The Middle East has long been recognized as a global hub for the oil, gas, and energy industry. With the rapid advancements in technology, additive manufacturing, also known as 3D printing, has emerged as a game-changer in various sectors.
This blog by AM Chronicle explores the application of additive manufacturing in the Middle East’s oil, gas, and energy industry, highlighting key government initiatives, private companies, and real-world use cases.
Government Initiatives Driving Additive Manufacturing Adoption
Recognizing the potential of additive manufacturing, governments in the Middle East have taken proactive steps to promote its adoption. The Egyptian government has launched a number of initiatives to promote 3D printing, including the establishment of the 3D Printing Center in Cairo. The Turkish government has also been supportive of 3D printing. In 2017, the government announced the establishment of the Additive Manufacturing Technology Development Center. The Israeli government has also been supportive of 3D printing. In 2016, the government announced the establishment of the Additive Manufacturing Industry Initiative. In 2018, the government announced the establishment of the 3D Printing Center at the Jordan University of Science and Technology. The initiatives taken by the governments of Egypt, Turkey, Israel and Jordan have broad aims, one of which included application of technology for the oil and gas industry.
The United Arab Emirates (UAE) has been at the forefront, launching the “Dubai 3D Printing Strategy” in 2016, which aims to use 3D additive manufacturing for resolving critical challenges of oil and gas industry. Additionally, Saudi Arabia’s “Vision 2030” plan includes the development of a 3D printing industry to foster innovation and enhance local manufacturing capabilities.
Petroleum Development Oman (PDO) is the largest oil and gas company in Oman. In recent years, PDO has been exploring the use of 3D printing for a variety of applications. PDO partnered with Spare Parts 3D (SP3D), a French startup, to assess the 3D printability of 150,000 unique spare parts. This project helped PDO to identify a number of spare parts that were suitable for 3D printing, and it also helped to develop a 3D printing adoption matrix that can be used to assess the feasibility of 3D printing for other spare parts.
Standards and Certifications for additive manufacturing in oil and gas industry
DNV introduced a technical standard (DNVGL-SE-0568) in March 2023, setting safety and efficiency specifications for 3D printed products in the oil and gas and general energy production sectors. The standard aims to support the adoption of additive manufacturing (AM) technology in the industry to gain cost and efficiency benefits. DNV has been exploring the opportunities and challenges of AM since 2014, and in 2017, it published the first guideline for AM in the maritime and oil & gas industries. In 2018, DNV opened the Global AM Center of Excellence to foster research and development in 3D printing for the oil and gas, offshore, and maritime sectors.
The American Petroleum Institute (API) also announced The standard, titled “Additively Manufactured Metallic Components for Use in the Petroleum and Natural Gas Industries,” aims to drive the adoption of 3D printing in the oil and gas industry. It introduces three additive manufacturing specification levels, establishing requirements for technical, quality, and qualification aspects of 3D printed metallic components. The standard also addresses training, inspection, monitoring, measuring equipment, material testing, and quality control. API aims to optimize component design, reduce lead times, and drive efficiency, safety, and technological advancements across all segments of the industry.
These initiatives by DNV and API highlight the growing recognition of the potential of additive manufacturing in the oil and gas industry. By setting standards and specifications, these organizations aim to ensure the safe and effective use of 3D printed components, leading to reduced production shutdowns, lower supply-chain carbon footprints, improved efficiency, and cost savings.
Key Use Cases of Additive Manufacturing in Oil, Gas, and Energy
Additive manufacturing enables the production of complex and customized spare parts on-demand, reducing the need for extensive inventories. This flexibility allows energy companies to address maintenance and repair needs efficiently, minimizing downtime and associated costs.
3D printing accelerates the prototyping process for oil, gas, and energy equipment. Engineers can quickly produce scale models and functional prototypes, facilitating iterative design improvements and reducing time-to-market for new products.
Additive manufacturing allows for the seamless integration of sensors and other electronics into equipment and structures. This capability enhances data collection and monitoring, enabling real-time condition monitoring, predictive maintenance, and increased operational efficiency.
Vallourec, an oil and gas firm, has 3D printed the first ever pressure-containing component for the energy sector. The part, a water bushing, is used to block hydrocarbon surges from wells during their construction. It was 3D printed using the Wire Arc Additive Manufacturing (WAAM) process, which allowed for a whole new level of geometric freedom.
The design freedom offered by additive manufacturing allows for the creation of intricate geometries and lightweight structures. This capability is advantageous for optimizing components, reducing material usage, and enhancing overall performance.
Siemens Energy is an supplier of turbines to the oil and gas companies in Middle East, which is using additive manufacturing to produce turbine at the site.
In remote or offshore locations, accessing spare parts or specialized equipment can be challenging and time-consuming. 3D printing offers the possibility of on-site manufacturing, allowing companies to produce parts and tools where they are needed. This capability reduces logistics complexities, shortens lead times, and improves overall operational efficiency.
Additive manufacturing has the potential to transform offshore operations by enabling the fabrication of parts and equipment on-site. This eliminates the need for lengthy and costly supply chains, improving operational efficiency and reducing the environmental impact.
Conclusion
Additive manufacturing is reshaping the oil, gas, and energy industry in the Middle East, offering significant benefits such as reduced costs, improved operational efficiency, and enhanced sustainability. With strong government support and private sector initiatives, the region is embracing this transformative technology. As additive manufacturing continues to advance, we can expect further innovation and expanded applications in the Middle East’s energy sector, driving growth and ensuring a competitive edge for companies operating in this vital industry.
About AM Conclave Middle East
AM Conclave Middle East is an initiative to bring the entire Additive Manufacturing and 3D Printing ecosystem in the Middle East on one platform including Government, Users, Software Providers, Hardware, Material Manufacturers, Research Institutes and Standards & Certification Bodies, with an aim to advance the adoption of AM in line with the various initiatives and strategies in the region to catalyze manufacturing.
The event will feature application and technology focussed conference mapping the latest developments and trends in the world of Additive Manufacturing. A high quality technical conference will also be supported by a technology showcase and networking zone for the industry stakeholders to showcase their solutions and exchange ideas.
For more information visit: https://amconclave.com/
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