Vallourec PressPack Offshore Oilandgas
Vallourec PressPack Offshore Oilandgas
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PRESS KIT
OFFSHORE OIL AND GAS ACTIVITIES
MARCH 2015
CONTENTS Page
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OFFSHORE OIL AND GAS ACTIVITIES
MARCH 2015
Beyond 200 meters water depth, human intervention is no longer possible; it is replaced by remotely
operated vehicles (ROV’s). . Beyond 300 meters, the installations are typically floating, anchored on
the seabed and sensitive to weather conditions. From 1,000 to 1,500 meters, conditions for
operation and intervention become much more difficult. At that depth, the temperature of the water
is around 4°C, creating a risk of hydrate and paraffin formation, which can obstruct the pipe during
production phases. Also, the pressure reaches 150 bars at a depth of 1,500 meters and increases by 1
bar every 10 meters.
In such an environment, the challenge consists of perfecting systems which prevent the oil from
cooling and resist the pressure, to keep it fluid and ensure it can be raised to the surface.
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Operating in deep water also causes particular difficulties to drillpipe and casing strings as loads can
be very high. The strength of conventional tubulars are not sufficient and a specific design must be
used to prevent the tubes from crushing in the jaws or slips tongues which hold them on the rotary
table during installation operations. . Robust connections with high-performance sealing must also
be used.
The drill pipes are subject to great tension stresses. In order to drill more complex wells in deeper
water, the use of high torque connections is necessary to transmit the rotation of the drill string from
the drill bit at the base of the well to the drill floor. .
Also, after the 2010 Deepwater Horizon incident in the Gulf of Mexico, the regulations and
requirements of oil companies and service and equipment suppliers have become even more
stringent, demanding ever greater risk mitigation during the drilling and production process.
MAIN PLAYERS
The development of offshore oil and gas is an entire network, in which oil companies and businesses
in the oil-related sector work side-by-side.
Oil companies
As the technological investments necessary for offshore operation are particularly high, the
international oil companies (notably Total, Chevron, Shell, BP and Exxon Mobil) share most of the
market amongst the international oil companies (IOC’s). However, the national oil companies (NOC’s)
of producing countries, such as Petrobras or Statoil, represent a very large part of the investments in
this field. Amongst the 10 main players in ultra-deep offshore, Petrobras is the world leader, with
nearly 50% of investments made in 2014, far ahead of Total and Shell.
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The range of products (OCTG tubes, line pipes, drill pipes…) and services from Vallourec is aimed
both at the oil companies and companies in the oil-related sector.
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Vallourec's range of offshore products covers the entire hydrocarbon production chain, starting with
OCTG (Oil Country Tubular Goods) tubes intended to equip wells during the exploration and
production phases. Vallourec also has a complete range of products intended for drilling offshore
wells. These threaded seamless tubes are fitted with VAM® connections (a family of premium
threading invented and patented by Vallourec), which provides perfect sealing for the drill strings.
Downstream of the oil and gas wells, the Group markets tubes for offshore flowlines for transporting
hydrocarbons to the surface, as well as welded tubes for umbilicals, flowlines, and structural tubes
intended for offshore platforms.
The Group also offers a range of on-site services dedicated to the offshore industry.
LLOG
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Vallourec's teams work in close collaboration with its customers to develop tailor-made solutions and
adapt the pipe and connections to the ever-higher technological demands characteristic of deep-
water and ultra-deep applications. The Group responds to these challenges by developing products
that are capable of withstanding corrosive environments, extreme mechanical stresses and high
pressure and temperature levels over the life of the well.
With "easy oil" drawing to an end, the development of innovative premium products is the Group’s
priority to meet the needs of its offshore oil and gas customers.
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In the oil and gas sector, the technical l challenges faced by the Group's customers in deep waters
("high pressure and high temperature" deposits, salt domes, etc.) require the development of more
resistant steel grades and higher performance threaded connections. For submarine flowlines,
subject to extreme mechanical stresses in operating conditions, Vallourec is developing coordinated
coating and welding services (pre-assembly).
