Piping insert technology

There have been many mining products and services designed and introduced into the market throughout the years that have been successful and useful for mine operators.

That trend continues with another product that has just been developed by Derek Hall and Lesley Clemens at Testlok.

The device has been developed for use in piping insert mechanisms. It has been designed for pressure process piping systems.

The reusable, multifunctional device is an alternative to the disposable pipe insert such as the temporary jumper spool or hose that commonly substitutes permanent inline equipment during plant commissioning and maintenance periods.

The Test Pup brings improved outcomes to overall efficiency, particularly the duration and safety of projects. It also assists the piping tester to conduct hydro, air and gaseous testing on process piping systems.

After 30 years of experience in the oil and gas, petrochemical and power generation industries, product inventor Derek Hall recognised the need for innovation in the area of processing pipe installations.

Hall wanted to discover a way to help project managers and mine operators handle large, complex problems with pipe manufacturing and waste management issues.

He was also concerned about the shortages of skilled labour as well as the increasing amount of environmental waste.

There was a need to find an innovative solution to some common problems affecting the mining industry within the pipe processing supply sector.

With the Test Pup, Hall brought about a way to make a seamless transition from conventional valve hopping methodologies to new and improved pipe insert methods.

“The main virtue of the Test Pup is that it eliminates the need for ‘valve hopping’, offering piping installers the freedom to install and test piping systems prior to the arrival of permanent inline equipment,” Testlok product inventor Derek Hall told Australian Mining.

Test Pup Features

The Test Pup is made out of a high strength alloy which is environmentally friendly in oil and gas and petrochemical applications.

Every part of the Test Pup can be re-adjusted or changed and the hydraulic seals can be re-configured.

The design allows the piping erector to achieve a correct fit by varying the relative length between the two telescopic flange faces.

The Test Pup also incorporates vent, drain and fill points for the insertion of pressure gauges and safety relief valves.

With pressure ratings of 150 to 2500 psi the Test Pup is pre-tested to all industry standards pressure ratings and comes complete with material certification traceability and internationally accredited pressure test certificates.

“Instead of having many different configurations, what happens is that the product works as a universal stop-gap measure,” Hall adds.

The Test Pup provides streamlined erection and alignment of piping systems, safer flushing and testing of piping protection of piping systems and process valves.

The Test Pup has been engineered as an adjustable, fully sealed pipe insert. It also incorporates vent, drain and fill points for the insertion of pressure gauges and safety relief valves.

With pressure ratings of 150 to 2500 psi the Test Pup is pre-tested to all industry standards pressure ratings and comes complete with material certification traceability and internationally accredited Pressure test certificates.

“Instead of having many different configurations, the product works as a universal stop-gap measure,” Hall added.

Benefits to projects

“With the utilisation of Test pups, man hours will be reduced on gas projects throughout WA, along with safety concerns for workers and equipment durability minimizing duplication” Hall said.

“This will in turn save the companies a lot of time and money in reducing the cost of building these pipes and of getting rid of them,” Hall said.

“The idea is to eliminate waste from bulk building of pipes which have a very short life span.”

According to Hall, “10 to 20 thousand man hours will be saved, with one man hour costing companies roughly $150 to $200.”

Another concern for Hall lies in the shortage of skilled labour in WA.

“There are not enough welders and pipe manufacturers to keep up with the high demand of mining projects in WA. With a boom in the WA resources industry in the last 25 years we can only hope the Test Pup will reduce the pressure on projects at a crucial re-commissioning stage,” Hall said.

“WA has very good manufacturing companies which are capable of franchising and expanding into the international market; Japan, USA and European manufacturers are interested in the idea,” Hall adds.

Under the direct guidance of Hall and Clemens, the product has generated interest within the Western Australian mining community and also in the international market.

For Hall and Clemens it has been a long process in the designing and development of the Test Pup. However they believe that the device will be a welcome solution within the Australian mining industry.

“The company was recently awarded a 70,000 Comet grant from the government.” Testlok business development manager Lesley Clemens, told Australian Mining.

“Prior to that all the research and development had been undertaken without any assistance or government help,” The design has gone through extensive testing and redevelopment in the last few months and is expected to be available on the market within the next six months,” Clemens said.

“At present, we do not have any sales as we need to complete the final testing before approaching clients.”

“We have had only good reports and feedback from people in industry, and we are endeavouring to keep the work that spans from the invention within Australia as much as practically possible,” Clemens said.

Lesley Clemens

Business development manager

Lesley.clemens@testlok.com.au

Derek Hall

Product Inventor

Derek.hall@testlok.com.au

Testlok

08 9278 2797

www.testlok.com.au