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Full scale Testing

Through the Full-Scale-Test Laboratory Centro Sviluppo Materiali S.p.A. has opened a specialized window on the world of OCTG products development and characterization.


Based on “premium connection” and “ pipelines and ducts” sections, the lab is involved in the On- and Off-shore technology business, representing a very specialized and unique testing supplier for steel tubular products manufacturers and end-user Oil&Gas companies.

Premium Connection Section

This section is endowed with the following testing apparata:
  • one bucking unit, equipped with a dedicated data acquisition PC, and designed to handle joints with a diameter range between 2 3/8” and 14” and exerting a maximum torque of 68kN*m (50000lb*ft). It is addressed to submit ”Premium Joints” for:

    • the characterization and qualification in terms of galling resistance through repeated Make-up and Break-out cycles;
    • Over-torque tests;
    • Torque-to-yield tests.
  • one combined loads facility developed to submit “Premium Joints” to:

    • sealability tests with combined loads (i.e., tension, compression, internal pression, external pression, bending);
    • failure tests.

      Apart from the data acquisition Hardware and Software, this equipment taylored to manage Lmax = 2000 mm and fmax = 356mm (14”) specimen, has the following characteristics:

      • Maximum tension 13 MN applied force;
      • Maximum compression 10 MN applied force;

      and is furtherly supported by:

      • two bending systems with two levels of maximum applied load (respectively, 70kN*m e 300kN*m applied torque;
      • one torsion system with a capaciity of maximum 50kN*m;
      • four pressure intensifiers (two for gas and two for liquids) able to exert a 2500 bar maximum pressure;
      • one thermal cycling system designed to check the “Premium Joints” sealability behaviour during thermal cycling coupled with combined tension and internal pressure.
        This equipment can submit the specimen to a temperature variation through a coupled induction coil and forced air/water spray nozzle for a temperature cycling between 250°C and room temperature.
    •  
      • One fatigue equipment set to carry out tests by combining tension and internal pressure loads, with plain bending exerted at low frequency (5 Hz), at a maximum applied torque of 50kN*m.
The section is also equipped with:
  • external pressure vessels with max pressure of 2000 bar;
  • a multiple specimens (up to 6) oven for 2 3/8” to 14” wide items with a maximum operating temperature of 350 °C;
  • two single specimen ovens with diameters from 2 3/8” to 10 3/4” and a max temperature of 500 °C.

Pipelines and ducts sections

This section of the Full Scale Testing Laboratory (FST Lab), equipped with ad hoc facilities for testing base plates, pipes, welded joints, tubular connections, etc., is able to reproduce the whole spectrum of in-field service conditions (high pressure, low temperature, fatigue, combined loading, dynamic impact, etc.).

This section capability is operated at the following different sites:

  • Rome, where the following tests are performed:

    • Full scale external damage testing on pressurised linepipes (up to 52” OD);
    • Full scale traction/bending tests on defected wide plates/pipes and welded joints at low temperature (up to 4000 tons);
    • Full scale fatigue tests on pressurised pipes (up to 2000 bar);
    • Hydraulic tests until failure on defective/sound steel pipes;
    • Dynamic Drop Weight Tear Testing (DWTT);
    • Strain gauges measurements;
    • Three dimensional measurements (1/100 µm accuracy);
    • High speed camera test monitoring (2000 photos/s);
    • X-Ray diffraction analysis.

  • Nettuno, (RM), where the following tests are performed:

    • West Jefferson testing carried out at temperature down to -50°C.

  • Perdasdefogu, Sardinia, where the following test is performed:

    • Full scale ductile fracture propagation burst testing in both onshore and offshore (sea water depth ≈30m) conditions (test line up to 147 m) on a loop designed to simulate the service conditions of high steel grade, large OD gas transmission lines (up to 56” OD);
  • Capoterra, Sardinia, where the following test is performed:

    • 250 ton multi-axial loading pipe testing.

These equipments permit to characterise materials and components in terms of::

  • Fatigue
    • Fatigue of welded joints for offshore structures;
    • Fatigue of longitudinal welded steel linepipes;
  • Fracture
    • Drop weight tear test;
    • Large scale fracture mechanics (wide plate);
    • Defects in girth weld at low temperature;
  • Ductile/Brittle fracture
    • West Jefferson test at low temperature;
    • Burst test for fracture propagation on linepipes (up to 56”);
  • Third part external damage:
    • Simulator of third part external damage on linepipe;
  • EAC of damaged linepipes (pressure cycling plus environment) and cathodic protection;
  • Hydraulic test on damaged/sound pipes;
  • Pipeline construction and service for test beds
    • In field cold forming of steel linepipes;
    • Full monitored loop for simulating service conditions;
    • Combined loading on tubulars and linepipe.

Here below some of the specification of the equipments is given:

  • HYDRAULIC CYLINDERS FATIGUE TESTING
    A full-scale fatigue bench rig for commercial pipes used for hydraulic cylinders application, opened at either or both ends. The system permits the tubular products to be administered sinusoidal/triangular fatigue cycles, at an operating pressure up to 700 bar and a frequency up to 10 Hz. Two independently fed test positions running in parallel and cooled by means of dedicated criogenic cell, are available.
  • FATIGUE OF GAS STEEL LINEPIPES (INTERNAL PRESSURE CYCLING)
    This bench rig is designed to handle tubes in the lengths between 6 and 8 meters and uses water as the pressurizing medium. The applied load frequency ranges in the interval 0.2 - 0.5 Hz.
  • DROP WEIGHT TEAR TEST (DWTT)
    This apparatus permits a fall height able to guarantee an impact energy up to 24,000 Joules at exteremly low temperatures.
  • LARGE SCALE FRACTURE MECHANICS (WIDE PLATE TEST AND DEFECTS IN GIRTH WELD)
    This machine has been conceived to be managed in accordance to two different operational modes: the former exerting a tension load, the latter a four-point bending on large OD pipes (up to 36”). It can exercise in both modes a maximum load of 40,000 kN. The specimen can be tested at a temperature of down to -50°C.
  • WEST-JEFFERSON TEST AT LOW TEMPERATURE (ductile/brittle fracture).
    This is a test station where the full-sized samples can be pressurized by means of a (90:10) mixture of water and air and cooled down to – 50°C .
  • FULL SCALE DUCTILE FRACTURE PROPAGATION ONSHORE BURST TEST
    It is a test station where 1 meter depth buried 36”-48”-56” 90-150m long lines may be tested by bursting at pressure of up to 250 bar by adopting gas or air as the pressurizing medium. The test line is fully sensorised.
  • FULL SCALE DUCTILE FRACTURE PROPAGATION OFFSHORE BURST TEST. This is a mobile test station for handling Offshore test lines 50m long, at 30m water depth. The Test rig maximum pressure is 250 bar obtained by means of a gas/water mixture.
  • SIMULATOR OF MECHANICAL DAMAGE IN OIL & GAS LINEPIPES. This is a fully controlled machine that can reproduce small (15 tons) and large size (35 tons) excavator damages.
    It is provided with a triaxial load cell (up to 100 tons of applied load) and a computer controlled impactor trajectory.
    Tests can be carried out on pressurized pipes with an outer diameter ranging from 24” to 52”.

© 2014 - Centro Sviluppo Materiali S.p.A. Via di Castel Romano, 100 - 00128 - Rome - ITALY
Ph. +39 06 50551 - Fax. +39 06 5055204 - Share Capital 1.050.000 Euro Fully Paid-Up
Registro Imprese di Roma CF 00477510580 R.E.A. di Roma 269973 - PI 00903541001