Sembcorp Marine: ABS approves 3D printed spare parts after successful tests on board an oil tanker

ABS approves 3D printed spare parts after successful testing on board an oil tanker

ABS, ConocoPhillips Polar Tankers, Sembcorp Marine and 3D Metalforge complete flagship “additive manufacturing” project

Singapore, November 24, 2021: ABS, ConocoPhillips Polar Tankers, Sembcorp Marine Ltd and 3D Metalforge have taken an important and tangible step towards making additive manufacturing (AM) – also known as 3D printing – a reality in the maritime industry thanks to a joint development project. The parts manufactured by AM and installed on an oil tanker by Sembcorp Marine six months ago have been validated in good working order.

This pioneering FA project began in February 2021 with the manufacture and laboratory testing of functional parts manufactured by additives, which were then installed on board the tanker. PolarEffort. After six months of operation, all parts have since been collected and inspected by the ship’s crew, followed by a remote investigation by ABS.

Mr. Patrick Ryan, ABS Senior Vice President, Global Engineering and Technology, said: “We are delighted with the performance of the parts and the success of the project. This is an important step forward for a technology that certainly has an important role to play. in the future of the maritime industry. ABS is committed to ensuring that these types of parts are introduced without compromising safety. ”

Additive manufacturing or 3D printing is the manufacture of parts by adding material layer by layer. This means that products and components can be manufactured locally or potentially aboard vessels and offshore assets, reducing the supply chain and lead times for specialized and complex parts, introducing new efficiencies through to design innovation, reduction of manufacturing time and improvement of parts availability.

Traditional parts used in shipbuilding and repair are made through casting or forging techniques. For this project, the consortium used AM to manufacture three types of parts that meet or may even exceed conventionally manufactured products in terms of quality. ABS has now approved these aftermarket parts manufactured with additives after successful onboard testing on an oil tanker.

The three parts were:

  • Boiler Fuel Feed Pump Gear and Gear Set: The gear set includes a drive gear that rotates the idler gear connected to the pump that creates a suction force to fill the fluid vacuum. The shaft connects the impeller to the motor / motor, which is the power source.

  • Flexible coupling for marine sanitation device pump: The flexible coupling connects a drive shaft to a driven shaft for power transmission. Both shafts include metallic components for two coupling sleeves and non-metallic components for the coupling spider which allow misalignment adjustments.

  • A freshwater generator ejection nozzle that increases fluid velocity to transform high static pressure into velocity pressure.

Mr. Robert Noyer, Engineering Superintendent of ConocoPhillips Polar Tankers, said: “The superior performance of these parts in service is a testament to the rigorous engineering, manufacturing and post-production tests put in place by the team involved. in this enterprise. We look forward to future opportunities to support our vessels with this technology. ”

Sembcorp Marine’s head of research and development, Mr. Simon Kuik, said: “The success of this project bodes well for the adoption of AM in the marine industry. Through AM, Sembcorp Marine is able to customize parts for our customers and reduce material wastage and eliminate supply chain inefficiencies. This increases our value proposition as a provider of innovative one-stop-shop solutions for the offshore, marine and energy industries and affirms our sustainability ethic. ”

Mr. Matthew Waterhouse, Managing Director of 3D Metalforge, added: “We are proud to work as a trusted partner, with companies like ABS, Sembcorp Marine and ConocoPhillips Polar Tankers to deliver greater value through solutions from new and innovative manufacturing; and to help respond to changing component manufacturing, supply chain and sustainability challenges. The inspection and validation of these additively manufactured components reinforces our belief in this technology and its application. This exposure to the capabilities of additive manufacturing will expand its commercial applications and acceptance in the future ”,

ABS has been supporting the industry with the introduction of FA since 2017. In 2021, ABS Guide to additive manufacturing has been published, focusing on two main categories of metal AM processes: powder bed smelting and directed energy deposition. The Guide defines the ABS approval and certification process for FA installations and parts by providing standards for FA design, raw materials, pre-construction, construction and post-construction processes, l inspection and testing. The Guide places a strong emphasis on the quality of the materials and the manufacturing process, both of which are key elements of the ABS process. Download a copy of the Guide here.

The polar effort

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Notes to Editors
For the high resolution version of the image above, please click here.

About ABS
ABS, one of the world’s leading providers of classification and technical advisory services to the marine and offshore industries, is committed to setting standards of safety and excellence in design and construction. Focused on the safe and convenient application of advanced technologies and digital solutions, ABS works with industry and its customers to develop precise and cost-effective compliance, optimized performance and operational efficiency for marine and offshore assets. For more information, please visit https://ww2.eagle.org/en.html

About polar tankers
Polar Tankers, a wholly owned subsidiary of ConocoPhillips, is located in Houston, Texas. Vessels operated by Polar Tankers use fully redundant operating and navigation systems as well as dual engine rooms, each capable of propelling the vessel to full capacity. The double-hull design has been engineered to exceed OPA 90 requirements for safe and efficient transportation of oil in the environments in which they operate. For more information, please visit https://polartankers.conocophillips.com/

About Sembcorp Marine
(Company registration number: 196300098Z)

Sembcorp Marine provides innovative engineering solutions to the global offshore, marine and energy sectors. Based in Singapore, we have nearly 60 years of experience in the design and construction of rigs, floats, offshore platforms and specialty vessels, as well as in the repair, modernization and conversion of various types of vessels. Our solutions focus on the following areas: Gas value chain; Renewable energy; To treat; Advanced drilling platforms; Living ocean; and maritime safety.

Our customers include large energy companies, owners of floating production units, shipping lines, and cruise and ferry operators. They are supported by four business units: Rigs & Floaters; Repairs and upgrades; Offshore platforms; and specialized shipbuilding.

Sembcorp Marine operates shipyards and other strategically located facilities in Singapore, Indonesia, UK, Norway and Brazil.

Find out more about https://www.sembmarine.com/

About 3D Metalforge
3D Metalforge (3DMF), one of the world’s leading additive manufacturing (AM) companies, helps leading companies meet their production printing needs on a global scale. 3D Metalforge’s high-tech facilities and engineering teams are based in the global cities of Singapore and Houston, Texas, USA. It is home to one of the most advanced lines of printing equipment, including multijet melting, powder bed melting and directed energy deposition. 3DMF’s range of AM services includes consulting (covering site and opportunity assessment and diagnosis), design engineering and optimization, production printing as well as post-production services. production. The key industries we support include marine, oil and gas, precision engineering, and manufacturing. For more information, please visit https://3dmetalforge.com/en/

For the PDF version of this announcement, please click here.

Media contacts

abs
Gareth Lewis / [email protected]

Polar oil tankers
Robert Walnut / [email protected]

Sembcorp Marine
Chua Mun Yuen / [email protected]Where
Lin Daoyi / [email protected]

3d metal forge
Bob Lytle / [email protected]

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