#03 - OCTOBER 2012 Vallourec at the heart of the Middle East · Zadco / UAE – Anil Remasan, ITS India – Stian Ronnevik, Ross Offshore / Norway – Joanna Salamaga, Woodside

T H E V A L L O U R E C O I L & G A S M A G A Z I N E

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THE TECH FILESPremiumconnection testing

ON THE MARKETHP/HT wells: A global, fast growing & technically challenging market

SOLUTIONSCustomized delivery solutions to meetthe markets’ demand

Vallourec atthe heart of the

Middle East

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Publisher: Vallourec Mannesmann Oil & Gas France - 27, avenue du Général Leclerc, 92660 Boulogne Billancourt Cedex - France - Editorial Team: Hassna Belmalek - E-mail: [email protected] - Phone: + 33 1 49 09 35 83 - Fax: + 33 1 49 09 37 13 - Thierry Wolkiewiez - E-mail: [email protected] - Production: Zabriskie.,Paris - Design: LeGrand8, Paris - Photographs: Thierry Truck, Vallourec, V & M USA, Neuf&9, SSPF, Engº A dilson Couto SEAINSPECT Assessoria & Perícias, VAM® Norge, VFSI,Fotosearch or as mentioned otherwise - All rights reserved.

Dear Readers,

VAM® is a registered trademark of Vallourec Mannesmann Oil & Gas France

w w w. c o n n e c t i o n - m a g . c o m w w w. v a m s e r v i c e s . c o m

I am pleased to introduce this new edition of Connection to you. Vallourec is well known to be a company that “walksthe talk” but sometimes we also have to “talk the walk” and it is precisely the aim of the Connection magazine.

Vallourec has a global approach to the Oil and Gas market, and is growing regionally to localize more operations andbe more responsive for our customers. We are focusing on value and aim at delivering it through innovation.

What could better exemplify our global footprint than the quiz which was organized for the launch of our newestunrivaled VAM® 21 thread. Case in point: the statistics from the VAM® 21 quiz, published in the last issue ofConnection, revealed winners working in countries as far apart as Australia, Brunei, Canada, France, India,Malaysia, Mexico, Nigeria, Norway, Pakistan, the United Kingdom, the United Arab Emirates, the USA… Thanksto all participants and congratulations to the winners!

To further illustrate our regional development and our long term commitment to the market, this issue contains a specialreport on Vallourec in the Middle East. More than 50 years of cooperation with operators in the region, and decisiveinvestments made over the last two years demonstrate our commitment to our local customers and partners.Then we turn to Ghana, where our aim is to bring value to the business and to the people by supporting bothour customers in a promising market, and addressing demands for local content. The success of our Tubular

Essentials training program there is particularly encouraging.

We also wanted to tell you about innovation with an insider look at our offerings for high-pressure, high-temperature wells, which have witnessed spectacular developments over the last ten years. Our engineerstackle those challenges by constantly stretching the limits of resistance of the most advanced connectionsyou use. In “The Tech Files,” you will discover the resources and methods we have at our disposal tosatisfy this demand.

We walk the talk! Enjoy the reading!

Didier Hornet,Managing Director of the OCTG Division

Member of the Vallourec Executive Committee

T H E V A L L O U R E C O I L & G A S M A G A Z I N E # 0 3 - O C T O B E R 2 0 1 24 5

THE NEW V & M DO BRASILACCESSORY PLANTInaugurated on July 6th 2012, the new V & M do Brasil accessory plant isoperating in a service base located in Rio das Ostras (Rio de Janeiro). The plant is currently producing premium accessories for the completion of oil wells using the V & M Tube-Alloy technology. V & M Tube-Alloy™ produces and repairs accessories used inside oil& gas wells. It specializes in complex threading operations and inmachining bespoke parts. Its production units are still located inBroussard and Houma (Louisiana), Houston (Texas) and Casper (Wyoming).

The goal of the new plant is to reachexcellence in client service by supplyinga complete local pack with seamlesssteel pipe, well accessories andmanagement. Located in a service basein Rio das Ostras, where V & M do Brasilalready employs 150 people, the newunit plant will employ 40 new people.

NEWPRODUCT: VAM® BOLTThe new large OD Flush premium connection for surface and intermediatecasing applications is now available insize from 11 7/8” to 18”. This size extension in 11 7/8” and 14” offersnew options for offshore operators dealingwith clearance issues, and high performancerequirements, especially focusing on Pre-salt challenges in Brazil, and moregenerally HP/HT and deep offshore wells. VAM® BOLT features include a dualmetal-to-metal seal and a quick make-upthread design.Orders have been booked already, and first runnings are expected in 2013 in Egypt, Mauritania, the USA,

Brazil, Azerbaijan...

Scan this QR code with your smartphone to watchthe VAM® BOLT video.

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PAGE 6VALLOUREC AT THE HEART OF THE MIDDLE EAST

THE TECH FILESPAGE 13PREMIUM CONNECTION TESTING

SOLUTIONSPAGE 18CUSTOMIZED DELIVERY SOLUTIONS TO MEET THE MARKETS’ DEMANDPAGE 20TUBES BY VALLOUREC & SUMITOMO DO BRASIL FOR PERENCO GABON

ON THE MARKETPAGE 22HP/HT WELLS: A GLOBAL, FAST GROWING & TECHNICALLY CHALLENGING MARKETPAGE 25GHANA: ENDLESS POSSIBILITIES

EVENTSPAGE 26VALLOUREC DEMONSTRATESTEXAS HOSPITALITYONS 2012 SEEN THROUGH THE EYES OF VAM® NORGE

PEOPLEPAGE 27STUART MITCHELL: DRIVEN

news VALLOUREC INCIPPE SHANGHAIVallourec participated in the 4thChina International Petroleum &Petrochemical Technology andEquipment Exhibition (CIPPE)which took place in Shanghaifrom 22nd to 24th of August. CIPPE Shanghai attracts 600 enterprisesfrom 35 countries and regions including the USA, Germany, Italy,Russia, France, Japan, Singapore, Canada etc. This was a great opportunity for the company to enhance its imageand reinforce its strong relationship with local and internationalclients. The team on-site highlighted topics such as innovation andpresented the VAM®products family (VAM®TOP, VAM®SLIJ-II, VAM®FJL...)and services. Also, discussions with participants proved to be veryfruitful, in particular regarding our cooperation with Tianda Oil Pipe.

