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UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-K
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the Fiscal Year Ended December 31, 2004 |
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934 |
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For the transition period
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Commission file number: 001-15423
Grant Prideco, Inc.
(Exact name of registrant as specified in its charter)
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Delaware
(State or Other Jurisdiction
of Incorporation or Organization) |
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76-0312499
(I.R.S. Employer
Identification No.) |
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400 N. Sam Houston Pkwy. East
Suite 900
Houston, Texas
(Address of Principal Executive Offices) |
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77060
(Zip Code) |
(281) 878-8000
(Registrants telephone number, including area code)
Securities to be registered pursuant to Section 12(b) of
the Act:
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| Title of Each Class |
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Name of Each Exchange On Which Registered |
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Common Stock, par value $0.01 per share |
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New York Stock Exchange |
Securities registered pursuant to Section 12(g) of the
Act:
None
Indicate by check mark whether the registrant (1) has filed
all reports required to be filed by Section 13 or 15(d) of
the Securities Exchange Act of 1934 during the preceding
12 months (or for such shorter period that the registrant
was required to file such reports), and (2) has been
subject to such filing requirements for the past
90 days. Yes þ No o
Indicate by check mark if disclosure of delinquent filers
pursuant to Item 405 of Regulation S-K is not
contained herein, and will not be contained, to the best of
registrants knowledge, in definitive proxy or information
statements incorporated by reference in Part III of this
Form 10-K or any amendment to this
Form 10-K. o
Indicate by check mark whether the registrant is an accelerated
filer (as defined in Exchange Act
Rule 12b-2). Yes þ No o
Aggregate market value of the voting and non-voting common
equity held by nonaffiliates of the registrant: $1,450,165,174.
This figure is estimated as of June 30, 2004, at which date
the closing price of the registrants shares on the New
York Stock Exchange was $18.46 per share.
Number of shares of Common Stock outstanding as of
March 18, 2005: 124,636,659
DOCUMENTS INCORPORATED BY REFERENCE
Listed below is the document parts of which are incorporated
herein by reference and the part of this report into which the
document is incorporated:
(1) Proxy Statement for 2005 Annual Meeting of
Stockholders Part III
TABLE OF CONTENTS
1
FORM 10-K
PART I
General
We are the world leader in drill stem technology development and
drill pipe manufacturing, sales and service; a global leader in
drill bit technology, manufacturing, sales and service; and a
leading provider of high-performance engineered connections and
premium tubular products and services. Our drill stem and drill
bit products are used to drill oil and gas wells while our
tubular technology and services are primarily used in drilling
and completing oil and gas wells. Our customers include drilling
contractors; North American oil country tubular goods
(OCTG) distributors; major, independent and state-owned oil
companies; and other oilfield service companies. We primarily
operate through three business segments: (1) Drilling
Products and Services, (2) Drill Bits and (3) Tubular
Technology and Services. In the first quarter of 2004, we
announced an organizational restructuring that resulted in our
former Marine Products and Services businesses now being
reflected in the Tubular Technology and Services segment. Prior
periods have been restated for comparability.
Our business is primarily dependent on the level of oil and gas
drilling activity worldwide, which, in turn, depends on the
level of capital spending by major, independent and state-owned
exploration and production companies. This capital spending is
driven by current prices for oil and gas and the perceived
stability and sustainability of those prices. All of our
business segments generally track the level of domestic and
international drilling activity, however, their revenues, cash
flows and profitability follow the rig count at different stages
within the market cycles. Drill pipe demand is also a function
of customer inventory levels and typically lags changes in the
worldwide rig count. In a declining market, customers are
contractually required to purchase ordered drill pipe even if
they will no longer need that pipe. This creates a situation
where our customers have an inventory of excess drill pipe.
Consequently, in a market with increasing activity, customers
delay purchasing until they no longer have sufficient inventory
to sustain current and near-term expected future activity. Drill
bit demand and this segments earnings and cash flows have
closely tracked the worldwide rig count. Within our Tubular
Technology and Services segment, there are four product lines:
Atlas Bradford premium connections, Tube-Alloy accessories, TCA
premium casing and XL Systems large bore connections and
services. Results for this segments Atlas Bradford,
Tube-Alloy and TCA product lines predominantly follow changes in
North American (in particular Gulf of Mexico) offshore drilling,
deep drilling and natural gas drilling rig counts, but
short-term demand for Atlas Bradford products also can be
affected by inventories at OCTG distributors. The TCA product
line also is affected by the level of U.S. OCTG mill activity.
This segments XL Systems product line generally follows
the level of worldwide offshore drilling activity.
Additional information regarding our revenues and foreign
investments by geographic region can be found in the footnotes
to our consolidated financial statements starting on
page 33 of this Annual Report on Form 10-K.
Grant Prideco was incorporated in Delaware on June 22,
1990. Our corporate headquarters is located at
400 N. Sam Houston Pkwy. East, Suite 900,
Houston, Texas 77060.
