News / Science & Technology

Oil Industry Joins World of 3D Printing

FILE - A staff member of Nihonbinary demonstrates their 3D printer MakerBot Replicator 2X as it prints an Acrylonitrile butadiene styrene pylon during the International Robot Exhibition 2013 in Tokyo, Nov. 8, 2013.
FILE - A staff member of Nihonbinary demonstrates their 3D printer MakerBot Replicator 2X as it prints an Acrylonitrile butadiene styrene pylon during the International Robot Exhibition 2013 in Tokyo, Nov. 8, 2013.
TEXT SIZE - +
Reuters
— General Electric's oil and gas division will start pilot production of 3D printed metal fuel nozzles for its gas turbines in the second half of this year, a major step towards using the technology for mass-manufactured parts in the industry.

Full production of the printed fuel nozzles is expected in 2015, Eric Gebhardt, chief technology officer at GE Oil & Gas, told Reuters.

The move follows hot on the heels of GE Aviation, which said last year it would use 3D printing to produce fuel nozzles for its LEAP jet engine, a high profile decision that for many sealed the commerciality of the technique.

Oil services firm Halliburton has also used 3D printing to produce parts used in drilling although not on such a large scale.

Forms of advanced manufacturing are increasingly vital in the oil and gas sector as companies move into extreme environments such as ultra deep-water or the Arctic.

3D printing allows complex shapes to be built up in layers from particles of plastics or metal, enabling engineers to realize designs impossible to mass-manufacture before.

GE Oil and Gas, one of GE's fastest growing divisions, is investing $100 million over the next two years on technology development with a “significant portion” going on 3D printing, also known as additive manufacturing. The division has installed dozens of plastic and metal 3D printers across its businesses.

Fuel nozzles, which feeds combustion in a gas turbine, are currently made by welding together a number of sub-components, a process hugely simplified by printing it in one piece.

The other piece of kit that GE Oil and Gas is looking to produce using 3D printers is electric submersible pumps used to artificially bring oil to the surface.

“Most of these are about four or five inches in diameter and then about an inch or two in height. It's the right size to put into some of the additive manufacturing,” Gebhardt said.

Rapid prototyping

The technology is still mainly used for prototyping, but even in this seemingly basic use, improvements can be dramatic.

At GE's pipeline inspection plant in Newcastle, where monitoring robots known as pigs are assembled, the design loop which once took 12 weeks is now done in 12 hours thanks to an on-site 3D printer the size of a hotel minibar fridge.

Pigs are custom designed to deal with the particular pipeline, whether it be hundreds of meters under the sea or full of corrosive sour gas.

Trial parts can now be printed on location, in plastic, to see whether they fit and work properly. Only then is the part ordered, paid for and delivered in the final material.

For senior engineer Dave Bell the printer is one of the biggest shifts he has seen in his 30 years at the site.

“It's a game changer,” he said. “Engineering is all about compromise and this allows you to trial concepts quickly and cheaply.”

But challenges remain, predominantly around the size that can be printed and the surface finish produced.

“Now we're going to have to see how large they can get over time,” Gebhardt said. “Will it follow Moore's law where it is going to double in size every 18 months? That's kind of what we're seeing right now. But when is it going to reach a natural inflection point? That's something we have to work through.”

For Richard Hague, a professor at Nottingham University and an expert in additive manufacturing, the size of much of the equipment used in the oil and gas industry is simply too big.

“It's cost effective if it's small and complicated, but when it's large and complicated it's much less effective,” he said.

You May Like

Abuja Blast Impacts Lives, Livelihoods

Officials say they are looking at ways to help bombing victims and boosting security More

Cambodia Technology Adviser Criticizes Cybercrime Draft Law

Phu Leewood says current criminal code can be used to prosecute offenders and that there is no need for a separate law More

Photogallery A Year Later, Boston Remembers Deadly Marathon Bombings

City pauses to honor victims and salute emergency workers who came to their assistance in frantic moments after blasts More

Featured Videos

Your JavaScript is turned off or you have an old version of Adobe's Flash Player. Get the latest Flash player.
Google Buys Drone Companyi
|| 0:00:00
...
 
🔇
X
George Putic
April 15, 2014
In its latest purchase of high-tech companies, Google has acquired a manufacturer of solar-powered drones that can stay in the air almost indefinitely, relaying broadband Internet connection to remote areas. It is seen as yet another step in the U.S. based Web giant’s bid to bring Internet to the whole world. VOA’s George Putic reports.
Video

Video Google Buys Drone Company

In its latest purchase of high-tech companies, Google has acquired a manufacturer of solar-powered drones that can stay in the air almost indefinitely, relaying broadband Internet connection to remote areas. It is seen as yet another step in the U.S. based Web giant’s bid to bring Internet to the whole world. VOA’s George Putic reports.
Video

Video Ray Bonneville Sings the Blues and More on New CD

Singer/songwriter Ray Bonneville has released a new CD called “Easy Gone” with music that reflects his musical and personal journey from French-speaking Canada to his current home in Austin,Texas. The eclectic artist’s fan base extends from Texas to various parts of North America and Europe. VOA’s Greg Flakus reports from Austin.
Video

Video Millions Labor in Pakistan's Informal Economy

The World Bank says that in Pakistan, roughly 70 percent work in the so-called informal sector, a part of the economy that is unregulated and untaxed. VOA's Sharon Behn reports from Islamabad on how the informal sector impact's the Pakistani economy.
Video

Video Passover Celebrates Liberation from Bondage

Jewish people around the world are celebrating Passover, a commemoration of their liberation from slavery in Egypt more than 3,300 years ago. According to scripture, God helped the Jews, led by Moses, escape bondage in Egypt and cross the Red Sea into the desert. Zlatica Hoke reports that the story of the Jewish Exodus resonates with other people trying to escape slave-like conditions.
Video

Video Police Pursue Hate Crime Charges Against Kansas Shooting Suspect

Prosecutors are sifting through the evidence in the wake of Sunday’s shootings in a suburb of Kansas City, Missouri that left three people dead. A suspect in the shootings taken into custody is a white supremacist. As VOA’s Kane Farabaugh reports, he was well-known to law enforcement agencies and human rights groups alike.
Video

Video In Eastern Ukraine, Pro-unity Activists Emerge from Shadows

Amid the pro-Russian uprisings in eastern Ukraine, there is a large body of activists who support Ukrainian unity and reject Russian intervention. Their activities have remained largely underground, but they are preparing to take on their pro-Moscow opponents, as Henry Ridgwell reports from the eastern city of Donetsk.
Video

Video Basket Maker’s Skills Have World Reach

A prestigious craft show in the U.S. capital offers one-of-a-kind creations by more than 120 artists working in a variety of media. As VOA’s Julie Taboh reports from Washington, one artist lucky enough to be selected says sharing her skills with women overseas is just as significant.
Video

Video UN Report Urges Speedier Action to Avoid Climate Disaster

A new United Nations report says the world must switch from fossil fuels to cleaner energy sources to control the effects of climate change. The Intergovernmental Panel on Climate Change released the report (Sunday) following a meeting of scientists and government representatives in Berlin. The comprehensive review follows two recent IPCC reports that detail the certainty of climate change, its impacts and in this most recent report what to do about it. VOA’s Rosanne Skirble has the details.
AppleAndroid