The Vallourec Oil & Gas magazine N°07 / November 2014 · The Vallourec Oil & Gas magazine N°07 /...

The Vallourec Oil & Gas magazine N°07 / November 2014

www.vallourec.com

Growing intoa major playerin Asia Pacific---------

The tech filesPURE - PremiumUpset Riser Ends

-------------SolutionsVAM® HTTC™:Groundbreakinginnovation for OCTGExtended Reach Drilling applications

-------------On the marketVallourec 2014 SalesAward for innovativeglobal solutions toTullow TEN project

-------------

Publisher: Vallourec Oil and Gas France - 27, avenue du Général Leclerc, 92660 Boulogne Billancourt Cedex - FranceEditorial Director: Damien de Montlebert - Chief Editor: Hassna Belmalek ([email protected]) – Phone: +33 1 49 09 35 83Interviews, articles and editing: Stephan Caso - Drilling section editor: Ludivine Laurent - Pipe Project section editor:Annette Karsten - Production: Zabriskie, Paris - Design: LeGrand8, Paris - Photographs: Thierry Truck, Vallourec, PT CitraTubindo, Serimax, Fotolia, Neuf&9, Stephan Caso, Patrick Fallouey, Philippe Dureuil or 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°07 / November 2014 / p.3

www.connection-mag.com www.vallourec.com

The world of oil & gas is both growing and changing. The industry is simultaneously explo-

ring new frontiers in extreme offshore environments and developing unconventional

resources. We are facing the challenge of both increasing reliability of more complex ope-

rations and improving cost efficiency to deliver the cash flow that will fuel E&P investments.

Our ambition is to support our customers in all their endeavors, everywhere in the world,

offering innovation, local value, and cost-effectiveness.

While VAM® leadership remains undisputed, when customers require the best available

technology, we are improving our supply and services model to increase our proximity

and deliver a better Total Cost of Ownership.

We are pursuing an ambitious regional development strategy with new production, R&D

and service facilities in Brazil, Europe, USA, Middle East, China and now Asia Pacific.

Our hub in Batam, Indonesia is a good example of this regional deployment. Thanks to

our 30-year partnership with PT Citra Tubindo, we are offering an integrated regional

supply chain for OCTG that provides green tubes with heat treatment and threading.

Furthermore, we have expanded our local offer to line pipe, accessories, field services,

as well as state-of-the-art testing capabilities and vast port logistics.

Reinforced by competitive local resources and our

hub expertise, we deliver premium quality with record

lead-time thanks to our latest investment in threading

capacities.

Every one of our hubs can deploy Global Solutions

that include all our products and services, blending

local resources with global support and product lines.

We are proud to bolster our local offers with cutting-

edge innovation like VAM® 21TM, VAM® HTTCTM connec-

tions for high torque, Saturnax 09 advanced welding

solution, or VM 105 DP SS+, for extreme sour service

drill pipe.

We are not just investing in the future of the oil & gas

industry, we are helping our customers shape it.

Happy reading!

Didier Hornet, Senior Vice President OCTG

and Drilling Sector


VISIT US AT…Nigeria Oil & Gas16-19 March 2015Abuja, NigeriaBooth #E104

SPE/IADC Conference & Exhibition17-19 March 2015London, UKBooth #501

NewsContents

Cover

Singapore city (Fotolia/Anekoho)

Page 6

FocusGrowing into a major player in Asia Pacific

Page 12

SolutionsVallourec and Dril-Quip:collaboration on a special production riser coupling to solve new challenges

Page 15

The tech filesPURE - Premium Upset Riser Ends

Pages 20-22-24

Solutions VAM® HTTC™: Groundbreakinginnovation for OCTG ExtendedReach Drilling applicationsVM-105 DP SS+: A new Drill Pipe grade to address increasing H2S-rich field challengesSaturnax 09 by Serimax: The state-of-the-art weldingtechnology with an outstandingtrack record

Page 27

On the market Vallourec 2014 Sales Awardfor innovative global solutionsto Tullow TEN project

0

EventsThe new Vallourec OCTG website is now live!Get our upgraded new version ofthe Vallourec Oil & Gas App now!

Page 31

PeoplePatrick Fallouey, a Maverick in Standardisation

VALLOUREC WINS AWARDFOR ITS CSR EFFORTS

Vallourec Star mill in Muskogee Oklahoma, US, was recognized for Excellence inSafety at the Muskogee City-County Port Authority annual Business and IndustryAwards. Nominated by Indian Capital Technology Center (ICTC) the Muskogee facilitiesachieved a 60% reduction in no-lost-time injuries from the previous year.

This award reaffirms Vallourec Star's cuture of safety. Kathy Adair, ICTC director commented,"They have incorporated safety into every business process and decision. They activelyseek input and feedback fromall team members... and im-plement and maintain a con-tinuous improvement-basedoccupational safety and healthmanagement system."

Gary Hauck, General Managerof Vallourec Star Muskogeeoperations commented, "Weare especially proud of thevalidation the award repre-sents. It substantiates thework we have done to streng-then our already robust safetytraining and the time and effortour team members put intothe program."

VALLOUREC STAR RECOGNIZED FOR ITS SAFETY PERFORMANCES

The Vallourec North America teams exhibited at the DUG Eagleford conventionheld in San Antonio (Texas) from September 15-18, 2014. This event bringstogether the entire industry related to this world-class shale play with 4,500+attendees, 350+ exhibitors, executive-level speakers, and hours of exclusive net-working opportunities.The many visitors to Vallourec booth discovered how the improved performancesof the casing and tubing produced at Vallourec Star, and the premium connectionsdeveloped by VAM® USA contribute to the reliability and safety of their uncon-ventional operations.According to Ronny Clark, Executive Vice President OCTG – North America, "thisconference allows us to share our know-how for onshore applications with ourexisting customers and the market as a supplier of reliable domestic solutions.The live presentations also bring practical knowledge operators can use rightfrom our booth." Experts from the North America teams presented performingproducts for optimized onshore oil and gas operations, such as steel grades withtighter tolerances and connections with proven field history.

VALLOUREC SHALE EXPERTISEAT DUG EAGLEFORD 2014

p.4 / The Vallourec Oil & Gas Magazine N°07 / November 2014

For the second year in a row, Vallourec was awarded an AGEFI Governance Prize for Corporate Social Responsibility.

This prize rewards Vallourec for its transparency and effective implementation of bestpractice in corporate social responsibility, particularly in the following areas: • employee shareholding and human resources• weighing of potential environmental impact when developing its business• fulfillment of stakeholder expectations, including those of its customers

and suppliers.

“We are delighted to receive this prize again. It reflects the quality of the dialogue wehave established with our stakeholders,” says Jean-Yves Le Cuziat, Vallourec Directorof Strategic Marketing and Sourcing. “This is a positive sign that encourages us touphold and expand our corporate social responsibility commitments.”

ONSHORE LINE PIPE & HYDROCARBONPROCESSING SEMINAR IN PARIS On 13 November 2014, the team of Vallourec Onshore Line Pipe and HydrocarbonProcessing activities held its first European customer seminar around the theme:“Vallourec – your Partner for Projects”. Representatives of the oil and gas industry,including operators, EPC’s and distributors gathered at Marriott Conference Centre inParis to learn about latest developments from Vallourec in terms of customer-drivenproject organization, specialty mills to enhance the premium offer and technologiesand innovations at the heart of Vallourec. Technical experts introduced customers tothe world of pipe manufacturing and two guest speakers from Conline Coating B.V.and Van Leeuwen Pipe and Tube Group were highlighting successful partnerships withVallourec for complex projects.The afternoon was dedicated to working group sessions focused on hydrocarbon pro-cessing and line pipe challenges, project management solutions, technical solutionsfor sour gas injection challenges and the creation of a value proposition for Fired Heaters.The positive response of the participants to the overall event has reinforced the plansof organizing a technical seminar in Dubai in 2015.

