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PETROMAKS2-Stort program petroleum

Subsea Additive Manufacturing for Lifetime Extension

Alternative title: Additive produksjonsteknikk for levetidsforlengelse av undervannsinstallasjoner

Awarded: NOK 10.5 mill.

Project Number:

317838

Project Period:

2021 - 2024

Location:

Partner countries:

The idea of the SAMLE (Subsea Additive Manufacturing for Lifetime Extension) project is to introduce the Additive Manufacturing (AM) method for repair of subsea components. The core of the technology is the unique habitat and robotic technology of Kongsberg Ferrotech (KF) combined with the hyperbaric welding competency form the partners, that will enable the Subsea Additive Manufacturing (SAM) process. The main R&D challenge is to establish the process-property-performance relationship of the Subsea AM (SAM) process to achieve predictive and controlled repair. The SAM process shall, for most cases, be applicable for hot repair i.e. repair of pipelines with active flow. The development process is based upon extensive simulations and verification of selected methods. The verified simulation models will be part of a digital twin, which becomes a key element in repair planning, quality control and documentation. The digital twin will be updated after each repair making "as built" parameters available for later use. The 3-year project is to be executed in a cooperation between KF and SINTEF, with Equinor and Gassco as participating partners. In the first year a design case, based on market needs is to be defined. The design case forms the basis for developing the SAM method with all design requirements for the control system, robot and habitat. Areas to be investigated is WAAM material, repair pattern, repair integrity and impact on the substrate material/component. The research method, based upon simulations, is to be verified in realistic laboratory tests to take place already towards the end of 2021. Successful simulations and lab tests shall give the design parameters for the final solution, such as power requirements, atmosphere requirements, gas flow capacities, control system accuracy, speed, materials etc. Following the successful testing, 1-2 design cases will be run through the same methodology, ending up with a set of repair methods at the end of the Project.

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The idea of the SAMLE (Subsea Additive Manufacturing for Lifetime Extension) project is to introduce the Additive Manufacturing method for permanent repair of subsea components to extend its lifetime. The core of the SAM technology is the unique habitat and control technology of Kongsberg Ferrotech (KF) combined with an innovative hyperbaric wire arc additive manufacturing (WAAM) process, which will enable permanent repair of subsea components. The main R&D challenge is to establish the process-property-performance relationship of the SAM process to achieve predictive and controlled repair. The SAM process shall, for most cases, be applicable for hot repair i.e. repair of pipelines with active flow etc. The development method is based upon extensive simulations and verification of selected methods. The verified simulation models will be part of a digital twin. The digital twin becomes a key element in repair planning, quality control and documentation. The project is planned to be executed in a cooperation between KF and SINTEF with Equinor and Gassco as participating partners. The project is estimated to a cost of MNOK 21 over 3 years and is expected to grow the business of KF significantly after a buildup period of 5 years following a successful SAMLE development. For the operators of subsea infrastructure, one successful repair, avoiding unplanned shutdown and time consuming repair, will have a huge financial benefit for each saved day of normal production.

Funding scheme:

PETROMAKS2-Stort program petroleum