TMK is self-sufficient in steel billets. Three of the Company’s four Russian pipe plants have their own steelmaking facilities and manufacture steel billets for seamless pipe; Sinarsky Pipe Plant however does not have a steelmaking capacity. The plant instead benefits from close proximity to Seversky Pipe Plant, which fully covers its steel billet needs. We also have a steel billet production capacity in the USA and Europe: the Koppel plant in Pennsylvania (USA), and TMK-RESITA (Romania). Almost all steel billets produced by these plants are consumed by the Ambridge plant (USA) and TMK-ARTROM (Romania) respectively, both located in close proximity to the steelmaking facilities.
With its own steel billet production capacity and supply arrangements in place, TMK is less reliant on third-party suppliers, and is better positioned to control the costs of finished products and ensure the quality of steel used to manufacture its tubular products.
TMK purchases scrap and HBI for steelmaking facilities in Russia from TMK CHERMET and Metalloinvest. TMK purchases most scrap on the spot market, while for HBI it was signed an annually renewing contract with Metalloinvest in 2016, with formula-based pricing and monthly price reviews. The contract enables TMK to diversify its feedstock sources and reduce the risks associated with the scrap market volatility.
Currently, TMK has the following mid-term contracts for the supply of semi-finished products used in welded pipe production: steel plate – MMK, Severstal, Salzgitter, Metalloinvest, Metinvest Eurasia, and Nippon Steel; hot rolled coil – Mechel, MMK, Metinvest Eurasia, NLMK, Severstal, and ArcelorMittalTemirtau. In 2018, some supplier contracts were based on formula pricing that factored in the costs of base materials, production costs, inflation rate, and fluctuations in the rouble exchange rate. The price could be reviewed on a monthly or quarterly basis subject to the specific contract terms.
In September 2017, TMK’s Board of Directors approved the Company’s new Strategy to 2027.
- To solidify TMK’s position as a leading supplier to the global OCTG market, the dominant supplier to the Russian oil and gas market and one of the leading OCTG producer in the USA
- To improve business efficiency and to consolidate position in the Top 2 global leaders by financial performance in the global OCTG market
- To develop a service offering of comprehensive design solutions for customers using cutting-edge digital technologies
- To enhance safety levels for our employees
- To improve environmental protection at all of TMK’s production facilities across all of the regions in which the Company operates
- To reduce leverage
- To maximise the operating cash flow and optimise the assets portfolio
- Enhancing leadership in key segments and entering new product niches
- Optimizing vertical integration to reduce costs and developing product and service ranges
- Enhancing the sales platform and leveraging TMK’s global scale
- Focus on innovation and digitalization
- Enhancing operational excellence
- Strengthening financial performance and investment appeal
Key 2018 highlights
- No. 1 globally by total shipments of tubular products
- 67% share in premium connections segment in Russia
- 63% share in seamless OCTG segment in Russia
- 46% share of high-tech products in the Russian division’s sales revenue
- + 43% year-on-year growth in revenue from premium connections sales across the Group
- Growing sales of steel billets
- Strategic partnership in wheel steel production segment
- Commissioning of a new heat treatment line for seamless pipes at TMK-ARTROM
- Commissioning of a new external coating facility at TMK IPSCO
- Developing conceptual engineering services (15% of premium connection shipments at the Russian division included engineering analysis of projects)
- Supplying products to over 80 countries
- Developing a sales network in key markets
- Increasing volumes of pipe shipped to the American division in terms of interplant cooperation (+ 13% year-on-year)
- The comprehensive digital transformation program has been developed and approved and is currently under implementation
- A transformation committee has been established, chaired by the CEO
- TMK eTrade was launched, a tubular goods online shop project to develop an e-commerce platform (recognized as the best e-commerce project in Russia in 2018)
- Launching an e-commerce procurement platform
- Continuing to implement a number of decisions to increase technology reliability
- Continuing to adopt lean production culture and implement a continuous improvement system
- Consolidated efficiency program developed
- In 2018, adjusted EBITDA margin stayed flat year-on-year at 14%
- Net debt / adjusted EBITDA ratio reduced from 4.44x as at the end of 2017 to 3.48x as at the end of 2018
4 million tonne
steel pipe sales in 2018 (+5% y-o-y)
Our geographically diversified assets and sales help us mitigate risks and uncertainties while leveraging the opportunities offered by each market.
