Subsea Control Module Manifold Additive Manufacturing
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Solution Overview
Problem
Current manufacturing methods for subsea control module (SCM) manifolds in the oil/gas industry are inefficient, requiring complex drilling and milling for hydraulic circuits, leading to numerous seals, components, and potential fluid path issues, which can result in reliability and maintenance challenges under high pressure conditions.
Innovation Solution
A method involving additive manufacturing, specifically 3D printing, to create a primary core with integrated fluid passages and functional devices, eliminating the need for subtractive techniques and reducing components, while allowing for customizable optional features to meet specific applications without requiring extensive validation or verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If subtractive manufacturing methods are used to machine and cross-drill complex hydraulic circuits, then the manifold can be manufactured with traditional methods, but the process requires numerous seals, components, and potential fluid path issues leading to reliability and maintenance challenges
Solution Approach 1:
The patent integrates multiple manufacturing operations (drilling, milling, threading, tapping) into a single additive manufacturing process. The manifold is built layer-by-layer with all internal hydraulic circuits, external ports, and structural features created in one continuous build process, eliminating the need for subsequent subtractive operations and assembly steps.
Solution Approach 2:
Instead of starting with a solid block and removing material through drilling and milling, the patent uses additive manufacturing to build the manifold from scratch, depositing material only where needed to form the complex internal passages and external features. This inverted approach transforms a subtractive process into an additive one.
2Ease of operation
If multiple seals and components are used to create preloaded fluid tight seals, then the manifold can be assembled with functional components, but the number of seals and components increases leading to potential fluid path issues
Solution Approach 1:
The patent integrates sealing features directly into the manifold structure through additive manufacturing. Seals, gaskets, and sealing surfaces are built as integral parts of the manifold body, eliminating the need for separate sealing components and their associated assembly steps. This merging of sealing functions into the base structure reduces the total component count.
Solution Approach 2:
The sealing features are created during the additive manufacturing process itself, before final assembly. The seals are pre-formed as part of the manifold structure with precise geometries and positions, ensuring proper sealing action is built-in from the start rather than requiring post-manufacturing adjustment and assembly.
3Adaptability or versatility
If complex drilling and milling are performed for hydraulic circuits, then the manifold can accommodate multiple fluid paths, but the manufacturing time and cost increase
Solution Approach 1:
The patent combines the creation of all hydraulic circuits, fluid paths, and structural features into a single additive manufacturing process. Multiple internal passages, external ports, and complex geometries are built simultaneously in one continuous build operation, eliminating the sequential drilling, milling, and threading operations required by traditional methods.
Solution Approach 2:
The patent utilizes the third dimension extensively in additive manufacturing to create complex internal hydraulic circuits that would be difficult or impossible to achieve with traditional drilling and milling. The layer-by-layer build process allows for intricate three-dimensional passages and features that transcend the limitations of conventional two-dimensional machining approaches.
4Ease of manufacture
If traditional manufacturing methods are used, then the manifold can be produced with established processes, but material usage increases and waste is generated
Solution Approach 1:
The additive manufacturing process pre-forms the manifold with exact material placement during the build process. Material is deposited only where needed to create the final part geometry, including all internal passages and external features, eliminating the need for subsequent material removal and reducing waste generation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in SCM manifolds that are more reliable, efficient, and cost-effective, capable of withstanding high pressures and rapid pressure fluctuations, with reduced material usage and minimized risk of fluid path issues, while ensuring compliance with safety and industry standards.
Implementation Method 1
additive manufacturing, specifically 3D printing, to create a primary core with integrated fluid passages
Data Source
Figure 1
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AI summary
A method of manufacture, such as for manufacturing apparatus for the oil/gas industry. Example apparatus includes a wellhead apparatus, such as a subsea control module ("SCM") manifold. Methods include defining a primary core generic to a plurality of apparatus. Methods of manufacture include additive manufacturing, such as 3D printing.