Metal and elastomer matrix composite test method

Abstract

The TDW Offshore Services’ SmartPlug(R) tool is designed to isolate a section of pipeline while it is pressurized. This enables pipeline repair without reducing pipeline pressure or bleeding down the entire pipeline system. High risk connected to jobs of such type lead to high safety level on the SmartPlug(R) tool. When a sealing element for the plug modules (also called a “packer”) is developed, it includes a lot of testing. The test methods TDW currently uses are not economically optimal, and room for improvements exists. In this master thesis the issues with the existing methods are addressed, and a totally new concept of testing the sealing element is developed. The main idea behind the new concept is to test a linearized “pizza slice” out of the circular full scale packer. This will lower the production cost of the test elements, make it easier and faster for workshop personnel to perform tests, and increase the test frequency. The new test concept has only one test rig that is adjusted and adapted for all different packer sizes. This leads to no occupation of resources usable in other categories, as well as savings in workshop and storage area. Volume and force calculation models had to be made to transfer the forces from full scale packers to the linearized coupons used in the packer test rig. A test duration estimate as well as a proposal for a practical test execution was done. The economical estimates for production of the test rig adapted for 3 outer limit configurations shows positive economical results. The conclusion from the work is that the test rig fulfills all design requirements. In theory the test method will work as expected, but tests must be performed to verify the concept and identify any deviations when compared to full scale testing.