From the creation of the VAM®1 connection in 1965 to the development of the VAM® TTR2, a
connection dedicated to offshore production risers that meets the operators’ highest requirements,
innovation has led to numerous breakthroughs. These have enabled Vallourec's customers to access
offshore resources which until then were not exploited, or to improve the performance of their
facilities. These innovations are attributable to the close working relationship that the Group enjoys
with its customers.
Meeting the need for reliability and safety while minimizing our impact on the environment
The increasingly stringent requirements regarding the reliability and safety of installations and
tougher regulations testify to the importance of innovation. In line with its premium positioning, the
Group's goal is to respond to the far-reaching and rapid changes in its customers' needs and to offer
suitable solutions which are safe, reliable and mindful of the environment. In order to meet this goal,
Vallourec has considerably strengthened its R&D capabilities over the past few years.
Innovation is not limited to developing new premium products. By improving our manufacturing
processes, particularly non-destructive tests, Vallourec innovations allows the creation of new
services so that customers can get the most out of our products.
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VAM® is the Group's premium connection intended for the most complex applications.
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Risers: pipes bringing the hydrocarbons to the surface.
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SOUTH AMERICA
- BRAZIL
Petrobras’ announcement, in 2007, of the first pre-salt fields discovery in a zone located 250 km east
of Rio de Janeiro was a major event due to the size of the estimated reserves.
In 2013, Vallourec signed two services contracts with the Brazilian national company, supplementing
the vast range of tubular products that Vallourec provides to its main Brazilian customer through a
framework contract of five years, renewed at the end of 2012.
The range of high-value-added services is the greatest ever supplied to Petrobras. It includes the
inspection and repair of tubes, on-site services, preparation of drilling operation equipment,
coordinating the supply of equipment for wells according to the drilling program… To this range of
services is added the organization of the supply chain in all ports from which Petrobras supplies its
offshore drilling platforms, managing tube tracking using RFID (radio frequency identification)
technology, providing engineers and special accessories rental.
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Dedicated solutions
These are the circumstances under which Vallourec develops and supplies Petrobras, within a long-
term supply contract (see framed section on the following page), state-of-the-art tubulars and
connections, which meet the specific requirements of the most difficult fields exploited by the
Brazilian oil company:
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Customized services
Beyond its VAM® licensee network which provides after-sales service, Vallourec do Brasil created
storage facilities at various logistic centers belonging to Petrobras in order to perform "just in time"
deliveries, reducing storage costs and sourcing deadlines for Petrobras.
PETROBRAS
A historical player in the offshore industry well before the discovery of the pre-salt fields
Since its first offshore discovery in 1968, Petrobras has continuously developed this area, reaching
ever greater depths (see the image below). The group produces most of its oil offshore, representing
1.8 million barrels per day out of a total of 2.1 million (average over 10 months in 2014). Still in the
process of development 7 years after their discovery, the pre-salt fields represent production of
more than 300,000 barrels per day since 2013.
Source Petrobras
With ultra-deep offshore production of about 420,000 barrels per day, Petrobras is now the world
leader in deep-water production.
The cooperation between Vallourec do Brasil, a wholly-owned subsidiary of Vallourec, and Petrobras
goes back to the very beginnings of Vallourec's factory at Barreiro (Minas Gerais), built in 1952 to
supply tubular products to the emerging national oil industry.
This historical relationship has led to close links and extensive cooperation between the two groups,
resulting in a long-term supply contract and extensive services contracts.
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GULF OF MEXICO
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WEST AFRICA
- ANGOLA
The solutions supplied by Vallourec include a wide range of services, such as the application of about
150 km of anti-corrosion coating on the flowlines, and the supply of some 700 bends curved by
induction. The production flowlines require the use of "pipe-in-pipe" technology to assure
hydrocarbon flow. They were preassembled directly in Angola.