Industry experts estimate that in 2018, global steel pipe production was 172 million tonnes, up 1% year-on-year. The key drivers behind the increase include a 3.7% year-on-year rise in global economic growth and a considerable increase in investment activity within the energy sector (particularly in the NAFTA region) due to hydrocarbon price recovery.
According to the current medium-term outlook for the global pipe market, the market growth rate is expected to remain flat in 2019 compared to the prior year. The energy sector is expected to see moderately higher investments and growth in drilling activity, which will lead to a recovery in demand for oil country tubular goods (OCTG). Subject to sustained levels and further growth of global hydrocarbon prices and drilling activity, and implementation of planned pipeline projects, the global steel pipe market has potential to grow by 1% to 2% yearon-year in 2019.
TMK Group’s steel pipe sales in 2018 were 4 million tonnes, up 5% year-on-year and driven mostly by a recovery in the North American pipe market. TMK retains its leading position among the global steel pipe producers in terms of pipe sales.
In 2018, about 78% of TMK’s tubular products were sold to consumers in the oil and gas industry.
>80 countries across the world
TMK supplies its products to customers in over 80 countries across the world, taking advantage of our geographically diversified network of dealers and formal representative offices around the globe.
In 2018, the Russian market accounted for 54% of our total revenue, the Americas for 32%, and the European market for 6%. CIS countries, the Middle East, and Central and South East Asia accounted for 8% of our total revenue. In 2018, the share of the American market in our total revenue increased year-on-year, due to growth in drilling activity as oil and gas companies increased their exploration and production budgets amid a more favorable price environment. Our geographically diversified assets and sales help TMK mitigate risks and uncertainties while leveraging the opportunities offered by each market.
our total share of the Russian pipe market
The Russian pipe market grew by 2% year-onyear in 2018, driven by higher consumption of OCTG (+ 3% year-on-year) and large diameter pipe (+ 29% year-on-year).
TMK maintained its leadership in the domestic pipe industry in 2018. Our total share of the Russian pipe market for 2018 was 24%, with a 63% market share in the OCTG segment, 59% in the seamless line pipe segment, and 67% in premium connections.
TMK’s share of the Russian pipe market in 2018,
by product type, %
Oil country tubular goods including drill, casing, and tubing pipes
Seamless line pipe
Pipes for short-distance transportation of crude oil, petroleum products, and natural gas
Seamless industrial pipe
Pipes used in such industries as car manufacturing, engineering, or energy
Pipes for short-distance transportation of crude oil, petroleum products, and natural gas
Large diameter pipe
Pipes used in construction of trunk pipelines for gas, oil, and petroleum product transportation
Welded industrial pipe
Pipes for multiple applications across various industries, including utilities and agriculture
Premium connections (TMK UP)
High-margin proprietary products for connecting OCTG in offshore drilling, low temperature, high pressure, and other difficult conditions
No. 1 pipe producer in Russia
Large Diameter Pipe
The Russian large diameter pipe (LDP) market grew by 29% year-on-year in 2018, driven by higher LDP consumption by Gazprom and Transneft. In 2018, Gazprom purchased LDP for the Gryazovets–Slavyanskaya CS pipeline section intended to feed gas into Nord Stream 2 and for repair and maintenance needs, while LDP shipments began for the Sakhalin– Khabarovsk–Vladivostok gas transmission system expansion project.
TMK’s share of LDP supply to the Russian market totaled 14% for 2018. In 2018, TMK supplied longitudinal welded pipes for Gazprom’s aforementioned large-scale infrastructure projects and was one of the major suppliers of pipe products for repair and maintenance needs of subsidiaries of Gazprom and Transneft.
In October 2018, TMK and PJSC Gazprom signed a technology roadmap to launch the production of pipes with integrated recording, processing, and switching components.
Oil Country Tubular Goods and Premium Products
In 2018, Russia increased its oil production by 1.6% year-on-year to 556 million tonnes. According to a forecast by Russia’s Ministry of Economic Development, domestic oil production will continue to grow through 2021. TMK expects a further increase in production drilling and well startups, driving OCTG consumption upward.
As the existing fields in Western Siberia gradually deplete, conventional oil and gas production methods are no longer sufficient for reaching performance and hydrocarbon production targets. To maintain the current hydrocarbon output levels, Russian companies are tapping into reserves via horizontal drilling, which requires more pipe. As a result, the share of high-tech horizontal drilling in Russia jumped from 11% in 2010 to 48% in 2018.
