Thursday 25 November 2021

AML3D, a global provider of large-scale metal additive manufacturing technology and solutions, has 3D printed the world’s largest high-pressure Oil & Gas piping component to be successfully tested and verified by Lloyd’s Register. This demonstrator component was printed as part of AML3D’s internal development program and it showcases capabilities in the subsea oil and gas sector.

The 940kg monocoque “piping spool” component is the first of its type to be metal 3D printed and independently pressure tested, in the world. At 850mm in length and 450mm in diameter, the 41mm thick high-pressure piping spool was printed according to the stringent and newly released American Petroleum Institute (API) Standard 20S and has met all test acceptance criteria. Finally, the component underwent industry-standard high-pressure testing which also passed the acceptance testing for ASME B31.3, a well used American standard for these applications.

The highly pressurised testing was undertaken by Trushape Engineering, specialists in high-pressure piping components testing. The component was pressurised to 34,790kPa and held for an extended period with no loss of structural integrity. The testing was independently witnessed and verified by Lloyds Register, one of the worlds leading marine verification authorities.

Typically a high-pressure component of this nature would be found in conditions that are generally within the Safety-Critical systems on Oil & Gas facilities, that contain hazardous fluids under very high pressures that are highly corrosive, and typically have high-temperature environments.

Using AML3D’s patented WAM®, this high-pressure component was printed as one piece, eliminating the need for using three separate components using traditional fabrication and welding methods. At the same time, the WAM® process has introduced improved material properties using a higher strength wire feedstock and optimised process parameters, while reducing the manufacturing time from months to just days.

AML3D believes this part to be a game-changer in the sustainable manufacture of medium to large scale parts for the $2.1T Global Oil & Gas Exploration and Production Market.

AML3D Managing Director Mr Andrew Sales comments on the achievement:

AML3D is thrilled with the results from the high-pressure testing witnessed and verified by Lloyd’s Register. We now have a high level of interest already shown by participants in the Oil & Gas sector and are in discussions with several opportunities. The ability to demonstrate to this sector the capabilities and outstanding test results of our patented Wire Additive Manufacturing (WAM®) process opens the door for far greater application.