Integra’s New Cementing Unit Has No Analogues in Russia

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The series production of the unit is scheduled for the end of 2007.
In discussion about the new complex took part representatives of such companies, as Integra, Uralmash-VNIIBT and Stromneftemash: Hans Klampferer, Vice President for Business Development and Marketing of Integra Group; Yuri Karpov, First Vice President for Production of the Uralmash-VNIIBT; and Alexei Sobolev, Chief Designer of Stromneftemash.

OGE: What could you tell us about the competitive advantages of the new product?

Hans Klampferer: Firstly, one of the main advantages of this cementing unit is the reduction of personnel needed for its operation. Previously up to 20 persons had to be involved in this process, and now their number is brought down to two-three persons, thus cutting our operating expenses substantially. 

Secondly, as the amount of drilling operations carried out in Russia continues to grow, such issues as safety of drilling operations, environment protection and accident prevention acquire paramount importance. Thirdly, a significant reduction of the term of delivery, which is currently three to seven months, gives us considerable competitive advantage. And the last, but not the least advantage, is the price of the complex, which is more attractive compared to its western analogues.

The high quality standards applied should also be mentioned. To give but one example, Stromneftemash is now undergoing certification according to ISO and API. As for other Integra plants, they have already been certified according to these ISO standards.  

OGE: When are you going to start series production of a new unit?

Yuri Karpov: Now we are at a “finishing strokes” stage. The company conducts negotiations with Gazprom (one of the major customers – editor’s note) to agree on the fields, where the complex will be installed. But it’s possible to say even now that they will be the fields of the Yamal peninsula. The commercial tests of the cementing complex will be soon started in New Urengoi by a branch of Tyumenburgaz (which itself is a part of Burgaz – editor’s note). Today in Russia there is no analogue of such equipment.

The new equipment designed by our company ensures the new quality level of productive cementing operations. Our design engineers put much effort and creativity into this work; they dedicated a lot of time to development of the new cementing complex. I would like to point out that while developing it, we also considered and used both customers’ comments on our other products and operation experience of the this unit’s “predecessor” – KCS-40. As a result of such integrated process, we succeeded in designing the first-rate equipment. The new cementing complex meets all the technical and process requirements, as well as the requirements of Rostekhnadzor (Russian Federal Service for Ecological, Technical and Atomic Supervision).

OGE: Have you cooperated with any scientific institutes or other external organizations while designing the unit?

Alexei Sobolev: We didn’t contact any specialized scientific research institutes while working on the unit. We had the experience of designing the previous model, KCS-40. Besides, numerous business trips and study of the field experience in different regions became the basis for the new unit. We consolidated all the existing experience with our customers’ requirements and wishes (in reference to chassis, drive and pump units). Thus, the product has been made, which we now offer to prospective customers.  

We closely cooperated with suppliers of the component parts. These companies have a competent and reliable support service, which recommended us different equipment items and component parts. To improve our cooperation, we set up the Innovation Department as a part of the Chief Designer Department. I personally recruited new employees with fresh modern ideas and views.

Y.K.: I would like to add, that at present we do not have to turn to scientific research institutes. To begin with, there are almost no institutions of that kind left in Russia. Besides, the mechanical-engineering block of Integra Group has a very strong engineering potential.

Moreover, we have good partnership relations with our customers. I dare say, they rendered us  strong support when we were working on the complex design. We closely cooperated with Gazprom, Rosneft, exchanged the experience, and were learning from them. Generally speaking, we established close, operative and fruitful customer-manufacturer relations.

OGE: Do you plan holding the niche in the market for this type of product, and do you expect strengthening of competition?

Y.K.: Of course, there is competition in the market, but we have already managed to develop such product that will help us not only to keep the niche but to get a big market share. Burgaz is our partner and customer, besides we receive more and more additional orders for 2008. I am sure that the news about our unit will spread among our customers very fast, and we will have plenty of orders.

OGE: Do you plan acquisition of other companies in the future or any alliances with foreign manufacturers, for example Chinese or European?

Y.K.: We heard our customers saying, “At last our dreams are coming true. Now, we see the product, which has been much spoken and thought about.” Similar statements refer to reduction of the operation personnel and the delivery time, as well as the reasonable price.

We’ll never turn away from anything new and promising. If we are offered (by Chinese or European manufacturers – editor’s note) attractive terms of cooperation, some new profitable ideas, than we’ll definitely enter such a partnership. We are open to cooperation and consider innovative development our main goal.

H.K.: Speaking of the complex’s unique properties, I would add that when Stromneftemash decided to start manufacturing of KCS-40 in 2002, we had already been very close to designing a new complex. But at that time many customers could not believe that all types of cementing operations could be done by a single unit.

When I visited cementing equipment manufacturers in different parts of Russia, their representatives told me that they already had new units, but at a closer look those units were just the embodyments of old ideas and concepts. As for this particular case, we succeeded in designing a unit that meets the latest requirements of the industry.

OGE: How the units offered by your company will be serviced?

Y.K.: Servicing is one of the major requirements in our product’s promotion. One of the new decisions of the mechanic-engineering block’s management allows for formation of dedicated servicing structure based on our plants as a major design option. At present, some of them are being integrated in a separate structure – a service company, which will provide full maintenance of each product, including minor repairs.

We provide a standard warranty for that type of products, which meets all GOST’s requirements: 12 months from the commissioning date and 18 months from the date of sale, and after the expiration of that period post-warranty service is provided.

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