Russian crude output, million barrels per day
Share of horizontal drilling in Russia’s total production drilling, %
Source: CDU TEK data, TMK estimate
TMK’s share of the Russian seamless OCTG market
Between 2010 and 2018, drilling volumes in Russia showed a steady growth of 7% per year on average.
In 2018, both the OCTG market and drilling volumes in Russia remained flat year-on-year. Rosneft was the most active player in the drilling market, accounting for 42% of the total drilling volume as it did in the preceding year.
TMK has been the dominant player in the Russian seamless OCTG market for many years. TMK’s share of the Russian seamless OCTG market was 63% in 2018.
Source: CDU TEK data, TMK estimate million tonnes
vs. drilling volumes, million meters
TMK consistently works to supply top-quality, high-tech, and reliable premium tubular products to oil and gas companies and to meet our consumers’ specific needs, helping them produce hydrocarbons in challenging climatic and geological conditions, including offshore and Far North locations.
TMK won tenders in 2018 to supply Rosneft subsidiaries with 6,900 tonnes of high-tech 13Cr (13% chromium) steel tubing pipe with TMK UP PF gas-tight premium connections. The shipments began in 2018 and will be completed in 2019 as per the delivery schedule.
Since 2018, TMK has been providing premium solutions for Rosneft’s offshore projects. In 2018, TMK won a tender to provide the casing supplies for most of Rosneft’s offshore projects: the Novaya 2 project (Sea of Azov; operator: PJSC Oil Company Priazovneft, a joint venture between Rosneft and LUKOIL), the Vostochno-Pribrezhniy License Block project (Sea of Okhotsk), and the Odoptu-More field project (Sea of Okhotsk).
In September 2018, TMK shipped a batch of corrosion-resistant casing pipe of 13Cr steel with TMK UP PF threaded connections to construct production wells at the Yuzhno-Kirinskoye field operated by Gazprom. TMK’s specialists supervised the sinking of the casing into the wells. The casing pipe was designed and manufactured specifically for Gazprom’s projects as per a longterm “future thing” agreement entered into by the parties in October 2015. TMK also signed a tubular product qualification and process validation agreement in 2018, which will see shipments of premium tubular product for well construction at Gazprom’s Kovyktinskoye field begin in 2019.
In 2018, TMK won Russia’s largest tender for the supply of corrosion-resistant TMK-C chromium-nickel alloy casing pipe with TMK UP PF threaded connections to LUKOIL-Komi, securing TMK’s dominant position among pipe suppliers in this market segment. TMK is Russia’s only manufacturer and supplier of corrosion-resistant chromium-nickel alloy pipes.
In July 2018, TMK shipped the first batch of 244.48-mm L80 grade casing pipes with TMK UP PF threaded connections to Sakhalin Energy. In November 2018, the pipe column was successfully launched from the Molikpaq platform at the PiltunAstokhskoye field in the Sea of Okhotsk with the involvement of TMK specialists. The order was part of a long-term renewable contract for the supply of premium oil country tubular goods signed between TMK and Sakhalin Energy in October 2017 and effective through 2022.
In 2018, TMK commenced industrial-scale manufacturing and supply of premium grade 340, 273 and 245-mm casing pipe with GreenWell lubricant-free coating for production drilling at the V. Filanovsky field, operated by LUKOIL in the northern Caspian Sea. The first 273-mm pipe column with GreenWell lubricantfree coating and TMK UP PF ET threaded connections has been successfully lowered. The shipments will continue through 2019 and 2020.
- For the fifth year running, TMK was recognized as the best supplier of industrial products and services for offshore oil and gas developments in the Tubular Goods category, beating its Russian and foreign rivals. The 2018 results were announced and the award ceremony was held as part of the 13th Offshore Oil and Gas Contracts (Neftegazshelf 2018) annual conference.
- The ranking has been compiled since 2013 to facilitate import substitution in offshore oil and gas developments and to improve the market’s information support, transparency and openness. Companies are rated through an annual survey of oil and gas companies focused on offshore development projects.
TMK works with Russian oil and gas majors under R&D cooperation programs, including import substitution programs.
The Gazprom – TMK R&D cooperation program is aimed at meeting Gazprom’s future demand for tubular products. The program covers cooperation between Gazprom and TMK in welded large diameter pipe, seamless line pipe, casing, tubing, and drill pipe, best practice sharing, and joint research. Under the cooperation agreement, TMK will launch 34 new high-tech tubular products by the end of 2020.
