Element HitchinPolymer testing for theOil and Gas sector

Updated April 2016

Founded in 1986

Specialists in non-metallic research and testing

Acquired by Element in 2012

40,000 sq ft across three buildings

Polymers, elastomers, thermoplastics, adhesives, composites

Materials and product testing, FE analysis, consultancy

Technology led R&D culture

International clients - Europe (73%), USA (20%), RoW (7%)

50 employees

Element Hitchin: Overview

• Value-Added and Client Driven R & D- focussed on customer commercial needs and time-scales

• Chemical Testing

- accelerated ageing, compatibility, permeation, gas decompression

• Mechanical Testing

- strength, fatigue, creep, corrosion, thermal properties....

• Finite Element Analysis

- stress, fatigue and fracture, life prediction, thermal, diffusion

Element Hitchin: Core Competencies

• Service Relevant Testing and Life Prediction

- test development, standard & non standard, multi-axial component testing, interpretation, material model development for FEA

• Third Party Inspection , Technical Audit of Manufacturing and Design Methodologies

• Training

- Specialised training on material testing, sealing, finite element analysis,

• Conferences

- Oilfield Engineering with Polymers (2016)

Element Hitchin: Core Competencies

High Pressure High Temperature TestingExposure In SWEET Environment

Chemical testing: accelerated ageing, compatibility, RGD

Materials: Elastomers, Plastics and CompositesQualification: Standards NORSOK, API, ISO,

NACE, ASTMEnvironments: Sweat Gases, Brines, Treatment FluidsN° of Vessels: 90

Standard Tests: Pressure 1,000 bar (14,500 psi)Temperature 230 °C (445 °F)

Custom Tests: Pressure 1,400 bar (20,000 psi) Temperature 315 °C (600 °F) Purpose Build Test Lab

High Pressure High Temperature TestingExposure In SOUR Environment

Chemical testing: accelerated ageing, compatibility, RGD

Materials: Elastomers, Plastics and CompositesQualification: Standards NORSOK, API, ISO,

NACE, ASTM Environments: H2S ( up to 100 %), O&G Mixtures

N° of Vessels: 50

Conditions: Pressure 300 bar (4,350 psi) Temperature 240 °C (464 °F)

Custom Tests: Pressure 700 bar (10,00 psi) Temperature 300 °C Purpose Build Test Lab

High Pressure High Temperature Testing

Permeation and Diffusion

Materials: Elastomers, Plastics and CompositesEnvironment: Single gasesN° of Vessels: 6

Sweet Conditions: Pressure 1,000 bar (15,000 psi) Temperature 170 °C (340 °F)

Sour Conditions: Pressure 17 bar (60 psi) Temperature 130 °C (270 °F)

Test Set-up

Rapid Gas Decompression/Blistering

Elastomer qualification to RDG damage: • NORSOK M710/ISO 23936-2 • NACE TM0192, TM0297 • Shell/Cox RGD rig• TOTALFINA SP-TCS-142• Customer specific

Thermoplastic qualification to blister damage: • API 17J• Customer specific

Composite RGD damage:• Customer specific

High Pressure High Temperature Testing

1. Before testing 2. Before decompression

3. Immediately after decompression 4. After degassing of sample

High Pressure High Temperature TestingIn-Situ Observation at Pressure and Temperature

This set up enables: • In-situ measurements of swelling• Deformation/extrusion of seals• Identify the exact time and mode of failure

Mechanical TestingMechanical Testing

Materials: Elastomers, Plastics and CompositesTest Modes: Tensile, Compression, ShearTest Type: Static, Dynamic, Creep, Stress Relaxation,

Impact (Charpy & Drop Weight)Environments Chamber -80 to 250 °C (-112 to 480 °F)Screw Driven Machines: Four Zwick Machines: 5, 20, 50, 100 & 250 kN capacityServo-hydraulic Machines:• MTS 831: 5 kN, -50 to 200C, up to 400 Hz• MTS 810: 250 kN, Multi-axial, 10 Hz• Dartec: 100 kN, 10 Hz Static Test Lab

Tension

Compression-after-Impact Iosipescu Shear

Compression

Interlaminar strength

Tension

Pure Shear/Planar

Biaxial

Simple Shear

Mechanical TestingTest Types

Analytical Lab

Physical Testing & Characterisation

Materials: Elastomers, Plastics and Composites

Test Equipment: • DMA • DSC • TGA• GC • Thermal conductivity• Microscope (SEM/Optical)

Thermal Insulation CoatingsSimulated Service Testing of Insulation Coatings

To qualify the insulations according to:• ISO 12736 • Total GS EP COR 227 • Exxon GP 65-0801

Test Setup: • 1 or 2 Pipe Test Samples ~ 5000mm length• 800 mm ID chamber• Sealed chiller room; 2 a/c units• External water temperature 4°C (40 °F)• Internal pipe temperature 200°C (390 °F)• External water pressure 250 bar (3,600 psi) Test Vessel

Thermal Insulation CoatingsSimulated Service Testing of Insulation Coatings

Test Set-up:

• Controlled/monitored by remote computer• Internal pipe temperature – multiple heater zones;

multiple thermocouple monitors• External pipe temperature – multiple monitor

thermocouples• Water temperature, pressure and flow rate controlled

and monitored• External air temperature controlled and monitored

Data Measurements

Thermal Insulation Coatings

Mechanical Property Testing Post SST

Mechanical and thermal property tests are performed as per ISO 12736 to assess the influence of ageing on the insulation coatings.