YOUNGSTOWN OHIO NEW MILL ROLLS ITS FIRST PIPEThe new Vallourec plant in Youngstown(Ohio) achieved another step in the start upprocess with the successful rolling of its firsttube on September 17th, 2012. JoelMastervich, president of V & M Star, explained:“This is a noteworthy milestone in the rampup of our new FQM mill. Our teams are nowworking towards our goal to produce greentube in the fourth quarter of this year.” The new plant will produce up to 500,000 metric tons of seamlesspipe in sizes 2 3/8” to 7”, destined to the booming shale oil and gas exploitation market in North America. It will complement the existing adjacent steel plant and rolling mill that currently manufacturespremium quality OCTG and line pipe in sizes 5” to 10 3/4”.

VISIT US AT…3rd annual DUG Eagle Ford Conference & Exhibition: 15-16 October 2012, San Antonio, TX, USA - Booth #366

4th Annual DUG EAST Conference& Exhibition: 14-15 November 2012,Pittsburgh, Pennsylvania, USA - Booth #460

11th Annual Deep Water Angola Summit:14-15 November 2012, Luanda, Angola

Shale Gas World Europe 2012:27-29 November 2012, Warsaw, PolandDon’t miss out to attend our presen-tation “The Shale revolution - Drawing from Vallourec experience in the USA and its implication for Poland” to be held on November 28th at 2.30 pm in Hilton Warsaw Hotel.

VAM® 21 QUIZ: AND THE WINNERS ARE…We would like to thank all our readers who participated in the VAM® 21 quiz to win an iPod Shuffle.The correct answer to the question “What is the meaning of MTS in the VAM® 21 torque table?” is:Maximum Torque with Sealability. We are delighted to share with you the names of our winners. Faizan Bari Khan, Pakistan PetroleumLtd – Etienne Bourdelet, Groupement Timimoun / France – Patrick Chong, UMW Oilpipe Services /Malaysia – Hugo Ernesto Finkenthal, Weatherford de México – Kevin Fizer, FI Canada Oilfield Services /Canada – John Jiju, Zadco / UAE – Ryan Kauppila, Citi Research / UK – Camille Montin, Total E&PBorneo / Brunei – Ikenna Mwabueze, Total E&P / Nigeria –George Neil, 2Source Manufacturing / Canada –Derek Napier, Ramco Tubular Services / UK – Naseem M Owais, Pakistan Petroleum Ltd – Krishanasamy Rajagopalan,Zadco / UAE – Anil Remasan, ITS India – Stian Ronnevik, Ross Offshore / Norway – Joanna Salamaga, Woodside /Australia – Chuck Schilling, Energy OCTG / USA. Congratulations to all of you!

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VAM® LICENSEE AWARDS

Best Overall VAM® LicenseeWeatherford Industria e Commercio LtdaCaxias do Sul – Brazil

Best Licensee of the ThreadingFacilitiesV & M Deutschland GmbHRath – Germany

Best Accessory Repair ShopNorse Oilfield Services ASStavanger – Norway

Best O.E.M.Halliburton Manufacturing andServices LtdArbroath – U.K.

Best Quality ImprovementDezhou Shelf Oil Tools Co.Shandong – China

Best Drilling LicenseeVAM® Drilling USAHouston – U.S.A.

Congratulations!

In recognition of their outstanding contribution and of the high qualityachieved in the manufacture of VAM® products according to VAM®

Services standards, the best licensees in 2011 are:

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In the Middle East, Vallourechas maintained commercialrelations with the main playersin the oil and gas industry forover 50 years. With passingdecades, the Vallourec teams incharge of this region, crucial forthe global energy equilibrium,have had to continually adapttheir offer of products, servicesand organization in order tomeet the evolving needs oftheir clients as effectively aspossible. The last two years inparticular have been exceptionalfrom this standpoint.

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VALLOUREC AT THE HEART OF THE MIDDLE EAST

T H E V A L L O U R E C O I L & G A S M A G A Z I N E # 0 3 - O C T O B E R 2 0 1 2 T H E V A L L O U R E C O I L & G A S M A G A Z I N E # 0 3 - O C T O B E R 2 0 1 2

Dubai, United Arab Emirates

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FraserMacDonald

General Managerof Vallourec & MannesmannMiddle East FZE

/... Philippe Crouzet, Chairman of the VallourecManagement Board and Olivier Mallet, Member ofthe Management Board and Chief Financial Officerand General Counsel, recently visited Jebel Ali,in the Free Zone of Dubai, where Vallourec &Mannesmann Middle East FZE established itself inSeptember 2011. Fraser MacDonald, GeneralManager of this entity, sees this as a clear indicationof the strategic importance of the investments madeby the Group into the region in the past two years:

“Even if the Group directors regularly visit our different sites around the world, it is clear that this visit – before the future official inaugurationof our new facilities – is linked to the technical,commercial, organizational and financial stakes that our business unit represents for Vallourec.” With 60 % of global oil reserves and 40 % of globalgas reserves and an economy that is in a period ofgreat diversification, the Middle Eastern countriesare a major geopolitical force on the international

stage, at the heart of our planet’s energy equilibrium.The world’s producers of tubular products for theexploration and production of fossil fuels are wellaware of this. As such, competition has becomeincreasingly fierce in recent years to win the callsfor tender launched by the big nationaland international companies and by numerous independent companies. Thestrategic importance of client companies'activities further intensifies this battle tobe the best. Some clients prefer to tenderfor contracts and, in doing so, encourageas many suppliers as possible to bid.However, others prefer to have a moreselective approach to purchasing OCTG,based on very specific criteria, such asseverity of application, quality, reliability,technical performance and after sales support.In this fiercely competitive market, it is importantto consider the assets that allow Vallourec to continue to stand out from the rest and conserve its leadership.