In 2018, TMK and Gazprom signed a roadmap for the production of pipes with next-generation integrated recording, processing, and switching components. TMK will develop innovative large diameter pipes for Gazprom, with highly sensitive sensors embedded under the pipe coating to monitor Public recognition pressure, temperature, pipe stress, and deformation in real time. The pipes will also be fitted with smart RFID tags for reliable identification within the pipeline throughout their entire service life. The operator will be able to integrate sensors into a single system that monitors the condition of individual gas pipeline sections. The new pipe products are expected to be used in areas of high seismic activity, active tectonic faults and unstable soils, and at points of intersection of gas pipelines with transportation lines. It is expected that the innovative pipe will improve the reliability and safety of gas pipelines, allow more accurate assessments of their technical condition, and optimize troubleshooting, maintenance, and repair costs.
In 2018, TMK signed a Cooperation Memorandum for offshore projects with Rosneft and updated its 2018–2020 program of pipe import substitution in offshore projects.
In Russia, the consumption of both seamless and welded industrial pipe shrank in 2018 by 12% and 1% year-on-year, respectively. The decrease was driven by lower demand for pipe products from end consumers in the construction and engineering industries. Although TMK mainly focuses on OCTG production, we continuously develop new products used in the construction and utilities sectors, as well as in the engineering and nuclear industries.
TMK’s most significant shipments of seamless industrial pipe in 2018 included shipments to the construction site of ZapSibNeftekhim, a petrochemical complex project currently operated by SIBUR in Tobolsk, shipments of specialty pipe products to Gazprom Neft for the Omsk Oil Refinery revamp project, and shipments to the construction site of Yamal LNG’s natural gas liquefaction plant.
TMK continues selling pipes to customers in the automotive industry, power engineering, aircraft manufacturing, and nuclear sectors. In 2018, Taganrog Metallurgical Works (TAGMET) received an IATF 16949:2016 certificate of conformity for its quality management system. This enables the plant to sell round carbon and alloy steel billets to international vehicle component manufacturers, thus diversifying TMK’s sales.
According to Baker Hughes, the average rig count in the United States increased by 18% to 1,032 rigs in 2018, up from 876 rigs in 2017.
Ongoing recovery in hydrocarbon prices in North America led to a 25% increase in oil and gas companies’ drilling and completion spending year-on-year according to Spears, resulting in increased drilling activity and higher volumes of welded and seamless OCTG consumption.
U.S. gas and oil rigs, units
Source: Baker Hughes
Shipments of welded and seamless OCTG pipe in the United States in 2018 increased 2% above the level of 2017. Shipments of welded OCTG pipe decreased by 11% year-on-year, which was partially offset by an increase in shipments of seamless OCTG pipe by 10% y-o-y. The primary reason for lower shipments of welded pipes was the introduction of duties and quotas on imports of steel products in the United States, which limited supplies from South Korea, a leading supplier of welded OCTG to the United States. OCTG inventories grew during 1H 2018 (due to an inflow of imports in anticipation of the adoption of Section 232) followed by a steady decline through the end of the year. Relative OCTG inventories ended 2018 at 3.8 months of stock compared to 4.6 months at the end of 2017 based on unadjusted figures from the Preston Pipe and Tube Report.
U.S. OCTG shipments, thousand tonnes
Source: Preston Pipe & Tube Report
The total rig count in horizontal and directional drilling reached 94% in 2018, up from 92% in 2017. Horizontal and directional drilling is characterized by a higher level of pipe consumption.
U.S. OCTG inventories, million tonnes
U.S. rigs by drilling method
Source: Baker Hughes
As a result of higher rig count and increased demand for OCTG, as well as the restriction of steel products import into the United States, prices on the American pipe market improved significantly in 2018. Average composite OCTG seamless and welded pipe prices increased 15% and 17% year-on-year respectively.
The American division benefited from the ongoing recovery in the North American market and demonstrated significant improvement of operational and financial performance. In 2018, the Company strengthened its competitive position in the North American market through a launch of its new coating facility at Wilder facility. The 250 thousand tonnes of annual coating capacity for pipes up to 609.6 mm in diameter is available in Fusion Bond Epoxy (FBE), Abrasion Resistant Overcoat (ARO) and Specialty Coating. Coating protects line pipe against corrosion, mechanical damage, and weathering. The facility is certified for compliance with industry standards, including the most demanding (in North America) Canadian national specification CSA Z245.20, NACE SPO394 and AWWA C213 specifications, as well as the standards of specific end users. The new facility has the latest equipment to control the materials used and ensure high quality products.
