Investigation of Additive Manufacturing of Components for the Oil & Gas Industry

Felix Hiebler

Research output: ThesisMaster's Thesis

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Abstract

Drilling operations and production facilities of the oil and gas industry are spread around the globe, also in remote locations, offshore or in the desert. In several cases, it is impossible to make the right component available at the right time to the right location, without enormous additional costs or effort. Manufacturing the required component to the exact specification directly at the location certainly adds huge benefits. Other industries such as automobile, aerospace have applied this just-in-time strategy very effectively by using the fast-developing additive manufacturing technologies. This thesis is embedded in an overall project which is performed by the Chair of Drilling and Completion Engineering together with OMV E&P GmbH. It investigates the usage of additive manufacturing in the oil and gas industry. The content of the thesis is divided into three main phases: testing of additive manufactured parts, an oil and gas specific SWOT-Analysis and a methodology describing the workflow for spare part manufacturing. During the first phase of the thesis the additive manufactured parts, which were produced from the selected material, 1.4542 (17-4 PH), are evaluated and compared to a conventionally manufactured part and the metal grade API C-110, which is a controlled yield strength casing or tubing grade. This phase includes the preparation of the specimens, testing and analysis of the results. The static behavior of the material in hardness, tensile and Charpy-V notch impact tests is evaluated. Sulfide stress cracking (SSC) and hydrogen-induced cracking (HIC) tests were conducted in an external lab. For the second phase a SWOT-Analysis is performed to evaluate the general opportunities and shortcomings of this manufacturing method, as well as the specific chances for embedding it into the supply chain of an oil and gas production or service company. During the third phase of the thesis, a methodology or workflow to produce an additive manufactured part is evaluated and established. The workflow starts at the point, where it is recognized that a specific component is needed at the rig or the production facility and ends when the manufactured part can be delivered to this location. Therefore, different methods are investigated and researched to create a 3D model where a blueprint may not be available for a variety of reasons. The main objectives of the thesis are to gain knowledge about the properties, particularities and limitations of additive manufactured parts, especially for the application in the oil and gas business. Furthermore, the benefits of integrating this technology in certain areas are shown, to get one step closer to a safe and efficient way to use it in the oil and gas industry.
Translated title of the contributionUntersuchung von Additiver Fertigung von Teilen für die Öl- & Gasindustrie
Original languageEnglish
QualificationDipl.-Ing.
Awarding Institution
  • Montanuniversität
Supervisors/Advisors
  • Ravi, Krishna, Supervisor (internal)
Award date22 Sept 2020
Publication statusPublished - 2020

Bibliographical note

embargoed until null

Keywords

  • additive manufacturing
  • material testing
  • spare parts
  • warehouse management
  • SWOT-analysis
  • reproduction workflow
  • oil and gas industry

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