Challenge:
Aramco faced significant challenges with the durability and efficiency of traditional sand screens used in their water filtration systems. The conventional metal screens were prone to corrosion and required frequent replacements, leading to increased operational downtime and costs. The need for a more reliable, corrosion-resistant, and cost-effective solution was critical to enhance system longevity and efficiency.
Solution:
3D Printed screen
Namthaja proposed the use of 3D printed Polymer – ASA sand screens. The solution involved:
- Design for Additive Manufacturing (DFAM): The original sand screen design was optimized for 3D printing, ensuring high precision and performance. Design modifications included intricate filtration channels to enhance water flow and particle capture.
- Material Selection: Polymer – ASA was chosen for its excellent mechanical properties and high corrosion resistance, making it ideal for the harsh operational environment of water filtration systems.
- 3D Printing Technology: The sand screens were produced using advanced 3D printing technology, which allowed for rapid production, high accuracy, and the ability to create complex geometries that traditional manufacturing methods could not achieve.
- Increased Efficiency & Reliability: The new sand screens significantly improved operational reliability and reduced downtime, enhancing the overall efficiency of the water filtration systems.
- Cost Efficiency: Overall costs were reduced by eliminating the need for frequent replacements and minimizing downtime. The first ever paid contract for 3D printed parts at Aramco marked a milestone in leveraging additive manufacturing for industrial applications.