Sales at the American division, thousand tonnes
EBITDA, $ million
In 2018, sales of tubular products at the American division increased 19% year-on-year to 804 thousand tonnes, while OCTG sales grew by 20% year-on-year to 580 thousand tonnes. Full-year EBITDA increased by 44% year-on-year to $164 million in 2018.
TMK IPSCO’s product offering includes 29 types of threaded connections for OCTG, some of which are market leaders, and a number of connections meeting or exceeding API standards. TMK IPSCO also manufactures line pipe for transporting crude oil and natural gas from fields to processing facilities and refineries, as well as standard, mechanical, and industrial pipe for agriculture, construction, and automotive industry. TMK IPSCO also successfully develops a number of proprietary steel grades for OCTG, as well as various corrosion-resistant grades for OCTG and line pipes.
In 2018, increasing complexity of drilling and higher share of horizontal and vertical drilling in the U.S., which require more advanced technology solutions, resulted in the increased sales of seamless OCTG with TMK UP premium threaded connections. Premium connection sales increased by 30% year-on-year to 231 thousand tonnes.
During 2018, TMK IPSCO successfully launched its new TORQ® premium connections series. The TORQ series of premium connections are used in challenging environments including extended-reach laterals, high pressure, and high temperature. In 2018, TMK IPSCO released three new premium TORQ® connections: TORQ TMK UP SFW, TORQ TMK UP ULTRA QXW and TORQ TMK UP DQW.
+ 44% y-o-y
Full-year EBITDA in 2018.
Premium connection sales at the American division, thousand tonnes
For the period from January 01, 2017 to December 31, 2018, we served more than 200 end users, with our largest end user accounting for approximately 7% of revenue during this period.
+ 81% y-o-y
EBITDA in 2018.
In 2018, the European steel pipe market slightly decreased year-on-year due to a lower demand from pipeline construction companies, which was partially offset by increased upstream CAPEX and recovering demand from engineering and construction industries. The introduction of preliminary protective measures against the import of steel and aluminum products from July 19, 2018 to February 01, 2019 led to improvement in the pricing environment. At the same time, higher selling prices allowed European manufacturers to offset increased prices of raw materials (scrap) and graphite electrodes. In 2018, the Company retained its stable position in the European seamless industrial pipe market with a 16.1% share. Total pipe sales at the European division in FY 2018 amounted to 201 thousand tonnes, being up 8% year-on-year. EBITDA was up 81% year-on-year to $51 million.
Pipe sales by European division, thousand tonnes
EBITDA, $ million
In February 2018, a new integrated heat treatment line for seamless pipes was commissioned at TMK-ARTROM. Its capacity stood at 165 thousand tonnes of pipe per annum. The facility enables a full range of heat-treatment services, such as tempering and quenching, normalization, soft annealing and hot straightening. The high-tech equipment enables precise control of the heat treatment process and monitoring of individual pipe treatment parameters. As a result, the new facility will provide heat treatment for 60–273 mm pipes with 5–60 mm pipe walls, enabling more efficient and cost-effective production of popular premium products. The heat treatment facility significantly reduces natural gas consumption and environmental impact, as well as reduces nitrogen oxides and carbon dioxide emissions.
Geographical diversification of consumers and a wide product range allow the European division to mitigate risks. The European division sells its products to almost 400 regular customers across 37 countries, focusing its efforts on the European market and on the countries of North America and Latin America. The share of the largest customer in the division’s revenue in 2018 accounted for less than 8%, and the share of the 10 largest customers – for less than 25%.
The marketing activity of TMK’s European division was focused on activities enabling to adapt quickly to changing market conditions and offer most optimal solutions to our customers. In 2018, TMK-ARTROM continued its marketing activity to promote TMK products to big oil and gas companies which developed projects in East Europe, such as ExxonMobil, SerbiaGas, NIS Gazprom, but also to customers from automotive and energy sectors.
In the reporting year, TMK-ARTROM continued to develop cooperation with leading European automakers and maintained the Renault-Nissan category B qualification. We continued to realize the second project with Renault for the new model Dacia Duster.