INTERNATIONAL SUCCESSES WITH THE NEW SOUR SERVICE DRILLINGVallourec’s drilling products division has beenmaking great strides in developing SourService products for the most challengingsour environments. Our commercial andtechnical success has been visible through-out the world. Recently a major land rig contractor has purchased our new VM-120DP S grade of drill pipe to drill complex wellsin the Sultanate of Oman. In South America,a major offshore service company in Brazilpurchased VAM® DPR HPTM risers developedin combination with our new VM-95 DP SS+grade, which exhibits enhanced resistanceto Sulfide Stress Cracking in the weld zone.And in the North Sea, a major IOC has beenusing our very first string of VM-120 DP MSgrade of drill pipe in the UK, and has com-pleted its first development phase success-fully.

Focus

Vallourec’s reach is sometimes the fruit of long-lasting partnerships and powerful local strategies. P.T. Citra Tubindo (PTCT), in Indonesia, is a striking example of such partnerships. In under 30 years, PTCT has grown from a local company into a world-class partner of Vallourec throughout the Asia Pacific area and beyond.

Growing into a major player in Asia Pacific

The Vallourec Oil & Gas Magazine N°07 / November 2014 / p.7p.6 / The Vallourec Oil & Gas Magazine N°07 / November 2014

/...

PTCT’s facilities are located in Kabil Integrated IndustrialEstate, Batam, Indonesia, and provide heat treatment,Premium connections such as VAM® and other pro-prietary OCTG products in addition to oilfield acces-sories and a wide range of services and logistics solu-tions. Together, we can cover most of the tubular needsin Oil & Gas of all the major National and InternationalOil Companies. As partners, ourscope has expanded vastly, andwe can now deliver high-value global solutions worldwide with adedicated focus for the regionalAsia Pacific market.

On the road to successwith powerful localcontent Partner The story of PT Citra Tubindobegan with founder CEO KrisWiluan, in 1983, on the island ofBatam, Indonesia, located just20km south of Singapore. The company started with aprocessing facility that delivered pipe threading for seam-less pipes as well as couplings and oilfield accessories,predominantly for its domestic market. PTCT, under theleadership of Kris Wiluan and a strong partnership withVallourec, developed quickly, becoming a VAM® licenseeas early as 1985 and an associate of Vallourec sinceits public listing in 1989. By 1994, in addition to con-nections and accessories, PTCT had integrated its original pipe threading plant with a state-of-the-art OCTGprocessing center that contained the first tubular heattreatment facility in Southeast Asia. Three decades afterits foundation, PTCT has grown into a major logisticscenter, boasting a vast facility that includes OCTG and

drilling products, accessories as well as an all-encom-passing port that delivers far beyond Indonesia.Kris Wiluan shares the early strategy of the company:“We started off with a profound desire to be a part ofthe energy sector as it plays such an important role in the development of our country. Indonesia has considerable natural resources and we were proud to

help contribute to the wealth of the country. Our philosophy has beento bring local answers for the pro-duction of oil and gas in the verycountry where these resources areexploited. We have sought to bringcompetitive answers efficient logis-tics to a fast-growing industry whilestimulating our national growth.” Didier Hornet, Senior Vice PresidentOCTG and Drilling Sector, adds,“With partnership with PTCT,Vallourec is closer to all its custo-mers in Asia Pacific. We can provide

faster responses to their needs and requests and relyon a powerful local network to deliver even the mostdemanding customers. We best serve our clients whenwe work with PTCT’s local resources and logistics.Together, we have a unique insight on the Asia Pacificmarket and a privileged strategic proximity. Our reachover this vast area is definitely enhanced by the powerfullocal content of PTCT.” But the conquest of the Indonesian and Asia Pacificmarket was no easy task, as Kris Wiluan continues:“Our challenge was to face the huge demands andpotential of our oil fields and prove we were able to supply the materials, equipment and services locally.It was quite a task, as we started from scratch. We built

our teams, our expertise and know-how step by step.We were able to demonstrate, very early on, that wecould indeed answer the requirements and specificationsof Oil & Gas companies. With time, we widened andimproved our spectrum of services and capabilities, showing we were able to exceed expectations, deliveringricher and more comprehensive solutions to a growinglycomplex market.”

Batam, a port at the heart of PTCT’s reach PTCT’s Kabil port in Batam is unique and strategicallylocated, with 78.4 ha of infrastructures. The deepwaterport is at the very heart of the industrial center, providingthe infrastructure and reach to serve global export of allthe company’s products and services worldwide. Today,over 75% of its products are shipped to major InternationalOil Companies as well as State Oil Companies, from Batam. The port can support all operational requirements for off-shore drilling as a logistics and operational base for oiland gas companies, logistic companies and industriesto stock and fabricate oilfield equipment, including jettyservices, stevedoring, trucking, wharfage, open storageyards, and warehouses.

A vast array of products and servicesPTCT manufactures a wide range of pipes, connectionsand accessories. The seamless pipes heat treatment plant has an annualproduction capacity of 120,000 metric tons and canproduce pipe sizes ranging from 2-3/8” to 13-3/8” in bothstandard API, Premium and proprietary grades. The company manufactures thread protectors and packagingsystems for threaded pipes through integrated solutionsto reduce the dependency from other suppliers.

Supplying accessories and maintenance in record timeShort delays and reactivity are the very nature of the acces-sory activity, and PTCT delivers according to customerneed, from a couple of weeks down to a couple of daysafter order. PTCT supplies Pups, Cross-overs, lifting equip-ment, TMC services (threading) on completion and well

With partnership with PTCT, Vallourec is

closer to all its customers in Asia Pacific.


‘‘

‘‘

News Focus The tech files Solutions On the market Events People

• Threading of seamless pipes from 2-3/8” to 20” in diameter, according to American Petroleum Institute (API) standards.

• Manufacturing of couplings in accordance to APIstandards.

• Drift testing and alignment of pipes, hydro-testingthe pipes to withstand specific pressure.

• Surface treating of threads and couplings suchas phosphating, tin-plating, copper-plating andzinc-plating.

• Inspecting, repair and cleaning of pipes and theirthreads.

• Producing various range of threads and accessoriesbased on licensing agreements from the world’sleading seamless pipes producers, including thetechnical services from Vallourec for manufacturingand repairing threaded pipes and accessories ofVAM® and BIG OMEGA®.

• Thermal Spray Alumunium (TSA) coating for specialpipe corrosion control.

All within record supply lead time for the region.

Pipe Threading and services

PTCT in Batam,Indonesia, justacross the waters of Singapore, at the heart of Asia Pacific.

The world-class threading facility supplying the full range of VAM® and NS® products.

TESTING FACILITY

heads. Thanks to its OCTG core business, PTCT alsosells base pipe for sand screens.As accessories are a specific market segment, PTCT setup a workshop with a dedicated team to offer optimalservice. Flexibility is of the essence and the accessorydepartment can deliver all items for connections rangingfrom 2 3/8” to 22”. In addition, the facility’s workshop canalso handle the maintenance of OCTG and Drilling con-nections, including the most complex products like VAM®

BOLTTM and VAM® 21TM.

The most advanced testing facility in Southeast AsiaWith Oil & Gas companies exploringand drilling in tougher oil fields and environments, product behavior is key:testing the performance of all productsand accessories is crucial to ensurewell integrity. To verify the reliability of the final product, a fully calibrated in-house inspection facility was createdby PTCT to carry out a large number

of destructive and non-destructive tests. In addition, Citra Tubindo created an in-house Connection Deve-lopment Evaluation Centre (CDEC), under VAM® qualitysupervision, to perform combined load gas testing forpremium connections. The center houses a 1,000 tonhorizontal load frame providing axial loading in ten-sion and compression, internal and external pressure

application, bending loads and elevated temperature testing. Also located within the CDEC facility is the CNCthreading and torque/turn, stress/strain, equipment.Validating performance in specific well conditions caneven help improve the design for each specific well. The Batam facility is unique in the region: Vallourec and PTCT can claim having the most advanced and comprehensive testing facility in the Asia Pacific area.

