world, Scott’s contribution has helpedour customers mitigate risks and increase reliability when choosing a drill string.
Work Life BalanceScott concludes: "When not at work, I dedicate my timeto my family, to my wife Isabelle and daughters Coline,4, and Berenice, 2. It is a wonderful and unique experience to raise my girls both in France and in theUS. It's true that my job is challenging, but giving all myattention to the girls can take up just as much energyand patience!"
News Focus The tech files Solutions On the market Events People
I’ve been fortunate to work with
different teams and departments
in the United Statesand in France,
allowing me to callVallourec not only my place of work
but my family
ScottGranger,R&D engineer at VallourecDrilling Products
‘‘‘‘
The acquisition of Anhui Tianda Oil Pipe marks an important milestonein Vallourec’s Transformation Plan and represents a major step change toVallourec’s international industrial footprint.
Vallourec has been working closely with Tianda eversince the acquisition in 2011 of 19.5% of its share capital.The opening up of the Chinese market to foreign inves-tors and the recent modification of its steel policy enabledthe company to go even further and in January 2016,the acquisition agreement between Tianda and Vallourecwas reached. On 23rd November 2016, the Group cele-brated the successful completion of the acquisition withan official ceremony in Chuzhou. Tianda’s industrial assets include a state of the art PQF*rolling mill with 550kt capacity as well as heat treatment,threading and testing facilities. The company has 1,500employees. From the start of the partnership with Tianda, Vallourechas operated as the exclusive distribution channel forTianda OCTG exports and for hollows for premium con-nections. Now, Vallourec has put in place an integrationtask force to improve its industrial performance and to
bring Tianda in line with Vallourec’s standards in termsof safety, quality and on-time delivery.
A qualified product lineTianda has already obtained major qualifications fromChinese customers such as SINOPEC, CNPC orCNOOC and major operators and national oil companiesincluding TOTAL, SHELL, KOC, ADCO, Repsol, PDVSAand PTTEP. A detailed plan has been established todevelop the portfolio of customer qualifications for the full range of products over the next three years. Inaddition to OCTG from Tianda, Vallourec will offer VAM®
premium connections from its threading facilities in Chinaand Indonesia. Tianda will also offer line pipe to custo-mers and international distributors such as Van Leeuwenand TC Gulf. The integration process at Vallourec is always conductedwith respect of local cultures, building upon the expertiseof local management and employees. “The integrationof Anhui Tianda Oil Pipe fulfils a long-term strategic vision,”said Edouard Guinotte, in charge of the Middle East andAsia Region. “By combining Vallourec’s leadership inpremium solutions with Tianda’s highly competitive ope-rations, we are able to offer a wide range of competitiveproducts that are perfectly suited to our customers’ needsand challenges”.
Strengthened presence in China
* PQF = Premium Quality Finishing technology
5production
sites
+ 2,000employees
550 ktcapacity
seamless steel tubes
Thanks to its unique range of expertise, Vallourec provides fully integrated solutions, along with a commitment to lowering its customers’ Total Cost of Ownership. Its solutions include all the goods and services needed to enable each project, from conception to completion and beyond. Whether it is well design, supply chain management, yard management, fi eld assistance, repairs, or training, Vallourec Global Solutions guides its customers through every step of the value chain by o� ering high added value solutions that allow cost savings for operators. With its highly skilled teams available 24/7, Vallourec contributes to making all your projects possible, wherever you need us, whenever you need smart tubular solutions. vallourec.com
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