Vallourec has equipped Total with a 3D printed waterbushing for the EIG well in the North Sea.

The beginning of 2021 marks a turning point in offshore equipment manufacturing. The first ever pressure-containing component to be produced using Wire Arc Additive Manufacturing technology (WAAM) was successfully ran on Total’s EIG Elgin-Franklin rig in the North Sea. The component, designed by Vallourec, is 1.2 meters high and weighs 220kg.

Waterbushings: essential safety components

Waterbushings are a safety-critical component used in the oil and gas drilling industry to counter hydrocarbon kicks from wells in construction. Their strength and reliability is paramount as failure can result in equipment destruction.

Edwige Ravry (pictured above), Additive Manufacturing (3D Printing) Lead at Total Manufacturing, commented: "This is the first time that a safety-critical component has been created using additive manufacturing in the Energy industry. It was essential for us to have the right partner and a good business case. Vallourec, as a longstanding partner, provided us with that confidence."

Andrew Heddle, Drilling & Wells QA/QC Lead at Total Exploration & Production UK, added: "Additive manufacturing has the potential to revolutionize the O&G supply chain by enabling companies like Total to order made-to-measure components as and when they are needed.”

Vallourec worked with Total to deliver the project in just over a year using Wire Arc Additive Manufacturing (WAAM), rigorously testing the product before field deployement in February. “The project came out of an open innovation collaboration with RAMLAB, a Rotterdam-based startup”, explains Bertrand Maillon, Additive Manufacturing Business Development manager at Vallourec. “The aim of this project was to go beyond Proof of Concept to successfully develop the Quality Assurance and Quality Control frame of supply for components using WAAM technology.” 

The manufacturing process we developed leverages Vallourec’s decades-long expertise in welding, metallurgy and non-destructive examination together with our recognized strengths in threading, coating and pressure testing to enable manufacturing of components to customers’ exact specifications.

KeyFacts Energy Industry Directory: Vallourec