DESTRUCTIVE TEST • Tensile Test• Spectrometer Test• Hardness Test• Charphy Test• Metallography Test• Collapse test.

NON-DESTRUCTIVE TEST • Special End Area Magnetic Particle

Inspection of the pipes • Magnetic Particle Inspection• Ultra Sonic testing�• Electro Magnetic Inspection • Hydrostatic Test�• Dimensional Inspection.

Global Solutions. Building a strategy for the future“Asia Pacific is a very competitive area. Selling even the widest range of products isn’t enough to remain an influential player in the industry of Oil & Gas, especiallywith so many low-cost suppliers blossoming in Asia…”explains Kris Wiluan, “In our Oil & Gas industry today, we aim to be higher in the food chain. We can supply port logistics, repairs and maintenance, training, local organization and oilfield services in addition to our products because this is where we can bring value tothe market. With our sister companies, we are even widening our offer to supply rigs and field equipment.” A remarkable example of a Vallourec’s global solutionsoffer is the ongoing Total Brunei project that combineshigh-end premium products and PTCT’s best logisticsand services (see box). In addition, Vallourec will enhance its Asia Pacific areaoffer with solutions for subsea, supplying offshore linepipe for SURF projects with PTCT. Vallourec will be delivering 7,118 tons of flowline to Technip for the Jangkrikgas field development project (for Eni Muara Bakau B.V.,the Operator of the Muara Bakau PSC, off the coast ofMakassar Strait, Indonesia).

Didier Hornet concludes: “Batam proves a powerful hubfor Vallourec’s reach in Asia Pacific. PTCT is a key partnerand its wide scope of logistics and services are a majorasset in a highly competitive area. We are confident wecan continue to expand our reach in the Asia Pacific bycombining innovation, strong local value and bold globalsolutions for our most demanding customers!”



Superior solutions for the most challenging operating conditions

The Total Brunei project will be operated by Total’s affiliates Total E&P Borneo, in Brunei and will be operating in extremeenvironments. The development wells will be producing at depths greater than5,000 m, in a highly corrosive environment and sustaining HighPressure/High Temperature. These conditions position the project at a new frontier of field development. This project consolidates Vallourec’s leadership in premium solutions for theOil & Gas industry operating in very complex environments andits position as a strong global solutions and local player.Didier Hornet declared: “We are honored to have been selectedby Total for this complex offshore project. This contract recognizesVallourec’s ability to provide the most advanced premium tubularsolutions and services in the most challenging environments.We will work alongside Total to develop the local contributionand deliver the highest value to this project.” Vallourec will equip the wells with premium pipes, the majorityof which is high alloyed, corrosion-resistant grades, threadedwith its latest premium connection VAM® 21TM. Casing and tubingwill be manufactured in Vallourec’s European & PTCT plants,with the logistics and facilities of PTCT. The drilling operationsare scheduled to start in the second half of 2015.

Project content: a new frontier for materials & connections• Connection types

- Latest connections: VAM® 21TM & VAM® HPTM

- 5 dimensions tested under the most severe conditions- 3 out 4 R&D qualification engineers / 18 months of tests

• Materials- VM 125 SS- VM 110 13ECRSS CY: enhanced Super 13%Cr- VM 22: material and QC at the highest limits

• Accessories- Fit-for-purpose products (Inconel, drill cross-over blank pipes, etc).

A very efficient organization• Dedicated project team set-up with key account

management organization• Dedicated plant, QA/QC, sales focal points• Monthly follow-up meetings with Total Brunei drilling team.

Global services • Advanced Logistics

- Production hub with PTCT giving high flexibility and verystrong reactivity to Total requests

- Logistic focal point based in Singapore with technical supportand Operations General Management

• Local content requirement- Local VAM® Field Service Branch- Local maintenance and repair solutions with PTCT.

The Total Brunei Project

Make to order,short lead time,stock management,PTCT offers a fullscope of logisticsand services.

Our challenge was to face the huge

demands and potential of our oil

fields and prove wewere able to supply

the materials, equipment and services locally.

‘‘

‘‘

The Campos Basin tension leg wellhead platform (TLWP)project called for a high fatigue resistant coupling tomeet the environmental and system loading conditions.Furthermore, for flow assurance, the riser is coated with2 in. of thermal insulation. The insulation and the requi-rement for cathodic protection created several challen-ges for running the riser and for attaching the earthingstrap to each of the submerged riser joint couplingswhile ensuring electrical continuity.

A single internal handling toolDril-Quip has previously developed internal running tools(IRT) for use with their PR-80™ riser couplings alongwith numerous other marine riser connections. The production riser systems for the TLWP are designed

with weld-on and threaded and coupled riser joint connections. The utilization of two types of joint connectors results in a reduced string weight while meeting the high fatigue resistance and loading requirements. Seeing the opportunity to provide a singleriser joint handling tool to run both types of riser con-nections, Dril-Quip worked with Vallourec to developthe special VAM® TTR™ coupling with an internal hand-ling profile, as shown in Figure 1. The major benefitsfrom the single IRT include minimized rig operations andreductions in required backup equipment. As the ope-rator changes between the various riser joints (PR-80™and VAM® TTR™) and specialty joints, the same runningtool is utilized to eliminate down time in changing outequipment as well as reducing operator error by main-taining the same functionality in tool make-up. Dril-Quip’sIRT is hydraulically operated and functions with an internalpiston actuating radial segments into the internal handlinggrooves of the coupling. The tool is designed with mechanical secondary locksand visual indicators to provide positive tool make-upwhen fully installed in either the Dril-Quip PR-80™ orVallourec’s VAM® TTR™ coupling. The PR-80™ and VAM® TTR™ internal running tool wassuccessfully load tested to 2.25 times the tool rating inboth couplings to industry requirements.

New features for VAM®

Based on the design proposed, Vallourec tookthe challenge of incorporating the new featuresinto their 14” VAM® TTR™ connection. The VAM®

TTR™ connection is a field proven design thatfeatures an internal metal to metal seal, fatigueenhanced threads, fatigue bending profile(swoosh) and external metal to metal seal. It wasfirst successfully run 10 years ago in the Gulf ofMexico and since on multiple products. Through Finite Element Analysis (FEA), the couplingdesign with internal handling grooves was modeledand tested to verify there were no adverse effectson the tension, compression or fatigue perfor-mance of the connection. The FEA simulated theload steps of an ISO13679 CAL-III test on the pipeand connection using techniques developed byVallourec within the elastic-plastic strain metho-dology. Comparison of the new coupling designto Vallourec’s large library of FEA and physicaltesting of similar connections showed positiveresults. The stresses in critical areas of the specialcoupling are consistent with standard VAM® TTR™connections.

