Case study · Geoscience & subsurface studies

Custom triple-cell test rig for reservoir formation damage analysis at 400 bar, 250°C

For a global energy leader, IRIAN Mecatronics designed and built a triple-cell test rig to characterize reservoir formation damage. The equipment simulates downhole conditions (400 bar / 5,800 psi, 250°C / 482°F) and withstands extremely corrosive drilling fluids, including 15% hydrochloric acid.

Client: A global energy leader
Field: Geoscience & Oil and Gas
Technique: Fluid-rock interaction & formation damage

01 — The research question

How to measure the impact of complex, corrosive fluids on rock permeability under downhole conditions?

Understanding how a porous medium degrades when exposed to fluids under pressure and temperature is a key challenge in many fields, from geoscience to catalysis. Measuring this interaction in the lab, known as damage, helps predict the behavior of a geological reservoir or the lifetime of a material, but it requires simulating often extreme conditions.

Our client, an energy leader, needed to quantify the permeability reduction in reservoir rock caused by complex drilling fluids to optimize their operations. No standard equipment could meet all their constraints at once: 400 bar pressure, 250°C temperature, resistance to highly aggressive fluids (15% HCl), a radial flow geometry, and the ability to run three parallel tests on samples of various sizes.

Ensuring reliable and repeatable fluid-rock interaction measurements while simultaneously containing high pressure, high temperature, and extremely corrosive fluids across three parallel, independent tests.

02 — Our approach

A custom design for reliability under extreme conditions

To overcome this challenge, our engineering team made design choices driven by safety, measurement repeatability, and the client's R&D productivity.

Ensuring resistance to multi-fluid corrosion

The test fluids included a mix of strong acids and abrasive muds, whose corrosivity is amplified by pressure and temperature. We therefore built all wetted parts from Hastelloy C-276, an alloy that is inert to the entire range of fluids. This allows the user to run consecutive tests without cross-contamination or equipment damage.
Tripling test productivity safely

Operating three HPHT systems is demanding, especially with heavy Hastelloy components. To maximize productivity within the same footprint, we integrated the three cells vertically on a single frame, equipped with an assisted lifting system. Sample loading is fast and safe for operators.
Adapting to different samples and protocols

R&D requires the flexibility to vary sample sizes and flow regimes. Each cell thus incorporates a floating piston that automatically adjusts to the rock sample's height, and dedicated fluid circuits allow for selecting the flow mode. The equipment offers great versatility without requiring major mechanical changes.

03 — Beyond this project

Does your project share similar constraints?

Deep geothermal energy and geological storage (H2, CO2)

The challenge is to study the interaction between rock and fluids (steam, H2, supercritical CO2) under corrosive HPHT conditions. The special alloy construction, P/T control, and the principle of measuring permeability changes would be retained.

Chemistry and heterogeneous catalysis

This involves parallel testing of solid catalyst aging under a flow of corrosive reactants at HPHT, as with our 6-reactor bench. The multi-reactor bench principle, special alloy construction, and centralized control would remain the same.

Nuclear Industry

The objective is to study the long-term leaching of storage materials exposed to corrosive fluids at HPHT. The robustness of the containment cell, its corrosion resistance, and its ability to maintain stable conditions would be retained.

04 — Specifications

The values for this project. Every system is custom-built, so they adapt to your requirements.

Show specifications · 400 bar (5,800 psi) · 250°C (482°F) · 3 independent vertical cells

Technical specifications — Custom triple-cell test rig for reservoir formation damage analysis at 400 bar, 250°C
Maximum operating pressure	400 bar (5,800 psi)
Maximum operating temperature	250°C (482°F)
Architecture	3 independent vertical cells
Wetted materials	Hastelloy® C-276

IRIAN Mecatronics designs and builds custom high-pressure, high-temperature equipment for research laboratories, technical centres and industry.

About the company

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05 — FAQ

Frequently asked questions

Can this test rig be used with fluids containing H2S (sour gas)?

Yes, our equipment can be designed for H2S service. The choice of Hastelloy C-276 already provides an excellent basis for resistance. For a specific application, we would validate its compatibility with the planned concentrations and conditions, select appropriate seals, and integrate the required safety features (gas detectors, enhanced ventilation).

Is it possible to design a similar system for higher pressures and temperatures, for example, 1,000 bar and 350°C?

Yes, our engineering team regularly designs equipment for extreme conditions exceeding these values. Such an increase would require a complete mechanical redesign of the cells, the selection of suitable materials (e.g., nickel-based superalloys), and a review of the pressure generation and heating systems. The principle of a robust and safe design would remain the same.

Is the system suitable for long-duration tests, such as material aging over several months?

Absolutely. The system is designed for continuous and stable operation. For long-duration tests, we pay special attention to the reliability of the control loops, automated data acquisition, and options for remote monitoring. The robust special alloy construction ensures stable conditions and prevents test contamination over the long term.

How is safety managed if the test fluids are flammable (ATEX zone)?

Safety is our priority, and our equipment is designed to comply with applicable directives, including ATEX when required. This involves a detailed risk analysis and the use of certified components (motors, sensors), appropriate ventilation systems, and the integration of active safety features like gas detection. Our test bench for flammable gases is an example of this capability.

Are your fluid-rock interaction tests limited by the corrosion, pressure, or temperature ratings of your current equipment?

Describe your challenge, no matter how specific. Our engineering team will analyze your project's feasibility and get back to you with a proposed approach.

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