New Additive Manufacturing Service Set to Disrupt Flow Control MRO Market

Summary

Additive manufacturing has the potential to revolutionize in-field control valve maintenance, potentially saving process and industrial plants millions of dollars a year in maintenance, repair and operation (MRO) costs.

The impact of high-velocity media within a valve trim is one of the leading causes of cavitation, erosion, and vibration; all of which can combine to cause poor process control, premature failure, and unplanned downtime for critical flow control applications.

Full valve replacements typically incur huge opex and capex commitments given the significant logistical requirements. However, a new high-performance valve trim replacement service which combines additive and traditional manufacturing methods is set to radically disrupt the valve MRO market.

Retrofit3D, pioneered by IMI Critical Engineering, focuses on the engineering of bespoke drop-in replacement internal components. These include disk stacks and valve trims (inclusive of seat and plugs), ensuring the body of the valve can remain in situ throughout the process.

The use of additive manufacturing technology represents a game-changing shift in valve replacement services, as it enables the design and production of parts which would not be possible using only traditional manufacturing processes. Each replacement part can be custom-made to the specific process conditions of the valve in question, in a fraction of the time, weight and cost.

Unlike like-for-like legacy component replacements, Retrofit3D components integrate IMI Critical Engineering’s DRAG technology, which divides the flow into a series of right-angled smaller passages. The multi-stage, multi-path DRAG technology directs the medium through a tortuous path to incrementally reduce the differential pressure and increase control, preventing the root cause of the original problem from reoccurring.

The service is now capable of producing drop-in replacement trims for valves up to 20” in diameter and can be used in a broad range of critical pipeline applications including bypass valves and large anti-surge valves. Retrofit3D produces replacement trims for valves manufactured by IMI Critical Engineering, as well as those from other valve manufacturers.

Bertrand Maillon, Retrofit3D Business Leader at IMI Critical Engineering, commented, “Today’s energy landscape places a great emphasis on reliability, maintenance and performance. However, full valve replacements can incur significant time and cost for operators, due to the extensive engineering, scheduling, and intervention activity required. Moreover, even a like-for-like replacement of core internal components is no guarantee of long-term success, especially if the maximum flow velocity isn’t initially managed properly within the valve or the original valve trim is no longer suitable for the current process requirements.

“Through the launch of Retrofit3D, we can now offer a custom-made drop-in replacement service for most control valves with a trim diameter of up to 20”. The integration of DRAG technology will provide better flow control across the valve opening to tackle noise, cavitation and erosion issues. Additionally, the use of additive and traditional manufacturing technologies ensures bespoke replacement parts can be designed, produced, shipped and installed in a fraction of the time it would take to undergo a full valve replacement.”

Mr Maillon concluded, “Since launching the service, we have retrofitted more than 200 valves for customers across the power and oil and gas sectors; and we are incredibly excited at the growth potential for additive manufacturing-led flow control solutions.”

About IMI Critical Engineering

IMI Critical Engineering (IMI Critical) has long been recognised as a world-leader in the provision of flow control solutions. Our products allow vital industries to operate safely, cleanly, reliably and efficiently, so that they can provide us with the energy, resources and materials that underpin modern lives.

IMI Critical’s family of specialist companies design, manufacture and service bespoke valves and actuators that precisely control the flow of steam, gas and liquids under extremes of pressure and temperature, as well as intensely abrasive or corrosive operating conditions.

Our valves can be found in a myriad of industrial plants and processes around the world, enabling the production of oil and gas, power, petrochemicals, metals, pharmaceuticals, cosmetics, food and beverages, water and sanitation, pulp and paper, ethanol and sugar. Our products are also widely deployed on ships and submarines.

Our engineering expertise means that we can make hazardous processes safer, cleaner and greener. By helping clients reduce emissions, improve safety, and make processes more efficient, we have a direct and positive impact on the world. That is why we describe our purpose as ‘Breakthrough Engineering for a better world.'

About IMI plc.

IMI plc, the specialist engineering company, designs, manufactures and services highly engineered products that control the precise movement of fluids. Its innovative technologies, built around valves and actuators, enable vital processes to operate safely, sustainably, cleanly, efficiently and cost effectively. IMI employs around 10,000 people, has manufacturing facilities in 19 countries and operates a global service network. The Company is listed on the London Stock Exchange and is a constituent of the FTSE4Good Index.​