Serimax, the subsidiary of Vallourec specializing in flowline welding services for the oil and gas
market, worked for 7 months with its Saturnax 09 welding equipment on board Seven Borealis, the
flowline laying ship belonging to Subsea 7. Over 5,500 welds on the flowlines, including sections
sensitive to corrosion and fatigue, were provided.
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FPSO: Floating Production Storage and Offloading Unit
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KAOMBO: premium tubes and connections to equip the ultra-deep offshore Kaombo project
Located 150 km off the Angolan coasts, the Kaombo oil field is one of the largest oil projects
operated by Total in this area. . The Kaombo project comprises 59 wells drilled in varied and complex
geologies requiring different types of wells.
A third of the wells require drilling through salt layers to reach the desired depth. The drilling
conditions there are particularly difficult, with water depths of between 1,400 and 2,000 meters, and
reservoirs located up to 5,000 meters below the sea bottom. .
Vallourec will supply 27,000 metric tons of tubular solutions (OCTG) to equip the offshore oil wells,
including VAM® 21 premium connections, VAM® SLIJII, and VAM® BOLT premium integral
connections.
The casing and production tubes used will be manufactured and finished in France, Indonesia and
Brazil. First production was finished in December 2014. The drilling operations, which will begin in
the third quarter of 2015, should finish in 2021.
- GHANA
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- NIGERIA
Located 130 km from the Nigerian coast at a depth of 1,750 meters, the Egina offshore oilfield is
operated by Total Upstream Nigeria. It is in development and should be in production at the end of
2017.
Vallourec supplies premium undersea flowline tubes to Bell Oil & Gas, a Nigerian oil and gas company.
Out of the 24,000 metric tons of tubes ordered for this offshore project, 16,000 metric tons will be
used as undersea flowlines for production, water injection and the transport of gas. The remaining
8,000 metric tons will be supplied for the construction of a "pipe-in-pipe" riser.
Vallourec, which is participating in the Human Capacity Development Program (a Nigerian skill
development program) is currently training young Nigerian engineers in pipe production and
applications, thus complying with requirements for local content in the project.
Nyonie Deep
Diaman 1
Nene Marine
The offshore pre-salt fields off West Africa are gradually revealing their potential through major
discoveries, including Diaman 1, a deep water project discovered by Cobalt and operated by Total
Gabon, and Nene Marine, a shallow water project discovered by ENI. Numerous drilling projects are
currently in progress.
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NORTH SEA
Serimax, a subsidiary of Vallourec and an international welding company, was selected to carry out
the welding work on Technip's assembly base at Evanton (United Kingdom). The contract specifies
the welding of 62.6 km of 10 inch gas export flowlines and 33.5 km of 10 inch oil export flowlines.
MIDDLE EAST
The Middle East region is well known for its production of onshore oil and gas, but it has an active
offshore segment, from shallow waters to very deep water operations.
Given its recognized expertise in this field, Vallourec is particularly well-placed to participate in the
exploration and development of new fields in the Red Sea and Arabian Gulf which have huge
potential.
Since 2012, Vallourec has signed several orders for VAM® 21 connections in Saudi Arabia to equip
offshore and deep-water offshore exploration wells located in the north part of the Red Sea, near the
Gulf of Suez.
Thanks to its unique sealing and mechanical resistance properties, the VAM® 21 connection is clearly
the best-adapted solution for the extreme conditions encountered when tapping complex deposits.
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EPC: Engineering Procurement and Construction
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In the region, Vallourec has drilling production centers at Jebel Ali and Abu Dhabi as well as an
Internal Plastic Coating (IPC) center in Abu Dhabi.
SOUTH-EAST ASIA
- INDONESIA
PRELUDE: process tubes for the first Liquefied Natural Gas floating unit
Shell will launch the first LNG floating platform, known as "Prelude", over a gas deposit located 200
km off the Australian coast and south-east of Indonesia, where it will remain for 25 years, the entire
period of deployment. This offshore facility, the surface area of which is greater than four football
fields, will open access to new and complex gas deposits.
