Material Developing & Product Testing

Our capabilities include a mixing lab to cultivate new material recipes. Freudenberg Flow Technologies’ elastomer research group is focused on developing new formulations targeted for solving the most stringent challenges encountered by materials used in the oil and gas industry, from extreme temperature and pressure conditions to exposure to harsh drilling and completion fluids.

The mixing lab has all the necessary equipment for compounding new material recipes for seals, BOPs, packers and other non-metallic based parts. Freudenberg Flow Technologies developed a full range of elastomers, from commercial NBR, HNBR, NR, and EPDM base polymers to high-performance FKM grades and FFKM-Grades, including GAZGUARD^® - our trademarked RGD-resistant compounds.

Purpose
Develop new elastomer material recipes

Product Example
O-Rings, Tensile Test Specimen, Compression Set Buttons, and Disks

Equipment
3L Mixer / 2 Roll Mill / Heaters for the mill and mixer / Hydraulic press / Molds / Oven / 

This facility is equipped to conduct a wide variety of tests on the mechanical properties of Elastomers and Plastics – Tensile Testing, Flexural Strength and Modulus, Compression Stress Relaxation Testing, quad lap shear, heat aging and fluid aging, (sour gas H2S, industry standard fluid and customer supplied fluids) including immersion testing with flammable fluids. The Material Properties Test Lab performs physical testing on materials before they are applied to O-Rings, Spring Seals and T-Seals, among other solutions.

Equipment
Tensile Tester (Ambient and elevated temperatures) / Manual clicker press / Densimeter / Microscope / Hardness tester Shore A, D and IRHD / Heating oven / Compression stress relaxation fixtures / Rheometer / DSC

Types of Tests Performed
ISO 48 / ISO 37 / ISO 527 / ISO 34-1 / ISO 1817 / ISO 11357-1+2 / ISO 188 / ISO 815 / ISO 1183 / ASTM D 429 / ASTM D 412 / ASTM D 638 / ASTM D 395 / ASTM D 790 / ASTM D 2240 / ASTM 3767 / ASTM D 2000

Example Tests Performed

• Mechanical Properties
• Hardness
• Compression set
• Immersion testing (in flammable fluids)

Our Thermal Test Lab is dedicated to product function testing for a variety of sealing solutions such as Spring Seals, T-Seals and FS Seals. This facility utilizes an environmental chamber, a gas booster and an accumulator vessel.

Equipment

• Thermal chamber (48 x 48 x 48 inches, max load 2,500 lbs.)
• Gas booster + accumulator vessel

Typical Tests Performed

• ISO 10423 and ISO 14310 pressure temperature cycling test
• API 6A F 1.11
• Customer-specified tests

Temperature Range

• Typical temperature cycle: -04°F to 250°F (-20°C to 121°C)
• Chamber is capable of temperature range: -100°F to 375°F (-73°C to 191°C)

Pressure Range

• Standard test: atmospheric pressure to 15,000 psi (103 MPa)
• Customer specific test: with new vessel design can get up to 20,000 psi (138 MPa)

Gases / Fluids

• Standard gases: 100% N2
• Other gas combinations to be evaluated upon request

Our HPHT (High Pressure High Temperature) Test Lab uses Rapid Gas Decompression (RGD) Testing and Steam Immersion Testing to assess material and function prior to being used in products such as O-Rings, FS-Seals, Spring Seals and T-Seals. The lab includes insulated, self-contained test vessels with band heaters between vessel and insulation.

Equipment
Insulated self-contained test vessels, with band heaters between vessel and insulation

Typical Tests Performed
Norsok M-710 RGD / ISO 23936 / NACE TM 0187 / Shell DODEP / Total GS-PVV-142 / Customer-specified tests

Temperature Range
Room temperature, to 430°F (220°C)

Pressure Range

• Standard test: atmospheric pressure to 15,000 psi (103 MPa)
• Customer specific test: new vessel design can get up to 20,000 psi (138 MPa)

Gases / Fluids

• Standard gases:
  5% CO2, 95% CH4 / 10% CO2, 90% CH4 / 100% N2 and 100% CO2
• Customer specific test: other concentrations or gas combinations to be evaluated upon request

Our Product Test Area is designed to perform function testing for products such as BOPs, (Annular Elements, Ram Packers) and Metal to Metal Seals. The facility is capable of running API 16A testing, as well as customer-specific tests to elevated and low temperatures. Typical tests cover water, control fluids, drilling muds and glycol. 

Typical Tests Performed

• API 6A
• API 16A
• ISO 14998
• Customer-specified tests

Pressure and Temperature Range

• Up to 15,000 psi (103 MPa)
• Up to 500^oF (260^oC)
• Down to 20^oF (-6.7^oC)

Gases / Fluids

• Nitrogen
• Fluid test: water, control fluids, drilling muds, glycol
• Other fluids will be evaluated upon request

Our Sour Gas Lab tests a broad spectrum of gases and fluids, as well as customer-specific combinations as requested. Material and function tests include atmospheric pressure to 2,000 psi and immersion testing to 15,000 psi, as well as Norsok M-710 sour gas testing. We also have the capability of running hydrogen immersion testing to 10,000 psi (68.9 MPa) and 302^o F (150^o C).

Equipment

• 2 test vessels with stands, heater bands and insulation in the ventilation hood
• Wet scrubber for air purification

Pressure Range

• Standard test: atmospheric pressure to 2,000 psi (13 MPa)
• Customer-specific immersion testing to 15,000 psi (103 MPa)
• Hydrogen immersion testing to 10,000 psi (68.9 MPa)

Gases / Fluids

• Standard gases:
  2% H2S, 3% CO2, 95% CH4 / 10% H2S, 5% CO2, 85% CH4 / 100% N2 / 100% H2
• Other concentrations or gas combinations will be evaluated upon request