Drilling Products and Services Segment
Our Drilling Products and Services segment manufactures and
sells a variety of drill stem products used for the drilling of
oil and gas wells. The principal products sold by this segment
are: (1) drill pipe products, including tool joints,
(2) drill collars and heavyweight drill pipe and
(3) drill stem accessories.
Our drill stem products wear out through a combination of
friction and metal fatigue and generally are utilized by our
customers for a three to five year period assuming regular use.
Demand for our drill stem products is impacted primarily by
changes in drilling activity and worldwide rig activity.
However, since drill stem products are not consumables and
represent a capital investment by our customers, demand for
these products also is significantly impacted by the level of
inventory held by our customers and their perceptions as to
future activity and their near-term need for new drill stem
products. As a result, even in periods of rising or
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strong drilling activity, our customers may elect to defer
purchases until their own inventory reaches levels at which
additional purchases are necessary to sustain their existing
drilling activities.
With the increased complexity of drilling activity, demand for
our proprietary line of
eXtremetm
drilling and other premium drilling products has remained
strong. This value-added product line coupled with our XT®
(eXtreme torque) connections is specifically designed for
extreme drilling conditions such as extended reach, directional,
horizontal, deep gas, offshore and ultra-deepwater drilling, as
well as high-temperature, high-pressure and corrosive well
conditions. Operators and drilling contractors have embraced
this product line as a way to improve their efficiency and
assure performance when drilling under extreme conditions. We
believe that our eXtreme product line offers some of the
highest-performance drilling products ever brought to market and
provides our customers with engineered solutions for some of
their most challenging drilling applications. In addition to our
eXtreme product line, our premium drill pipe products can also
include our
CT-M57tm
connections that can withstand external pressures exceeding
25,000 psi and internal pressures nearing 30,000 psi, along with
proprietary sour-service grades and other proprietary products.
Our drill stem products are sold to a variety of customers,
including oil and gas drilling contractors, rental tool
companies and major, independent and state-owned oil and gas
companies. Our customers purchasing decisions are
generally based on operational requirements, quality, price and
delivery. The principal competitors for our drill stem products
include Drilco Group (a subsidiary of Smith International Inc.),
Texas Steel Conversion, OMSCO Industries (a subsidiary of
ShawCor Ltd.), IDPA and various smaller local manufacturers in
the U.S. and in foreign countries. We typically compete on
quality, technology, price and delivery and we believe we are
the technological leader in our industry.
The following is a description of our principal drill stem
products:
Drill pipe is the principal tool, other than the rig, required
for the drilling of an oil or gas well. Its primary purpose is
to connect the above-surface drilling rig to the drill bit. A
drilling rig will typically have an inventory of 10,000 to
25,000 feet of drill pipe depending on the size and service
requirements of the rig. Joints of drill pipe are connected to
each other with a welded-on tool joint to form what is commonly
referred to as the drill string or drill stem.
When a drilling rig is operating, motors mounted on the rig
rotate the drill pipe and drill bit. In addition to connecting
the drilling rig to the drill bit, drill pipe provides a
mechanism to steer the drill bit and serves as a conduit for
drilling fluids and cuttings. Drill pipe is a capital good that
can be used for the drilling of multiple wells. Once a well is
completed, the drill pipe may be used again in drilling another
well until the drill pipe becomes damaged or wears out.
In recent years, the depth and complexity of the wells our
customers drill, as well as the specifications and requirements
of the drill pipe they purchase, have substantially increased.
We estimate that over 95% of the drill pipe we sell outside of
China is required to meet specifications exceeding minimum
American Petroleum Institute (API) standards. We offer a
broad line of premium drilling products designed for the
offshore, international and domestic drilling markets. Our
premium drilling products include our proprietary lines of XT
connections and
57/8-inch
drill pipe that delivers hydraulic performance superior to
standard
51/2-inch
drill pipe and weight benefits superior to standard
65/8-inch
drill pipe.
Drill collars are used in the drilling process to place weight
on the drill bit for better control and penetration. Drill
collars are located directly above the drill bit and are
manufactured from a solid steel bar to provide necessary weight.
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Heavyweight Drill Pipe and Other Drill Stem
Products |
Heavyweight drill pipe is a thick-walled seamless tubular
product that is less rigid than a drill collar. Heavyweight
drill pipe provides a gradual transition zone between the
heavier drill collar and the lighter drill pipe.
We also provide kellys, subs, pup joints (short and odd-sized
tubular products) and other drill stem accessories. These
products all perform special functions within the drill string
as part of the drilling process.
