IMI and TotalEnergies Deploy 3D-Printed Valve Components for Sour-Gas Applications

Successful Implementation of Additive Manufacturing

IMI and TotalEnergies EP Denmark have achieved a significant milestone by qualifying and deploying 3D-printed nickel-based alloy valve components for sour-gas applications. A total of seven anti-surge valves now utilize these additively manufactured parts, showcasing a pivotal advancement in the oil and gas industry's use of additive manufacturing technology.

Addressing Valve Challenges

The initiative was launched to tackle valve passing issues in anti-surge systems that operate under extreme conditions, where hydrogen sulphide (H₂S) partial pressures can reach up to 3.3 kPa. Although nickel-based alloys are traditionally employed in oil and gas applications, their application in 3D-printed components for sour-service settings had previously been limited, necessitating a comprehensive qualification program before deployment.

Advanced Manufacturing Techniques

IMI’s engineering team employed Laser Powder Bed Fusion (LPBF) technology to create the valve trim components and developed a proprietary heat treatment process to enhance material properties. The additively manufactured components underwent rigorous mechanical and corrosion testing, proving their performance to be on par with conventionally manufactured nickel-based alloy parts. They also met the DNV-ST-B203 AMC Level 3 qualification requirements, leading to the approval of the valve installations by TotalEnergies.

Future Implications

Bertrand Maillon, Retrofit3D Leader at IMI, emphasized the project's focus on reliability in demanding sour-gas conditions, highlighting the importance of corrosion resistance and long-term material integrity. Similarly, Bertrand Levaché, Head of Additive Manufacturing at TotalEnergies, noted that the partnership successfully addressed valve reliability challenges, paving the way for future engineering collaborations and advanced manufacturing solutions in the sector.