3D Printed Nickel Alloy Components Revolutionize Sour Gas Valves

3D Printing Takes a Leap in Critical Applications for Southeast Asian Factories \\[n] In a significant move that could reshape the way factories in Southeast Asia approach maintenance and upgrades, TotalEnergies EP Denmark has successfully installed seven anti-surge valves with 3D printed nickel-based alloy disk stacks from IMI. These components are designed to operate in harsh environments where hydrogen sulfide (H₂S) partial pressures can reach up to 3.3 kPa, a common challenge in the region's oil and gas industry. The successful deployment of these 3D printed parts not only meets but exceeds the performance of traditionally manufactured components, passing DNV-ST-B203 AMC Level 3 qualification. This achievement is a testament to the potential of additive manufacturing in critical, safety-sensitive applications. \\[n] For factories in Thailand, Vietnam, Indonesia, and Malaysia, this development means a new avenue for enhancing operational efficiency and reducing downtime. The ability to produce high-quality, corrosion-resistant parts on-demand can significantly lower maintenance costs and improve overall equipment reliability. This is particularly relevant in countries like Indonesia and Malaysia, where offshore oil and gas operations are prevalent and the corrosive effects of H₂S are a constant concern. \\[n] The project began with a specific operational issue: valve passing in anti-surge systems under demanding service conditions. The high levels of H₂S made it challenging to approve any new component, as it had to demonstrate superior corrosion resistance, reliability, and mechanical performance. IMI’s engineering team, in collaboration with TotalEnergies, developed a proprietary heat treatment process tailored for sour-service conditions, ensuring the 3D printed parts met all necessary standards. \\[n] Bertrand Maillon, Retrofit3D leader at IMI, emphasized the importance of proving reliability over mere printability. “Our goal was to show that these 3D printed components could perform reliably in a highly corrosive environment, where long-term integrity is crucial,” he said. This collaborative effort between IMI and TotalEnergies highlights the power of innovation through partnership, as both companies worked closely to develop and validate the printed disk stacks. \\[n] The Retrofit3D program, which designs custom 3D printed control valve trims, offers a unique solution for upgrading existing valve bodies without the need for extensive modifications. By replacing only the internal trim, the risk and cost associated with cutting and re-welding pipework are minimized. This approach has already been successfully implemented in projects across China and other regions, and now, it is making its mark in sour service. \\[n] Other major players in the industry, such as ConocoPhillips and Shell, have also embraced 3D printing to extend the life of their equipment. ConocoPhillips, for instance, retrofitted its choke cage valves with 3D printed cages, extending valve life and improving uptime. Shell, on the other hand, received CE certification for a 3D printed pressure vessel, demonstrating the growing acceptance of 3D printed parts in critical applications. \\[n] For factory buyers in ASEAN, the key takeaway is the potential for 3D printing to revolutionize maintenance and upgrade processes. By leveraging this technology, factories can achieve higher operational efficiency, reduce downtime, and ensure the longevity of their equipment. As more companies adopt 3D printing, the benefits will become increasingly evident, driving the industrialization of additive manufacturing in the region.