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IntelliServtm
Joint Venture |
We own 50% of this joint venture partially sponsored by the
U.S. Department of Energy to commercialize intelligent
drill pipe that permits real-time transfer of data through the
drill string. This modified drill pipe is embedded with a
telemetry system that permits two-way data transmission along
the drill string at rates of up to two million bits per second,
which is exponentially greater than the data transmission rates
for measurement in the drilling and logging systems utilized
today. We currently are in the field trial testing and
refinement stage and have not yet introduced a product
commercially. Due to the unproven nature of the technology and
that it is still in its development state, we can provide no
assurances that it will be successful or be able to be marketed
and sold on a commercial basis.
Our major drill stem manufacturing plants are located in the
U.S., China, Italy, Mexico, Singapore and Indonesia. These
products are sold and serviced through over 16 sales and service
facilities located around the world. During the fourth quarter
of 2003, we completed an evaluation of our existing
manufacturing capacities and locations. Following this
manufacturing rationalization study, we determined that we had
excess capacity and duplicate operations in certain locations
that could be eliminated without affecting our ability to
quickly and efficiently react to market increases. As a result,
we shut down our Bryan, Texas facility, significantly downsized
our Canadian operations and rationalized certain operations in
our Veracruz, Mexico and Navasota, Texas locations.
We believe we are the only fully vertically integrated drill
pipe manufacturer in the world, controlling each facet of the
drill pipe manufacturing process. We manufacture (through a
50.01% owned joint venture) the green tube (drill pipe tube that
has not been heat-treated or processed), the tool joint and
complete the finishing and welding operations. We believe this
unique manufacturing strategy provides us with significant
competitive advantages over other drill pipe manufacturers,
including those located outside the U.S. that may have
labor and other cost advantages over our U.S.-based
manufacturing operations. By controlling each facet of the drill
pipe manufacturing process, we are able to tailor our processes
and techniques to meet our customers demanding product
specifications, particularly with respect to green drill pipe
tubes with body wall thickness, wall uniformity and other
features that exceed minimum API standards and are not readily
available from third-party mills.
Drill Bits Segment
Our Drill Bits segments products and services are
comprised of the operations of ReedHycalog. This segment is a
leading global designer, manufacturer and distributor of drill
bits and related technology to the oil and gas industry. This
segment also services its customer base through a technical
sales and marketing network in virtually every significant oil
and gas-producing region in the world. Drill bits are generally
sold directly to oil and gas operators and, to a lesser extent,
drilling contractors on turnkey and footage contracts.
Competition is based on technical performance, price and service.
The drill bit market consists of two product types: fixed-cutter
bits and roller-cone bits. We manufacture and sell both product
types on a global basis.
Drilling through subsurface strata to locate oil and gas
requires a drill bit to be run on drill pipe or conveyed through
coiled tubing and rotated by surface rig equipment or downhole
motors and turbines. Selecting the optimal bit for a particular
application represents one of the many challenges faced by oil
and
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gas companies and drilling contractors in planning a well.
Similar to the drill stem market, the primary market driver is
worldwide drilling activity or, more specifically, total footage
drilled. In addition, demand is a function of well depth and
complexity with demand for fixed-cutter bits tied more strongly
to offshore, directional or horizontal drilling.
Drill bits constitute a very small percentage of total well
costs, but are a critical component of well-construction
economics. The time required to drill a well is directly related
to a drill bits rate of penetration and footage drilled
prior to becoming dull and requiring replacement. On a
cost-per-foot basis, selecting the appropriate drill bit
significantly reduces drilling costs by decreasing drilling time
and the number of trips required in and out of a well.
Typically, roller-cone bits are most appropriate for shallow
land rig operations, while higher performance roller-cone or
fixed-cutter bits with better rates of penetration and longer
lives offer the most economic choice for offshore and deep wells
where rig rates and trip costs are high. However, there is a
trend towards increased use of fixed-cutter bits in operations
that traditionally have utilized roller-cone bits.
We provide a complete series of drill bits incorporating
advanced materials technology and a range of
performance-enhancing features. This broad product offering
provides customers with maximum flexibility in selecting drill
bits. In addition, we provide drill bit selection and
well-planning services through our field sales organization and
bit optimization engineers.
Our principal competitors for the sale of drill bits are Hughes
Christensen (a division of Baker Hughes Inc.), Smith Bits (a
division of Smith International Inc.), and Security DBS (a
division of Halliburton Company) as well as numerous smaller
competitors throughout the world.
ReedHycalog first manufactured fixed-cutter natural diamond bits
in 1953 and synthetic polycrystalline diamond compact
(PDC) bits in 1974.
The predominant fixed-cutter bit used in the oil and gas
industry is the PDC bit. PDC bits have no moving parts and are
therefore intrinsically more reliable than roller-cone bits, but
they are generally more sensitive to geological changes. PDC
bits drill with a shearing action to remove rock by dragging the
diamond elements through the formation as the drill bit body
rotates. PDC bits allow faster rates of drilling penetration and
can drill complete well sections without the need for bit
replacement. As a result, they are used in high cost drilling
locations (such as offshore or in remote locations) where their
technical advantages reduce drilling time sufficiently to
justify the higher cost product.
