Case study · Geoscience & subsurface studies
Retrofitting proprietary high-pressure pumps for PVT analysis
For a geoscience services laboratory, IRIAN Mecatronics performed a complete retrofit of three high-pressure pumps used for PVT analysis. The upgrade replaced an obsolete proprietary control system with an open, standard architecture while restoring the equipment's mechanical integrity.
At a glance
- Client
- Geoscience services laboratory
- Field
- Reservoir fluid analysis
- Technique
- Mechanical and electronic retrofit, custom software development
01 — The research question
How to upgrade lab equipment when its proprietary control system is no longer supported?
Many pieces of lab equipment, while mechanically sound, become unusable when their proprietary control electronics reach end-of-life. Without support from the original manufacturer, a single board failure can sideline a critical instrument, and replacement with a new unit represents a major investment. This was the case for three high-pressure pumps essential to our client's Pressure-Volume-Temperature (PVT) analyses. Faced with an irreparable obsolete control system and mechanical failures, the only viable option to preserve the initial investment in their precision mechanics was a <a href="https://irian-mecatronics.com/maintenance-retrofit-requalification-services/">complete retrofit</a>.
How to replace the entire control chain (electronics, motor, software) of a proprietary high-pressure pump with standard industrial components, while preserving its precision mechanics and developing a software interface that replicates the original user experience?
02 — Our approach
A three-part approach: mechanics, electronics, and software
Restoring mechanical integrity
The pumps showed significant damage to the piston and lead screw. A full disassembly allowed us to inspect and replace all critical and wear parts. This refurbishment was a prerequisite to ensure safe, leak-tight operation up to 980 bar, as confirmed by factory leak tests.
Replacing the proprietary control system with an open architecture
Faced with undocumented original electronics, we replaced the entire control chain with a standard solution: a programmable logic controller (PLC), motor, and drive. This choice eliminates the risk of a hazardous repair and ensures the equipment's longevity, as its components are now easy to source.
Developing custom software for immediate adoption
To avoid disrupting existing test protocols, we developed a software interface that faithfully mimics the original ergonomics. Operators were able to use their familiar work modes (constant pressure, flow rate, and volume) without extensive training, ensuring the continuity and consistency of their measurements.
03 — Technical specifications
| Control pressure | up to 980 bar (14,200 psi) |
|---|---|
| Pump volume | 300 mL |
| Number of units retrofitted | 3 |
| Control modes | Constant pressure, constant flow rate, constant volume |
04 — Other applications
Is your equipment limited by obsolete electronics?
Chemistry / Petrochemicals
Upgrading <a href="https://irian-mecatronics.com/process-development-chemical-pilot-plants-instrumented-experimental-systems/">pilot reactors</a> or catalytic test benches. The principle is the same: replace the electronics with an industrial PLC and develop a custom HMI to preserve operator habits, adapting the control loops to the specific physical parameters.
Materials testing
Refurbishing older hydraulic presses or compression frames. The approach involves integrating a PLC for precise force or displacement control, and dedicated software for programming test cycles and acquiring data.
Energy
Upgrading test rigs (hydrogen storage, CO₂ capture) with rigid initial controls. The retrofit methodology based on standard components provides the flexibility needed to implement new protocols, adapting the design to specific constraints (materials, ATEX).
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