In 2018, the European division’s corporate quality management system seccessfully passed a recertification audit for ISO 9001:2015; ISO 14001:2015 and ISO 45001:2018 requirements (the new revision of the OHSAS 18001 specification). The audit was conducted by the British company Lloyd’s Register.
In a highly competitive market, TMK’s main objective throughout 2018 was to retain its market presence in strategic regions, widen the scope of its supplier qualifications with state-owned and private companies, and ensure timely and flawless deliveries of products and related services under the existing contracts.
The oil price recovery had a positive impact on OCTG consumption given the low production costs in most Middle Eastern countries. As many Middle Eastern countries benefit from their low-cost leadership position in oil production on the global market, local producers can achieve positive margins even in a record low oil price environment.
Despite the challenging environment and stiff price competition, TMK continued to expand its footprint in the Middle East and North African markets. We received and completed major orders to supply welded casing and line pipes with TMK GIPI coating to PDO’s project, and focused on winning service contracts for pipe coating.
In 2018, the Company shipped pipe products manufactured by the Russian division plants, completing a major order to supply seamless line pipe to Saudi Aramco, winning the first order from Agiba Petroleum Co. (an ENI JV) to supply casing and tubing pipe, and sinking the first casing pipe with TMK UP PF connections in Egypt, for Petroshahd (a Kuwait Energy JV), with the involvement of TMK specialists. We also continued shipments of line pipe for India’s Oil and Natural Gas Corporation (ONGC) offshore projects, completed a supplier qualification process and the first order to supply vacuum insulated tubing pipe to Oil India Ltd.’s pilot project on the Baghewala oil field in India and successfully lowered pipes into the first well in November, with the involvement of TMK specialists.
TMK is one the world’s largest premium connection manufacturers and the leader in the Russian premium connections market.
Pipes with premium threaded connections are designed for use in oil and gas wells operating in challenging climatic and geological conditions, including offshore, deep-water and Far North locations, horizontal and directional wells, and hard-to-reach hydrocarbon (shale oil, shale gas, and oil sand) field development. These connections offer high strength and tightness, along with enhanced resistance to high torsional, bending, and tensile stresses.
TMK UP EVOLUTION
+ 33% y-o-y
Sales of premium connections produced at the Russian and American divisions
Sales of premium connections produced at the Russian and American divisions were up 33% year-on-year and reached 414 thousand tonnes in 2018.
In the reporting year, TMK maintained its leadership in the Russian market for tubular products with premium threaded connections, with a 67% market share.
The Russian division’s sales of premium connections, including estimates of field concept engineering projects, were up by over 20% year-on-year. These concept engineering services sales accounted for 15% of the total premium connections sales.
Backed by many years of experience in premium product shipments, we are always ready to offer our customers unique engineering capabilities and highly effective pipe solutions delivered to all expectations.In 2018, TMK continued to develop and launch new premium connections. In February 2018, we successfully completed testing of the unique proprietary TMK UP KATRAN premium connection as part of the Gazprom Scientific and Research Institute of Natural Gases and Gas Technologies (Gazprom VNIIGAZ) program. TMK UP KATRAN HD is a unique, quick-assembly high-torque connection that has been developed entirely by TMK and is the first 100% Russian product of its kind – previously this type of connections could only be purchased abroad. KATRAN is the only connection that can be used in all Russian offshore projects at any depths and in the most challenging climatic conditions.
In the reporting year, we expanded our customer base and received new orders for tubular products with TMK UP CENTUM premium threaded connections. The connection is certified to ISO 13679 CAL IV, the strictest international industry standard for premium threaded connections, and demonstrates 100% tension and compression efficiency.
In 2018, TMK shipped its first batch of casing pipe with TMK UP PF threaded connections to Sakhalin Energy. The pipe column was successfully launched from Molikpaq platform at Piltun-Astokhskoye field in the Sea of Okhotsk with the involvement of TMK supervisors. In the reporting year, the Company obtained qualification from Shell qualification for its TMK UP PF connection.
In 2018, TMK IPSCO successfully launched TORQ®, a new proprietary connection series. TORQ premium connections are designed for use in challenging conditions, including highly deviated well drilling, high pressures, and high temperatures. The new connections have been specifically developed and manufactured for applications involving high torque, which can see twice the limits of torsional stresses endured compared with conventional connections. The new connections are available in a wide range of sizes and have been tested for compliance with industry specifications applicable to shale and offshore drilling. In the reporting year, TMK IPSCO launched three new TORQ® premium connections: TORQ TMK UP SFW, TORQ TMK UP ULTRA QXW, and TORQ TMK UP DQW.
