Case study · Geoscience & subsurface studies
Custom HPHT Permeameter for Rock Permeability Testing at 500°C / 500 bar in Corrosive Fluids
For a public geoscience research institute, IRIAN Mecatronics designed and built a custom high-pressure, high-temperature (HPHT) permeameter. The equipment measures the permeability of rock samples over long periods under extreme conditions—500 bar (7,250 psi) and 500°C (932°F)—while exposed to aggressive aqueous fluids.
At a glance
- Client
- Public geoscience research institute
- Field
- Geoscience & subsurface studies
- Technique
- Permeability measurement
01 — The research question
How to measure the permeability of a porous material under HPHT conditions with corrosive fluids?
Measuring rock permeability involves flowing a fluid through a sample and measuring the resulting pressure drop. Keeping these conditions stable and repeatable becomes a major challenge as pressure and temperature rise, especially with corrosive fluids. The equipment design must ensure a perfect seal, chemical compatibility of all materials, and accurate temperature measurement at the core of the experiment, as temperature governs fluid viscosity and thus the final calculation. Our client needed to simulate conditions found in geothermal reservoirs or CO2 storage sites, involving temperatures of 500°C (932°F), pressures of 500 bar (7,250 psi), and aggressive fluids (acids, bases). Off-the-shelf permeameters cannot simultaneously reach these pressure and temperature levels.
The challenge: To maintain a perfect, long-lasting seal around a rock sample subjected to very high pressure and temperature with corrosive fluids, without compromising measurement accuracy or operator safety.
02 — Our approach
A design driven by measurement accuracy and operator ergonomics
Inverting the cell architecture for safer, faster handling
Conventional HPHT cells require handling a heavy lid. To make serial testing easier, we inverted this architecture: the top cap is fixed, and the cell body moves down. This gives the operator direct access to the sample without lifting any heavy parts, making changeovers safer and faster.
Placing instruments at the core for reliable temperature measurement
Fluid temperature is critical for calculating permeability. Measuring it on the outer wall would be inaccurate. We integrated three thermocouples as close as possible to the rock, with two directly in the fluid. This gives the user the true temperature, eliminating a major source of error in their calculations.
Ensuring a 500°C seal with polymer-free gaskets
At 500°C (932°F), polymer seals are destroyed. To guarantee a seal at 500 bar (7,250 psi), we implemented a technology based on compressed graphite gaskets. This solution, proven on our <a href="https://irian-mecatronics.com/project/500c-130-bar-corrosion-test-reactors-for-materials-research/">custom corrosion test reactors</a>, allows the equipment to operate safely across its entire functional range.
03 — Technical specifications
| Operating pressure | 500 bar (7,250 psi) |
|---|---|
| Operating temperature | 500°C (932°F) |
| Sample dimensions | Ø 1.5" x 3" (Ø 38.1 x 76.2 mm) |
| Wetted materials (pore fluid) | Inconel 625 |
| Cell body and caps material | 316LN |
| Injection pump (upstream) | 0.1 µL/min to 105 mL/min, 517 bar max, volume 223.5 mL |
04 — Other applications
Does your project involve one of these applications?
Geothermal energy
To assess reservoir performance, it is crucial to measure how rock permeability changes when exposed to hot, corrosive brines. The HPHT cell's architecture, corrosion-resistant materials, and core temperature measurement would remain relevant.
Nuclear waste storage
Studying the long-term behavior of containment materials like clays and concretes requires maintaining stable conditions over long periods. This rig's ability to operate with specific fluids and perform low-flow measurements would be directly transferable.
High-temperature hydrogen production
Characterizing electrode materials in contact with superheated steam is a key challenge. The cell's principle, precise heating system, and high-temperature sealing would be kept, while adapting materials for <a href="https://irian-mecatronics.com/hydrogen-atex-test-benches/">hydrogen compatibility</a>.
An engineer from our design office replies as soon as possible.