Hydraulic Make-Break Tool for Tubing Hanger Running Tool & Test Cap

This project involved the design, analysis, and procurement of a hydraulic tool to remove and install a pressure test cap from a tubing hanger running tool (THRT). The project scope of work is listed below.

  • Create 3 concepts for the tool and a scaled general arrangement drawing of existing equipment.
  • Compare several component alternatives & design features.
    • 800 Lb test cap support options: pipe roller support, trailer wagon, industrial cart, motorcycle scissor jack, machine skate, pipe stand, transmission jack, pallet jack, forklift with lift straps.
    • Power sources: hydraulic hand pump, electric pump, & pneumatic pump. Drill or jack screw.
    • Collars: Split or full.
    • Force reactions: diameter lip, pins, standard bolts, custom bolts.
  • Create Preliminary Design: construction drawings, a hydraulic schematic, cost estimate, structural calculations, & design feasibility calculations.
  • Attend meetings with project manager and end users to discuss & revise the design.
  • Take field measurements of equipment the tool will interface with.
  • Review ANSI B36.1, API 5L, ASTM A53 to determine if components can be economically created from standard pipe. Pipe tolerance was too large & strong pipe material was not common, so a forged round was trepanned.
  • Research Coatings for weldment. Choose appropriate type & identify a local quality coating applicator.
  • Complete tolerance study while considering manufacturing methods. Assign tolerances.
  • Investigate weld electrode class callout.
  • Project manage engineer hours, invoices, purchase orders, quotes, and logistics.
  • Review technical literature of pump to commission the tool & ensure pump compatibility with site power sources & double acting cylinders.
  • Revise preliminary design to detailed design.
  • Witness critical steps in manufacturing, assembly & commissioning of tool.
  • Review as-built dimensional noncomformances & disposition accordingly.
  • Order accessories and spares for parts likely to break or be lost.
  • Revise drawings to correct fitting error.

A picture of the THRT with test cap and a picture of the final tool is below.

IMG_4967 IMG_8791

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