On September 25, 2024, Vallourec, a prominent French manufacturer specializing in tubes, demonstrated a significant advancement in manufacturing technologies by successfully employing wire arc additive manufacturing (WAAM) to produce a downhole component that adheres to the strict American Petroleum Institute standards. This development indicates a significant shift towards the adoption of 3D printing technologies in the oil and gas sector.
Vallourec, which boasts a revenue of $3.4 billion and a global workforce of 17,000, is renowned for its seamless steel tubes across industries, including energy and automotive. Olivier Tartar, Vallourec’s Head of Additive Manufacturing, shared on LinkedIn that their latest success involves the production of a downhole component using WAAM that meets the rigorous API 5C5:2017 CAL-IV standards for tubing and casing connections.
Although the oil and gas industry initially showed reservations about WAAM, the technology is now recognized for its efficiency and cost-effective benefits, especially in the energy sector. Vallourec’s efforts to enhance this technology include the integration of robotic arms and ultrasonic testing in their production cells, which permits the creation of substantial parts measuring up to 2 meters in height and 1 meter in diameter—dimensions crucial for industries requiring speedy and high-quality production outputs.
WAAM technology has seen varying levels of acceptance and implementation over time. Initially popular, its application decreased because of issues such as post-processing and limited control capabilities. Vallourec, however, has improved the technology by incorporating robotic solutions and sophisticated inspection methods, allowing for the production of superior parts.
Vallourec has notably created a lifting plug for a Timor Sea oil platform, designed to bear a load of 100 tons. This component was produced more quickly and cost-effectively than its traditional forged counterpart, highlighting WAAM’s ability to meet pressing demands in fields like oil and gas exploration and production by reducing operational downtime.
Another significant achievement for Vallourec was the development of a WAAM-printed downhole component that met the stringent requirements of the API 5C5:2017 CAL-IV standard. This standard confirms that tubing and casing connections can withstand the intense pressure and temperature conditions found in oil and gas environments. The component tested was a 9 5/8” cross-over tube, which underwent rigorous testing under extreme tension, compression, and internal and external pressures reaching 1,000 bars and 600 bars, respectively.
Olivier Tartar has pointed out that this component’s success is proof of WAAM’s ability to compete with traditional manufacturing methods like casting and forging. Vallourec’s continuous enhancements to the technology suggest its growing potential for broader adoption in essential industries.
Source: 3dprint.com
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