A REAL TECHNICAL ADVANTAGEThe days of ‘easy oil’ are over and operators in theMiddle East, just like in the rest of the world, arefaced with increasingly complex technical difficul-ties: very deep deviated wells, offshore characterizedby high pressures and high temperatures. The operators are pushing their operational envelopewhether it’s to achieve a 70 % recovery rate or to

Vallourec is far from being a new arrivalin the region. Vallourec’s commercial rela-tions with Al Qahtani & Sons, its agent inSaudi Arabia, began 50 years ago. Those with

ADOS in the United Arab Emirates 40 years agoand those with Ahmad Al Fahad General Trading inKuwait around 30 years ago. Direct contact withthe technical teams of the big national companiessuch as Saudi Aramco, ADCO, ADMA, ZADCO andKOC are also longstanding and characterized bymutual trust and respect. Over the years, theVallourec team managing these countries have learned that you cannot approach a deal in theMiddle East as you would in Brazil or the UnitedStates demonstrating the importance of respectingMiddle Eastern culture when conducting business.

Given the significance of the Middle East marketVallourec took the decision to be permanently present in the region in the early 1990s. Vallourec& Mannesmann Middle East FZE established justover a year ago is responsible for all the membercountries of the Gulf Cooperation Council (GCC):Saudi Arabia, Bahrain, Oman, Qatar, the UnitedArab Emirates and Kuwait, as well as Yemen (anobserver within GCC), Iraq, and Jordan. Businessin Turkey and Syria is managed from France and anoffice has been created in Egypt.

“We have left our former Dubai offices to join ourcolleagues in Jebel Ali from VAM® Drilling and theLine Pipe Division in order to form a hub devotedto oil and gas activities in the region", explains FraserMacDonald. "It was obvious that we needed to havea bigger and more independent entity to create thenecessary synergies to satisfy our clients’ needs.The business unit that Vallourec & MannesmannMiddle East FZE represents today already consistsof more than twenty-five employees.”

Saudi Arabia

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Bahrain

Kuwait

IraqSyria

Egypt

Turkey

Yemen

Qatar

UAEOman

Jordan

Manufacturing plant in Dammam

Sales and Services office in Jebel Ali, Dubai

Accessories and RepairVAM Licensee Facilities®

“It had become crucial to have a bigger and more independent entityin order to createthe necessary synergies to satisfyour clients’ needs.”

/...

A long history

The VAM® network in the Middle East

SSPF threading plant in Saudi Arabia.

boost gas production to satisfy domestic consumptionrequirements. Operators are exposed more andmore to high ratios of H2S and CO2, as is largelythe case in the geological formations spreadingfrom Iraq to Abu Dhabi, (Khuff and pre-Khuff) driving the need for high quality, advanced OCTGtechnology. From this standpoint, given its vast

experience in delivering high end, tech-nical oil and gas projects, Vallourec isviewed by many operators as the OCTGpartner of choice, in part, thanks to itsunrivalled range of VAM® premium gastight connections. A recent illustrationof this has been the acclaimed intro-duction of the VAM® family’s latest pioneering premium connection: VAM®

21, the first connection which is asresistant as the tube, regardless of the loads placed upon it. In addition,Vallourec also boasts a strong presencein the field of Corrosion Resistant Alloys(22 % chrome or more) with its stra-

tegic partner Tubacex, as well as the developmentof Cleanwell® Dry, a dope free solution that pre-serves the environment whilst simplifying the customers’ tubular supply chain. Another exampleis the comprehensive technical support offered by Vallourec to satisfy the increased demands fromits customers on product testing (see ‘The TechFiles’ section of this issue). These customized solutions demonstrate Vallourec’s proximity to themarket and its depth of understanding of its clientscurrent and future needs.

AN ALL-ENCOMPASSING SERVICE OFFER Proposing duly validated high-tech products is goodbut it is not enough. The most sophisticated solutionsare valuable only if they are accompanied by theessential services that ensure they are implementedcorrectly. This is true in all fields and especially inthe field of OCTG. Just over a year ago, Vallourecdeveloped an offer named VAM® Global Solutions

and a specially-dedicated structure counting morethan twenty specialists to define and organize – eventake charge of – all the services that could simplifythe work of the operators, from the moment the products leave the plants, to the time they are runin the well. The team offers a whole range of servicesfrom designing a well, proposing a complete rangeof accessories, stockholding, defining the supplychain organizing personalized delivery condition; infact all the way through to comprehensive customizedtraining programs provided by experts:“For our clients in the Middle East, who are increasinglyinterested in such services, VAM® Global Solutionsis totally transparent because the principle is toprovide our customers with the support they need”,emphasizes Fraser MacDonald.As well as this full array of ‘tailor-made’ services,there is the VAM® Field Service offer (assistanceand supervision on the operating sites) and a solidnetwork of VAM® licensees spread over the entireregion: 23 qualified and monitored partners in theMiddle East capable of working to very short dead-lines thanks to their close proximity to the theircustomers drilling sites.

DECISIVE INVESTMENTS In November 2011, Vallourec clearly showed its inte-rest in the Middle East by acquiring a production unitin Dammam, Saudi Arabia. Saudi Seamless PipesFactory (SSPF) now employs around a hundred people

and has the finishing lines necessary to provide premium products to Saudi Aramco, the biggest oilproducer in the world, as well as other key clients inthe region. The plant, which has heat treatment andthrea-ding equipment allowing it to produce 100,000tons per year, will see its capacity increase with thecreation of additional VAM® threading lineswhich is part of a sustained investmentprogram with the objective of extendingthe product range to be manufacturedlocally in Saudi Arabia. Amongst the otherrecent investments, we should of coursemention the establishment of Vallourec &Mannesmann Middle East FZE and theconstruction of its facilities in Jebel Ali,within the oil and gas hub that the Groupwishes to create at the heart of the region.Less visible but just as important are theR&D investments which have allowed the Group todevelop and qualify specific products aimed at localclients, such as VAM® KSX bringing enhanced clearanceand VAM® 21 HT for highly deviated offshore wells.Obviously, the strengthening of Vallourec’s presencein the Middle East takes into account the differentcountries’ demands in terms of local content. Whilethere continues to be certain diversity in the policiesfollowed, it is clear that, as is the case in SaudiArabia, local production and support, training andemployment of local personnel can only encouragethe establishment of solid and lasting commercialrelations. “The Middle East market has changed considerablyin the past 10 years”, adds Fraser MacDonald. “Itis much more competitive, demanding and moreexciting than ever! I am convinced that the effortsrecently made by Vallourec and the motivation ofthe teams in Vallourec & Mannesmann Middle EastFZE will allow us to stand out from our rivals andbe very successful in the coming years, not onlyon high-tech projects but also on more standardoffers where we must remain competitive.”

