Tenaris Achieves Technical Breakthrough with Corrosion-Resistant Alloy and Dopeless® Technology in Offshore Brazil Wells
Tenaris has marked an important technical achievement in offshore Brazil, successfully deploying corrosion-resistant alloy (CRA) tubulars enhanced with its proprietary Dopeless® technology in two challenging ultra-deepwater wells located in the Búzios and Jubarte fields. This milestone demonstrates Tenaris’s ability to integrate advanced materials and innovative surface treatments to meet the demanding conditions of the Brazilian Pre-Salt, one of the world’s most technically complex offshore environments.
In both operations, more than 400 pipes were installed per well. These tubulars featured Superduplex 25Cr steel grade, a high-performance alloy designed for superior resistance to corrosion in aggressive subsea conditions. They were fitted with TenarisHydril Blue® premium connections and coated with Dopeless® technology — a multifunctional surface treatment applied directly at the manufacturing mill. This coating significantly reduces the need for manual handling, lubricant application, and thread preparation during offshore operations. The result is a streamlined process that enhances both operational safety and efficiency, while also lowering the environmental footprint of drilling campaigns.
Meeting Pre-Salt Challenges with Advanced Materials
The Brazilian Pre-Salt presents a unique set of operational challenges, including high pressures, extreme depths, and corrosive conditions caused by the presence of CO₂, H₂S, and other aggressive elements in the reservoir. CRA tubulars, such as the Superduplex 25Cr used in this deployment, are specially engineered to combat these harsh conditions, delivering long-term durability and performance.
However, running CRA pipe comes with its own difficulties. One of the most significant operational risks is galling — a form of damage that occurs when two metal surfaces seize together during make-up. Galling can lead to slower running speeds, connection failures, and higher rejection rates, driving up project costs and timelines.
Dopeless® technology addresses this challenge by providing a consistent, high-performance lubrication layer that minimizes galling risk. This ensures a smoother, more reliable make-up process, even with the hard, corrosion-resistant surfaces of CRA tubulars.
Boosting Speed and Reliability Offshore
In the recent Búzios and Jubarte projects, the use of Dopeless® technology proved to be a game-changer. The technology enabled the running of stands in triples — or “stands of three” — rather than singles or doubles, which is often necessary with CRA pipes to avoid galling. This operational advantage translated into a 50% reduction in installation time, a significant gain in high-cost offshore environments where every hour saved directly impacts overall project economics.
“Tenaris has pioneered the integration of CRA materials with Dopeless® technology in some of the most demanding offshore operations worldwide,” said Tomás Castiñeiras, Tenaris Technical Sales Global Director. “Since introducing this combination in the Barents Sea back in 2005, we have consistently demonstrated its ability to deliver safer, faster, and more reliable operations. These recent deployments in the Pre-Salt reaffirm our leadership in ultra-deepwater environments, where advanced materials and cutting-edge technologies are critical to long-term performance and reliability.”
Castiñeiras, who was part of the original team that introduced Dopeless® technology in Norway over two decades ago, emphasized the technology’s enduring relevance. “Our approach is built on proven field experience. We’ve refined the process over the years, and today it stands as an industry benchmark for efficiency and environmental stewardship.”
Environmental and Operational Benefits
Beyond performance gains, Dopeless® technology delivers measurable environmental benefits. Because the coating is applied at the mill, no thread compounds or lubricants are required offshore, eliminating the need for on-board waste disposal or cleaning processes. This reduces water consumption and cuts the generation of chemical waste, aligning with operators’ increasingly stringent sustainability targets.
“We are bringing meaningful differentiation to the Brazilian market, building on our track record of successful offshore applications globally,” noted Renato Catallini, Tenaris President in Brazil. “These projects represent an important step forward for our participation in the Pre-Salt. We are delivering an environmentally friendly, ready-to-run solution that not only enhances operational performance but also supports our customers’ environmental commitments. Consistent performance is critical for CRA applications, and Dopeless® technology ensures that level of reliability.”
Strengthening Tenaris’s Position in Brazil
The success of these deployments in the Búzios and Jubarte fields strengthens Tenaris’s position as a key technology partner for operators working in Brazil’s deepwater and ultra-deepwater plays. The combination of CRA tubulars and Dopeless® technology is expected to see broader adoption in the region, particularly as operators face increasingly complex well designs and seek ways to improve operational efficiency while meeting strict environmental regulations.
By marrying high-grade materials with innovative surface engineering, Tenaris continues to demonstrate that it is not only responding to industry challenges but actively shaping the future of offshore tubular technology. With proven results in some of the most challenging offshore basins around the world, the company’s solutions are set to play an even greater role in the success of Brazil’s ambitious offshore development plans.
