Valland 3D prints 70% more compact DB&B valve for oil and gas

The Italian valve manufacturer Valland has developed a compact double-block-and-bleed auxiliary valve for existing oil and gas facilities. The PVT valve is additively manufactured by the Valland3D division and, according to the company, is already in use at an offshore facility operated by Vår Energi. Compared with the smallest machinable version, the component volume is reduced by more than 70 percent.
The retrofit solution is designed to isolate valve chambers twice and safely relieve their pressure. In double-expanding gate valves, trapped gas can complicate maintenance work. Relieving pressure through conventional drain ports also carries the risk of hydrate formation, which can block flow paths. According to Valland, conventional DB&B units were too heavy for existing ½-inch NPT connections, thereby placing stress on the threaded connection.
The component is manufactured from corrosion-resistant Super Duplex F55 on a EOSM 290. The laser Powder Bed Fusion the aforementioned process fuses metal powder layer by layer based on a CAD-model. This allows internal flow paths to be integrated into the valve body without separate pipe sections. Within a 35-millimeter overall length, the design combines a primary barrier, a relief channel, a secondary barrier, and an outlet.
“Additive manufacturing enabled us to reduce the component volume by more than 70 % compared with the smallest version that could be produced by machining. In a length of just 35 mm, we were able to integrate four independent internal channels: the first barrier, the relief channel, the second barrier, and the outlet. This is simply impossible with conventional processes”, said Gianluca Acquistapace, AM Manager, Valland3D.
Valland developed the printing and heat-treatment parameters in-house. The process and quality assurance were qualified according to DNV-ST-B203 and at Additive manufacturing Component Level 2. More than 100 units were reportedly produced, tested, and deployed; the tests cited included pressure, emissions, and fire testing.
“The PVT valve uses a double-block-and-bleed configuration, with the primary and secondary barriers formed by needle valves and an intermediate bleed plug. It can be designed with the same inlet interface as the valve on which it is installed, making it suitable for retrofitting existing operating facilities”, said Daniele Brambilla, Technical Manager, Valland.
Here, 3D printing serves less to optimize weight alone than to integrate functions within a tight installation space. Continued use will depend on documented process stability, material testing, and suitability for the respective operating pressures. The retrofit capability can eliminate the need to replace complete main valves and thereby limit downtime.