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/...


“Our clients inthe Middle Eastare increasinglyinterested in the servicesbundled in ourVAM® GlobalSolutions offer”

“The Middle Eastmarket is muchmore competitive,demanding andmore excitingthan ever!”

External view of SSPF.

Staff working at Weighting, Measuring, Marking and Stamping station (SSPF threading plant in Saudi Arabia).

V & M MiddleEast FZE team

in Jebel Ali Free Zone.

#03

HP/HT wells are now reaching up to 250°C and 20,000psi reservoir pressure. Premium OCTG products arerequired to demonstrate their performance to be adaptedto withstand the extreme load conditions. The threadedconnection especially must remain gas tight in the wellconditions, as well as keep the mechanical integrity ofthe string and allow for multiple assemblies (make-upand break-out, so-called M&B for Make & Break).End-users have developed procedures to test connec-tions, in conditions that are representative of the wellconditions they experienced. In the 80’s, a first version

of API RP 5C5 was issued by American PetroleumInstitute, giving recommendations and test protocolsfor premium connections evaluation. Some customersalso specified their own testing requirements (NAM TEO3 by Shell, URC procedure by Exxon…). Since 2002, API RP 5C5 rev3 / ISO 13679 1st editionhas become the reference for premium connectiontesting Standard, defining four Connection ApplicationLevels (CAL I to CAL IV) representative of the test severity,from CAL I (least severe) to CAL IV (most severe).

Post-Macondo regulations and lessons learnt empha-sized the need to demonstrate the performances ofall components of the well, including OCTG products.

The worst case scenarios are determined to calculatethe maximum load cases that the OCTG products willhave to withstand. Tests are done accordingly. /...

As Oil & Gas companies are drilling always deeper and in more severeenvironments, OCTG products need to prove reliable for use in theseconditions.

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the tech files

Premium Connection Testing


Specimen 1

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Series CThermal Cycles with IP + TP

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CAL I CAL II CAL III CAL IVG A SL I Q U I D

ISO13679(2002)CAL presentation –Test flow-charts

#03

/...

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NEWS FOCUS SOLUTIONS ON THE MARKET EVENTS PEOPLE THE TECH FILES


PREMIUM CONNECTION TESTING

Process of connection testing consists in the following steps:• Thread machining• Surface treatment• Assembly(ies)• Static sealability tests and/or other tests (fatigue,failure, expansion...)

A / SAMPLES DESCRIPTION AND MACHININGTo guarantee the performance of any single joint thatgoes out from production mill, the first condition is totest the thread in the most critical design configurations:this is achieved by machining test samples in the extremetolerances allowed by the product drawing, that areknown to be the most critical for specific performances:worst sample configuration for M&B, other ones forSealability, etc. ISO 13679(2002) defines the designconfiguration cases, specifying seal and thread inter-ferences, as well as pin and box thread taper, to coverthe extreme cases of the product drawing tolerances.To prepare the test samples, special care must betaken as the targeted dimensions are much narrowedcompared to production tolerances (reduced to onetenth of the tolerance). Test samples are thus machi-ned on dedicated CNC lathes, in R&D facilities, andrequire an accurate set-up for each piece.

CNC lathe – Vallourec testing facility.

B / SURFACE TREATMENT AND M&B TESTSA first performance to be validated is the multipleassembly: tests consist in applying the surfacetreatment specified by the connection designer (e.g.raw surface, sand-blasting, phosphate, copperplating…) and to repeat make-up and break-out in the critical conditions of thread compound typeand quantity, and torque values.The M&B tests evaluate the galling resistance of thethreads, since the product should not be damagedduring assembly, and connections may need to bedisassembled many times on the rig (in case of work-overs, wrong initial assembly…). Vallourec testing facility has a complete range of tongto perform vertical or horizontal make up. We havedeveloped also specific protocol to simulate specificcondition: arctic or desert condition, misalignmentmake-up or hard stabbing.Cleanwell® and Cleanwell® Dry, that are innovatingcoating solutions applied on threads to replace storageand make-up thread compound have been extensivelytested on different thread designs to guarantee thebest M&B properties.

VAM® TOP connection with Cleanwell® Dry.Make-up test done at -30°C - Vallourec testing facility.

C / COMBINED LOADS SEALABILITYDifferent loads, such as tension, compression, torsionand pressure, internally and externally, apply to thecasing and tubing strings downhole. Depending onthe drilling and production phases, as well as forma-tion and reservoir conditions, loads are combinedand will repeat over time.To evaluate the mechanical and sealability perfor-mance of premium connection, ISO 13679 definesSeries A, Series B and Series C load points cyclesthat will be applied on the limits of service load envelope for a given premium joint.

Example of ISO13679 load points, for the testing of VAM® 21: the loadsapplied on the sample are based on the connection ratings vs. the pipebody yield strength (in the case of VAM® 21, the connection is 100%as strong as the pipe, the ellipses match entirely).

These tests consist in applying pressure (gas or liquid,internally and externally) combined with tension orcompression (Series A), doing tension and internalpressure cycles at elevated temperature (135°C up to180°C, Series C) and bending (Series B), in static loadframes. ISO 13679 also specifies the equipments forgas leak detection to be installed around the thread.Failure tests are part of the product evaluation anddefined in ISO 13679. They are performed with thesame equipments. It consists in increasing the loadvalue up to the mechanical limit (collapse, burst,internal pressure and tensile force until parting…).

D / SPECIFIC TESTSFor dedicated applications, other types of tests aredone in Vallourec facilities:• Solid expandable product expansion, up to 25% ofoutside diameter increase. Expansions of VAM® ETWISE samples are performed in the facility ofAulnoye (France), and the connection is tested afterexpansion in static frames for sealability performance.

