Case study · Precision pumps & injection systems

Fail-safe high-pressure pump with non-reversible drive for long-duration experiments

For a client in geoscience research, IRIAN Mecatronics designed and built a custom high-pressure pump. The equipment simulates geological reservoir conditions (750 bar / 10,880 psi) and guarantees pressure is maintained during a power failure, securing long-duration experiments.

Client: Geoscience research organization for the energy sector
Field: Geosciences, fluid mechanics
Technique: Confining pressure maintenance, ultra-low flow rate fluid injection

01 — The research question

How to maintain a high, stable static pressure, even during a power outage?

In many geoscience, chemistry, or materials science experiments, pressure stability is non-negotiable. When a test runs for several days or weeks, a simple power outage can cause depressurization and ruin all the work. The challenge is to combine very fine motorized volume control with a safety mechanism that guarantees confinement in case of failure.

Our client needed to simulate geological reservoir pressure conditions (750 bar / 10,880 psi) in the lab to study fluid behavior. Commercial high-pressure pumps did not offer a satisfactory solution: those with fine flow control were reversible and would lose pressure in an outage, while more secure alternatives lacked the resolution for precise control over long periods.

To provide ultra-fine motorized control of volume at very high pressure while making the system mechanically non-reversible to maintain confinement during a power failure.

02 — Our approach

Designing an inherently safe pump

The pump's reliability is based on three design choices focused on passive safety and durability: the drive mechanism, the body material, and the selection of moving parts.

Ensuring a non-reversible drive

The challenge was to prevent the fluid pressure (750 bar / 10,880 psi) from pushing the piston back if the motor failed. We used a drivetrain with a very high gear reduction, which is naturally non-reversible. The experiment's safety becomes intrinsic to the mechanics, without adding a brake that could fail, and the gear reduction provides very high control resolution.
Selecting a fatigue and corrosion-resistant body material

The pump body had to withstand mechanical fatigue from the pressure and be compatible with potentially corrosive reservoir fluids. A high-yield stainless steel was chosen for its ability to handle the pressure without excessive oversizing and for its corrosion resistance, preserving the purity of the samples.
Preventing piston galling and seal wear

To avoid galling under high load between the piston and the steel body, the piston was machined from a non-ferrous alloy with a low friction coefficient. This choice, combined with an elastomer seal offering broad chemical compatibility, ensures the pump's reliability and longevity by reducing maintenance.

03 — Beyond this project

Does your project require stable and secure pressure?

Fine chemistry / Polymerization

For precisely injecting reactants into a pressurized reactor, where a failure could compromise a batch. The non-reversible drive principle would remain key to ensuring dosing safety and protecting the production.

Materials testing / Rock mechanics

For applying a stable confining pressure during triaxial compression tests, where measurement validity depends on this stability. The non-reversibility and high-pressure capability would be retained.

Food industry / Supercritical CO2 extraction

For keeping the pressure of a supercritical fluid stable, where any variation affects the yield. The precise volume control and inherent safety of the pressure hold would be directly transferable, with materials adapted to food-grade standards.

04 — Specifications

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

Show specifications · 750 bar (10,880 psi) · PC-based Human-Machine Interface (HMI) · Ethernet connectivity, compatible with standard industrial protocols

Technical specifications — Fail-safe high-pressure pump with non-reversible drive for long-duration experiments
Operating pressure	750 bar (10,880 psi)
Control	PC-based Human-Machine Interface (HMI)
Integration	Ethernet connectivity, compatible with standard industrial protocols

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

About the company

They trust us

05 — FAQ

Frequently asked questions

Can this non-reversible drive pump be adapted for different volumes or flow rates?

Yes, the operating principle is independent of the pump's size. For different requirements, our engineering team resizes the cylinder and piston to achieve the desired volume, and adapts the drivetrain to obtain the required flow rate range and resolution. The main benefit—inherent safety—is maintained across all our precision injection systems.

What types of corrosive fluids can such a high-pressure pump handle?

Chemical compatibility is determined by the choice of wetted materials. This model uses a high-performance stainless steel, but for highly corrosive fluids (H2S, concentrated brines, acids), we select superior alloys like Hastelloy or Inconel for the body, piston, and fittings, as we do for our Hastelloy test rigs.

Does this pump's design comply with the Pressure Equipment Directive (PED)?

Yes, absolutely. Like all our equipment, this pump is designed in full compliance with the Pressure Equipment Directive (PED 2014/68/EU). We perform the risk analysis, compile the technical file, and apply the necessary CE marking according to the equipment's risk category.

How does this pump integrate into an existing test rig?

Integration is one of our priorities. The pump is delivered with its PC control interface but can be controlled by an external system. It communicates via standard industrial protocols (Ethernet). We can also provide a function library (DLL) for direct integration into your existing supervision software (LabVIEW, etc.).

Do you need to guarantee your experiment's pressure, no matter what?

Describe your pressure, flow rate, and safety constraints. Our engineering team will analyze your project's feasibility and get back to you with a technical proposal.

Discuss your project Download the case sheet (PDF)