IMI and TotalEnergies EP Denmark have successfully qualified and deployed additively manufactured nickel-based alloy valve components for demanding sour-gas applications. The collaboration has resulted in the installation of seven anti-surge valves fitted with 3D-printed components, marking an important development in the use of additive manufacturing technology in the oil and gas industry.
The project was undertaken to address valve passing issues in anti-surge systems operating under challenging conditions, where hydrogen sulphide (Hâ‚‚S) partial pressures can reach up to 3.3 kPa. Although nickel-based alloys are commonly used in oil and gas applications, their use in additively manufactured components for sour-service environments has been limited. This made a detailed qualification programme necessary before the technology could be introduced into operational service.
IMI’s engineering team used Laser Powder Bed Fusion (LPBF) technology to manufacture the valve trim components. The company also developed a proprietary heat treatment process to improve material properties and ensure reliable performance in sour-gas environments.
The components underwent extensive mechanical and corrosion testing to establish their suitability for the intended operating conditions. The results confirmed that the additively manufactured components delivered performance equivalent to conventionally manufactured nickel-based alloy parts. The solution also successfully met the requirements of DNV-ST-B203 AMC Level 3 qualification. Following the successful completion of the qualification programme, TotalEnergies approved the installation of seven anti-surge valves equipped with IMI’s additively manufactured nickel-based alloy disk stacks.
Bertrand Maillon, Retrofit3D Leader at IMI, said the project focused on demonstrating the reliability of additive manufacturing in demanding sour-gas conditions rather than simply producing components using a new manufacturing process. He highlighted the importance of corrosion resistance, long-term material integrity and the development of a specialised heat treatment process. He added that successful qualification and the entry of the first valves into service marked an important achievement for both companies.
Bertrand Levaché, Head of Additive Manufacturing at TotalEnergies, said the partnership began with the objective of addressing valve reliability challenges in an Hâ‚‚S environment and developed into a successful industrial application. He acknowledged IMI’s contribution in applying additive manufacturing technology to meet the project’s technical requirements. The deployment demonstrates the potential of additive manufacturing to deliver qualified valve components for specialised oil and gas applications, while opening opportunities for further engineering collaboration and advanced manufacturing solutions.