• Resonant Fatigue tests, either for Riser products(VAM® TOP FE, VAM® TTR…) evaluation, or forOCTG products to simulate applications causingfatigue loads (Drilling with Casing, Shale gas frac.cycles and extended reach…). Fatigue tests havebeen performed on many VAM® connections, e.g.VAM® SG, VAM® TOP, DWC/CTM, VAM® SLIJ-II, VAM®

21, DINO VAM®).• Rotating fatigue for Drill products (e.g. VAM®

Express, VAM® EIS, VAM® CDS).


/... Testing protocol: what is next?The new ISO 13679 FDIS2011 (final draft), alt-hough rejected during country vote end of 2011,indicates the direction that the industry wantsto take for premium connection testing: testsare more severe, increasing the number of loadpoints, and the number of tests at elevated tem-perature (including with external pressure). Asa consequence, tests will take longer and requireupgraded equipments, increasing testing costs.API working group continues to work on the next

revision of API 5C5, with the same approach.Vallourec actively participates in the API discus-sion to define the next generation of tests for Oil& Gas industry needs.

Vallourec already answers the customer requestsbased on ISO13679/FDIS protocol. VAM® 21product line has been successfully qualifiedaccording to the most severe FDIS2011 CAL IVtests, on 100% pipe body envelope.

Vallourec premiumconnection testing at a glance• 4 R&D facilities for premium connection testing,involving more than 150 technicians and engineers- VMOGF Aulnoye, France- VAM® USA, Houston- VMB, Brazil- PT Citra Tubindo, Indonesia

• R&D partnership with Sumitomo Metal Industriesfor VAM® connection testing and development.

• 3 shifts/day, 24/7 working hours for tests.

VAM® connections benefit from the largest testingcapacity of all OCTG premium suppliers.This capacity will continue to expand to meetthe growing and more severe testing needs fromthe Oil & Gas industry.

Static frame for sealability tests –Vallourec testing facility.

Resonant frame for fatigue tests –Vallourec testing facility.

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Scan this QR code withyour smartphone to watch the testimonial of Bruno Jeaumart, testing facility operator in Aulnoye-Aymeries (France).

#03/...

Vallourec has always been the leader for premiumconnection testing, with VAM® connections being themost extensively tested OCTG products. These testsare done in compliance with relevant industryStandards and customer specifications, the referencetoday being ISO 13679(2002) / API RP 5C5. Due to the growing demand for qualifications by customers, and due to the type of tests (seeISO13679/FDIS2011, around 70% longer than theprevious protocols, and more severe), Vallourecdedicates a lot of R&D testing resources. This is a

consequence of the more challenging E&P projects,and the request from customers to have demonstratedperformances to mitigate the operational risks. Vallourec is investing continuously in equipmentupgrade and testing capacity to keep its technicalleadership and innovation excellence in VAM®

products and OCTG solutions.

NOTE: The qualification program for a critical HP/HT project, with different products to test as per ISO 13679protocol will usually cost a few millions USD, and last more than 6 months.

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NEWS FOCUS SOLUTIONS ON THE MARKET EVENTS PEOPLE


THE TECH FILES


Contact: [email protected]

CONCLUSION AND PERSPECTIVES

SOME MAJOR ACHIEVEMENTS ON VAM® CONNECTION TESTING:• More than 400 qualification test programs donefor customers on VAM® connections. VAM® TOPproducts have been the most tested. This includesmany isolated products tested for specific HP/HTprojects, required by customers.

• Sealability combined load testing as perISO13679 performed at 250°C for an extremeHP/HT project, with internal and external pressure.One of the main challenges was to develop inno-vative equipments to achieve external pressuretest at this temperature (external pressure vesseldesign & seals, pressurizing media, heating andcooling methods, high-sensitivity leak detection).

• VAM® threads coated with Cleanwell® Dry have beenmade up at -30°C, to simulate arctic conditions.

• More than 35 VAM® connection product lines havebeen developed. Examples of recent test validation

programs are: VAM® 21, VAM® SG (Shale Gas),VAM® BOLT, Cleanwell® Dry on VAM® TOP andVAM® 21…

• Tests as per new ISO13679/FDIS2011 CAL IV,successfully passed with VAM® 21 connection,on 100% Von Mises Envelope of the pipe.

• Gas-tight expandable products (VAM® ET family),tested after both hydraulic or mechanical process,in fixed-free, fixed-fixed and free-fixed conditions,up to 25% diameter increase. Samples are testedafter expansion in combined loads frames.

• VAM® TTR and VAM® TOP FE are threaded andcoupled premium connectors dedicated to riserand offshore applications. Both have been exten-sively tested in fatigue with more than 200 sam-ples of various sizes and grades. VAM® TTR hasa fatigue resistance better than SAF 1.5 and VAM®

TOP FE fatigue resistance is rated better than 2.0 vs. DNV-B1 curve.

EXAMPLE OF FLOW-CHART FOR A CUSTOMER QUALIFICATION PROGRAM (ISO 13679/2002 CAL IV)

T P IT P I

T P IT P I

T P I

• Official testing procedure agreed between Vallourec and the customer• Material manufacturing Plain end and coupling stock• Material properties testing• Samples threading and gauging 16 pins, 8 couplings, + spares• Surface treatment e.g. Phosphate, or Cleanwell®

• M&B and Assemblies 10 minimum for tubing, 3 for Casing• Sealability tests 4 Series A, 6 Series B, 4 Series C• Failure tests• Report (TPI: Supervised by a Third Party Inspection)

Approximate duration of tests (in days, full time in the static frame) :Series A (ISO 13679)Series B (ISO 13679)Series C (ISO 13679)

5 days

2 days

3 days


Connection: What is the customized delivery solutionyou recently developed?Caroline Camuset: At VAM® Global Solutions, ourgoal is to design and introduce services which allowVallourec to best meet clients’ needs. Our standardlead time is five to six months after receipt of a POfor make to order (MTO). This accounts for 80% ofour business or client needs. For the remaining 20%,when our clients are facing an urgent need, we areoffering two new services. The first reduces this timeto 12 or 15 weeks compared to MTO; the second,to only 2 weeks by using our VAM® Stock in theDutch city of Coevorden. To summarize, all clientsnow have three choices to customize their deliveries:standard MTO (6 months), Fast Track (12 to 15weeks) and VAM® Stock (2 weeks).

