1. Element Hitchin
Polymer testing for the
Oil and Gas sector
Updated April 2016

2. 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

3. • 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

4. • 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

5. High Pressure High Temperature Testing
Exposure In SWEET Environment
Chemical testing: accelerated ageing, compatibility, RGD
Materials: Elastomers, Plastics and Composites
Qualification: Standards NORSOK, API, ISO,
NACE, ASTM
Environments: Sweat Gases, Brines, Treatment Fluids
N° 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

6. High Pressure High Temperature Testing
Exposure In SOUR Environment
Chemical testing: accelerated ageing, compatibility, RGD
Materials: Elastomers, Plastics and Composites
Qualification: 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

7. High Pressure High Temperature Testing
Permeation and Diffusion
Materials: Elastomers, Plastics and Composites
Environment: Single gases
N° 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

8. 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

9. 1. Before testing 2. Before decompression
3. Immediately after decompression 4. After degassing of sample
High Pressure High Temperature Testing
In-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

10. Mechanical Testing
Mechanical Testing
Materials: Elastomers, Plastics and Composites
Test Modes: Tensile, Compression, Shear
Test 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 capacity
Servo-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

11. Tension
Compression-after-Impact Iosipescu Shear
Compression
Interlaminar strength
Tension
Pure Shear/Planar
Biaxial
Simple Shear
Mechanical Testing
Test Types

12. Analytical Lab
Physical Testing & Characterisation
Materials: Elastomers, Plastics and Composites
Test Equipment:
• DMA
• DSC
• TGA
• GC
• Thermal conductivity
• Microscope (SEM/Optical)

13. Thermal Insulation Coatings
Simulated 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

14. Thermal Insulation Coatings
Simulated 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

15. 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

16. 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.

17. Composite Materials and Pipes
Pipe Specific Tests
Compression platen
Deformed Shape
• Ring tension & compression (ageing)
• Flexural (ageing)
• Burst testing (up to 10mm and 700bar)
• Permeation
• RGD (blistering)

18. Composite Materials and Pipes
Testing on Tubular Pipe Sections
• Following modified ASTM D5448, D5449, D5450
• Tension
• Compression
• Shear via torsion

19. Composite Materials and Pipes
Fracture Mechanics Based Fatigue Delamination Growth Life Predictions
0
200
400
600
800
1000
1200
1400
1 100 10000 1000000
Stress[MPa]
Fatigue Cycles to Onset of Failure
Pristine specimens
Specimens with
initial defect
Asymmetric Laminates
Points: Experimental Data
Lines: Predictions
failure location
© Rolls-Royce
Rolls-Royce's composite fan blade
demonstrator
Source: http://www.flightglobal.com

20. Composite Materials and Pipes: NDT2DT Approach
Validation of Approach

21. 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

22. Large Scale Structural Testing
Large scale bespoke composite structural evaluation
Use of strain gauges for local and Digital image correlation (DIC) for global measurements

23. Bespoke Testing
Hail Impact Compression After ImpactIn-Service Loading Simulations

24. Finite Element Analysis
Seal Stack: Long term creep of thermoplasticsEngine Assembly
Crack Growth in Engine Mount
Diffusion Through Elastomers
Fatigue Life Predictions of
Structural Adhesives
Cycles to Failure
PeakCyclicForce
Experiment
Prediction
no crack growth
SN Curve
Impact Analysis
Crack Growth in Welded Joints
After 25 YearAfter 1 Year
Rubber Stack

25. Finite Element Analysis
Seal Behaviour During Different Stages of Life Cycle
(a) Initial State
(c) Squeeze
(d) Temperature
rise 100C
(e) Pressure
(f) Viscoelastic Analysis
Creep under constant P
(g) Return to ambient
conditions
(h) Unload
(b) Assembly

26. 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)
Stress(MPa)
Double shear 23C
Double shear 50C
Double shear 100C
Double shear 150C
Predicted Strain Distribution in the Seal at failure
Extrusion of Seal Tensile Test Data

27. Finite Element Analysis
Predicting Long Term Deformation of Polymeric Seals
After One Year
After 25 Year
Strain Distribution Predicted Plastic

28. Conference
Deadline for abstracts
30 April 2016

29. 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.

30. 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