Case study · Geoscience & subsurface studies

Custom multi-sample permeability test rig for corrosive HPHT studies | 140 bar

For a research center of a global energy company, IRIAN Mecatronics designed and built a test rig to measure the permeability of six samples in parallel. The equipment ensures high-precision (0.05%) differential pressure measurements under extreme corrosive conditions at 140 bar (2,030 psi) and 130°C (266°F).

Client: Research center of a global energy company
Field: Geosciences, Carbon Capture, Utilization, and Storage (CCUS)
Technique: HPHT permeability measurement in corrosive media

01 — The research question

How can you accurately measure a very small pressure drop when the fluid and operating conditions actively degrade the measurement system?

Characterizing the permeability of porous media under reservoir conditions (high pressure, high temperature) requires precise fluid flow control over extended periods. The experiment's reliability hinges on the system's material integrity. Corrosion in the flow path introduces particles, contaminates the fluid, and causes measurement drift, masking the very phenomena being studied.

The project's objective was to study carbonation by injecting CO2-saturated brine at 140 bar (2,030 psi) and 130°C (266°F). At these conditions, the fluid becomes a highly aggressive carbonic acid. Standard stainless steel components would corrode rapidly, generating particles that damage valves, distort pressure measurements, and prevent any reliable study—a challenge we also addressed in our custom Hastelloy reactor systems.

Ensuring stable and accurate high-precision differential pressure measurements when the operating conditions (corrosive fluid, HPHT) actively degrade both the flow path materials and the sensors.

02 — Our approach

Design driven by measurement integrity

To ensure long-term data reliability, every design choice aimed to eliminate the root causes of drift and failure, rather than merely compensating for their effects.

Eliminating corrosion at the source

The process fluid (brine + CO2 at 130°C / 266°F) is highly corrosive to stainless steels. We built all wetted parts from Hastelloy C-276, a material that is inherently inert in this environment. This design choice ensures the equipment's long-term integrity and prevents fluid contamination, guaranteeing repeatable measurements.
Ensuring direct and stable pressure measurement

To measure a very low pressure drop, we selected sensors with diaphragms made of a corrosion-resistant alloy. This approach avoids complex fluid separation systems, which are sources of leaks and measurement artifacts. The digital output preserves signal integrity all the way to the PLC, providing a direct, reliable, and precise measurement.
Improving the reliability of the automated circuit

Particles from the sample or from corrosion can damage the seats of conventional needle valves and cause leaks. We used a valve technology with an operating principle that is less sensitive to solid particles. This choice increases the reliability of the automated system and prevents failures during long-duration tests.

03 — Beyond this project

Could this approach apply to your project?

Geosciences and CO2 Storage (CCUS)

For characterizing rock-fluid interactions (permeability, reactivity) under reservoir conditions with brines, CO2, or H2S. The core principles—a fully inert HPHT circuit, high-precision pressure measurement, and automation—would be directly applicable.

Fine chemistry and materials science

For qualifying the aging resistance of materials (alloys, polymers) exposed to critical fluids like wet H2 or geothermal brines. The HPHT control architecture, use of high-performance alloys, and data acquisition system would be identical, with the pressure vessel design adapted as needed.

Chemical process development

For developing synthesis processes involving highly corrosive reagents or solvents under extreme conditions. The robust sealing, chemically inert flow path, and precise control of parameters (pressure, flow rate) are directly transferable to reactors or pilot plants.

04 — Specifications

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

Show specifications · 140 bar (2,030 psi) · 130°C (266°F) · Up to 6 slim tubes simultaneously

Technical specifications — Custom multi-sample permeability test rig for corrosive HPHT studies | 140 bar
Maximum operating pressure	140 bar (2,030 psi)
Maximum operating temperature	130°C (266°F)
Capacity	Up to 6 slim tubes simultaneously
Pressure measurement accuracy	0.05%
Pressure measurement resolution	0.01 bar (0.145 psi)
Wetted materials	Hastelloy C-276 (as-described version) or Stainless steel (base version)

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 permeability test rig be used with H2S-containing fluids?

Yes, the design principle is suitable for highly corrosive environments, including those with sour gases like H2S. The material selection (in this case, Hastelloy C-276) is validated for each specific application based on concentrations, pressure, and temperature to ensure full compatibility. The overall architecture of the test rig would remain the same.

Can this system be adapted to test the permeability of rock cores?

Absolutely. The fundamental principles—an inert flow path and precise differential pressure measurement—are independent of the sample size. The main adaptation would be to design custom HPHT analysis cells to hold rock cores. The pumps and instrumentation would be sized accordingly for the new flow rates and volumes.

Can the test rig be controlled to perform alternating or pulsed flow injections?

Yes, the system is controlled by a PLC (Programmable Logic Controller), which provides significant flexibility. It is entirely possible to program complex injection sequences, such as flow reversal, pressure cycles, or pulsed injections at very low flow rates. The performance will depend on the valve manifold configuration and the chosen HPHT injection system.

Does the equipment design comply with NACE standards for corrosive environments?

Yes, our equipment is designed to meet the industrial standards required for the application. For corrosive environments, we select materials (alloys, elastomers) and qualify welding procedures in accordance with NACE recommendations (e.g., NACE MR0175 / ISO 15156). All our equipment also complies with the Pressure Equipment Directive (PED).

Are corrosion or system instability affecting your permeability measurements?

Describe your fluid, operating conditions, and target accuracy. Our in-house engineering team will analyze your challenge to propose a suitable technical solution.

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