RMS was recently contracted by a refinery customer to complete a critical project involving the replacement of two riveted impellers for a centrifugal compressor in plant air service. With time running out due to an impending outage, RMS and the customer decided to use a cutting-edge additive manufacturing process to 3D print the replacement impellers.
The use of 3D printing enabled a significant reduction in production time, with delivery times reduced by 50% compared to conventional manufacturing processes. Thanks to the expertise of the RMS metrology team and the use of advanced engineering resources, the project was successfully implemented. The existing design of the riveted impellers, which had a diameter of 23.5 inches, presented a particular challenge as the largest available print bed was limited to a diameter of 23 inches. This required a redesign of the geometry to meet the customer’s performance requirements despite the smaller size.
To achieve the required performance, RMS engineers carried out extensive modeling work, including a full structural and aerodynamic analysis using CFD (Computational Fluid Dynamics). These studies ensured that, despite their reduced size, the new impellers could meet the stringent requirements, including a tip speed of over 1000 ft/s, and operate reliably.
The impellers were manufactured from Inconel 718, a material known for its exceptional strength and durability and which meets the latest API 20S standards. Additive manufacturing was carried out using a laser melting process in which the Inconel was fused layer by layer from a powder bed. During the manufacturing process, several test samples were produced and inspected for quality to ensure compliance with all required performance standards.
The end result was two 3D printed impellers that not only represented a first for the customer’s compressor fleet, but also highlighted the capabilities of modern manufacturing techniques. This successful collaboration emphasizes RMS’s commitment to innovative technologies and ability to deliver bespoke solutions even under strict time constraints, increasing operational efficiency and reliability.
This project illustrates RMS’s commitment to innovation and excellence in additive manufacturing and positions the company as a leading provider of advanced solutions for the most demanding industrial requirements.
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