Outstanding testing resultsFollowing FEA evaluation, physical testing wascompleted to further validate the coupling design.Vallourec performed a full ISO13679:2002 CAL-IIItest of the VAM® TTR™ connection in addition tofatigue testing utilizing six samples. The connec-tion test results matched the FEA in tension, andmost importantly in compression, as this was thearea that could be most affected by the presenceof the lifting grooves. The internal handling profile,as well as the anode threaded attachment hole,presented areas of high stress concentrationswhich potentially could limit the fatigue life of theconnection. Dril-Quip took this into considerationwhen creating the shape of the internal handlingprofile, allowing large radii and smooth transitions.However, the threaded area of the anode attach-ment hole, with its sharp thread start, was still anarea of special interest. In order to mitigate poten-tial concerns, Vallourec subjected the connectionto fatigue cycles using the eccentric mass cyclicbending method, shown in Figure 2. In thismethod the pipe and connection experience apredetermined stress via bending induced by aneccentric mass. The resulting alternating bendingmotion resembles that of a school ground jump–rope at 20 to 30 Hz. By subjecting the VAM®

TTR™ connection and pipe to the fatigue stresscycles, it was demonstrated that the connectionwas able to achieve over 6,000,000 cycles witha resulting SAF of less than 1.5 using the DNVB1 2005 curve (air). This high level of fatigue per-

formance gave great confidence inthe coupling design and allowedmanufacturing to move forward.

From the drawing board to manufacturingSince the internal handling profilebecame an inherent part of thecoupling design, Vallourec had toidentify the best way to machine theprofile using standard manufacturingprocesses. The most critical pointwas to machine the IRT handlingprofile in the correct location withinthe specified tolerances while main-taining the production efficiency.Typically the shoulder region doesnot require high tolerances thus allowing the coupling face to shoulderlength to be controlled tightly. Thekey innovation to success was to design a single direction high tolerance coupling. For standardcouplings both sides A and B areidentical; no distinction is made forwhich side can be made up to thepipe pin thread. However, in orderto accommodate proper IRT make-up, the internal profile was indicated off of onecoupling side during machining. This “quality con-trol by design” method drastically reduced thereject rate such that the coupling could be manu-factured in an economically viable way. In orderto ensure visual identification of the high toleranceIRT engagement side, a special band was paintedon the coupling along with an explicit instructionprocedure for coupling to pipe makeup. The firstmanufacturing order of the pipe and couplingswas completed in late 2012.

The success of a partnershipWhile the project presented challenges and required new developments, the design synergyprovided the greatest benefit to the end user byreducing operational time and risk. The productionriser coupling met all performance criteria andwas successfully manufactured to meet the project demands. Dril-Quip’s knowledge andexpertise in designing and creating running tools,as well as Vallourec’s VAM® Riser connectiondeveloping, testing, and manufacturing expe-rience, allowed the two companies to create thisinnovative solution.

Darren Mills, Capital Equipment Engineering Manager, Dril-Quip, Inc. Michael Tricarico, Technical Sales Managerfor Threaded and Coupled Risers, Vallourec USA. Article ran in the August issue of Hart’s E&P and is beingreprinted with permission.




Vallourec and Dril-Quip, leaders in riser systems, collaborated on an innovativedesign and manufacture of a special couplingto meet the installation requirements of asingle barrier top tension production riser.

Collaboration on a specialproduction riser couplingto solve new challenges

Vallourec and Dril-Quip

Figure 1:Dril-Quip Riser Handling Tool installedin VAM® TTR™ and PR-80™ Riser Couplings.

Figure 2:VAM® TTRTM riser coupling during fatigue testing.

#07

/...

��News Focus The tech files Solutions On the market Events People

PURE -PremiumUpsetRiser Ends

PURE

orbital

welding.

PURE is a ready for service solution for offshore applications developed by Vallourec specifically to eliminate

the need for pre-matching pipe ends and to give more consistent fatigue

performance.



p.16 / The Vallourec Oil & Gas Magazine N°07 / November 2014 The Vallourec Oil & Gas Magazine N°07 / November 2014 / p.17

Driven by Deepwater,the new frontierThe ongoing shift towards deepwater and ultra-deepwater

fields in Oil & Gas calls for more specialized and superior

technologies in pipe design and metallurgy. These new

solutions must overcome increasing technical cons-

traints while reducing project and operational costs.

Deep and ultra deep field constraints, like high pressure/

high temperature, high fatigue loads and stresses, lead

to a high level of technical and safety requirements to

ensure end-to-end integrity.

With exploration in offshore areas for Oil & Gas extending

to deeper waters, Vallourec has set out to develop pro-

ducts that can withstand increasing workloads in more

extreme environments. High resistance against fatigue,

in combination with optimized tolerances at pipe ends,

are therefore crucial in selecting products for steel catenary

riser (SCR) applications.

The main target for expanding the possibilities of SCR

applications is to significantly enhance fatigue life.

Technically, that means optimizing the riser pipe-end

and welding capabilities to guarantee superior fatigue

performance.

PURE stands for “Premium Upset Riser Ends”. It is

a ready-for-service solution for offshore applications

developed by Vallourec providing an assured pipe end

match, minimum stress concentration factors as well

as an unaffected media flow. A complex heat treatment

and an optimized chemical composition result in assured

mechanical properties over the entire upset end line pipe.

WeldabilitySAIPEM, a major EPC in the market explains : “Thecosts of subsea projects increased a lot, driven bychallenging applications like HP/HT, Deepwater, andhighly corrosive environments. In this context, thewelding operations contain a high saving potential within the supply chain (lower defect rates, faster ope-ration). It is important to be aware of the risks at anearly stage of the project and to share the responsibilityof saving costs between all parties involved in the project. This includes the features of the pipe in termsof materials and geometry which have direct impact on the weldability.”

Welding qualification requirements are indeed getting

more and more demanding and can be a critical factor

as they can seriously delay a project (delays can

amount to 1 million$/day in cost). Today, the biggest

challenge for ultra-deepwater projects is that clients

are requesting both higher yield strength and heavier

walls at the same time. This simultaneous increase of

both characteristics was a barrier until PURE was deve-

loped. High strength steel and wall thicknesses above

1.0 inch, make it very difficult to meet all the corrosion

standards required by NACE1

in the weld, including

the heat-affected zone. GeometryFurthermore, the geometrical features of the pipe

have a considerable impact on the welding. For Steel

Catenary Riser applications, counterbored pipes, and

even end-trued pipes, have more limitations than an

upset pipe end. Upset pipe ends are ideal as upsetting

does not display any eccentricity and machining is

perfect: all pipes ends are concentric to each other.

This enables an efficient, quick and constant fit-up

of the pipes, operating with a very low repair rate.

SAIPEM confirms this with hands-on, with their field

experience: “This is a great contribution to the produc-tivity of our laying vessels. Our experience with theinstallation of PURE Riser for the P55 project offshoreBrazil has convinced us that our common route withVallourec is the further development of pipe end solutionconcepts like PURE.”

Vallourec PremiumTubular SolutionsThe development of innovative pre-material is key.

Vallourec is well established in alloying concepts for

the X65 and X70 grades with high strength properties.

Saipem has successfully pre-qualified the pipes for

the Total EGINA project, for instance. Our collabora-

tion comprises a full qualification of high strength

steel chemistries, which meet Saipem’s requirements

in terms of weldability.

#07

1 - NACE is a standards-writing organization accredited by the American National Standards Institute (ANSI).

There are three categories of NACE standards: Standard Practices (SPs), Material Requirements (MRs) and Test Methods (TMs).

PURE pipe end

after machining.

PURE

dEsign



PURE MAIN FEATURES

• Internal and external upsetting of pipe ends with subsequent machining to perfect geometry

• Perfect ID tolerances of +/- 0.001 inch (+/- 0.25 mm)

• Enhanced OD tolerance of +/- 0.003 inch (+/- 0.75 mm)

• No pipe end misalignment

• Easy line-up for welding

• Enhanced fatigue properties

• No need for end machining at location and no need for pipe sorting or end dimensioning

• Uniform wall thickness and surface finish for reliable AUT (no need for various calibration blocks and thus

reduced inspection time

• Available in sizes 8 5/8” (219.1mm) up to 16” (406.4mm)

• PURE design is feasible for reel-laying

ConclusionAfter extensive testing, the PURE design has successfully

been used by major Oil & Gas players in deepwater offshore

conditions. The PURE design meets the most stringent

requirements in terms of fatigue life as well as end dimen-

sioning tolerances.

