Session: 

Paper Number: 173543

Advancing Offshore Oil & Gas Production Through Additive Manufacturing of Customized Interlayer Structures in Multi-Layer Pressure Vessels 

Scope and Objective

This research explores the advanced industrial application of additive manufacturing (AM) technologies for the development of customized interlayer structures within multi-layer pressure vessels, specifically designed for offshore oil and gas production platforms. These platforms operate in highly demanding deepwater environments, where traditional pressure vessel designs encounter significant limitations. Key challenges include stringent weight restrictions, the necessity for exceptional corrosion resistance, and the requirement for structural integrity under prolonged and extreme pressure cycling. The objective of this study is to address these challenges by introducing innovative AM-based solutions that enhance performance, durability, and cost-efficiency.

Methods, Procedures, and Process

The core innovation of this research lies in the utilization of metal-based additive manufacturing techniques—namely Directed Energy Deposition (DED) and Selective Laser Melting (SLM)—to fabricate engineered interlayer structures with tailored mechanical properties. These AM processes enable the creation of complex geometries and material compositions that are not feasible with conventional manufacturing methods. The study integrates advanced AI tools to streamline the entire design-to-manufacturing workflow. ChatEngineer AI is employed for autonomous design generation, while AI-based finite element analysis tools are used for structural optimization. Additionally, materials prediction tools such as MaterialsGPT are leveraged to accurately forecast material behavior and properties, eliminating reliance on traditional CAD/CAE software and enabling a fully AI-driven development pipeline.

Results, Observations, and Conclusions

The research successfully addresses several critical industry pain points through a multi-faceted approach:

Material Development: Optimized process parameters were established for printing high-performance nickel-based superalloys and corrosion-resistant steel alloys, both suitable for harsh offshore conditions.

Structural Innovation: Lattice-based interlayer designs were developed to improve mechanical strength while significantly reducing overall vessel weight.

Smart Integration: Embedded sensor channels were incorporated into the interlayer structures, enabling real-time monitoring and diagnostics. Their feasibility and performance were thoroughly evaluated.

Quality Assurance: Practical inspection and certification protocols were formulated to align with existing industry standards.

A scaled prototype vessel (400 mm diameter, rated at 16 MPa) was fabricated and subjected to accelerated life-cycle testing simulating 20 years of deepwater service. AI-driven analysis revealed a 22% reduction in total weight, a 35% improvement in fatigue life, and enhanced pressure cycling resilience compared to conventional designs. Although initial manufacturing costs were 15–20% higher, autonomous lifecycle cost analysis indicated a return on investment within 4–6 years, with projected lifetime savings of approximately 27%.

This research offers immediately deployable solutions for next-generation offshore pressure vessels and opens pathways for broader applications in subsea processing and other high-pressure systems requiring enhanced durability.

 

Presenting Author: Mohamed Elbaz ADNOC OFFSHORE

Presenting Author Biography: Summary
• Mechanical Engineering 20+ Experience in Refineries, Petrochemical, oil & gas field Project covering related scope in Engineering & Design, then Inspecting & Testing, Fabrication, Construction and ended by necessary Supervision in Pre-commissioning and commissioning of Mechanical Static Equipment such as such as pressure vessels, S& T heat exchangers, printed circuit plate type exchanger, air coolers reactors, columns, distillation towers, and storage tanks (Hot & Cold) also special items such as pig launchers/ receivers (Scrapers), Skid Mounted Separators, Static Mixers, Heating Coils, Hairpin exchangers, suction heaters...;etc for FEED and EPC projects for Chemical, Petrochemical, oil & gas industries; either upstream / downstream Offshore, Onshore. With Experience with international codes and standards (ASME BPVC since 2000 to latest Edition, API 650,620,625,2000, API 660,661, API 934, TEMA Ninth Edition, ANSI B31.3, 16.5, ASTM, AWS, ISO,EN, PD, WRC 107, 297, NACE MR 0175, NACE MR 0103, NFPA. OSHA, AD 2000 Merkblatt…etc), major companies specifications (Shell DEPs, SAES Aramco, UOP, CB&I SPS, Lummus…etc) and main Licensors (Shell, Axens, UOP, ABB Lummus, , …etc).
• Keep Hand on Boilers, Fired heaters & Flares as well as Mechanical Packages Equipment such as Gas Dehydration and Glycol Regeneration Unit.
• Conduct engineering studies & consultation during FEED, PMC and/or EPC detailed projects for Petrochemical, oil & gas industries; either Offshore, Onshore related to Mechanical Static Equipment.
• Provide Technical assessments, evaluation, analyses technical consulting services and investigations to solve the operational plant Mechanical Static Equipment problems as well as Troubleshooting in order to keep plant running and improve refinery & the petrochemical facilities or operations.
• Prepare & Review engineering deliverables according to the required procedures/ specifications, Mechanical Datasheets in compliance with the relevant codes/ standards, as well as Vendor prints.
• Understating or preservation requirements and Conduct required Unit system Starting up commissioning and pre commissioning required review tasks such as tightening testing and leak test also PSSR and Punch listing, also review and mechanical completion certificate ..etc
• Awareness of corrosion allowance criteria for removable and no removal parts, as well as familiarity with H2S sour service and material special requirements such as hardness, PWHT, Low service and MDMT requirements and such special impact testing, also material failures mechanism and it’s necessary required precautions and countermeasure as per API 571 and NACE.
• Keep hand on mechanical design calculation Software user such as PVElite, Tank, Codecalc, Compress 7110 with heat exchanger or any equivalents, Compress inspect creep assessment, Life estimation, FFS, CAESAR-II, Nozzle pro stress analysis and nozzles load as per WRC 107 and 297 (WRC 537) & cyclic service- Fatigue Stress analysis as per API 579-1 software or ASME B31.3, also consideration deflection calculation for vertical column or towers and (FIV) requirements.
• Experience with process units such as CDU, VDU, KHT, DHT, Acid Gas Removal unit, NGL, SRU, TGTU, DCU, Hydrogen generation unit, Flare unit, Potable Water, and Caustic Unit.
• Experience with interface with project disciplines other leads such as process, piping, instrumentation and control ..etc and required IDCs.
• Coaching Young Engineers to provide them with KNOWHOW to do their Job also through OJT & supervise their work to ensure proper transfer of required work skills.
• Expert Trainer for several Static Equipment Stuffs.

Authors:

Mohamed Elbaz ADNOC OFFSHORE
Nouf Ahmed Braik ADNOC OFFSHORE