The FLNG (Floating Liquefied Natural Gas) technology is revolutionary allowing offshore operations
near gas deposits, suppressing the need for pipes to transport the product or installing treatment
facilities for production on land. Shell's floating LNG structure will be able to liquefy the gas directly on
board, store it and transport it throughout the whole world.
At the end of 2012, Vallourec supplied Samsung Heavy Industries with 1,000 metric tons of process
tubes in steel alloy and carbon steel used for surface installations and for the hull of the floating LNG
platform.
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- BRUNEI
ML SOUTH: a 100 million dollar contract to supply premium tubes and VAM® 21 connections
The development well will produce at a depth greater than 5,000 meters, in a highly corrosive
environment, with particularly high levels of pressure and temperature (HP/HT).
Vallourec will equip the wells with premium tubes, most of which are composed of highly alloyed
grades of steel, resistant to corrosion, and are threaded with the latest premium VAM® 21 connections.
The casing and production pipe will be manufactured in Vallourec's European and Indonesian mills.
The tubes will be delivered to Total E&P Borneo for the drilling operations, which are planned to begin
during the second half of 2015.
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Products
o OCTG (tubing, casing and
connections)
o Drilling tools (drill pipes, well bottom
tools and accessories)
o Line pipe (risers and flowlines)
o Accessories (Completion equipment
mechanical tubes, well screens, etc.)
o Umbilicals
o Tubes for FPSO and other platforms
(flowlines and structures)
Services
o VAM® Field Services Offshore
o Welding (Serimax)
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This coupled solution is perfectly suited to the most extreme environments, such as HP/HT (High
Pressure/High Temperature) deposits, highly deviated wells, or when drilling-with-casing.
Furthermore, the VAM® 21 facilitates self-alignment of the tubes, ensuring secure and rapid make up
on the rig. It can be used with the Cleanwell® Dry coating, which preserves the environment while
allowing dope-free tube connection.
VAM® 21 threading can be carried out in most of the Group’s threading units around the world and
maintenance is provided by the many VAM® licensees based in over 50 countries.
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CLEANWELL®, THE FAMILY OF GREASE-FREE COATING PRODUCTS FOR THE DIFFICULT CONDITIONS
OF THE NORTH SEA
There is strong demand for products that are environmentally-friendly and facilitate the installation
of tubes, particularly in the North Sea.
Cleanwell Dry®, the latest edition to the Cleanwell® family, is a lubricant ('dry' coating) developed for
threaded connections which avoids the use of dope and effectively protects tubes against galling and
corrosion, including under extreme low temperature conditions.
Vallourec is the leader in the market for threaded and coupled connections used for riser
applications. The threaded tubes that link top-side wellhead systems to the sub-sea wellheads have
to withstand exceptional levels of fatigue, therefore cutting-edge technology and specific approval
tests were developed. Several projects are currently taking place in Brazil, Australia, the Gulf of
Mexico and Indonesia.
VAM® TTR:
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DRILLING PRODUCTS
- a range of connections providing torque, tension and hydraulic performance adapted to a wide
variety of drilling programs
- a wide range of steel grades and wall thicknesses for handling the stresses encountered during
drilling operations
- steel grades dedicated to drilling in an H2S environment
- products for specific offshore applications and, in particular, a range of Landing Strings, for
installing undersea equipment or casing. In particular, the CrushFreeTM landing string enables
work at very great depths of water. However, other more conventional products are adapted to
shallow water.
- Work-over riser systems, for carrying out maintenance operations on mature wells or installing
casing.
In addition to its portfolio of products, Vallourec Drilling is developing tube maintenance and
inspection services for customers in the North Sea, to extend the life of these remedial well
operation tools..
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Riser: pipe connecting the surface platform to the flowlines which are on the seabed. / Flowline: pipe laid on
the seabed for transporting hydrocarbons (oil and gas) and water injected into the reservoirs.
