ESP Stators
Engineered with intricate channels for optimized fluid dynamics and durability
Material: CoCr Metal Alloy
Technology: SLM
Oil & Gas
Lead Time
85%
Reduction
Cost
50%
Reduction
Part Hardness
4x
Than Original
Manufacturing steps
25%
Reduction
Challenge:
Schlumberger faced significant challenges with the durability and complexity of manufacturing ESP stators. Traditional methods involved multiple steps and materials that did not provide the required hardness and longevity. The need for a more efficient, durable, and cost-effective solution was critical to enhance product performance and reduce manufacturing complexities.
Solution:
Namthaja proposed the use of 3D printed CoCr metal alloy ESP stators. The solution involved:
- Design for Additive Manufacturing (DFAM): The original stator design was optimized for 3D printing to ensure high precision and performance. Design modifications included intricate channels to enhance fluid dynamics and overall durability.
- Material Selection: CoCr metal alloy was chosen for its superior hardness and durability, being 4x harder than the original material, making it ideal for the demanding operational environment of ESP stators.
- 3D Printing Technology: The ESP stators were produced using advanced 3D printing technology, allowing for rapid production, high accuracy, and the ability to create complex geometries that traditional manufacturing methods could not achieve.
- Increased Efficiency & Reliability: The new ESP stators significantly improved operational reliability and reduced the number of manufacturing steps by 25%, enhancing overall efficiency.
- Cost Efficiency: Overall costs were reduced by minimizing the number of manufacturing steps and leveraging the precision of 3D printing technology, leading to reduced time and material usage.