As new offshore discoveries go deeper the need for increased

fatigue life will be of major importance together with

reduced times for line-up and welding. Vallourec is once

again a pioneer and leader in developing and industrializing

the most complex solutions for the most demanding Oil &

Gas players in the world.

The ProcessTo realize optimal pipe end tolerances for Hi-Lo’s2 in offshore

installations, the pipe ends are upset at the outer diameter

(OD) and inner diameter (ID). Upsetting is followed by a full

body heat treatment. Afterwards, the inside and outside of

the pipe ends are machined to achieve the inner diameter

tolerance of ± 0.25 mm and the outer diameter ± 0.75 mm.

Since the upset pipe end is machined to nearly original

nominal wall thickness, there is no weight increase of the

product. Eccentricity and out of roundness are no longer

a concern. The flow assurance is unaffected. During

laying operations, each PURE steel catenary riser and

subsea flowline can therefore be immediately welded to the

following pipe with optimal processing parameters, without

prior sorting, thus requiring less weld re-work and cut-outs.

2 - Hi-Lo stands for the difference of either the external ot internal diameter of 2 pipe ends which will have to be welded together. The bigger

the Hi-Lo the less mechanical strength the final weld will have.

#07

In operation, PUREresults in a significantlylonger service life of the

weld under dynamicstress conditions.

‘‘ ‘‘PURE pipe end

after upsetting.



Vallourec enriches its VAM® premium connections offer fortubing and casing, creating a new benchmark in high torquecapability, high tensile efficiency and gas tight sealability.Aykut Yanik, Marketing and Technical Senior Manager forVallourec in the Middle East tells the story: “In 2009, ZADCO(Zakum Development Company), was working on behalf ofAbu Dhabi National Oil Company in conjunction with ExxonMobil. They decided to build a network of artificial islandsamid the Arabian Gulf rather than offshore platforms. A choiceencouraged by exceptional circumstances: the seabed offthe shores of Abu Dhabi is robust and shallow (6-13 meters).In this instance, artificial islands for Oil & Gas are cost effectivein this area where running an installation on firm land is lesscostly than running an array of several offshore platforms.Fields are safer and offer the convenience of onshore exploi-tation. Technically, however, the island network requires alarge amount of connection for long horizontal wells ratherthan for vertical wells to reach the fields, and, in addition,offer superior torque capability while preserving 100% tight-ness. These connections needed to outperform anythingavailable on the market.”Leonardo Azeredo, Marketing & Technical Sales, pro-duct leader for VAM® HTTC™, continues: “To answer the challenges of this project, Vallourec set off to design andengineer a cutting-edge technological solution, VAM® HTTC™,that delivers extreme torque capabilities while ensuring fullconnection integrity.”

Building a solution together: a worldwide achievement for VallourecVAM® HTTC™ is the fruit of an impressive global partnership,within Vallourec and beyond. Many players worked togetherto design, validate and qualify every phase of the development.Leonardo Azeredo explains “The main design, developmentand testing was carried out in our Houston R&D facility andwas managed by the business manager in France, with thesupport of our R&D facility in Aulnoye. Experts and technical

sales were mobilized in the Middle East, Europe and theUnited States, cooperating continuously with the end-user in Abu Dhabi, ZADCO, as well as with ExxonMobil.”Aykut Yanik continues, “Beyond the technical achieve-ment, this was a fantastic experience in terms of relationsand communication. Coordination was a daily challenge,considering there were so many different players in theproject, in so many different places. In this kind of deve-lopment, communication is key at every stage of rese-arch, engineering and qualification, especially when youconsider we had to work in a narrow timeframe and bea-ring in mind the huge technical barriers we had to break.”

Technical challenge and qualificationWith previous existing connections, the limit of torquetolerance would draw the line of mechanical and drillingcapabilities. But as end-users have started requestingboth higher technical performance and safer, more reliablesolutions, we were challenged to design a new, superioroption for the market. The remarkable feature of VAM®

HTTC™ is that we have brought torque performanceconnections to a whole new level, with a self-lockingcapability that guarantees the connection is operationaland sealed.“After we have applied this extreme high torque to theapplication, the connection remains gas-tight. You mustunderstand that well integrity is paramount! Optimal performance must be maintained, even after maximumtorque is reached. That is what we have achieved andthat’s what makes the difference for the client.” explainsLeonardo Azeredo.In addition to the most stringent Vallourec testing protocols,technical qualification was successfully run throughExxonMobil’s own connection test procedure, consideredamongst the most demanding in the world. VAM® HTTC™has proved a superior and reliable solution, above all otherexisting options on the market.Aykut Yanik continues: “Technical qualification rounds arestill ongoing and should be finalized by December 2014.Commercially, the first awards for the artificial islands should

be attributed in Q1 of 2015. Hoping we are awarded, firstdelivery is expected towards the end of the year 2015.”

Ready for the future!Leonardo Azeredo concludes: “Beyond the artificial islandsproject, this is a high-value niche product: wherever youcannot drill vertically, then VAM® HTTC™ is the ultimate tor-que capable product and safest solution for lateral drilling!”

Extended Reach Drilling (ERD) market was looking for new technical solutions for the toughest long reach oil fields.Vallourec designs new extreme high torquepremium connection for ERD applications.

VAM® HTTC™

ERD schematicmade by Vallourec.

VAM® HTTC™ in a nutshellAPPLICABLE RANGE• Available soon from 3 1/2" to 11 7/8”

Standard, alternative and special drifts• Carbon, Martensitic stainless steel (13%Cr & Super 13%Cr), Duplex, Super

Duplex and Nickel base Alloys. Yield Strengths from 80 ksi to 125 ksi.

APPLICATIONS• Extended reach wells and horizontal wells with long laterals• Rotating while cementing • Drilling with casing/reaming with casing• Production casing, tie-backs and liners.

PERFORMANCE• Sealability as per the most stringent outcoming test procedure API

5C5:2013 CAL-IV• Tension: 100% PBYS capacity• Compression: 80% CYS compression for sealability

(100% PBYS uniaxial compression)• Internal pressure: 100% pipe pressure rating• Collapse: 100% Pipe collapse• Bending: 95% PBYS capacity (40% under ISO)• Extreme high torque capacity.

BENEFITS• Extreme High torque capability (2 times above standard premium)

allowing string rotation through highly deviated & long lateral sections• Full sealability performances as per API: 2013 CAL IV maintained even

after high torque application• Simple, reliable and easy running.

20” Surface Casing

VAM® HTTCTM 9 5/8” Production Casing

VAM® HTTCTM 6 5/8”Production Liner

13 3/8” Intermediate Casing800.00 m

9,175.00 m12,700.00 m

4,700.00 m


Groundbreaking innovationfor OCTG Extended Reach Drilling applications

Steel tubular products, such as drill pipe, may beexposed to Hydrogen Sulfide (H2S) during drilling operations in the event of well control loss, or if thedrill pipe are used with under-balanced drilling tech-niques. When one or more factors are combined, thiscontact can lead to a crack initiation that can propa-gate and lead to catastrophic failure, and this evenwith stresses largely below the yield limit of the steel.With the increasing demand of gas worldwide, somehighly sour oil and gas reservoirs have been exploredin Russia, the Middle East, China and North America.The development of such fields, which contain a highpercentage of sour gas, represents significant drillpipe integrity and operational safety challenges. Thecombination of tubular failures due to Sulfide StressCracking (SSC) and rising HSE concerns when dealing with sour gas have led the industry to developnew drill pipe grades with enhanced resistance toSSC.