We provide fixed-cutter bit types and technology under various
brand names including
TReXtm,
SteeringWheeltm,
Rotary Steerable and many others. One of the most significant
innovations is our TReX cutter technology, which significantly
increases abrasion resistance (wear life) without sacrificing
impact resistance (toughness). This technology produces material
that maintains a sharp, low-wearing cutting edge that is
producing results that exceed conventional standards for PDC bit
performance.
During 2004, this segment acquired the assets of Novatek
International, Inc. (Novatek), a manufacturer of PDC cutters, as
well as Diamond Products International, Inc., a leading provider
of bi-center bits.
ReedHycalog has manufactured roller-cone bits since 1916 and
produces roller-cone bits for a wide variety of oil and gas
drilling applications. Roller-cone bits consist of three
rotating cones that have cutting teeth, which penetrate the
formation through a crushing action as the cones rotate in
conjunction with the rotation of the drill pipe. This cutting
mechanism, while less efficient than fixed-cutter bits, is more
versatile in harder formations, or where the geology is
changing. We manufacture roller-cone drill bits with milled
teeth and with tungsten carbide insert teeth, which have a
longer life in harder formations.
We market our roller-cone products and technology globally under
various brand names including
TuffDutytm,
Titantm
and
TuffCuttertm.
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We manufacture fixed-cutter bits in Stonehouse (U.K.) and in
Houston, Texas and roller-cone bits in Singapore and a separate
facility in Houston, Texas. In January 2005, in connection with
an expansion of our Singapore operations, a significant portion
of the production of roller-cone bits has been moved from
Houston, Texas to Singapore. All facilities are ISO 9001 and
14001 certified.
We market our drill bits through a global sales and marketing
network with our employees strategically positioned around the
world. Sales people are located in North and South America,
Europe, CIS, Africa, Middle East and Asia. The sales force is
technologically sophisticated and has developed strong regional
expertise.
Tubular Technology and Services Segment
Our Tubular Technology and Services segment provides a full
range of premium threaded connections for casing, production
tubing and other accessory equipment. This segment also
manufactures and sells premium casing for use with third-party
connections and is a leading supplier of tubulars and threaded
connections for the large-bore tubular market. During 2003, we
made a strategic decision to exit the manufacture and sale of
premium tubing. Additionally, in 2004 we sold our Texas Arai
couplings business which is now reflected as discontinued
operations in our accompanying financial statements.
Although we sell our large-bore tubulars and connections on a
world wide basis, the demand for the majority of our tubular
technology and services is heavily dependent upon North American
natural gas drilling activity, and it is more particularly
dependent upon rigs drilling for deep gas in the Gulf of Mexico.
On a short-term basis, demand for many of these products is also
affected by the level of inventory held by distributors of OCTG.
Distributors often reduce purchases until their inventory
positions are brought in line with then-prevailing market
conditions.
Over the long-term, a key factor positively impacting demand for
our tubular technology and services is the U.S. dependence
on natural gas as a fuel. Gas wells generally encounter higher
reservoir pressure and corrosive environments, which both
typically increase proportionally with increased depths.
Therefore, gas wells can require larger-diameter tubulars with
thicker walls, higher strength steel grades and special
metallurgy that is resistant to corrosive elements. For these
wells, premium connections, as opposed to standardized API
connections, are typically used to ensure the integrity of the
tubulars throughout the life of the well. Also, depletion rates
for natural gas wells in the U.S. have significantly
increased during the past decade, which indicates that more
wells will need to be drilled to keep production levels
constant. This increased demand in North America for natural gas
should increase the number of natural gas wells being drilled
and completed, thus increasing demand for our tubular technology
and services.
The following is a description of our principal premium
connections and tubular products and services:
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Atlas Bradford® Threading and Service |
We market our premium engineered connections primarily through
our Atlas Bradford product line, which has been recognized as
one of the industrys leading connections for more than
40 years. We offer this product line primarily in the U.S.
and Canada due to a licensing arrangement that we previously
entered into in which the international rights to our Atlas
Bradford connection line were licensed to a third party. We also
manufacture and sell connections for drilling with casing and
expandable operations on a worldwide basis and recently
introduced our licensed
ATS-Etm
semi-premium connection for sale on a worldwide basis.
Our customers use premium connections when they need a
connection that maintains a gas-tight seal while subjected to
extreme tension, pressure and compression forces or while
drilling near environmentally sensitive areas. The failure of a
premium connection can be a catastrophic event, leading to the
loss of a well or a blowout.
We actively promote our premium connections to oil and gas
operators, the ultimate end-users of the products, while selling
the premium connections through a network of major distributors
in the U.S. and
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Canada. Additionally, we provide tubular (casing, liner and
tubing) string design recommendations, a full range test and
demonstration facility, plus field service personnel to assist
in the running of the products. Our principal competitors for
premium connections are Hydril Company, Vallourec and Mannesmann
Tubes, the Tenaris Group, Sumitomo, Kawasaki Steel, Lone Star
Steel, Citra Tubindo, Hunting Interlock, Inc., Benoit, Inc. and
numerous other competitors domestically and internationally.
