Case study · Fluid dynamics & phase behavior

Turnkey PVT laboratory for reservoir fluid studies | 1000 bar, 200°C

IRIAN Mecatronics designed and built a complete, turnkey laboratory for a leading oil and gas service company to perform comprehensive reservoir fluid analysis. The system characterizes the thermodynamic behavior (PVT, viscosity, density) of fluid samples at pressures up to 1000 bar (14,500 psi) and temperatures up to 200°C (392°F).

Client: A leading national oil and gas service company
Field: Oil & Gas / geosciences
Technique: HPHT PVT, viscosity, and density analysis

01 — The research question

Characterizing the thermodynamic behavior of complex fluids at high pressure and temperature

Optimizing oil and gas field production requires a precise understanding of the reservoir fluids' thermodynamic behavior. Pressure-Volume-Temperature (PVT) studies are essential, and they must accurately replicate downhole conditions, which can exceed a thousand bar and several hundred degrees.

Our client required a complete laboratory to perform the entire analysis workflow—from sample preparation to viscosity measurement—at conditions up to 1000 bar (14,500 psi) and 200°C (392°F).

The challenge was to ensure highly accurate measurements for a complex analysis workflow (PVT, viscosity, density) at extreme conditions, without using mercury for pressurization and volume measurement.

02 — Our approach

An integrated approach for maximum reliability

We designed this laboratory around three key principles to deliver a complete, reliable, and safe solution, ensuring we had full control over every component.

Ensuring overall performance with an integrated solution

Instead of supplying separate pieces of equipment, we served as the single integrator and manufacturer for the entire laboratory. This turnkey approach ensured the consistency and safety of the complete measurement workflow and gave the client a single point of contact for design, installation, training, and maintenance.
Achieving reliable, mercury-free PVT measurement

The heart of the system is a 400 cc full-visibility PVT cell. It enables precise measurement of volume changes and detection of phase transitions (bubble point, dew point). Direct visual confirmation via an HD camera provides unambiguous validation of the automated measurements.
Extending the analysis to viscosity and density

To provide a comprehensive dataset, we developed dedicated analysis instruments (a viscometer and a densitometer) that operate under the same extreme conditions. This approach eliminates any weak link in the analysis chain and guarantees consistent data, which is critical for reservoir simulation models.

03 — Beyond this project

Does your project share similar constraints?

Energy (carbon capture and storage - CCUS)

The same approach can be used to characterize the phase behavior of supercritical CO2 mixtures. The core principles—a full-visibility cell, precise pressure and volume control, and fine temperature regulation—are directly applicable to custom CCUS reactor systems.

Chemistry / Polymers

To study solubility or monitor reactions in supercritical media, the HPHT cell design, efficient stirring, and visual observation capabilities are directly transferable. The primary adaptation would be the integration of in-situ analytical probes.

Geosciences / Geothermal

For simulating the behavior of geothermal fluids, the system's ability to operate continuously at high pressure and temperature is a proven asset. The robust mechanical design would be maintained, with the primary challenge shifting to the selection of specific corrosion-resistant alloys.

04 — Specifications

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

Show specifications · 1000 bar (14,500 psi) · 200°C (392°F) · 400 cm³

Technical specifications — Turnkey PVT laboratory for reservoir fluid studies | 1000 bar, 200°C
Maximum operating pressure	1000 bar (14,500 psi)
Maximum operating temperature	200°C (392°F)
PVT cell volume	400 cm³
Viscometer measurement range	up to 6000 cP

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 type of PVT lab analyze corrosive fluids like sour gas (H2S)?

Yes, absolutely. The operating principle and measurement systems are identical. The primary adaptation involves selecting specific materials, such as nickel-based alloys like Hastelloy or Inconel, for all wetted parts. Our engineering team selects the most appropriate grade to ensure long-term corrosion resistance and safety.

Is it possible to design a fluid analysis system for pressures above 1000 bar?

Yes, designing high-pressure equipment is our core business. The principles of the variable-volume cell and dedicated instruments still apply. The mechanical design, material selection, and component thicknesses would be calculated and adapted to meet the requirements of the Pressure Equipment Directive (PED), ensuring both safety and measurement accuracy at pressures of several thousand bar.

Can other types of analysis (e.g., compositional analysis) be integrated into this HPHT measurement chain?

Yes, our role as an integrator allows for this. We can design the system to include secure sampling ports or to integrate online analyzers (such as chromatographs or spectrometers) directly into the high-pressure loop. The key challenge, managed by our in-house design office, is to ensure a reliable, safe, and zero-dead-volume interface.

How is maintenance handled for such a complex PVT analysis laboratory?

Maintainability is a core part of our design process. As the designer and manufacturer of the complete system, we provide full preventive and corrective maintenance. This includes the supply of spare parts, on-site service from our technicians, and the option to upgrade or retrofit the equipment to meet future requirements.

Is your fluid analysis limited by standard equipment?

Tell us about your required pressure and temperature conditions and any specific fluid constraints. Our engineering team will review the feasibility of your project and propose a technical approach.

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