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Revolutionizing Spare Parts Production in Oil and Gas Industry

The oil and gas sector is witnessing a pivotal change in its approach to spare parts production, thanks to a collaboration between four innovative players: Assembrix Ltd., HP, Sparely, and Korall Engineering AS. Recently, these companies successfully completed a series of secure remote additive manufacturing (AM) operations designed to produce certified spare parts for the energy sector. This landmark achievement exemplifies how distributed manufacturing can facilitate the efficient, secure, and scalable production of vital components close to where they are needed most.

With the oil and gas industry often facing the threat of downtime, caused by the failure of equipment, this initiative is expected to enhance operational resilience significantly. By enabling a digital production method that emphasizes rapid response, the collaboration not only aims to enhance productivity but also to reduce costs.

The Process Behind the Innovation

The successful series involved printing certified polymer spare parts at various partner sites equipped with HP's Multi Jet Fusion (MJF) systems. This process was integrated with Assembrix's advanced software platform, ensuring each build was securely encrypted and monitored in real-time. The products that emerged from these operations included specialized polymer valve handwheels designed for use in oil and gas applications, marking a significant step in the evolution of 3D printing within the sector.

Korall Engineering's designs, which received validation from DNV, represent the first-ever qualification of HP 3D High Reusability PA12 materials for offshore applications. These materials are crafted to withstand corrosive environments while minimizing weight and resource consumption. This innovative approach affords manufacturers an avenue to enhance sustainability in production, ultimately helping mitigate the environmental impacts traditionally associated with industrial operations.

Enhancing Efficiency and Sustainability

For oil and gas companies, minimizing downtime is crucial. With this secure model of distributed manufacturing, spare parts can now be delivered in mere days, vastly reducing lead times and logistics-related costs compared to traditional methods, which often required months of waiting. This capacity not only facilitates swifter responses to equipment failures but also diminishes the need for extensive inventory storage - a significant financial burden for many operators.

Moreover, localizing production serves to further advance sustainability efforts within the sector. It significantly curtails transportation emissions as parts can be produced and implemented nearer to their point of use. Oil and gas companies can thus transition towards a low-carbon manufacturing model that emphasizes responsible consumption and waste reduction.

Setting New Standards in Additive Manufacturing

The partnership stands as a blueprint for future initiatives seeking to harmonize design, certification, and production within a secure global network. The ability to seamlessly connect various aspects of manufacturing processes in a digitized manner is driving forward the transformative power of additive manufacturing in critical industries.

Bruno Maffei, CEO of Korall Engineering, succinctly articulated the outcome of this collaboration: "By combining our unique capabilities, we have illustrated that essential components can now be produced safely and locally for certified field use."

As each organization involved moves towards increased digitalization and innovation, they are not just adapting to industry trends; they are actively defining the new industrial standards for manufacturing. The successful execution of this project demonstrates that secure, distributed AM is not merely a concept but a practical reality that is poised to reshape the landscape of manufacturing across the globe.

In summary, this collaboration marks a significant milestone for the oil and gas sector, showing that when it comes to spare part production, the future is both secure and scalable. This advancement offers a glimpse into the essential role that technology will play in ensuring the resilience and efficiency of energy suppliers worldwide.