Redefining Resilience: Additive Valve Innovation in the Oil and Gas Sector

The components in question were check valves used in a produced water pipeline, an environment that frequently exposes parts to highly corrosive saltwater and other chemicals. For this application, traditionally manufactured parts, made from expensive and specialized materials like super duplex steel, required replacement as frequently as every six months.

This rhythm created a significant maintenance burden. The high volume of these parts in use meant that teams had to maintain a massive inventory at all times to avoid operational downtime. Compounding this issue was an incredibly long lead time for conventional metal parts, often exceeding 52 weeks.

The combination of high replacement frequency, massive inventory requirements, and a precarious supply chain resulted in exorbitant costs.

Furthermore, the first iteration of an AM-produced polymer part, which mimicked the original metal design, failed catastrophically during high-pressure gas testing, exploding upon reaching 325 psi. This failure highlighted the need for a fundamentally different, more sophisticated design approach that could only be achieved through advanced simulation and design for additive manufacturing expertise.

The collaboration delivered a transformative impact across the entire value chain. The most immediate and significant result was the dramatic reduction in lead time — from over 52 weeks for the original super duplex part to just one week for the AM-produced polymer component. This monumental shift streamlined the supply chain while also enabling a true digital spare part program, eliminating the need for vast, costly physical inventory.

The redesigned components demonstrated exceptional performance under pressure. They passed all hydrostatic shell and seat tests up to 450 psi and 325 psi, respectively, with flawless results. Most impressively, the new parts achieved “bubble-tight performance” during extended-duration air and high-pressure nitrogen gas tests, a feat the initial design was unable to accomplish. The integrity of the parts was further validated during a 60-minute extended-duration hydrostatic test at maximum load, which showed no signs of creep or plastic deformation.

The principal engineer at the global valve services provider expressed his delight, stating that the parts “passed all of the pressure testing flawlessly. The results are better than expected.” He continued, highlighting the durability and sealing capabilities of the AM part, “In particular, the results of the last two tests, one on air and the other on nitrogen at high pressure, showed excellent results with regard to bubble-tight performance.”

In addition to performance gains, the project resulted in a 15% lighter component and a total cost of ownership reduction of at least 30%. The components also met rigorous industry standards, including API 598 and API 6D. These achievements demonstrate that AM can provide a superior, more resilient, and more economical solution for critical infrastructure in the oil and gas sector, and for manufacturers in general.