Connection: How can MTO drop from 24 to 12 weeks? Caroline Camuset: Together with our plants we havedeveloped Fast Track, a market first. It guaranteesa lead time of 12 weeks for carbon steel casing andtubing and 15 weeks for 13Cr tubing. We managedto halve the standard time by maintaining a couplingstock inventory, whose grade and threading may bemodified as needed. It usually takes 14 weeks tomanufacture coupling — which represents the mainpart of the production lead time for MTO. To sum up,the time guaranteed by Fast Track is the time neededto manufacture the tubes and the coupling stock. I would like to add that these services concern most ofour standard products, including our showcase connec-tion, VAM® 21, which has been implemented in FastTrack and will eventually be included in our VAM® Stock.

Connection: How is the VAM® Stock different fromthe Coeverden One Stop Shop that already existedin the Netherlands?Caroline Camuset: On our behalf, the Bakker Companyalready managed a stock of tubes in Coevorden primarily for shipments to the Netherlands. Now,we have built up a free stock which can be shippedworldwide. This close collaboration with Bakker,together with the support of Vallourec MannesmannOil & Gas Netherlands, guarantees a premium qualitystock management.

Connection: Have any clients used these services yet? Caroline Camuset: In fact there are two types of

needs: the last-minute demand and the needs tosupply the first batch(es) of large orders in a shorttime. Just to give an example, we recently bookeda large order in Iraq. A determining factor was ourability to meet a tight schedule to deliver the first2,500 metric tons. We used our VAM® Stock to makesome tubes available in a few weeks and Fast Trackto deliver more in under three months, while MTOwork was under way. This demonstrates the flexibility afforded by ourthree customized delivery services and our capacityto meet the market’s demand.Since the launch of customized delivery servicesabout a year ago, we have a perfect track record!

CUSTOMIZED DELIVERY SOLUTIONS

TO MEET THE MARKETS’ DEMANDVallourec introduces two new services for clients on short schedules. “Fast Track” halves the time between the signature of the purchase order andthe release from the plant and “VAM® Stock” cuts it back to just a few weeks.

18 19

NEWS FOCUS THE TECH FILES SOLUTIONS ON THE MARKET EVENTS PEOPLESOLUTIONS


CarolineCamuset

Demand Managerat VAM® GlobalSolutions.

In brief ...

MAKE TO ORDER• Customized productswith standardlead time.

VAM® STOCK• Standard carbon casing and tubing with a commitment of 2 weeks (EXW).

FAST TRACK• Customized products with a commitment of 12 weeks (EXW)for carbon casing and tubing and 15 weeks (EXW) for 13Cr tubing.

• Third-party inspection (TPI) onrequest.

Aerial view of the Coeverden One Stop Shop.

Unloading of Vallourec pipeson the Coeverden yard.

Vallourec pipes on theCoeverden yard.

20

SOLUTIONS


SOLUTIONS

The VAM® Global Solutions team together withthe Overseas Department of Vallourec keep aclose eye on the first shipments of tubes fromVallourec & Sumitomo Tubos do Brasil (VSB).Some are already in the hands of Perenco Gabon...

TUBES BY VALLOUREC & SUMITOMO DO BRASIL

Three vessels carrying tubes from our VSB plant have already come in. Three scenarios are possible:part or full load may be headed for our VAM® Stock in Coeverden, the Netherlands; part of it has beenmanufactured according to an MTO order and will be dispatched to the clients after transshipment in Antwerp, Belgium; and another part may have been affected to another client during shipping andwill be dispatched as well. In the last two cases, tubesunloaded at Antwerp are shipped out to recipientswithout going through Coeverden. The first vessel sentto us from Brazil, the Harefield, was carrying amongother an order of 9 5/8” VAM® TOP for Perenco Gabon,

a subsidiary of Perenco, an independent French oilcompany. Vallourec reinforced inspections during loading inBrazil and transshipment in Antwerp. Arnaud Pardé,Freight Solution Manager at VAM® Global Solutionsand Théophile Huguet, Logistics Manager GlobalSolutions (Overseas Department) travelled first to Antwerp to ensure everything was in order, before sending the pipes to the quay, to be loaded on a anothervessel sailing to West Africa, Port Gentil.

Arnaud, Théophile and Jean-Marc Layet,General Overseas Manager, went also to PortGentil in order to meet our logistics partnersand customers.For companies like Perenco Gabon, responsive-ness, flexibility, and short lead times are deter-mining factors in the choice of a supplier.That is why our customized delivery solutionis so valuable. But our business becomes trulygratifying when our contacts start to realizethe importance of availability in terms of pro-ducts, a wide range of course including standardproducts, and people, men and women, offeringservices with high added value together witha large worldwide licensee network.

Harefield vesselat Rio de Janeiro port.

© Engº Adilson Couto SEAINSPECT Assessoria & Perícias.

© Engº Adilson Couto SEAINSPECT Assessoria & Perícias.

VSB pipes loaded on the Harefield vessel.

VSB pipes arrivedat the port of Rio de Janeiro.

© Engº A dilson Couto SEAINSPECT Assessoria & Perícias.

FOR PERENCO GABON

23T H E V A L L O U R E C O I L & G A S M A G A Z I N E # 0 3 - O C T O B E R 2 0 1 2

SOLUTIONSON THE MARKET

HP/HT WELLS: A GLOBAL MARKETHP/HT wells have always existed; however the actualdefinition and boundaries have been dependent onthe technologies available to drill and complete thewells. The modern definition of HP/HT wells has comefrom developments in the North Sea and America.The North Sea is one of the most mature fields in theworld, in which the ‘easy oil’ has gone. The major operatorsin the North Sea have seen advantages to produce highpressure, high temperature condensates from the CentralGraben area. To develop these fields the operators havereviewed the equipment available and discovered thatnew solutions had to be developed.

A GLOBAL, FAST GROWING & TECHNICALLY CHALLENGING MARKET

Exploration and Production activity has spectacularly increased for High Pressure/High Temperature wells around the world in the last 10 years, as the search for additional hydrocarbon reserves drives operators to more challengingareas. These wells push the barriers of technology to allow exploration and developmentof the fields economically andsafely.

HIGH PRESSURE/HIGH TEMPERATURE WELLS

/...