Tubular accessories are manufactured and sold through our
Tube-Alloy product line and include flow control equipment, such
as vacuum-insulated tubing, pup joints and landing nipples. Our
vacuum-insulated tubing represents an advanced flow-control
solution used to minimize paraffin deposits, gas hydrate
formation and annular pressure buildup in deepwater production
environments. Through our Tube-Alloy product line, we thread
third-party tubular products with our Atlas Bradford connections
as well as with third-party connections licensed to us. Our
competitors for these products and services include Hunting
Interlock, Inc., Benoit, Inc., Oil Tools International,
international steel mills and numerous other regional
competitors in the U.S. and worldwide.
Premium casing products are offered through our TCA product
line. These product offerings are designed to address that
segment of the oilfield tubular casing market that requires
special product characteristics and performance not generally
offered by the tubular steel mills. Our TCA product line also
provides tubular processing services for major tubular steel
mills.
We manufacture and sell premium casing, which includes
high-performance, proprietary and custom-designed OCTG from 5 to
17 inches in diameter as well as API casing. Our premium
casing is designed for critical applications. To capitalize on
the high value spot market, we maintain common and high-alloy
green tube inventories to provide quick delivery of
custom-finished casing and coupling stock. To meet exact
customer specifications and delivery requirements, we offer our
specialized Premium Pipe
Paktm
product line. Premium Pipe Pak is an innovative bundling of
proprietary casing, premium engineered connections and
inspection services offered in conjunction with an independent
third-party inspection company. This product line allows the
customer the option of having threaded and inspected
critical-service casing shipped rig-ready directly
to the customers well site, which reduces costs and
delivery times.
Our XL Systems product line offers the customer an
integrated package of large-bore tubular products and services
for offshore wells. This product line includes our proprietary
line of wedge thread marine connections on large-bore tubulars
and related engineering and design services. We provide this
product line for drive pipe, jet strings and conductor casing.
We also offer weld-on connections and service personnel in
connection with the installation of these products. We also
completed development of our new high strength
Vipertm
weld-on connector that we believe will permit us to penetrate
traditional markets that do not require the enhanced performance
of our proprietary wedge thread design.
Risers range from
95/8-inches
to
133/8-inches
and represent that section of the offshore production system
from the wellhead and mudline up to the offshore production
platform, which is typically either a floating platform, tension
leg platform or SPAR. We currently offer top tension production
risers and have begun to bundle our riser products with other
third-party technology to offer a complete line of riser
products. Our risers are sold with our various marine riser
connectors. The tubular and coupling components of our riser
products are often manufactured for our XL Systems product line
by our Atlas Bradford and TCA product lines.
Our XL Systems product line competes with DrilQuip, Vetco, Oil
States, Franks and various other competitors domestically and
internationally.
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Our Tubular Technology and Services segment operations are
located in Texas, Louisiana, Oklahoma, Wyoming, Vlissingen, The
Netherlands and Canada. We also offer accessory threading
services in Venezuela. In connection with our TCA operations in
Muskogee, Oklahoma, we have entered into a long-term supply
agreement with U.S. Steel Corporation that we expect will
supply the majority of our steel needs at this location for the
next several years. In addition, during the latter part of 2003,
we moved our XL Systems Asia Pacific facility from Singapore to
a new manufacturing location in Batam Island, Indonesia.
Other Segment
Our Other segment included our industrial drill pipe operations
and our construction casing and water well operations. We exited
the industrial drill pipe business in the second quarter of 2003
and the construction casing and water well business with the
sale of Star Iron Works (Star) in the first quarter of 2003. As
of the end 2004, the remaining inventory related to the
industrial drill pipe operations had been sold.
In 2003, we moved our joint ventures relating to POS-GRIP
technology from our Tubular Technology and Services segment to
our Other segment. Prior periods have been restated to reflect
this change. During the first quarter of 2004, we sold to our
partner our rights to the POS-GRIP technology for jack-up
exploration applications and have granted our partner an option
to purchase our rights to POS-GRIP technology for subsea
applications.
Other Business Data
We maintain an active research and engineering program. The
program improves existing products and processes, develops new
products and processes, and improves engineering standards and
practices that serve the changing needs of our customers. Our
expenditures for research and engineering activities totaled
$20.5 million, $17.7 million and $3.2 million in
2004, 2003 and 2002, respectively. These costs do not include
amounts expended by our IntelliServ joint venture, which is
accounted for as an equity-method investment. The significant
increase from 2002 to 2003 related primarily to the ReedHycalog
acquisition, which has an extensive research and engineering
program.
