Composite Material Testing
Composite testing capabilities require specialized equipment to meet the required specifications, standards, and regulatory requirements for each request. With our recent acquisition of Protek Systems, we have increased our testing capabilities significantly. We can offer fluid pressure testing to 15,000 PSI and temperatures up to 350F. Hydrostatic testing to 12,5000 PSI and mechanical compressive and tensile testing for crush and pull data.
The Gund Company can help get composite tools to the market quickly, assisting with our rapid prototype components and testing every step of the way. Whether you would like to test something as small as a slip band break or a full frac plug assembly pressure test, we can help!
Composite testing plays an essential role across the composites supply chain and for the life of the product. A range of challenges regarding safety, quality, process control, regulatory compliance, and performance can be encountered. With that in mind, defeating these challenges can give your business a notable advantage.
Our composite material testing services include the following:
- Frac Ball Test – We set up our frac ball test vessel and set the seat percentage to the customer’s test specifications, along with their requested frac ball size and type. This can be done with or without heat to 15K PSI. The pressure is applied using a low-volume/high-pressure hydraulic Maximator pump; both are controlled behind an armored wall. The heating process takes approximately 6 hours, making it a full day if heat is used. Ambient tests are about 2 hours.
- Complete Plug Test – We set a complete frac plug in a 36” piece of oil casing using an Enerpac 150-ton horizontal pull jack. We then cap the casing and apply heat (250 F-350F) and pressure (0- 10.5 K PSI). The heat is applied using Gaumer heater bands placed around the casing and controlled using a thermostatic controller. The pressure is applied using a low-volume/high-pressure hydraulic Maximator pump, both of which are controlled behind an armored wall. The heating process takes approximately 6 hours, making it a full-day test.
- Hi-Tech Tube Pull Test – Tube pull testing is performed to determine the amount of torque required to achieve the maximum tube-to-tubesheet joint strength in your condenser retubing project.
- Hydrostatic Pressure Test – The test is performed by filling (pressurizing) the vessel or piping being examined and subsequently monitoring the level of pressurization for changes.
- Mandrel Head Shear Test – We attach a setting tool adapter to the mandrel head of a plug, and using the Enerpac horizontal pull jack; we pull the mandrel against the setting ring until the pins shear to make sure the mandrel head can take the setting forces. This is a quick 30-minute test.
- Slip Test – We assemble a steel version of the mandrel and cone from the customer’s plug design along with their plug’s element. We insert this assembly into a test chamber casing. Then using our Dake 150-ton vertical press, we set the plug assembly with the press using approximately 30,000 lbs of force. Next, we cap the test casing off and apply heat and pressure in the same manner as the complete plug test. Because of pressure hold times, these are typically 3 hours to all-day tests.
- Mule shoe Thread Test – We have a mandrel machined and threaded to the customer’s specification but threaded on both ends. We have two shoes machined to specification, and we attach both shoes to the mandrel, and with fixturing, we pull the shoe threads apart with the Enerpac horizontal pull jack. This is a quick 30-minute test.
- Mandrel Head Test- We have the mandrel head machined to the customer’s specification but shortened to only 4 inches below the head. We then run the mandrel head through a test baffle, and then we insert the baffle/mandrel into our test chamber. We seal it off with a frac ball and add water, pressure, and heat to the customer’s requirement. This test can be 3 hours to all day, dependent on holds and temperatures.
- Cone Crush Test – We have a steel outer fixture made representing the outline of the slips. The fixture fits over the cone, a piece of steel all thread runs through the cone, and a steel disc backs it. The Enerpac horizontal pull jack pulls the cone into the fixture and eventually crushes the cone. The data is logged, and the failure point is the slope on the data line where pressure initially falls off. This test is quick, 15-20 minutes.
- CMM Probe Measurement
- Stereo Microscopy
- Slot Cell Full-Length Dielectric Strength
- O & G, ILSS, and Hub Shear Tests
- Load Ring Test
- Yield Band Burst Strength Test
- Frac Plug Environmental Test
- Scanning Electronic Microscopy (SCEM)
[video_popup url=”https://youtu.be/rD9PYzhjEvg” img=”https://thegundcompany.com/wp-content/uploads/2021/07/RATCHET-RING-TESTING.png” text=”Click here to see a video of the Ratchet Ring Test”]