Industrial AMPrinted nickel alloy valve parts clear DNV qualification for sour gas at TotalEnergies
TotalEnergies EP Denmark has put seven anti-surge valves into service with 3D printed nickel alloy disk stacks from IMI. The parts met DNV-ST-B203 AMC Level 3 and matched conventionally made nickel alloy components in testing. It is a documented case of laser powder bed fusion in a safety-critical sour-gas setting.
Key facts- Seven anti-surge valves with printed nickel alloy disk stacks installed by TotalEnergies EP Denmark
- H2S partial pressure in service reaches up to 3.3 kPa
- Qualified to DNV-ST-B203 AMC Level 3, performance equal to conventional nickel alloy parts
- Parts made by laser powder bed fusion with a sour-service heat treatment
Context Sour gas contains hydrogen sulphide, which attacks many metals, so any part in contact with it needs proven corrosion resistance before approval.
What was installed and where?
TotalEnergies EP Denmark fitted seven anti-surge valves with additively manufactured nickel-based alloy disk stacks supplied by IMI. The valves handle gas with hydrogen sulphide partial pressures of up to 3.3 kPa. The parts were built by laser powder bed fusion, and IMI paired them with its own heat treatment tailored to sour service.
How were the printed parts qualified?
The starting point was valve passing, a leakage problem in anti-surge systems under harsh conditions. Because the gas is corrosive, any replacement part had to prove corrosion resistance, reliability and mechanical performance first. Printed nickel alloys have little track record in sour service, so qualification carried the project. IMI and TotalEnergies ran extensive mechanical and corrosion tests. The parts matched conventional nickel alloy components and satisfied DNV-ST-B203 AMC Level 3, after which TotalEnergies approved installation.
What is the Retrofit3D approach?
The disk stacks belong to IMI's Retrofit3D offering: custom printed trims that fit into existing valve bodies. They use IMI's DRAG multi-stage, multi-path flow design to lower differential pressure. Only the internal trim is exchanged, so the pressure boundary and actuator stay as they are, and no pipework needs cutting or re-welding. IMI says installation can take hours and that it has upgraded hundreds of valves, including projects in China and for Griffith Energy.
How does it fit wider oil and gas practice?
Other operators also print parts to keep installed equipment running. ConocoPhillips retrofitted choke cage valves with printed cages after the OEM stopped supplying them, and Shell obtained CE certification from LRQA for a printed pressure vessel. DNV GL ran joint industry projects with 20 partners on qualification guidelines for LPBF and WAAM, and Protolabs was reportedly the first powder bed fusion producer certified by DNV for oil and gas.
What it means
For manufacturers considering AM in energy and process industries, the lesson is that qualification, not printing, is the main effort. A DNV-ST-B203 route, plus a material-specific heat treatment and corrosion data, defines the timeline and cost of a first part. Retrofit trims for existing valves offer a limited-risk entry, since the pressure boundary is untouched. Smaller European suppliers will likely join such programmes as qualified partners rather than lead them.
Frequently asked questions
What standard did the printed valve parts meet?
They met DNV-ST-B203 AMC Level 3 qualification. Tests showed performance equal to conventionally manufactured nickel alloy components.
Which process made the disk stacks?
They were made by laser powder bed fusion in a nickel-based alloy, followed by a heat treatment IMI developed for sour-service conditions.
What does Retrofit3D change in a valve?
Only the internal trim, either the cage or the full trim set, is replaced with a printed one. The pressure boundary and actuation stay untouched, and no pipework is cut.
This summary was written with the help of AI from the linked reports, under the editorial responsibility of Svetozar Kolesar.