Many of our business lines rely on patents and proprietary
technologies. We currently have numerous patents issued or
pending. Many of our patents provide us with competitive
advantages in our markets. Although we consider our patents and
our patent protection to be important for our existing business
and for the development of new technologies and businesses, we
do not believe that the loss of one or more of our patents would
have a material adverse effect on our business as a whole.
As of December 31, 2004, we had a product backlog of
$270.5 million, representing 29% of our total revenues for
the year ended December 31, 2004, which we expect to
complete during 2005. This backlog was comprised of
$203.3 million from Drilling Products and Services and
$67.2 million from Tubular Technology and Services. We had
a product backlog as of December 31, 2003 and 2002, of
$120.6 million and $87.2 million, respectively. These
year-end backlogs represented 15% and 14% of our total revenues
for those years, respectively. The increase in product backlog
from 2003 to 2004 reflects the strengthening of overall market
conditions for oil and gas drilling.
We believe that we maintain insurance coverage that is adequate
for the risks involved. However, there is always a risk that our
insurance may not be sufficient to cover any particular loss or
that our insurance may not cover all losses. For example, while
we maintain product liability insurance, this type of insurance
is limited in
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coverage, and it is possible that an adverse claim could arise
that exceeds our coverage. Further, insurance rates are subject
to wide fluctuations, and changes in coverage could result in
increases in our cost or higher deductibles and retentions.
We do not maintain political risk insurance (generally designed
to cover expropriation and nationalization exposures), but do
maintain all-risk property insurance that covers losses from
insurrection, civil commotion and uprising. This insurance does
not cover losses resulting from a declared state of war and
provides a limited range of coverage from terrorist attacks.
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Federal Regulation and Environmental Matters |
Our operations are subject to federal, state, local and foreign
laws and regulations relating to the energy industry in general
and the environment in particular. Environmental laws have over
the years become more stringent, and compliance with such laws
increases our overall cost of operations. In addition to
affecting our ongoing operations, applicable environmental laws
can require us to remediate contamination at our properties, at
properties formerly owned or operated by us, and at facilities
to which we sent waste materials for treatment or disposal and
impose liability for related damages of natural resources. While
we are not currently aware of any situation involving an
environmental claim that would likely have a material adverse
effect on our business, it is always possible that an
environmental claim could arise with respect to one or more of
our current businesses or a business or property that one of our
predecessors owned or used that could have a material adverse
effect.
Our expenditures to comply with environmental laws and
regulations were not material in 2004, and are not expected to
be material in 2005. We also believe that we are in material
compliance with applicable environmental requirements and our
costs for compliance with environmental laws and regulations are
generally within the same range as those of our competitors.
However, we can offer no assurance that our costs to comply with
environmental laws will not be material in the future. Prior to
our acquisition, ReedHycalog was conducting remediation of
groundwater at certain of its facilities. Based on currently
available information, the indemnification provided by
Schlumberger in the acquisition agreement and contractual
indemnities from other third parties, we do not believe that
these matters will result in any material effect on the
Companys capital expenditures, earnings or competitive
position. However, there can be no guarantee that the
indemnities will be available to cover all costs or that
material expenditures will not be incurred.
Our operations are also affected by trade laws affecting the
import of OCTG, drill pipe and other products into the
U.S. Although the majority of our manufacturing operations,
including the capital investment, employees and costs and
expenses associated therewith, are located in the U.S., we have
key manufacturing facilities located outside the U.S., including
our drill bit operations in the U.K. and Singapore, our 50.01%
owned Voest-Alpine Tubulars GmbH & Co KG (Voest-Alpine)
subsidiary located in Austria and our tool joint manufacturing
operations in Mexico and Italy, that support our domestic
operations. Our premium tubular business also is affected by the
level of foreign imports of tubular products into the U.S.
Imports of products from our foreign locations that are utilized
by our domestic manufacturing operations can be the subject of
investigations, including antidumping and countervailing duty
orders, into whether such products are unfairly priced at low
levels (i.e., dumping) and causing material damage to the
domestic industry, as well as investigations under
Section 201 of the trade laws into whether such imports
have seriously damaged the domestic industry. Although we
believe we are the clear price leader for drill pipe and other
drill stem products and do not utilize imports from our foreign
facilities to dump our products, our products have
been, and may in the future be, the subject of such
investigations.
As of February 28, 2005, we had 4,064 employees. Certain of
our operations are subject to union contracts. These contracts,
however, cover approximately 9% of our total employees. We
believe our relationship with our employees is good.
9
We file annual, quarterly, and other reports and other
information with the Securities and Exchange Commission
(SEC) under the Securities Exchange Act of 1934 (the
Exchange Act). You may read and copy any materials
that we file with the SEC at the SECs Public Reference
Room at 450 Fifth Street, NW, Washington, DC 20549. You may
obtain additional information about the Public Reference Room by
calling the SEC at 1-800-SEC-0330. In addition, the SEC
maintains an Internet site (http://www.sec.gov) that
contains reports, proxy information statements, and other
information regarding issuers that file electronically with the
SEC, including us.
