Reusable pipe integrity test head systems and methods

1. A test head comprising:

an end cap assembly, wherein the test head is configured to be secured to an open end of a pipe segment such that the open end of the pipe segment is sealed therein and the end cap assembly comprises:

a cap end plate configured to cover the open end of the pipe segment;

a cap sleeve configured to be disposed circumferentially around the pipe segment; and

a reusable cap fastener mechanism configured to:

run circumferentially along an inner surface of the cap sleeve; and

expand radially inward such that the reusable cap fastener mechanism circumferentially engages a tubing outer surface of the pipe segment to facilitate securing and sealing the open end of the pipe segment within the test head;

a bore plug assembly comprising a reusable plug fastener mechanism that comprises a plug fluid bladder, wherein the plug fluid bladder is configured to be disposed within a pipe bore of the pipe segment and to expand radially outward such that the plug fluid bladder circumferentially engages a tubing inner surface of the pipe segment to facilitate securing and sealing the open end of the pipe segment within the test head;

an inflation fluid port that opens through the end cap assembly;

an internal inflation fluid conduit that fluidly connects the inflation fluid port to the plug fluid bladder to enable inflation fluid to be supplied to the plug fluid bladder, extracted from the plug fluid bladder, or both; and

an annulus fluid port that opens through the end cap assembly, wherein the annulus fluid port is configured to facilitate testing integrity of the pipe segment at least in part by enabling annulus test fluid to be supplied to a tubing annulus of the pipe segment, enabling annulus fluid to flow out from the tubing annulus of the pipe segment, or both.

2. The test head of claim 1 , comprising:

a support clamp, wherein the support clamp is configured to be secured circumferentially around the pipe segment external to the end cap assembly; and

a support member configured to be secured to the support clamp and to the end cap assembly to facilitate securing the open end of the pipe segment within the test head.

3. The test head of claim 2 , comprising a bolt and a nut, wherein:

the support clamp comprises a first clamp flange having a first fastener opening and a second clamp flange having a second fastener opening;

a threaded end of the bolt is configured to be inserted through the first fastener opening in the first clamp flange and the second fastener opening in the second clamp flange; and

the nut is configured to be tightened on the threaded end of the bolt to facilitate:

tightening the support clamp circumferentially around the pipe segment tubing; and

securing the support clamp to the support member.

4. The test head of claim 3 , wherein:

the reusable cap fastener mechanism comprises a cap seal;

the end cap assembly comprises:

a cap end ring configured to be disposed circumferentially around the pipe segment such that the cap sleeve is disposed between the cap end plate and the cap end ring and the cap seal is disposed between the cap sleeve and the cap end ring;

a threaded cap shaft configured to be inserted through a first shaft opening in the cap end plate and through a second shaft opening in the cap end ring; and

an end plate nut configured to be tightened on the threaded cap shaft behind the first shaft opening in the cap end plate and an end ring nut configured to be tightened on the threaded cap shaft in front of the second shaft opening in cap end ring to axially compress the cap seal between the cap sleeve and the cap end ring such that the cap seal expands radially inward; and

the support member comprises a support chain having a first end configured to be shackled to the threaded cap shaft between the cap end ring and the cap end plate and a second end configured to be shackled to the bolt between the first clamp flange and the second clamp flange on the support clamp.

5. The test head of claim 3 , comprising a support securement nut, wherein:

the support member comprises a threaded support shaft configured to be disposed between the first clamp flange and the second clamp flange on the support clamp;

the reusable cap fastener mechanism comprises a cap seal configured to be disposed circumferentially around the pipe segment;

the end cap assembly comprises:

a cap end ring configured to be disposed circumferentially around the pipe segment such that the cap sleeve is disposed between the cap end plate and the cap end ring and the cap seal is disposed between the cap sleeve and the cap end ring; and

an end plate nut configured to be tightened on the threaded support shaft behind a first shaft opening in the cap end plate and an end ring nut configured to be tightened on the threaded support shaft in front of a second shaft opening in cap end ring to axially compress the cap seal between the cap sleeve and the cap end ring such that the cap seal expands radially inward; and

the support securement nut is configured to be tightened on the threaded support shaft in front of the first clamp flange and the second clamp flange on the support clamp to facilitate securing the end cap assembly to the support clamp.

