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.
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

Video Analysts: Beijing Parade a 'Bazaar' of Stolen Technology

Show commemorating victory over Japan in World War II involved long, medium and short range missiles, a range of tanks and 200 fighter aircraft More

Bernie Sanders Surge Reflects US Shift on Socialism

Although most analysts say it is unlikely he will get the Democratic nomination, Sanders' campaign opens up questions and issues that are otherwise marginalized More

Video On IS Frontline, Kurdish Fighters Ready for Offensive

Peshmerga soldiers say although they need more heavy artillery, they are poised to take the fight to the Islamic State extremists on their turf More

Featured Videos

Your JavaScript is turned off or you have an old version of Adobe's Flash Player. Get the latest Flash player.
Drowned Migrant Toddler Photo Triggers European Outragei
X
Henry Ridgwell
September 04, 2015 11:36 AM
The harrowing picture of a drowned three-year-old Syrian boy washed up on a Turkish beach appears to have galvanized Europe’s leaders into doing more to address the refugee crisis. France, Germany and Italy issued a joint call Thursday for compulsory quotas of refugees for all EU states. But there were chaotic scenes in Hungary as police tried to force migrants off a train heading for Austria. Henry Ridgwell has more. And a caution, some of the images in this report may be disturbing.
Video

Video Drowned Migrant Toddler Photo Triggers European Outrage

The harrowing picture of a drowned three-year-old Syrian boy washed up on a Turkish beach appears to have galvanized Europe’s leaders into doing more to address the refugee crisis. France, Germany and Italy issued a joint call Thursday for compulsory quotas of refugees for all EU states. But there were chaotic scenes in Hungary as police tried to force migrants off a train heading for Austria. Henry Ridgwell has more. And a caution, some of the images in this report may be disturbing.
Video

Video Russians Observe 11th Anniversary of Beslan School Attack

This week, Russians have been observing the 11th anniversary of the attack by Islamic militants on a school in Russia's North Caucasus region that killed more than 330 hostages, including 186 children. The three-day siege and massacre that started on September 1, 2004 took place in Beslan, a town in the republic of North Ossetia, and is one of the bloodiest terrorist acts ever in Russia. VOA's Mike Richman reports.
Video

Video Native Americans Debate: Father Serra, Saint or Sinner?

Pope Francis will canonize an 18th century missionary to Spanish California during a papal visit to the United States this month.  But some Native Americans have criticized the elevation to sainthood of the missionary priest, Junipero Serra. VOA's Mike O’Sullivan has more from Los Angeles.
Video

Video Calais School Offers Another Face of Europe’s Migrant Crisis

Europe is facing mounting criticism over how it’s handling its biggest migration crisis since World War II. But not all Europeans believe building walls or passing repressive policies are the answer. A school for migrants in the French port city of Calais, is opening doors and building bonds across nationalities. VOA's Lisa Bryant reports.
Video

Video Kurdish Fighters on IS Frontline Ready for Offensive

Finger on the trigger, the Kurdish Peshmerga soldier stared across the dust at a village taken over by Islamic State extremists. The Kurdistan’s Khazir frontline, just 45 minutes from the Islamic State stronghold of Mosul. And at this point, the militants were less than two kilometers away. VOA's Sharon Behn reports.
Video

Video China Announces Troop Cuts at WWII Parade

Chinese President Xi Jinping Thursday announced plans to cut the world’s largest military force by 300,000 troops. The announcement was made during a massive military parade to commemorate victory over Japan in World War II. The event was shunned by most Western leaders and for some is raising fresh concerns about China’s military ambitions. VOA’s Bill Ide has more from Beijing.
Video

Video Russia-Japan Relations Cool as Putin Visits China for WWII Anniversary

Russian President Vladimir Putin is in Beijing for commemorations of the 70th anniversary of China's WWII victory over Japan. Putin is expected to visit Japan later this year, but tensions between Tokyo and Moscow over islands disputed since the war, and sanctions over Ukraine, could pour cold water on the plan. VOA's Daniel Schearf reports.
Video

Video Yemen ‘on Brink of Disaster’ as Medical Shortages Soar

Aid agencies warn Yemen is on the brink of humanitarian disaster – with up to half a million children facing severe malnutrition, and hospitals running out of basic medicines. There are fears Yemen's civil war could escalate as the coalition led by Saudi Arabia tries to drive back Houthi rebels, who seized control of much of the country earlier this year. Henry Ridgwell reports.
Video

Video Apps Helping Kenyan Businesses Stay Ahead of Counterfeiters

Counterfeit goods in Kenya cost the government as much as $1 billion each year in lost tax revenues. The fake goods also hurt entrepreneurs who find it hard to carve out a niche in the market and retain customers. But as Lenny Ruvaga reports from Nairobi, information technology is being used to try to beat the problem.
Video

Video Nobel Prize Winner Malala Talks to VOA

Nobel Peace Prize winner Malala Yousafzai met with VOA's Deewa service in Washington Sunday to talk about women’s rights and unveil a trailer for her new documentary. VOA's Katherine Gypson has more.
Video

Video War, Drought Threaten Iraq's Marshlands

Iraq's southern wetlands are in crisis. These areas are the spawning ground for Gulf fisheries, a resting place for migrating wildfowl, and source of livelihood for fishermen and herders. Faith Lapidus has more.
Video

Video Colombians Flee Venezuela as Border Crisis Escalates

Hundreds of Colombians have fled Venezuela since last week, amid an escalating border crisis between the two countries. Last week, Venezuelan President Nicolas Maduro ordered the closure of a key border crossing after smugglers injured three Venezuelan soldiers and a civilian. The president also ordered the deportation of Colombians who are in Venezuela illegally. Zlatica Hoke reports.
Video

Video Rebuilding New Orleans' Music Scene

Ten years after Hurricane Katrina inundated New Orleans, threatening to wash away its vibrant musical heritage along with its neighborhoods, the beat goes on. As Bronwyn Benito and Faith Lapidus report, a Musicians' Village is preserving the city's unique sound.
Video

Video In Russia, Auto Industry in Tailspin

Industry insiders say country relies too heavily on imports as inflation cuts too many consumers out of the market. Daniel Schearf has more from Moscow.
Video

Video Scientist Calls Use of Fetal Tissue in Medical Research Essential

An anti-abortion group responsible for secret recordings of workers at a women's health care organization claims the workers shown are offering baby parts for sale, a charge the organization strongly denies. While the selling of fetal tissue is against the law in the United States, abortion and the use of donated fetal tissue for medical research are both legal. VOA’s Julie Taboh reports.

VOA Blogs