We also make available free of charge on or through our Internet
site (http://www.grantprideco.com) our Annual Report on
Form 10-K, Quarterly Reports on Form 10-Q, Current
Reports on Form 8-K, and other information statements and,
if applicable, amendments to those reports filed or furnished
pursuant to Section 13(a) of the Exchange Act as soon as
reasonably practicable after we electronically file such
material with, or furnish it to, the SEC.
The following table describes the principal manufacturing, other
facilities and offices we currently own or lease. We believe
that our manufacturing facilities are well maintained and
suitable for their intended purpose.
| |
|
|
|
|
|
|
|
|
| |
|
|
|
Facility | |
|
|
| |
|
|
|
Size | |
|
|
| Location |
|
Tenure |
|
(Sq.Ft.) | |
|
Utilization |
| |
|
|
|
| |
|
|
|
Drilling Products and Services
|
|
|
|
|
|
|
|
|
|
Navasota, Texas
|
|
Owned |
|
|
347,000 |
|
|
Manufacture of drill stem products |
|
Veracruz, Mexico
|
|
Leased |
|
|
303,400 |
|
|
Manufacture of tool joints and drill pipe |
|
Baimi Town, Jiangyan, Jiangsu China
|
|
Leased |
|
|
49,428 |
|
|
Manufacture of drill pipe |
|
Jianjin, China
|
|
Owned |
|
|
100,912 |
|
|
Manufacture of unfinished upset to grade drill pipe |
|
Turin, Italy
|
|
Owned |
|
|
60,400 |
|
|
Manufacture of tool joints |
|
Jurong, Singapore
|
|
Leased |
|
|
33,600 |
|
|
Manufacture of drill collars, accessories, and threading services |
|
Batam Island, Indonesia
|
|
Owned |
|
|
25,984 |
|
|
Manufacture of drill pipe |
| |
|
Drill Bits
|
|
|
|
|
|
|
|
|
|
Houston, Texas
|
|
Owned |
|
|
403,000 |
|
|
Manufacture of roller-cone bits |
| |
|
Owned |
|
|
50,256 |
|
|
Manufacture of fixed-cutter bits |
| |
|
Leased |
|
|
58,920 |
|
|
Manufacture of bi-center drill bits |
|
Stonehouse, U.K.
|
|
Owned |
|
|
71,000 |
|
|
Manufacture of fixed-cutter bits |
|
Jurong, Singapore
|
|
Leased |
|
|
169,663 |
|
|
Manufacture of roller-cone bits |
|
Provo, Utah
|
|
Leased |
|
|
39,038 |
|
|
Manufacture of PDC cutters |
| |
|
Tubular Technology and Services
|
|
|
|
|
|
|
|
|
|
Muskogee, Oklahoma
|
|
Leased |
|
|
195,900 |
|
|
Manufacture of TCA premium casing and premium threading |
|
Houston, Texas
|
|
Leased |
|
|
249,893 |
|
|
Manufacture of Atlas Bradford connectors |
| |
|
Owned |
|
|
54,500 |
|
|
Premium threading services and manufacture of tubular accessories |
|
Houma, Louisiana
|
|
Owned |
|
|
101,150 |
|
|
Manufacture and threading of downhole accessories |
|
Broussard, Louisiana
|
|
Owned |
|
|
55,920 |
|
|
Premium threading of downhole and specialty equipment |
10
| |
|
|
|
|
|
|
|
|
| |
|
|
|
Facility | |
|
|
| |
|
|
|
Size | |
|
|
| Location |
|
Tenure |
|
(Sq.Ft.) | |
|
Utilization |
| |
|
|
|
| |
|
|
|
Casper, Wyoming
|
|
Owned |
|
|
28,181 |
|
|
Premium threading of casing and tubing |
|
Beaumont, Texas
|
|
Owned |
|
|
17,838 |
|
|
Premium threading services and manufacture of conductors |
|
Vlissingen, The Netherlands
|
|
Leased |
|
|
65,800 |
|
|
Premium threading services and manufacture of conductors |
|
Batam Island, Indonesia
|
|
Owned |
|
|
14,400 |
|
|
Premium threading services and manufacture of conductors |
| |
|
Corporate
|
|
|
|
|
|
|
|
|
|
Houston, Texas
|
|
Leased |
|
|
39,350 |
|
|
Corporate headquarters |
|
The Woodlands, Texas
|
|
Leased |
|
|
61,831 |
|
|
Sales and administrative offices |
|
|
| Item 3. |
Legal Proceedings |
In the ordinary course of business, we are the subject of
various claims and litigation. We maintain insurance to cover
many of our potential losses and we are subject to various
self-retentions and deductibles with respect to our insurance.