22

The solutions developed were specifically designed,tested and manufactured with an increased level ofquality assurance. Alongside bespoke running proce-dures this enabled these HP/HT fields to be placedinto production in the early 2000s. Since these field developments other operators arenow looking at HP/HT wells for additional production.These operators are of varying sizes from the supermajors to the smaller independent oil companies.These HP/HT fields are now being found globallyincluding, the USA, the UK, Norway, Denmark, theNetherlands, Egypt, Israel, Africa, Saudi Arabia, India,China, Indonesia, Malaysia, Australia and Brazil.

DEFINITION OF HP/HT WELLSThere is no actual industry definition for HP/HT well.However Vallourec uses guidelines that place HP/HTwells into categories of both bottom hole pressure and

bottom hole temperature. The HP/HT boundaries are being pushed further into ‘Extreme’ and ‘Ultra’conditions, meaning temperatures in excess of 200°C(392°F) and pressures in excess of 17,500 psi.

A GROWING MARKETThe number of HP/HT wells around the world has tripledin the last 10 years; this has been encouraged due to the technology to explore these wells being widelyavailable and the expertise being transferred globally. To ensure that these wells are economically viable theoperators are now pushing the boundaries of technologyand need additional support to ensure that operationsare as successful as possible. An HP/HT well can cost from $31 million to $1.5 billion forthe operator to drill. They must ensure that they have allthe specialized equipment required to allow the operator totest and/or produce from the well, this includes the casing.

HP/HT fields aroundthe world


TYPE OF WELL BOTTOM HOLE PRESSURE BOTTOM HOLE TEMPERATURE

Psi Bar MPa °C °F

Non-HP/HT <10,000 <689 <68.9 <150 <302HP/HT 10,000 689 68.9 150 302Extreme HP/HT 15,000 1,033.5 103.4 180 356Ultra HP/HT 17,500 1,205.75 120.6 200 392

24 25

SOLUTIONSON THE MARKET

HP/HT CHALLENGES Drilling and completing HP/HT wells is very difficultand dangerous. The effects of the pressure and temperature of the well bring unique challenges that require specific solutions to ensure the successof the operation. This includes operating with smallerdrilling windows, depletion of reservoirs, increasedcorrosions issues and finding rigs that are capableof performing HP/HT operations. Below is a list of some of the main challenges experienced byoperators.

In terms of the supply of tubulars for HP/HT projects,various aspects are crucial. First of all, initial consi-deration must be performed on the well design and the pipe selection. In fact, the traditional diameters of casing and tubing are generally not suitable for use in HP/HT wells due to the increasedloading required. Therefore non-standard dimensionsare required to maintain the hole size and ensurethat the needed volume of liquid/gas can be brought

to surface. This is critical during the drilling opera-tions to guarantee that there is enough flow of mudto circulate the cuttings and then cement the casingat location. This design process is required for themain well including contingency options. Another aspect to consider is material selection. The material must have the strength to cope withthe loadings of the well combined with the corrosionperformance needed to cope with the down hole fluids. This can be challenging as the combinationof the performance is also affected by temperaturede-rating. This must be considered for the casingand tubing strings and also all the accessories. As the well is exposed to numerous loading scenariosthroughout its lifecycle from both operations and changes in local geology, this includes changes in temperatures, pressure and applied loading. There-fore evaluation testing of both pipes and connectionsis needed to validate the performance and make certain that it meets the critical demands.Finally the management of all ancillary equipment isessential; within the well this can potentially be the ‘weak’point. The material and connections using these ancillarieshave to be able to meet all the requirements in terms ofperformance, loading and ability to manufacture.

EARLY COLLABORATION FOR A SUCCESSFUL RUNNINGTo meet all the demanding challenges of an HP/HTwell, solutions are required throughout the full planningof the well to ensure that it is optimally designed sothat operations are run safely. It is extremely importantthat these early discussions start at least 18-24 monthsprior to the spudding of the well. These early discus-sions with Vallourec ensure that the operator choosesthe most optimized solution for their HP/HT wells,which includes selecting the pipe dimensions, gradesand connections or if required developing new productsor services. This is now fundamental due to the recent accidentsthat have occurred offshore in the last couple of years.The requirement for enhanced quality assurance,validation, competence, control and management iscrucial in ensuring that the well is delivered successfully.

Vallourec has been involved in some of the most severe HP/HT wells around the worldincluding; BG Jackdaw, Shell Shearwater, Total Elgin Franklin, Marathon Earb, GDF Suez, Maersk Culzean, Petronas andConocoPhillips.


The discovery of offshore deposits starting in 2007put Ghana on the map of oil-producing countries.Independents and even some majors currently extractthe precious natural resource from the Gulf of Guinea,in Ghanaian territorial waters. Among them is TullowOil plc, a British company with a far-reaching Africanpresence. It operates in Mauritania, Uganda, Gabon,Liberia, Ivory Coast, Sierra Leone, Kenya, Guinea, and now ... Ghana. Over the last five years, the riskmanagement strategy pursued by the company has paid off with an average success rate of 80%. To date, 24 of the 29 wells it has drilled in Ghana have yielded hydrocarbons. Tullow exploits a third ofthe resources in the country and depends mostly onVallourec for its tube supply. "Tullow is our main client in Ghana," explained Thomas Feldhaus, VallourecWestern Africa Sales Manager. "An extremely pro-mising client that only orders premium products likeVAM® TOP and DINO VAM® and that we also suppliedwith a shipment of Cleanwell® last year."

ACHIEVING LOCAL CONTENTGhana wants to see local content and Vallourec hasrecently responded to this ambition by participatingfor the first time in the Ghana Summit, whose thirdedition was held this March in Accra. The event wasthe ideal occasion for better understanding the expec-

tations of local authoritiesand their partners, and itwas quickly followed inJune by a Tubular Essen-tials session, part of a vasttraining program offeredby Vallourec through itsVAM® Global Solutions. After a three-day lecturesession, the 18 partici-pants—hailing from GhanaNational Petroleum Corpo-ration (GNPC), Tullow,Kosmos, Hess, and AfricaOilfield Services Ghana Ltd(AOS)—took the opportu-nity to visit AOS, the VAM®

Licensee based in Takoradi,Ghana. They watched pipebeing threaded and got aconcrete grasp of the premium-connection specificitiesthey had just studied. They also got first-hand exposureto gauge labs, phosphating, make and break, and copperplating operations during their AOS visit.This session gave our customers a good understandingof OCTG products to help them in the future whendesigning wells or handling our products.