• Collapse• Peel• Ageing of insulation polymers• Thermal• Mechanical

Peel TestRing Test

Pull-off Test

Shear Test

Ring Shear Test

Failure Analysis

A comprehensive failure analysis service is offered to help identify the root cause of in-service failures.Failure analysis is supported by mechanical, analytical and numerical analysis techniques.

Composite Materials and PipesPipe Specific Tests

Compression platen

Deformed Shape

• Ring tension & compression (ageing)

• Flexural (ageing)

• Burst testing (up to 10mm and 700bar)

• Permeation

• RGD (blistering)

Composite Materials and PipesTesting on Tubular Pipe Sections

•Following modified ASTM D5448, D5449, D5450

•Tension

•Compression

•Shear via torsion

Composite Materials and PipesFracture Mechanics Based Fatigue Delamination Growth Life Predictions

0

200

400

600

800

1000

1200

1400

1 100 10000 1000000

Stre

ss [

MPa

]

Fatigue Cycles to Onset of Failure

Pristine specimens

Specimens withinitial defect

Asymmetric LaminatesPoints: Experimental DataLines: Predictions

failure location© Rolls-RoyceRolls-Royce's composite fan blade demonstratorSource: http://www.flightglobal.com

Composite Materials and Pipes: NDT2DT ApproachValidation of Approach

Composite Materials and Pipes: NDT2DT Approach• Skin/Stringer – impact damage -> stringer pull-off

• Flat panel – Compression After Impact (ASTM - D7137)

• 90° Flange – Manufactured inclusion -> Bending

C-scan FE model Experiment

Large Scale Structural TestingLarge scale bespoke composite structural evaluation

Use of strain gauges for local and Digital image correlation (DIC) for global measurements

Bespoke Testing

Hail Impact Compression After ImpactIn-Service Loading Simulations

Finite Element Analysis Seal Stack: Long term creep of thermoplasticsEngine Assembly

Crack Growth in Engine MountDiffusion Through Elastomers

Fatigue Life Predictions of Structural Adhesives

Cycles to Failure

Peak

Cyc

lic F

orce

ExperimentPrediction

no crack grow th

SN Curve

Impact Analysis

Crack Growth in Welded Joints

After 25 Year After 1 Year

Rubber Stack

Finite Element Analysis Seal Behaviour During Different Stages of Life Cycle

(a) Initial State

(c) Squeeze

(d) Temperature rise 100C

(e) Pressure

(f) Viscoelastic AnalysisCreep under constant P

(g) Return to ambient conditions

(h) Unload

(b) Assembly

Finite Element Analysis Predicting Seal Failure Under Service Conditions

Strain to failure at 100C = 100%

0

2

4

6

8

10

12

0 50 100 150 200 250

Strain (Percent)

Stre

ss (M

Pa)

Double shear 23CDouble shear 50CDouble shear 100CDouble shear 150C

Predicted Strain Distribution in the Seal at failure

Extrusion of Seal Tensile Test Data

Finite Element Analysis Predicting Long Term Deformation of Polymeric Seals

After One Year After 25 Year

Strain Distribution Predicted Plastic

Conference

Deadline for abstracts 30 April 2016

Joint Industry Projects (JIPs)The goal of a JIP from Element is to develop new knowledge and “know-how” about a particular technical challenge that may be too complex or too expensive for any single organisation to fund themselves and which also requires the application of specialised knowledge, skills and equipment that are not available directly within their own organization.

As a world leader in material testing, product qualification testing and failure analysis, Element is ideally placed to develop and manage complex JIPs for its clients.

Element has many years of experience in successfully running JIPs.

Completed JIPs

Seal Life: Seal performance under different conditions

SOUR/SOUR2: Performance of oil & gas polymers in sour applications

COMPAT: Compatibility of elastomers and thermoplastic materials in oil and gas applications

ELBO/ELBO2: Developing test methods for rubber to metal bonding 

CAPP: Effect of chemical ageing on the performance properties of polymers

FE Project: Developing FE codes for evaluating the fatigue life of elastomeric bearings

COLD/COLDX: Characterization of polymeric materials in cold (0°C to -60°C) oil and gas production conditions

DAFM: Design analysis of adhesive joints based on fracture mechanics