Highly Sour Fields: A New Frontier Some highly sour oil and gas reservoirs are currentlybeing explored with H2S content beyond what couldhave been imagined a decade ago. In order to explore,appraise and develop these new fields, which oftencombine sour and deep/complex well profiles, significant safety challenges must to be overcome,including maintaining drill pipe integrity. From a normative standpoint, regional initiatives con-tinue to be influential, with the upcoming revision ofIRP Volume 1, but also the emerging use of IRP Volume6 in the industry. This volume addresses critical sourunderbalanced drilling, and, although it was publishedin 2004, it has only been used recently. Furthermore,the Chinese government has put together its ownstandard placing more stringent requirements on SourService drill pipe used in sour gas wells. The standardwas issued by the National Energy Administration ofChina and implemented in 2012*. The specificationis largely influenced by sections 1.8 & 6.3 of the IRP

Standard, and includes high strength steels and SSCrequirements in the assembly zone of the drill pipe. From a product point of view, the new challenges asso-ciated with particularly sour fields require innovative,highly engineered, drill string solutions to increase thesafety margin related to SSC failure risks, especiallyin the upset and welded zones.

Vallourec’s Latest Innovation to Address Drilling Challenges in High H2S EnvironmentsVallourec is a premium manufacturer of drilling products. We are perpetually developing new gradesable to extend the current drilling envelope, andpushing the frontiers of sour gas development, safely.One of our latest products developed to addresshighly sour fields, VM-105 DP SS+, exhibits SSC resistance in the weld and pipe body upset areas,exceeding IRP 1.8 requirements. Sour Service drillpipe have long been used with tool joints and tubesfulfilling separate criteria for Sour Service as defined

by IRP. Both the upset area and the friction weld weremore vulnerable in terms of SSC resistance due tometallurgical factors, such as the heterogeneity of themicrostructure, different chemical compositions between the tool joint and the pipe body, as well ashigh hardness values close to the weld line.To achieve our outstanding results, we implementedseveral improvements in drill pipe tool joint chemistryand post-weld heat treatment. As a result, the hard-ness gap between the pipe body and the tool jointhas been significantly decreased. The weld line is nolonger distinguishable using micro-hardness map-pings, indicating a more homogeneous microstructure.The SSC resistance of both the welds and upset areashas been assessed according to the NACE TM177Method A and Solution A. This new grade of drill pipehas been fully qualified to provide higher safety marginscompared to any other existing grades on the market.

Vincent Flores, Global Product Line Manager, Vallourec Drilling Products.

p.22 / The Vallourec Oil & Gas Magazine N°07 / November 2014 The Vallourec Oil & Gas Magazine N°07 / November 2014 / p.23


VM-105 DP SS+

It is well known that H2S is hazardous to human health, living organisms,

and more generally to the environment.Historically, this is the reason wells

containing sour gas were often carefully plugged and abandoned.One of the latest drilling products

developed by Vallourec to address highly sour fields, VM-105 DP SS+, exhibits SSC resistance in the weld

and pipe body upset areas, exceeding IRP 1.8 requirements.

A new Drill Pipegrade to address

increasing H2S-rich field

challenges

The SSC resistance of both the welds and upset areas has been assessed accordingto the NACE TM177 Method A and Solution A.

* Petroleum and Natural GasIndustries – OCTG used forspecial environment. Part 2-Drill pipe used in sour oil &gas fields (National EnergyAdministration of China,2012).

An amazing system, “made for welders by welders”This new system also meets customer expectationswhen it comes to cut-back reduction. The cut-back is the distance over which the end of the pipe is bare,with the coating removed. The more the cut-back isreduced, the less pipe protection materials need to be

installed on the production line, and the fewer materialsneed to be transported to the laying site. Saturnax 09reduces this cut-back distance by about 70 mm on ajoint to be welded in the case of a concrete element at90°, and with a concrete element at 45° can evenreduce it to 100 mm. With the operational involvement of our internal expertise

A versatile, advanced welding solution The fact is that this new unit is extremely versatile, withthe ability to handle multiple welding processes, whichallows us to offer�customers a unique tool with a hugescope of applications, and to ensure compatibility withall kinds of pipeline projects. The processes that can

be accommodated range from the traditional DualGMAW to the Dual PGMAW, covering the CMT (coldmetal transfer) process as well. Through our continualimprovement process, the evolution of this latest bugand band system is capable of welding on any type ofedge� (V, J, K) in any position (1G, 2G, 5G, 6G), onSerimax Classic bands.


The CLOV project was located offshore Angola, in the vicinityof Girassol, Dalia and Pazflor fields. Operated by Total E&PAngola, the CLOV SURF contract was awarded to Subsea 7. Itwas the first real-world mission for the Saturnax 9, in 2013.Serimax had won the pipeline welding scope of work onboardSubsea 7’s flagship vessel, the Borealis, and was eager to testthe Saturnax in a full-scale project. The workscope includedwelding 10” and 12” X65 pipes over 120 km in the J-Lay positionand approximately 20km in S-Lay, with production estimatedto take nine months. The award came after successful prelimi-nary weldability tests operations with Subsea 7 onboard theAntares and Polaris vessels.

The CLOV Project was the first outing for Saturnax 09’s, usingthe pulsed GMAW dual-torch process. A dedicated Project andWelding Engineering Team had been assigned to CLOV, workinghand-in-hand with the R&D and Operational Methods Team tosupport Subsea 7 for seamless integration of the new technologyand processes onboard the Borealis.The Saturnax 09 welding equipment operated for 7 months onboardSubsea 7’s pipe laying vessel, Seven Borealis. Serimax success-fully completed its mission in August 2013, having accomplishedaround 5,500 welds on pipes, including corrosion and fatigue-sensitive sections, exceeding client expectations, with recordwelding times and minimal repair rates.

2013 - CLOV: The first operational success for the Saturnax 09First project in APAC region using the new Saturnax 09, theDamar project successfully delivered 1,768 CRA welds with 1.13%repair rate. For Serimax, it is also a good and first track recordboth of CMT application on CRA production worldwide and ofthe use of Scanvision (internal camera) in this region. Besides,Serimax integrated the OMS expertise on pipe dimensioning(onshore) and pipe SmartFitTM (offshore) to achieve HiLo requi-rement.This project required dynamic planning, with short mobilizationnotice for equipment as well as personnel. Serimax also ensuredsuitable training when assigning new roles such as ScanvisionTechnicians or Technical Supervisors and Dimensioning

Operators. Moreover, a close coordination with �the internal teamas well as risk anticipation helped meet the client’s expectationsin terms of quality, safety and schedule.The outcome? Gaining experience on Saturnax 09, CMT,Scanvision and technology transfer to the Asia Pacific region.The project also widens the reach and potential of advancedtechnologies for future missions in this area.In addition to the CLOV and Damar projects, the Saturnax09 performed outstandingly in the Block 31 project inAngola, the Ofon 2 project in Nigeria and the Martin Lingeproject in Norway, setting a new standard in the industryand making Vallourec a leader in welding services.

2014 - DAMAR project in Malaysia:�The Saturnax 09 winning over Asia Pacific

Saturnax 09 by Serimax

The state-of-the-art welding technology with an outstanding

track record

Welding is at the heart of onshore and offshore projects and constitutes one of

the most crucial stages in the field. To satisfythe specifications of the various different line

pipe types (CRA, Deepsea, Structural, andArctic), technically demanding projects, and

a higher level of precision, Serimax hasdeveloped a new groundbreaking welding

bug and band system with an extensiverange of application: the Saturnax 09.


/...


Saturnax 09 is a versatile bug and bandwelding system for premium materials. It offers enhanced productivity and qua-lity as a result of its multi-welding capa-bilities and two independent stick-out system. It is also possible to deploy up to four synchronized bugs on pipes over22 inches.