GHANA: ENDLESS POSSIBILITIES/...

• Deeper wells

• Casing wear

• Wellhead capability

• Requirement for contingency strings

• Small mud window due to pore – fracture gradients

• Annular pressure build-up

• Increased corrosion potential

• Heavy Duty rigs required

• Timing and costs of the well from authorization to completion

• Compaction of the depleted reservoirs

• Clearances between strings

• Electronics capability at temperature

• Increased cyclic loading

• Management of accessories

• Reduced safety factors in the well design

Contact: [email protected] Customers visiting AOS in Takoradi.

Ghana has rapidly become an El Dorado for a few bold oil companies like Tullow Oilplc, which relies almost exclusively on Vallourec for premium tubular products. The country expects to benefit from its recently discovered reserves and intends to havelocal content play an increasing role in agreements reached with partners.

Vallourec pipes onTullow's yard in Takoradi.

Make and break unit at AOS (VAM® Licensee in Takoradi).

PEOPLE

26 27

SOLUTIONSEVENTS


There's been more than one drivingforce behind Stuart Mitchell’s evolution within the oil industry.

The 32-year-old, who describes himself asdriven, is now an Onshore InspectionSupervisor with Vallourec. That’s a role he’soccupied for three and a half years. However,Stuart, father to six-year-old Ewan andAndrew (five), initially started as a VAM®

Field Service engineer in 2005.

What triggered the career changefor the gym loving Bucksburn resident?

When an onshore role opened up it was a naturalprogression for me,” said Stuart.

“After a total of eight years working offshore, I neededto be onshore to discover another side of VAM® FieldService engineer job. I enjoy more of a routine but nextmonth there’ll be another shift in emphasis when Itake on a post as field service Technical Manager, providing technical field support to the 11 VAM® FieldService centers in the world.”

Stuart’s career in the oil sector started withWeatherford in 2000. He spent five yearsoffshore with them.That’s a stark contrast from his first jobas an apprentice panel beater before hedecided to follow a family path into theoil industry.

I’m glad I decided to take a leap of faith andleave the motor trade.

I’ve seen some places I’d never have and met some greatpeople. Anyone considering becoming a field serviceengineer should go for it but be prepared to be adaptable,reliable and customer oriented.

I became familiar with life in the North Sea from a youngage through my dad, Stephen.

He’s 60 this year and has been with Transocean for 30years. His work ethic rubbed off on me.”

So what’s involved in Stuart’s daily routineand what qualities does he feel potentialoffshore technicians need?

Typically I’ll assign work to an inspector to carryout thread inspection duties,” continued Stuart.

I’ll generate work records on the internal system, keepmaintaining training records and ensure competenciesof VAM® Field Service engineers.

It’s important the offshore technician maintains openlines of communication with the oil company represen-tatives offshore regarding inspection work.

Another aspect is carrying out pre running inspectionduties of VAM® pipes and connections.

Supervising the handling and make up of operations of VAM® pipes during the running to ensure correct make up of connections is also vital for customer wellintegrity.

Following things up after the job with a report of eventsis another part of the position and these must be sub-mitted on time. This allows us to measure continuouslyCustomer Satisfaction for service improvement and toensure that our customers are happy!”

STUART MITCHELL

DRIVENThe month of May saw the return of the Offshore Technology Conference (OTC*)in Houston, Texas. This mega oil and gas event has become a perfect backdrop for Vallourec North America to entertain customers in style.“Our local companies (V & M USA Corp, VAM® USA, V & M Tube-Alloy, VAM® Drilling,Serimax) seized this opportunity to show our appreciation toour domestic and international customers during a memorableevening”, said Edouard Guinotte, President of V & M USACorporation.This year’s event took place at America’s in the River Oaksneighborhood, in the designer setting, and delicious Latinfusion refreshments hallmark of renowned Chef Cordua.350 participants gathered in a joyous atmosphere, aroundspecialty ales and whiskey tasting, while enjoying cigars rolledon the spot.Our North American colleagues are already planning for anotherexciting event next year.

* The OTC is a major industry event focusing on the development of offshoreresources. Since its inception it has become a worldwide event attracting closeto 100,000 professionals from the offshore energy field to Houston each year.

A new edition of the Offshore Northern Seas event took place inAugust 2012 in Stavanger. This biannual exhibition is Norway’smost important oil industry event, and ONS 2012 attractedclose to 60,000 visitors from over 100 different countries.Vallourec was represented at ONS 2012 by the Stavanger-basedVAM® Norge and by VAM® Drilling. The VAM® Norge team charteredtwo 60’ yachts for the duration of the exhibition, berthing bothin Stavanger’s old harbour. Both vessels hosted client eventsthat week with lunch cruises around the fjords each day forselected clients and drinks receptions in the evenings. Bothevents proved popular throughout the week, and many of ourNorwegian clients and potential clients attended the evenings,making them a great success. For VAM® Norge, ONS is a great

opportunity for the local team to continue building on the strongrelationships with Norwegian clients that were first establishedwhen the business opened in 2008.ONS 2012 was the perfect platform to mix daily visits to exhibiting clients by key members of the local team with thehigh-value client events each day on board the yachts. More importantly, ONS was an excellent opportunity to show ourappreciation to existing clients in Norway, and also to showcaseourselves to potential clients.“Without exception, the feedback from our clients on the Vallourecpresence in Norway through VAM® Norge has been positive. I trulybelieve that this type of events adds value to our already closerelationships", said Roar Knutsvik, Country Manager - VAM® Norge.

VALLOUREC DEMONSTRATES

TEXAS HOSPITALITY

ONS 2012 SEEN THROUGH THE EYES

OF VAM® NORGE ‘‘

‘‘‘‘

#03 - OCTOBER 2012 Vallourec at the heart of the Middle East · Zadco / UAE – Anil Remasan, ITS India – Stian Ronnevik, Ross Offshore / Norway – Joanna Salamaga, Woodside

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