Monumental Manufacture & Measured Mastery Made Manifest

Tenaris, a global authority in steel pipe products and services, has achieved an industrial milestone by delivering its longest and heaviest BlueCoil coiled tubing string to date. The unit stretches 30,250 ft and weighs 192,000 lb, marking a production scale previously uncharted in the United States. This groundbreaking project showcases Tenaris’s engineering excellence and capacity to meet evolving demands within the shale industry.

Diameter Danger & Downhole Demand Demonstrated Dramatically

The 2 ⅞″ diameter of this BlueCoil string represents the first instance of Tenaris producing this larger size in its proprietary heat-treated line. This dimension allows higher-capacity downhole tools, increasing flow rates and improving efficiency during plug removal post-stimulation. In modern shale operations, longer laterals require longer tubing; the increased diameter ensures robust performance under heightened pressure demands.

Client Collaboration & Comprehensive Co‑creation Commemorated

In August 2024, Cudd Pressure Control issued a specific request for an unprecedented coiled tubing size. The partnership with Tenaris spurred a customized solution crafted through cross-functional cooperation. Teams from Operations, Supply Chain, and Technology united to design tubing that met Cudd’s specifications. This coordinated effort led to the production of the largest and heaviest BlueCoil string in US history.

Engineering Excellence & Exhaustive Execution Evident

By April 2025, Tenaris began manufacturing the record-setting string using advanced metallurgy and precise heat treatment processes. The manufacturing flow involved rigorous testing to ensure fatigue resistance and structural integrity. Using state-of-the-art automation and inspection protocols, Tenaris validated each segment’s compliance. The completed string was delivered in May, ready for deployment in U.S. shale basins.

Downhole Dynamics & Decisive Deployment Detailed

Coiled tubing plays a critical role in post-fracturing cleanup, specifically for removing composite plugs and debris. The BlueCoil string’s larger diameter accommodates high-capacity tools, accelerating clean-up and reducing non‑productive time. In extended laterals common in Eagle Ford and Permian regions, the string’s 30,250 ft length enables operators to reach further with greater precision. This will enhance well integrity and production performance.

Field Feedback & Future‑forward Focus Foretold

Cudd’s Operations Manager, Brandon Pugh, praised the project: “We challenged Tenaris to deliver something that had never been done before, and they delivered.” He emphasized the string’s game-changing impact on coiled tubing operations. Cudd’s Senior Corporate Business Development Director Christopher Schneider highlighted how the project demonstrates the value of integrated technical and commercial collaboration in expanding operational boundaries.

Platform Provenance & Performance Provenance Preserved

Since its launch in 2015, BlueCoil technology has been field‑proven with over 1,500 strings deployed worldwide. Its strengths lie in enhanced fatigue resistance and durability compared to conventional coiled tubing. The new string preserves this performance heritage while extending its operational envelope. It sends a message that innovation must be continuous, especially in high‑stress environments characteristic of shale extraction.

Integrated Infrastructure & Interdepartmental Ingenuity Illustrated

Tenaris’s internal orchestration was central to this success. Sales Manager Brandon Henderson highlighted the intensive coordination across supply chain logistics, metallurgical expertise, production oversight, and technical quality control. Each department contributed to meet the stringent requirements of the project. This showcases the corporate ability to deliver complex engineered solutions under tight timelines.

Regulatory Rigor & Rigorous Reliability Reinforced

U.S. shale operations require adherence to strict safety and environmental regulations. The BlueCoil string underwent multiple layers of inspection, testing, and certification to satisfy these standards. Tensile strength, fatigue cycles, and corrosion resistance were validated through independent labs and internal audits. The result delivers confidence in pipe integrity and compliance with field safety protocols.

Market Momentum & Milford’s Milestone Market Message

With operations scheduled in both the Eagle Ford and Permian Basins, this delivery is poised to change coiled tubing dynamics. Wells are becoming longer and more technical. Tenaris’s readiness to produce this scale of tubing signals an evolution in supplier capability. Industry analysts believe suppliers that can match scale with quality will shape the future of shale field services.

Strategic Significance & Sector‑wide Signal Sent

This project sends an unmistakable message to the energy services market. Tenaris is not only maintaining but redefining manufacturing limits to meet modern drilling challenges. It affirms Tenaris’s commitment to technological leadership and sets a new benchmark for competitors. The cooperation with Cudd exemplifies how strategic alliances can push performance thresholds.

Key Takeaways:

• Tenaris delivered a record‑breaking 30,250 ft, 2 ⅞″ BlueCoil string, weighing 192,000 lb, to Cudd.

• The unit enhances post‑fracturing flow rates, debris removal, safety & efficiency in shale wells.

The project exemplifies deep collaboration, regulatory compliance & engineering innovation across Tenaris.