Multi-Channel HPHT Test Bench for Carbonation Studies
For its advanced research, a major energy group contracted IRIAN MECATRONICS to design a unique HPHT test bench. The objective was to develop a multi-channel system for carbonation studies, capable of operating up to 140 bar and 130°C. Our solution consists of a custom frame integrated into an existing oven, operating 6 parallel “slim tubes” for high-precision differential pressure measurements.
Simulating Carbonation: Specifications for a Custom HPHT Test Bench
The client needed to study the flow of CO₂-laden water through slim tubes to simulate carbonation phenomena under HPHT conditions. The primary challenge was to measure small pressure variations with very high precision in a highly corrosive environment.
- Corrosive HPHT Conditions: The system had to operate up to 140 bar and 130°C with aggressive fluids (brine, CO₂), which posed a risk of accelerated corrosion for standard steels.
- Ultra-High Measurement Precision: The process, involving very low flow rates, required pressure sensors with extreme precision and resolution (0.01 bar) to detect minute pressure drops.
- Complex Integration: The entire hydraulic circuit (6 slim tubes, valves, etc.) had to be integrated onto a custom frame inside an existing oven (Memmert UF750plus), with significant space constraints and the need for bulkhead feedthroughs.
- Automation & Control: The client wanted to control the entire process (pumps, valves, data acquisition) from a single interface, with the ability to program automated sequences.
Ensuring Precision and Durability in a Corrosive HPHT Environment
Our engineering department met the challenge by focusing on material selection, high-precision instrumentation, and seamless software integration.
- Advanced Material Selection: To counter the corrosion risk from the combination of brine, CO₂, and high temperature, we specified and implemented a solution where all wetted components (tubing, valve bodies, sensors) are made of Hastelloy C-276. This choice ensures the long-term durability of the equipment and the integrity of the measurements.
- High-Precision Instrumentation: For the critical pressure measurement, we selected Keller LEX1 sensors with Hastelloy diaphragms. These sensors provide an accuracy of 0.05% and a resolution of 0.01 bar, making it possible to quantify the slightest variations in differential pressure between the slim tubes.
- Mechanical and Software Integration: We designed a modular aluminum profile frame to support the 6 slim tubes and the valve manifold inside the oven. The entire system is controlled by a PLC and a Human-Machine Interface (HMI) developed in LabView, allowing the operator to control the pumps, automated valves, and record all data.
Examples of our Custom Designs
