LSU and ExxonMobil Innovate Anti-Wicking Solutions with Roboze Technology

A team of engineering students from Louisiana State University (LSU) has successfully leveraged cutting-edge Roboze additive manufacturing technology to solve a critical machinery issue for ExxonMobil. Through innovative design and meticulous engineering, the LSU team has developed an advanced anti-wicking device that addresses longstanding challenges in ExxonMobil’s turbomachinery, offering a cost-effective, efficient, and reliable solution.

Industrial 3D Printing Supporting Machinery Maintenance

ExxonMobil, a global leader in the energy sector, relies on precise health monitoring of its critical turbomachinery to ensure operational efficiency and safety. A persistent issue has been the wicking of lubricant oil through thermocouple wires, leading to potential inaccuracies in temperature readings, costly shutdowns, and maintenance challenges.

Current anti-wicking devices could be expensive, heavy, and have long lead times. Additionally, these devices often lack proper mounting features and are prone to leaks over time, resulting in housekeeping issues and potential spurious trips. Recognizing the need for an innovative solution, ExxonMobil collaborated with the talented engineering team from LSU to address these challenges and leverage industrial 3D printing solutions. 

LSU Engineering Team Steps Up

The LSU team, consisting of Danielle DePierri, Carlos Fernandez, Declan Fortune, Joseph Piwko, and Gordon Willson, undertook the ambitious project under the guidance of their advisor, Dr. Michael Guillot, and instructor, Dr. Dimitris Nikitopoulos. The team’s primary objective was to redesign the anti-wicking device to allow thermocouple wire maintenance without requiring a machine shutdown and to address oil leaks with an improved internal sealing element. 

The Power of Roboze Technology

Central to the team's success was the utilization of Roboze's advanced additive manufacturing technology. Roboze, a leader in industrial 3D printing solutions, offers high-performance polymer material and precision manufacturing capabilities that are crucial for creating robust and reliable components.

Key Features and Advantages of Roboze Technology:

1.    High-Performance Materials: Roboze technology supports a range of high-performance thermoplastics such as PEEK, CF PEEK, and ULTEM™. These materials exhibit excellent mechanical properties, chemical resistance, and high-temperature performance, making them ideal for demanding industrial applications.

2.    Precision and Customization: Roboze’s 3D printing technology allows for precise control over the manufacturing process, enabling the creation of complex geometries and customized components tailored to specific requirements.

3.    Cost-Effectiveness: By utilizing additive manufacturing, the team was able to significantly reduce material waste and production costs. This approach also shortened the manufacturing lead time, ensuring a quicker deployment of the solution.

4.    Lightweight and Durable Design: The new anti-wicking device was designed to be lightweight yet durable, leveraging the strength and stability of high-performance materials to ensure a long lifespan and reliable performance.

Engineering Innovation in Action

The LSU team’s approach involved several key steps:

1.    Problem Analysis: The team conducted a thorough analysis of the existing anti-wicking devices, identifying their shortcomings and areas for improvement. They focused on enhancing the device’s maintenance efficiency, reliability, and cost-effectiveness.

2.    Design and Prototyping: Leveraging Roboze’s technology, the team developed multiple design concepts for the anti-wicking device. They evaluated various shapes and configurations, ultimately selecting a design that optimized weight, cost, and performance.

3.    Material Selection: The team meticulously selected high-performance materials suitable for the device’s demanding operational environment. They chose ULTEM™ for its exceptional mechanical properties and resistance to oil and chemicals.

4.    Manufacturing and Testing: Using Roboze’s 3D printing capabilities, the team manufactured prototypes of the anti-wicking device. They conducted rigorous testing to validate the device’s performance, including stress analysis, leak testing, and environmental impact assessments.

5.    Implementation: The final design incorporated a bayonet lid with an elastomer seal, ensuring a secure and leak-proof enclosure. The device also featured a T-bolt clamp mount for easy installation and maintenance.

Delivering Real-World Impact

The redesigned anti-wicking device developed by the LSU team has proven to be a game-changer for the energy sector. The new device not only prevents oil wicking but also enhances maintenance efficiency, reduces costs, and improves reliability. Key benefits of the new design include:

1.    Maintenance Without Shutdown: The device allows for thermocouple wire maintenance without the need for machine shutdowns, significantly reducing downtime and associated costs.

2.    Enhanced Reliability: The improved sealing mechanism prevents oil leaks, ensuring accurate temperature readings and reducing the risk of spurious trips.

3.    Cost and Weight Reduction: The optimized design and use of high-performance materials have reduced the device’s weight and manufacturing costs, making it a cost-effective solution.

4.    Environmental Benefits: The new device minimizes oil spills and reduces the environmental impact of maintenance activities, aligning with ExxonMobil’s commitment to safety and sustainability.

A Bright Future for Additive Manufacturing

The success of this project highlights the transformative potential of additive manufacturing in addressing complex industrial challenges. Roboze’s technology has empowered the LSU team to push the boundaries of engineering innovation, delivering a solution that meets ExxonMobil’s requirements. 

The innovative solution developed by the LSU team has exceeded our expectations. The new anti-wicking device not only solves a critical issue but also demonstrates the potential of advanced manufacturing technologies in enhancing our operational excellence.

Chris Beeson, Special Purpose Machinery Execution Supervisor and BRCX Additive Manufacturing Maintenance Lead at ExxonMobil
 

Witnessing Roboze technology making an impact in the Energy sector is very exciting. The LSU team’s success in addressing ExxonMobil’s machinery challenge highlights the power of additive manufacturing and the promising future it holds for industrial solutions. We are committed to preparing the advanced manufacturing workforce of tomorrow and have been collaborating with universities and global energy companies to achieve this goal.

Arash Shadravan, Global Director of Business Development at Roboze