Reusable Pipe Test Head With Inflatable Bore and Cap Sealing
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Solution Overview
Problem
Existing pipeline integrity testing methods often require a new, non-reusable test head for each pipe segment, which limits efficiency and increases costs due to the permanent deformation needed for securing the test head, making it difficult to reuse and potentially compromising the integrity of the pipe segment.
Innovation Solution
A reusable test head system that includes a bore plug assembly with a radially expanding plug fastener mechanism and an end cap assembly with a radially expanding cap fastener mechanism, allowing for secure sealing and testing of multiple pipe segments without permanent deformation, utilizing inflatable or mechanical fasteners that can be easily activated and deactivated for repeated use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional test head is used to secure to a pipe segment, then the pipe segment can be tested for integrity, but the test head causes permanent deformation to the pipe segment making it non-reusable
Solution Approach 1:
The test head employs a dynamic fastening mechanism using inflatable bladders that can be inflated to secure the test head to the pipe segment and deflated to release it. This dynamic approach allows the test head to be both securely attached during testing and easily removed for reuse, eliminating permanent deformation to the pipe segment.
Solution Approach 2:
The test head utilizes pneumatic inflation of bladders to create the securing force between the test head and pipe segment. By inflating the bladders with fluid pressure, the test head achieves firm attachment without mechanical deformation. Deflating the bladders releases the attachment, enabling reuse of both the test head and preservation of pipe segment integrity.
2Reliability
If a new test head is required for each pipe segment, then each pipe segment can be tested, but the cost and time for deploying multiple test heads increases
Solution Approach 1:
The test head is designed as a universal, reusable device that can be attached to and removed from multiple different pipe segments. The standardized interface and dynamic fastening mechanism allow the same test head to serve multiple pipe segments, eliminating the need to deploy a new test head for each segment and significantly improving testing efficiency.
Solution Approach 2:
Instead of discarding the test head after a single use, the invention enables recovery and reuse of the test head on subsequent pipe segments. The inflatable bladder mechanism allows for easy detachment without damage, making the test head a recoverable asset that can be repeatedly deployed across multiple pipe segments, reducing both cost and deployment time.
3Measurement precision
If a test head is securely attached to a pipe segment, then accurate integrity testing can be performed, but the attachment process may compromise the pipe segment integrity
Solution Approach 1:
The test head uses pneumatic inflation of bladders to create a secure yet non-damaging attachment to the pipe segment. The inflated bladders conform to the pipe surface and create sufficient friction and normal force for accurate testing, while the distributed pressure and lack of sharp mechanical contact points prevent damage to the pipe segment integrity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The reusable test head system enhances pipeline integrity testing efficiency by allowing multiple pipe segments to be tested with a single unit, reducing costs and minimizing the risk of pipe segment damage during the testing process, while maintaining accurate integrity assessments.
Implementation Method 1
The plug fluid bladder is to be disposed within a pipe bore of the pipe segment and expands radially outward such that the plug fluid bladder circumferentially engages a tubing inner surface of the pipe segment
Implementation Method 2
The reusable cap fastener mechanism that runs circumferentially along an inner surface of the cap sleeve and that expands radially inward such that the reusable cap fastener mechanism circumferentially engages a tubing outer surface of the pipe segment
Implementation Method 3
an internal inflation fluid conduit that fluidly connects the inflation fluid port to the plug fluid bladder to enable inflation fluid to be supplied to the plug fluid bladder, extracted from the plug fluid bladder, or both
Implementation Method 4
The annulus fluid port facilitates testing integrity of the pipe segment at least in part by enabling annulus test fluid to be supplied to a tubing annulus of the pipe segment, enabling annulus fluid to flow out from the tubing annulus of the pipe segment, or both
Data Source
AI summary
Techniques for implementing and/or operating a test head that includes an end cap assembly; a bore plug assembly including a plug fastener mechanism; an inflation fluid port and an annulus fluid port that open through the end cap assembly; and an internal inflation fluid conduit that connects the inflation fluid port to the plug fastener mechanism. The end cap assembly includes a cap end plate that covers an open end of a pipe segment, a cap sleeve to be disposed around the pipe segment, and a cap fastener mechanism that runs along an inner surface of the cap sleeve and that expands inward such that the cap fastener mechanism engages an outer surface of the pipe segment. The plug fastener mechanism is to be disposed within a pipe bore of the pipe segment and expands outward such that the plug fastener mechanism engages an inner surface of the pipe segment.