One of TMK’s business priorities is to deliver premium OCTG complete with related oilfield services. Our oilfield services include drill, tubing and casing pipe repairs, heat treatment, protective coating, manufacturing a vast range of pipe string components and downhole equipment, as well as pipe threading, pipe and pump rod maintenance service and repairs.
The Russian oilfield services division is headed by TMK Oilfield Services (Yekaterinburg). The division includes: Orsky Machine Building Plant (Orsk), Truboplast (Yekaterinburg), TMK NGSBuzuluk (Volga Federal District), and TMK NGSNizhnevartovsk (Khanty-Mansi Autonomous Area). The latter two facilities are located at the heart of oil and gas regions and provide well construction, repair and completion services to both large- and mid-size oil and gas companies and oilfield service providers.
In 2018, Orsky Machine Building Plant, TMK NGS-Buzuluk, and TMK NGSNizhnevartovsk, assisted by other Russian division plants, manufactured and shipped approximately 92 thousand tonnes of casing and tubing (up 12% year-on-year), including products with TMK UP threaded connections (up 14% year-on-year).
In 2018, TMK NGS-Buzuluk completed over 160 orders to provide engineering support for running over 240 casing and tubing strings in fields located in Russia, the CIS, and other countries. In 2018, we started providing engineering support for TMK pipe products in well construction at new Sakhalin Island offshore fields: Yuzhno-Kirinskoye (LLC Gazprom Flot), and Piltun-Astokhskoye field (Sakhalin Energy).
New technologies and innovative products are the key competitive drivers in the global pipe market.
TMK’s research centers, the Russian Research Institute for the Tube and Pipe Industries (RosNITI) located in Chelyabinsk (Russia) and TMK’s Houston-based R&D center (US), are engaged in extensive research, liaising with specialized R&D organizations and universities, and coordinating activities under research and technological cooperation programs between TMK and its major customers. Together with TMK’s plants of the Russian, European, American and Middle East divisions, our R&D centers explore production technologies, upgrade equipment, and identify innovative business opportunities, while assisting in ramping up new production capacity.
In 2018, as a result of findings from major metals companies and the readiness assessment of our key manufacturing processes, we added a digital technology deployment unit to our R&D cluster. TMK’s specific plans include developing new approaches to manufacturing threaded connections and delivering oilfield engineering services, as well as improving welding technology.
Our R&D centers focus on:
- Boosting the economic efficiency of pipe and billet manufacturing
- Improving pipe technologies to enhance the product’s operational properties, quality and exterior, cut costs, improve working conditions, and mitigate environmental impact
- Ramping up new production capacity at TMK plants
- Creating new technologies to manufacture new products
- Deploying digital technologies
- Improving the regulatory framework and technical documentation, developing national and corporate standards (the Company’s local standards) for pipe, billets, and flat-rolled products.
TMK’s R&D centers have the necessary capabilities to provide field concept engineering services:
- Cooperating with design bureaus on well design calculations,
- Developing software solutions for well design calculations,
- Determining the optimal version of casing strings and tubing,
- Training technical sales managers and customers’ staff,
- Designing a neural network to determine appropriate connections,
- Providing technical marketing services for OCTG products.
TMK’s Houston-based R&D center (US)
In 2018, we developed, tested, and deployed a considerable number of innovative technologies and solutions:
- We developed a number of corporate productrelated standards and control methods based on the latest available technologies, and contributed to the development of national and supranational standards,
- We developed and successfully tested new equipment to feed and spray lubricating and deoxidizing compounds on a pipe’s external surface; we also developed and ran a complete test program for new process solutions to apply lubricating compounds over threaded connections and apply glass lubricants,
- We developed a number of digital technology enabled solutions, including a digital twin of an FQM mill, and a new neural network model-based method of setting the operating parameters of a piercing mill,
- We launched the production of pipes that are extra resistant to local deformation and designed for subsea pipelines,
- We launched the production of corrosion-resistant highstrength tubing and couplings made of complex alloy steel grades,
- We were the first in the Russian pipe industry to launch the production of long pipes with electrochemical surface treatment; the pipes are made of a new, patented corrosion-resistant steel and designed for nuclear engineering applications,
- At TAGMET, we deployed individual and group rate-setting tools driven by computational analysis.