6. The test head of claim 2 , comprising a nut, wherein:

the support clamp comprises a first clamp flange and a second clamp flange; and

the nut is configured to be tightened on a threaded shaft disposed between the first clamp flange and the second clamp flange to facilitate securing the support clamp to the end cap assembly.

7. The test head of claim 2 , comprising a nut, wherein:

the end cap assembly comprises a first cap flange and a second cap flange; and

the nut is configured to be tightened on a threaded shaft disposed between the first cap flange and the second cap flange to facilitate securing the end cap assembly to the support clamp.

8. The test head of claim 1 , comprising:

another inflation fluid port that opens through the end cap assembly, wherein the reusable cap fastener mechanism in the end cap assembly comprises a cap fluid bladder that is configured to be disposed circumferentially around the pipe segment; and

another internal inflation fluid conduit that fluidly connects the another inflation fluid port to the cap fluid bladder to enable inflation fluid to be supplied to the cap fluid bladder, extracted from the cap fluid bladder, or both.

9. The test head of claim 1 , wherein the bore plug assembly comprises a plug shaft configured to be at least partially inserted into the pipe bore of the pipe segment, wherein:

the plug fluid bladder is secured to the plug shaft; and

the plug shaft, the cap end plate, and the cap sleeve are integrated together to form a shell.

10. The test head of claim 1 , wherein the bore plug assembly comprises a plug shaft configured to be at least partially inserted into the pipe bore of the pipe segment, wherein:

the plug fluid bladder is secured circumferentially around the plug shaft; and

the plug shaft comprises a tube bore that opens through the plug fluid bladder.

11. The test head of claim 10 , comprising a bore fluid port that opens through the end cap assembly to the tube bore of the plug shaft, wherein the bore fluid port is configured to facilitate testing integrity of the pipe segment at least in part by enabling bore test fluid to be supplied to the pipe bore of the pipe segment, enabling bore fluid to flow out from the pipe bore of the pipe segment, or both.

12. A test head comprising:

an end cap assembly within which an open end of pipe segment tubing is to be secured and sealed;

an annulus fluid port that opens through the end cap assembly;

a bore plug assembly comprising a reusable plug fastener mechanism configured to be disposed internal to the end cap assembly, wherein the reusable plug fastener mechanism is configured to facilitate securing and sealing the open end of the pipe segment tubing within the end cap assembly to enable integrity of the pipe segment tubing to be tested at least in part by flowing annulus test fluid into an internal annulus fluid conduit defined in an annulus of the pipe segment tubing via the annulus fluid port that opens through the end cap assembly; and

a supplemental support assembly comprising a support clamp configured to be secured to the end cap assembly such that the support clamp is external to the end cap assembly, wherein the support clamp is configured to be secured circumferentially around the pipe segment tubing to facilitate securing the open end of the pipe segment tubing within the end cap assembly.

13. The test head of claim 12 , comprising:

an inflation fluid port that opens through the end cap assembly, wherein the reusable plug fastener mechanism comprises a plug fluid bladder configured to be disposed within a pipe bore defined by the pipe segment tubing and to expand radially outward such that the plug fluid bladder circumferentially engages an inner surface of the pipe segment tubing to facilitate securing and sealing the open end of the pipe segment tubing within the end cap assembly; and

an internal inflation fluid conduit that fluidly connects the inflation fluid port to the plug fluid bladder to enable inflation fluid to be supplied to the plug fluid bladder, extracted from the plug fluid bladder, or both.

14. The test head of claim 12 , wherein:

the bore plug assembly comprises a plug shaft that defines a tube bore; and

the reusable plug fastener mechanism is secured circumferentially around the plug shaft.

15. The test head of claim 14 , comprising a bore fluid port, wherein:

the bore fluid port opens through the end cap assembly to the tube bore of the plug shaft; and

the tube bore of the plug shaft opens through the reusable plug fastener mechanism to enable bore test fluid to be supplied to a pipe bore defined by the pipe segment tubing, bore fluid to flow out of the pipe bore, or both via the bore fluid port that opens through the end cap assembly.

16. The test head of claim 12 , wherein the supplemental support assembly comprises a support securement fastener, wherein:

the support clamp comprises a first clamp flange and a second clamp flange that opposes the first clamp flange; and

the support securement fastener is configured to be tightened around the first clamp flange and the second clamp flange to facilitate:

tightening the support clamp around the pipe segment tubing; and

securing the support clamp to the end cap assembly.

