New technological leap at TotalEnergies: 3D printing can halve delivery times for critical spare parts
Pressure on supply chains and rising demands for operational reliability are opening the door to 3D printing of critical metal components in TotalEnergies’ offshore operations. Over time, this has the potential to transform lead times, spare parts logistics, and maintenance across the entire North Sea.
Copenhagen / Esbjerg
TotalEnergies Denmark, in collaboration with IMI, a global supplier in fluid and motion control, has completed a groundbreaking maintenance project: the development and installation of quality‑assured 3D‑printed metal components in critical process equipment.
Until now, the use of 3D‑printed spare parts in the offshore industry has largely been limited to less complex plastic components and minor modifications. The installation therefore marks a milestone for the global offshore industry.
“With supply chains under pressure and an increased focus on operational reliability, there is a need to think differently. Being able to install 3D‑printed metal components in vital operational processes in the North Sea marks a technological breakthrough that opens entirely new possibilities for the future maintenance of offshore equipment,” says Ticho Sander, Maintenance Methods Lead, TotalEnergies Denmark.
He emphasizes that the metal components have undergone extensive testing programs and meet all requirements for safety, robustness, and material integrity.
Supply Chain Pressure Accelerates Development
Spare parts for the offshore industry are characterized by long production and delivery times—both due to strained supply chains and the need to transport components over long distances before reaching platforms located more than 200 kilometers out in the North Sea. For the metal components in question, traditional lead times typically range from 35 to 52 weeks, increasing the risk of costly downtime.
With 3D printing technology, production and delivery times for metal components can be reduced by up to 50 per cent, increasing efficiency and operational flexibility in maintenance and operations.
The new 3D‑printed components are used in valves that protect the offshore platforms’ gas turbines.
“With a typical turbine costing several million dollars, the valves fitted with 3D‑printed metal components are critically important. I see this as just the beginning of a more flexible and optimized spare‑parts strategy,” says Ticho Sander.
The 3D‑printed components were installed on the Dan platform in June last year and are expected to further accelerate the use of additive manufacturing in new applications across the group’s global operations.
FACTS TotalEnergies Denmark has established a 3D printing unit to explore how additive manufacturing can strengthen offshore operations. Several 3D‑printed components are already in use offshore, including engine covers and seabed protection covers. Each 3D‑printed component undergoes a thorough risk assessment, covering safety, certification and approval requirements, as well as intellectual property considerations. The 3D‑printed metal component installed in critical process equipment has been developed in close partnership with IMI, which was responsible for:
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TotalEnergies media contact
Thorkild Diness Jensen / Head of External Communications for TotalEnergies Denmark / +45 20 20 42 36 / [email protected]
About TotalEnergies in Denmark
TotalEnergies has operated in Denmark for over 50 years and is among the country’s leading energy companies producing more than 80% of the oil and 90% of the gas in the Danish North Sea. TotalEnergies operates the Danish Underground Consortium with a 43.2% share together with partners BlueNord (36.8%) and Nordsøfonden (20%). With approximately 1,000 employees based in Copenhagen, Esbjerg, and offshore locations, TotalEnergies makes a significant contribution to Denmark’s energy supply, economy, and employment. As a multi-energy business, TotalEnergies in Denmark is developing a renewables portfolio, including offshore wind projects with a capacity of 405 MW, and advancing its Carbon Capture & Storage (CCS) initiatives in support of Europe’s low-carbon transition.
About TotalEnergies
TotalEnergies is a global integrated energy company that produces and markets energies: oil and biofuels, natural gas, biogas and low-carbon hydrogen, renewables and electricity. Our more than 100,000 employees are committed to provide as many people as possible with energy that is more reliable, more affordable and more sustainable. Active in about 120 countries, TotalEnergies places sustainability at the heart of its strategy, its projects and its operations.