3D Printing Processes

Shell site receives 3D printed heat exchanger parts in record time

Energy industry companies increasingly turn to metal AM for final parts production

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3D Metalforge, a global provider of AM services, delivered additively manufactured heat exchanger parts to Shell Jurong Island, a dedicated chemical site based in Singapore and owned by giant energy company Royal Dutch Shell plc (“Shell”). Shell Jurong Island engineers chose to use 3D Metalforge’s additive manufacturing (AM) technologies and processes to accelerate the required lead time to manufacture heat exchanger tube components.

3D Metalforge (3DMF) provided a full range of AM services including the creation of a digital file for the parts prior to printing and testing. The components were successfully installed and completed in the record time of two weeks, and the printed parts resulted in a lead time reduction. Projects like this validate 3D Metalforge’s approach to delivering critical spare parts faster and more cost-effectively to help leading energy and petrochemical companies reduce equipment downtime.

Shell site receives 3D printed heat exchanger parts from 3D Metalforge in record time as energy companies increasingly turn to metal AM

The Singapore-based 3D printing service provider worked closely with Shell Jurong Island to understand the part performance requirements from the engineers. 3D Metalforge’s design team then created a digital file for the parts prior to production, followed by printing and post-production certification of the final parts. During the post-production quality review, parts were subjected to integrity detection tests to assure these components met client specifications.

“We appreciate 3D Metalforge for their exceptional technical services and their timely and successful delivery of quality parts to Shell Jurong Island”, commented Pina Joshi, Asset Rejuvenation Senior Reliability Engineer in Shell Jurong Island.

Heat exchanger tube components are thin-walled metal tubes inserted into the inlet-end of condensers and heat exchangers to transfer heat or help prevent tube failures within the heat exchanger tube inlet-end.

In this case, 3D Metalforge’s goal in working with Shell Jurong Island was to help extend the lifespan of the existing equipment and produce replacement parts faster and more cost-effectively, particularly in time-sensitive situations where downtime or replacement create a significant impact on clients’ operations in the energy and petrochemical segments.

The scope of work in this project demonstrates the 3DMF’s continuing commitment to leading the way in the development of new additive manufacturing technologies; custom-engineered solutions and streamlined processes to deliver the faster response and shorter turn-around times that customers need. It also validates 3D Metalforge’s strategy that fit-for-purpose additive manufacturing capabilities can result in significant cost savings for clients.

“We were extremely pleased to provide our additive manufacturing technologies for this project for Shell Jurong Island in record time which ultimately helped improve the lifespan of existing equipment. Our primary goal is to be a trusted service provider, we work every day to provide greater value to our clients and this is an excellent validation of the benefits of our technology and of the increasing adoption of additive manufacturing,” said Matthew Waterhouse, 3D Metalforge Managing Director.

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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites VoxelMatters.com and Replicatore.it, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

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