Saturnax 09 is lightweight and allows forreduced cut-back to minimize on-site coa-ting operations. Its advanced plug & playmodular concept will help reduce mainte-nance crew costs and the welding skillsprofile required on-site. What’s more, withits built in fume extraction systems, it alsoexceeds even the most stringent HSErequirements while protecting our person-nel and the environment.

BENEFITS• Enhanced productivity • Multi-welding process�• 2 independent stick-out• Up to 4 synchronized bugs • Integral and real-time QA/QC • Reduced overall pipe laying costs • Reduced cut-back• Reduced spare parts • Integrated fume extraction.

EQUIPMENT MAIN DESCRIPTION• Overall Dimension:

L=250mm x W=420mm x H=366mm• Bug weight: 15kg• Operating Temperature: -40°C to +60°C• Bevel: Narrow Gap J type & API V type

Bevels.

PIPE DIAMETER CAPACITY�OD min• 6.63“ / 168.5mm�WELDING POSITION

CAPACITY�5G (S lay, Landlines) �2G (J-lay)�1G (Prefab, DJ)�6G (Fabrication, J-lay).

PROCESS SPECIFIC CAPACITYWelding processes:

• STT GMAW, CMT GMAW• Dual torches Pulsed GMAW• FCAW• Standard single or dual torch(es)

GMAW.Welding speed:

• 20 to 150 cm/min.Material Weldability:

• Carbon steel (from Grade A to x 100)• CRA - Inconel Basis• CRA - Stainless Steel Basis• CRA - Duplex / Superduplex Basis• CRA - Cryogenic.

POWER SUPPLY REQUIREMENTS• Electricity: 70 kVA - 440 Vac Tri-Phases

+ 220 Vac Single Phase - 50/60 Hz• Pneumatic: 8 bars dry• Shielding Gas: Bi-mix (Ar-He) or Tri mix

(Ar-He-CO2).



in maintenance and welding, our R&D team came upwith a design for a device that meets the wide range oftechnical challenges incurred in supporting the full scopeof project challenges The Saturnax 09 has also capturedpositive HSE improvements to the design including anautomated fume and smoke extraction system, and setsnew standards in the quality of ergonomics in use (versatiletwo-hand control of the latch-roller, torch alignment, etc.).

Tough, easy to use and easy to maintainThe design team overcame other challenges like, forexample, a reduction in weight and easier maintenance.

For a bug & band welding system, the weight of the bugis an essential consideration. On average, the bug ishandled a hundred times per shift. This makes it essentialthat the new unit is capable of taking� on whatever systemthe welders use. The new system is also retro-compatiblefor use by welders who have already worked on priorSaturnax products.For other users, as far as maintenance is concerned, the new unit is tough, easily accessible, and easy to maintain. Saturnax 09 offers Serimax a new tool at the heart of the profession, to win new markets andachieve new standards of excellence. The Saturnax 09delivers.

Vallourec will be delivering seamless offshore line-pipeand fully integrated services for a total of 15,000 tonspipes dedicated to the subsea infrastructure of produc-tion flowlines and gas export lines.Stéphane Chrobot, project manager for Vallourec’s pipeand SURF activities, explains: “We are supplying a com-plete package, a ready to install solution for the client.This is a fully integrated project for ultra-deep. To put itsimply, we’ll be delivering a final 24-meter long productthat includes pipe-in-pipe (PiP), coating, sleeves anddouble-jointing. We are coordinating every stage of theproject internally, with all the project players. From alogistics and organizational point of view, this is a newmilestone in subsea for Vallourec and a very effectivesolution for the client.”

Co-designing the TEN offer with product,services and project executionDiscussions with Vallourec began as far back as 2010-2011. The lead process was long and complex: TullowTEN had specific technical constraints and Subsea 7expected a high level of flow assurance. Subsea 7 wantedto keep the system as light as possible with a non-standardpipe-in-pipe, outside API dimensions. Technically,Vallourec offered a specifically designed pipe-in-pipethat performs outstanding tolerances for both the diameters of the outer pipe and inner pipe, with coating,dedicated sleeves and a unique welding solution.Indeed, Serimax is welding both the double-joints onland and the pipes on the vessel, during the laying cam-paign. This ultimately provides greater integrity for the

The Pipe Project Division of Vallourec was awarded the Tullow TENcontract, a major ultra-deepwater project, by Subsea 7, in November2013, thanks to an ambitious global solutions offer that includes ahigh level of execution and project management.

/...

Saturnax 09in a nutshell


Quality, productivity andflexibility: themost advancedwelding solutionon the market.

Vallourec 2014 Sales Awardfor innovative global solutionsto Tullow TEN project

flowlines and export lines as well as a very high level offlow-assurance.Furthermore, Tullow TEN raises the threshold of subseaoffers for Vallourec as it contains not only technical andindustrial value, but also a considerable amount of projectmanagement, coordination and logistics. DominiqueRichardot adds: “Stéphane Chrobot was appointedproject manager, he is our point of contact with Subsea 7

and he can be reached at anytime, for any question, by anyone of the partners in the pro-ject. This position helps keep afull vision and grasp on the pro-ject, every day.” In TEN, Vallourec is hands-on,piloting all the key stages fromthe mill to the 24 meter ready tolay pipe. Project management isclearly where we add innovativevalue for the customer. Masteringthe whole process means moreflexibility in production and morereliability. Documentation, forinstance, is often a headache,with hundreds and hundreds ofpages being handed over withthe product, from one supplierto the next, with heavy andrepeated checking and valida-ting. In Tullow TEN, our docu-mentation is integrated once for

all to the whole process, handled at project level, goingthrough production and handed over to the customerwith the finalized product in minimal time. A fantastictime-saver and a flawless procedure for the client!

A powerful European clusterIntegration reaches a new level with the European clusterthe Pipe Project Division created for Tullow TEN. Bychoosing its best partners in Germany, the Netherlandsand France, Vallourec maximized proximity and enhancedthe workflow of every stage of production, making logis-tics easier to handle and follow. Dominique Richardot develops: “We sought the most reliable and reputable partners in the industry for everycrucial stage like coating, welding and PIP. All the partnersare very close to one another, within the same northernEuropean area, with optimal synergies and monitoring.The carbon steel seamless pipes are produced inVallourec’s German mills of Rath and Mulheim; the anti-corrosion coating is executed by Conline in Rotterdam(3LPP anti-corrosion coating on outer pipes); the sleevesare cut by Vallourec Fittings, in Maubeuge, France; thewelding pre-qualifications achieved by Serimax in Mitry,France; the double-jointing and pipe-in-pipe are executedin Caen, France, in a continuous process line, respec-tively by Serimax for the welding and by ITP (InTerPipe),for the PiP; the final 24 meter long products are stockedin a dedicated port yard in Ranville, near Caen, and fedto the project according to Subsea 7’s schedule andneeds. Additionally, the headquarters of Subsea 7 arein London, just hours away from our own headquartersin Paris, which makes it very easy to meet and followthrough the project together.”

Integrated planning: the backbone of project executionAt the heart of Tullow TEN, the real-life challenge is tocoordinate and synchronize the various phases assmoothly as possible as well as optimize productionand workflow. Coordination is guaranteed by weekly

meetings for action logs between the mills, Serimax,the coating and pipe-in-pipe partners. A monthly steeringcommittee is held, attended by Dominique Richardot,the plant managers, managers of Serimax and our customer, Subsea 7. This “under the same roof” approachis efficient and time-saving: every player has the wholepicture, every issue is solved quickly, and any variationin the project schedule can be immediately translatedinto actions on all sites.Stéphane Chrobot describes: “Integrated planning,where you can monitor the whole execution, has a greatadvantage: at any given moment, you can trigger cor-rective actions and adapt the workflow of all partnersconsequently. We learned to become more adaptable,predict bottlenecks or foresee risks at a very early stage.Operating from a higher level, seeing the whole picture,we can better anticipate actions than at business unitlevel, as well as adapt to client modifications or needs.This is the ultimate time-saver. For instance, early in theproject, the client decided to increase the length of thesleeves. In theory, it was simple, but longer sleevesmeant an order modification, more pipe than initiallyplanned, more material, longer production time. In anon-integrated planning organization, we would nothave been able to modify all the slots on such shortnotice (mills, cutting, coating, pipe-in-pipe and double-joint). Thanks to our integrated planning, we were ableto instantaneously fine-tune the production slots withthe mills, alter the planning for Vallourec Maubeuge forthe new sleeves, and cascade the workflow so every-thing fitted right into the schedule. Today, our integratedplanning is fully operational, easy flowing, adaptableand reliable. It’s not just good for the client; it’s great forall the partners! There is no time wasted and we canfocus on quality and delivering.”

