Tool TESTING & Qualification program
Structural Tool Testing
As part of the qualification program at PipeLine UltraisolationGroup (PLUG), the structural integrity and sealing performance of the 24-inch plug module were tested and verified. The module was subjected to high differential pressure across the plug, along with full SET-side pressure applied to the cylinder. During the unsetting phase, both the self-locking pressure and the minimum required set pressure were evaluated to confirm reliable disengagement under controlled conditions.
● Test 1: Structural test of the 24in plug module to differential pressure with Safety factor 1.25.
● Test 2: External pressure test of control module with Safety factor 1.25.
● Test 3: Structural test of the hydraulic system with Safety factor 1.50.
● Test 4: Minimum Self-lock pressure over plug module (PM).
● Test 5: Minimum SET pressure required for sealing.
Systems Integration Test (SIT)
The 24in plug train comprises approximately 2,500 physical components, including the communications hardware.
Each component and subsystem underwent staged testing prior to a full Systems Integration Test (SIT), which successfully validated the plug train’s ability to track, control, and isolate pipeline pressure. The contingency UNSET function operated reliably, and battery capacity exceeded operational requirements.
Hydraulic performance and strain data were recorded for further analysis and to develop accurate stress calculations.
Pigging Test
To validate the piggability of the 24-inch plug train, the tool was successfully run through a test loop consisting of a launcher, straight section, 3D bend, check valve, and a receiver. The trial also assessed communication system performance and the differential pressure (DP) required for tool movement. Results confirmed that the tool operates effectively with just 20 psi DP. Additionally, the antenna system demonstrated high precision, consistently locating the tool within less than an inch.