Case study · Precision pumps & injection systems
Upgrading legacy high-pressure pumps: a control system retrofit
For an industrial client using high-pressure processes, IRIAN Mecatronics performed a complete refurbishment of two positive displacement pumps. The project covered both mechanical reconditioning and the development of a new control system to restore and secure their operation.
At a glance
- Client
- Industrial user or R&D lab working with high-pressure processes.
- Field
- High-Pressure Processes
- Technique
- Mechanical retrofit & control system modernization
01 — The research question
How do you maintain or upgrade precision equipment when manufacturer support is gone?
A piece of lab or production equipment can be mechanically sound but limited by an obsolete control system, recurring failures, or unavailable parts. Buying new is not always possible or desirable, whether for cost or lead time reasons, or because the original equipment has specific qualities that are no longer available on the market. In this project, the client was facing performance degradation and failures on two critical high-pressure pumps. With standard solutions (manufacturer maintenance or replacement) being unsuitable, they chose to entrust the refurbishment of their precision pumps & injection systems to a specialist capable of both restoring the mechanics and reinventing the controls.
The challenge: Modernize the control system and user interface of a precision mechanical asset without degrading its original performance and without access to the initial manufacturer's support or drawings.
02 — Our approach
A two-step approach: Restore the mechanics, reinvent the controls
Restoring the original mechanical integrity
Without manufacturer documentation, the first challenge was to diagnose the exact source of the wear. We conducted a complete inspection to identify every faulty component. The principle was to repair or remanufacture these parts as exact replicas to restore reliability and pressure containment, thereby extending the equipment's service life.
Developing a modern, intuitive control system
The original control system was obsolete. Rather than repairing it, we developed a modern automation system and a new graphical interface. This custom solution ensures perfect compatibility with the existing mechanics and allows the operator to finely control flow rate and pressure while monitoring key parameters in real time, just as on our custom HPHT test benches & pilot plants.
03 — Technical specifications
| Pump type | Syringe pump / Positive displacement pump |
|---|---|
| Monitored parameters | Pressure, flow rate, temperature |
04 — Other applications
Is your equipment mechanically sound but held back by an obsolete control system?
Aerospace
A common challenge is upgrading a hydraulic test bench whose electronics are no longer supported. The principle of keeping the power mechanics while replacing the control cabinet, sensors, and supervision software, as on this 3-in-1 geotechnical test bench (UCS, Tensile), would be identical.
Energy production
To renovate the regulation system of a rotating machine, the approach of adding modern sensors (vibration, temperature) and centralizing data on a new supervision platform to enable predictive maintenance would be the same.
Food & Beverage
For a production line automation system that no longer guarantees regulatory traceability, replacing the controller and operator interface, and integrating new data collection functions, would follow the same logic.
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