In 2018, we completed the main construction and installation works for the building of TMK’s R&D facility in Skolkovo, expected to become the Company’s third and largest R&D center. The corporate R&D facility in Skolkovo will use unique research and testing equipment to develop comprehensive material, design, and connection solutions for the increasingly complicated hydrocarbon production conditions.
In 2018, the first bench for full-size tests of new pipe threaded connections was assembled in Skolkovo, enabling the Company to significantly expand its range of connections to include connections up to 762 mm in diameter, and perform integrated performance tests under high temperatures, pressures, axial drag and bending stresses. The building of TMK’s R&D facility in Skolkovo is expected to be commissioned by mid-2019.
In 2018, TMK’s CAPEX amounted to $273 million (+ 17% year-on-year) mainly due to an unplanned and opportunistic real estate acquisition. The Company’s target CAPEX in the medium term is expected to be below $200 million.
Investment in production facilities, $ million
Key focus areas of TMK’s Strategic Investment Program in 2018:
TMK focuses on projects that allow us to increase production of high value-added products and improve product quality.
Volzhsky Pipe Plant
- Installation of an automated pipe gauging system for large diameter pipes was completed, and a final washing system was installed
- A mandrel machine and conservation coating equipment were commissioned
Seversky Pipe Plant
- As part of a comprehensive upgrade of the pipe-rolling unit, the heat treatment facility’s metal structures and foundations were reinforced, wall envelopes were installed, and foundations were prepared to install equipment in the heat treatment and water treatment facilities
- A pipe end calibration unit and pipe threading machines were put into operation, and crane equipment was replaced
- A pipe degreasing unit at production line No. 6 was commissioned
- Work was completed at the phosphating and GreenWell pipe end coating lines; pipe threading machines were installed and put into pilot operation
- A non-destructive testing unit was upgraded by installing a new ultrasonic pipe testing system that helps identify defects of less than 12.5 mm, which increased the unit’s capacity
Sinarsky Pipe Plant
- A coupling threading machine, coupling blank cutting equipment, and thermal diffusion galvanising equipment for couplings were commissioned
- A non-destructive pipe testing line and grinding equipment were commissioned
- External epoxy and abrasion resistant coating equipment for line pipes was commissioned, which enabled us to launch a new type of product in the market
- A non-destructive testing unit was commissioned at the Ambridge plant
- A new heat treatment facility with an annual design capacity of 165 thousand tonnes was completed and commissioned
In 2018, TMK completed the bulk of construction and installation operations at its R&D facility in Skolkovo.
The environmental initiatives implemented by TMK Group’s facilities as part of our investment strategy helped reduce gross pollutant emissions by 1%, wastewater discharges by 2%, and discharge of pollutants into water bodies by 11% year-on-year.
Improving liquidity profile remains one of our priorities, and we continue to carry out measures to maintain sufficient liquidity and improve loan portfolio structure.
Our total debt decreased from $3,239 million as at December 31, 2017 to $2,867 million as at December 31, 2018. Net debt decreased by $251 million, to $2,437 million.
The share of our short-term debt as at the end of 2018 was 31% compared to 18% as at December 31, 2017.
On January 29, 2018, TMK fully redeemed its Eurobond issue which matured in January 2018 (ISIN: XS0585211591). The nominal value of the redeemed Eurobond was $231 million. The $500-million Eurobonds with a coupon rate of 7.75% and a 7-year maturity were issued by TMK Capital SA on January 27, 2011 to finance a loan to PAO TMK. Part of the issue in the amount of $269 million was repurchased earlier under tender offers and canceled.
During the reporting year, TMK Group improved its liquidity profile, including by extending maturity dates, mitigating the foreign exchange risk, and decreasing debt financing costs. As at the end of 2018, the rouble-denominated portion of our debt represented 53%, the U.S. dollar-denominated portion – 43%, and the euro-denominated portion – 3% of our total debt. As at December 31, 2018, our weighted average nominal interest rate was 7.29%, i.e. an 87 bps decrease year-on-year.
On February 28, 2018, Moody’s Investors Service (Moody’s) changed the outlook on TMK’s credit rating from “negative” to “stable” and affirmed the Company’s B1 corporate family rating. Moody’s based this revision on the much stronger financial and operating performance by TMK’s American division, along with the sustainable performance of the Russian division in a volatile oil price environment. The updated outlook also includes expectations that TMK will be able to deleverage and maintain adequate liquidity.