See Business Other Business Data
Insurance. Although we are subject to various ongoing
items of litigation, we do not believe that any of the items of
litigation that we are currently subject to will result in any
material uninsured losses to us. It is possible, however, that
an unexpected judgment could be rendered against us in the cases
in which we are involved that could be uninsured and beyond the
amounts that we currently have reserved or anticipate incurring
for that matter.
|
|
| Item 4. |
Submission of Matters to a Vote of Security Holders |
No matters were submitted to a vote of the stockholders of the
Company during the fourth quarter of 2004.
PART II
|
|
| Item 5. |
Market for Registrants Common Equity, Related
Stockholder Matters, and Issuer Purchases of Equity
Securities |
Our common stock has a par value of $0.01 per share and is
listed and traded on the New York Stock Exchange
(NYSE) under the symbol GRP. The following
table sets forth for the periods indicated the high and low
sales prices of our common stock as reported on the NYSE:
| |
|
|
|
|
|
|
|
|
|
| |
|
High | |
|
Low | |
| |
|
| |
|
| |
|
2004
|
|
|
|
|
|
|
|
|
| |
First quarter
|
|
$ |
15.99 |
|
|
$ |
12.87 |
|
| |
Second quarter
|
|
|
18.56 |
|
|
|
13.90 |
|
| |
Third quarter
|
|
|
20.91 |
|
|
|
16.82 |
|
| |
Fourth quarter
|
|
|
22.31 |
|
|
|
18.80 |
|
|
2003
|
|
|
|
|
|
|
|
|
| |
First quarter
|
|
$ |
12.81 |
|
|
$ |
9.77 |
|
| |
Second quarter
|
|
|
14.87 |
|
|
|
10.75 |
|
| |
Third quarter
|
|
|
12.26 |
|
|
|
10.00 |
|
| |
Fourth quarter
|
|
|
13.68 |
|
|
|
10.00 |
|
We have not paid cash dividends on our common stock since
becoming a public company. We currently intend to retain any
earnings for use in our business and do not anticipate paying
cash dividends in the foreseeable future. In addition, our
senior credit facility and indenture governing our
95/8% Senior
Notes Due
11
2007 and our 9% Senior Notes Due 2009 contain restrictions
on our ability to pay dividends. Refer to
Part II Item 7
Managements Discussion and Analysis of Financial
Condition and Results of Operations Liquidity and
Capital Resources for further information.
At March 18, 2005, we had 2,815 record holders of our
common stock.
|
|
| Item 6. |
Selected Financial Data |
The following table sets forth certain of our historical
financial data. Until we were spun off on April 14, 2000,
we were a wholly-owned subsidiary of Weatherford International,
LTD. (Weatherford). This information has been prepared as if we
had been a stand-alone company during 2000. Additionally, in
April 2004 we sold the assets and business of our Texas Arai
division and prior year results related to this division have
been reclassified as discontinued operations. This information
should be read in conjunction with Managements
Discussion and Analysis of Financial Condition and Results of
Operations and the Consolidated Financial Statements
included elsewhere in this Annual Report on Form 10-K. The
following information may not be indicative of our future
operating results.
| |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Year Ended December 31, | |
| |
|
| |
| |
|
2004 | |
|
2003 | |
|
2002 | |
|
2001 | |
|
2000 | |
| |
|
| |
|
| |
|
| |
|
| |
|
| |
| |
|
(In thousands, except per share data) | |
|
Operating Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
Revenues
|
|
$ |
945,643 |
|
|
$ |
803,818 |
|
|
$ |
609,390 |
|
|
$ |
688,056 |
|
|
$ |
451,659 |
|
| |
Operating Income (Loss)
|
|
|
141,672 |
|
|
|
45,297 |
|
|
|
46,995 |
|
|
|
59,976 |
|
|
|
(11,029 |
) |
| |
Income (Loss) From Continuing Operations
|
|
|
64,793 |
|
|
|
4,657 |
|
|
|
13,690 |
|
|
|
24,809 |
|
|
|
(14,716 |
) |
| |
Income (Loss) Before Cumulative Effect of Accounting Change
|
|
|
55,266 |
|
|
|
5,190 |
|
|
|
13,046 |
|
|
|
28,090 |
|
|
|
(14,696 |
) |
| |
Net Income (Loss)
|
|
|
55,266 |
|
|
|
5,190 |
|
|
|
6,634 |
(b) |
|
|
28,090 |
|
|
|
(16,485 |
)(c) |
|
Income (Loss) Per Share(a):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (Loss) from Continuing Operations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
| |
|
Basic
|
|
|
0.53 |
|
|
|
0.04 |
|
|
|
0.12 |
|
|
|
0.23 |
|
|
|
(0.13 |
) |
| |
|
Diluted
|
|
|
0.51 |
|
|
|
0.04 |
|
|
|
0.12 |
|
|
|
0.22 |
|
|
|
(0.13 |
) |
| |
Net Income (Loss):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|