Just in time workflow and logistics Stéphane Chrobot continues: “The tricky part is ourlast stage, in Caen, where we finalize the 24meter longsections with the pipe-in-pipe and welding. We opti-mized the delivery of the pipes so there wouldn’t betoo many pipes at the same time, so we, or the clientwouldn’t have to manage ahuge yard (remember thewhole order is 15,000 tons,hundreds of kilometers!). Weset up an intermediary platformso the products would arriveregularly, smoothly, accordingto production and to the pro-ject’s real-time schedule. Thisdefinitely represents value for the customer, as he hasneither bottlenecks in terms of storage nor organization tomanage. For us, it’s timesaving and easier to coordi-nate the products and docu-mentation. Just in time is whatyou want to aim for.”Tullow TEN is a milestone inVallourec Global Solutions, a breakthrough in bringingvalue through the executionand project management. We created value where it counts,with local content, schedule risk mitigation and exe-cution risk mitigation. Our global solutions render faster and better execution, enhanced reliability whileassuring the highest level of product design and quality.Vallourec is passionate to deliver cost-effective globalsolutions!


The Vallourec Oil & Gas Magazine N°07 / November 2014 / p.29 p.28 / The Vallourec Oil & Gas Magazine N°07 / November 2014

By co-designing the pipes and sleeves with Subsea 7 from

the start, we were able to anticipate the needs

and constraints of the finalapplication with Subsea 7.

This in mind, we built an integrated offer that optimized the pipe for

the ultra-deep application,from the bare pipe to the double-jointing.

Dominique Richardot, Managing Director of Vallourec’s Pipe

and SURF activities.

‘‘

‘‘Vallourec’s involvement in several stages of the

TEN project demonstratesour ability to generate

added value for our clientsthrough flexibility, synergies

and close cooperation. By providing an importantnumber of non-standard

pipe dimensions and welding solutions we help

Subsea 7 facilitate the pipe-in-pipe design

optimization, and thusreduce total costs.

Dominique Richardot

‘‘

‘‘

double-jointing.

Pipe during laying.

A powerful European cluster,Vallourec integratedsolutions for Tullow TEn.




Happily retired after 40 years in Vallourec, PatrickFallouey, former Corporate Standardisation Director,representing the company in API, convenor of the ISOgroup in charge of the maintenance of the OCTG standards (in close contact with API), is hardly leadinga quiet retirement. Patrick is passionate about hiking,but, instead of roving through his beloved Alps, he isrunning from one committee to another, sharing hisinsight and experience with fellow professionals.“Retirement is really not what I expected! I thought I’dhave lots of time, but I’m actually more solicited thanever... and I’ve been asked to keep a little time some ofmy honorary positions.” Patrick admits he still enjoys theexcitement of debating with specialists of European andInternational certification committees around the world.

Patrick Fallouey is somewhat of a celebrity in the com-munity of standardisation where he is acknowledgedand respected as an expert. “There’s still lots to doand it’s great to stay in touch with all my contactsaround the world. You see, over 50% of the job ispublic relations and, in 25 years, you get to know everybody in the field!”

Patrick’s career path was unlike any other. “I started inVallourec 40 years ago, at the mill in Aulnoye, where I was production manager for 10 years. I wanted to benear the workers, the processes and products. Then,I specialized in quality for over 3 years. One morning, I was called in for a project in Russia: a mill was beinglaunched in Volgograd. Vallourec needed someone withexperience in production and quality, as well as fluentin French, German and English. I left for what was supposed to be a 3-month mission… and stayed 2 years! It was a fabulous experience, well worth thesacrifices and difficulties.”

When Patrick returned, in 1990, Vallourec entrustedhim with the creation of a standardisation department.“We nearly started from scratch! Our challenge was to participate in creating and building all the Europeanand worldwide standards to comply with growing world trade.” Patrick adds, “You see, standardisation is at the veryheart of production and holdstremendous strategic value. We setproduct and production standardsthat define part of the industry, fordecades. A standard can advan-tage or hamper suppliers in theirdevelopment. Sitting on a commit-tee, we influence the standards to benefit client and manufacturerinterests in terms of specification,quality and safety. It’s what I callcommercial lobbying.”

“A financial manager once askedme: ‘What is your financial contribu-tion to the company results?’ That night, I couldn’t sleep.The next day, I replied ‘I truly cannot tell you what I bringthe company financially, but I can tell you what it wouldcost if I wasn’t there...’ he seemed satisfied with myanswer and never asked again!”

In retirement as in his professional life, Patrick’s driveris definitely enthusiasm: he is still heavily engaged(France, Europe and worldwide) in NDT (non-destructivetesting) personnel certification activities for Vallourec,as well as in contact with API. He is also an advisorabout NDT for the French Aerospace Industry and theSNCF. A true maverick!

Vallourec OCTG launched itsnew website last July: www.vallourec.com/OCTG� The new website has been designed to provide the ultimateuser-friendly experience with improved navigation and tools,allowing you to access all the information you may need rela-ted to our Casing and Tubing products and services offers.The new site is articulated into 7 main sections:

Applications: a presentation of Oil & Gas applications,organized by challenge and technology. Click on a challenge or a technology to display a pagededicated to the selected application and highlight thechallenges met by Oil & Gas companies, together with thesolutions we can offer to answer those challenges.

Products: an introduction to our connections, materialsand accessories offer.

• A connection selection guide to get the most suitableVAM® connection for a specific application.

• A material selection guide to get our complete gradesoffer. Click on a grade family to display the list of allgrades offered with a detailed description for eachone.

• A section dedicated to our accessories offer. • A products list (connections, materials, accessories)

to get a direct access to our products in one click.

Solutions: our services offer through Vallourec GlobalSolutions, from conception to completion.

E-Library: enjoy our videos, read the latest news anddownload our brochures or our Vallourec Oil & Gas App…

ToolBox: a toolbox that gathers the most used tools:Connection Data Sheet, Blanking Dimensions, VAM®

Licensee Network, Mr. Help, Test Fixtures and the VAM®

Book. The Toolbox can be found on each page of the site,always in the top right column.

Contact us: a Google map will display our local contactswith address, phone and email.

Connection mag: a direct access to our Connectionmagazine online.

We hope that you will enjoy browsing our new site. Feelfree to share your feedback, we’d love to have your inputand comments!


The new Vallourec OCTG website is now live!

There’s still lots to do and it’s great

to stay in touch withall my contacts

around the world. You see, over 50% of the job is publicrelations and, in 25years, you get toknow everybody

in the field!

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a Maverickin Standardisation

Patrick Fallouey(on the left) receivingthe Havercroft Awardin 2012 in Durban (South Africa).

Patrick Fallouey,

The Vallourec Oil & Gas magazine N°07 / November 2014 · The Vallourec Oil & Gas magazine N°07 /...

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Transcript of The Vallourec Oil & Gas magazine N°07 / November 2014 · The Vallourec Oil & Gas magazine N°07 /...