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Integrated offers covering tubular requirements for "SURF" applications, take into account the
specific characteristics of each project to reduce risks and execution costs, and creating value for the
customer.
This is executed by offering an integrated set of products and services. Tubes for flowlines are
produced according to required specifications, interior and exterior coatings are applied to ensure
proper fluid circulation and pipe protection, and welding tubes for specific equipment and
installation at sea by its subsidiary Serimax, supported by an organization dedicated to project
management, allows Vallourec to develop innovative solutions for current and future projects.
UMBILICALS
Umbilicals are complex control lines dedicated to transporting fluids, supplying power and
transmitting information. They consist of small-diameter tubes, cables and optical fibers connecting
equipment installed on the seabed to their control stations on the surface.
Vallourec has a competitive premium range of products for this market. The know-how acquired by
the Group through its subsidiary, Vallourec Heat Exchanger Tubes, in the production of long welded
tubes has enabled the Group to reduce the number of orbital welding points for these small
diameter hydraulic tubes.. The umbilicals assembled with Vallourec tubes are lighter and provide
greater resistance to fatigue, which is substantial in a sub-sea environment...
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VAM® Field Service Offshore is a range of on-site services specifically dedicated to the offshore
industry. It is a service provided by Field Service inspectors on the rig, with teams overseeing the
correct installation and trouble-free running of the tubular systems..
This service is part of a complete range of innovative solutions known as "Vallourec Global Solutions",
designed to meet its customers’ most advanced requirements throughout their projects.
Developed for the oil and gas sector, and particularly for the offshore industry, this combines a set of
products and services that provide tailor-made solutions specific to each requirement of oil
companies, from pipe and connections manufacturing to their installation in the wells.
For offshore subsea flowline projects, coordinated coating and welding services (pre-assembly) are
now available in addition to the supply of tubes, thanks to the expertise and know-how of Serimax. A
wholly-owned subsidiary of Vallourec,
Serimax develops new technologies and
solutions that widen the Group’s range of
services for customers.
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Industrie &
The A (or “the”) leading supplier of
autres
premium tubular solutions for the 17,6%
energy markets (oil and gas, power
generation), Vallourec also provides its Pétrole et Energie
gaz, électrique
expertise to the industrial sector.
pétrochimie 10,7%
With more than 23,000 employees, 71,7%
consolidated revenue of €5.7 billion in
2014, 81% of which is generated
outside Europe, integrated production units, advanced R&D and a presence in more than 20
countries, Vallourec offers global innovative solutions adapted to the energy challenges of the 21st
century.
Specialized in the most complex applications, Vallourec relies on its six research and development
centers throughout the world and more than 500 engineers and technicians to maintain its
technological leadership and meet industries changing demands. Our control of the entire chain,
from steel production to finishing to installation, is a guarantee of the excellence and reliability of its
products.
For the oil and gas market, the Group designs and develops a complete line of products including
seamless tubes and premium connections (OCTG) intended for drilling and production operations,
and , and line pipes for subsea gathering systems. These products equip wells in the most extreme
conditions high-pressure, high-temperature or corrosive environments, highly deviated wells, and
deep-water offshore.
In the electrical power generation market, Vallourec offers a range of premium tubes that resist the
highest temperatures and pressures, allowing electrical operators to meet the challenges of energy
efficiency and control of CO2 emissions from power stations.
Vallourec also provides a wide range of tubes for petrochemical facilities (refineries), and tubular
products intended for mechanical applications (hydraulic jacks, machine tools, etc.), the automobile
industry and construction (stadiums and other
complex structures and buildings) and for other
industries.
Photos and illustrations, all rights reserved : Petrobras, Thiago Fernandes, Frédéric Lepla (avec l’aimable autorisation de Subsea 7), Getty Images/iStockphotos, Mark Hall, Phillippe
Dureuil, Ewen Weatherspoon, Photothèque Vallourec et Serimax.
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