17. The test head of claim 16 , wherein:

the end cap assembly comprises:

a cap end plate configured to cover the open end of the pipe segment tubing;

a cap end ring configured to be disposed circumferentially around the pipe segment tubing;

a cap sleeve configured to be disposed circumferentially around the pipe segment tubing between the cap end plate and the cap end ring;

a cap seal configured to be disposed circumferentially around the pipe segment tubing between the cap sleeve and the cap end ring;

a threaded cap shaft configured to be inserted through a first shaft opening in the cap end plate and through a second shaft opening in the cap end ring; and

an end plate nut configured to be tightened on the threaded cap shaft behind the first shaft opening in the cap end plate and an end ring nut configured to be tightened on the threaded cap shaft in front of the second shaft opening in cap end ring to axially compress the cap seal between the cap sleeve and the cap end ring such that the cap seal expands radially inward; and

the supplemental support assembly comprises a support chain having a first end configured to be shackled to the threaded cap shaft between the cap end ring and the cap end plate and a second end configured to be shackled to the support securement fastener between the first clamp flange and the second clamp flange on the support clamp.

18. A test head comprising:

an end cap assembly within which an open end of pipe segment tubing is to be secured and sealed;

an annulus fluid port that opens through the end cap assembly;

a support clamp configured to be secured to the end cap assembly and to be selectively tightened around the pipe segment tubing to facilitate securing the pipe segment tubing within the end cap assembly to enable integrity of the pipe segment tubing to be test at least in part by flowing annulus test fluid into an internal annulus fluid conduit defined within an annulus of the pipe segment tubing via the annulus fluid port that opens through the end cap assembly, wherein the support clamp comprises:

a first clamp flange having a first fastener opening; and

a second clamp flange having a second fastener opening, wherein the second clamp flange opposes the first clamp flange;

a bolt, wherein the bolt comprises a threaded end configured to be inserted through the first fastener opening in the first clamp flange and the second fastener opening in the second clamp flange; and

a nut configured to be tightened on the threaded end of the bolt to facilitate:

tightening the support clamp around the pipe segment tubing; and

securing the support clamp to the end cap assembly.

19. The test head of claim 18 , comprising:

a plug fluid bladder configured to be disposed within a pipe bore defined by the pipe segment tubing and to expand radially outward such that the plug fluid bladder circumferentially engages an inner surface of the pipe segment tubing to facilitate securing and sealing the open end of the pipe segment tubing within the end cap assembly;

an inflation fluid port that opens through the end cap assembly; and

an internal inflation fluid conduit that fluidly connects the inflation fluid port to the plug fluid bladder to enable inflation fluid to be supplied to the plug fluid bladder, extracted from the plug fluid bladder, or both.

20. The test head of claim 18 , comprising a support chain and a support securement fastener, wherein:

the support clamp comprises a first clamp flange and a second clamp flange that opposes the first clamp flange; and

the support securement fastener is configured to be tightened around the first clamp flange and the second clamp flange to facilitate tightening the support clamp around the pipe segment tubing;

the end cap assembly comprises:

a cap end plate configured to cover the open end of the pipe segment tubing;

a cap end ring configured to be disposed circumferentially around the pipe segment tubing;

a cap sleeve configured to be disposed circumferentially around the pipe segment tubing between the cap end plate and the cap end ring;

a cap seal configured to be disposed circumferentially around the pipe segment tubing between the cap sleeve and the cap end ring;

a threaded cap shaft configured to be inserted through a first shaft opening in the cap end plate and through a second shaft opening in the cap end ring; and

an end plate nut configured to be tightened on the threaded cap shaft behind the first shaft opening in the cap end plate and an end ring nut configured to be tightened on the threaded cap shaft in front of the second shaft opening in cap end ring to axially compress the cap seal between the cap sleeve and the cap end ring such that the cap seal expands radially inward; and

a first end of the support chain is configured to be shackled to the threaded cap shaft between the cap end ring and the cap end plate and a second end of the support chain is configured to be shackled to the support securement fastener between the first clamp flange and the second clamp flange on the support clamp to facilitate securing the end cap assembly to the support clamp.