High Pressure High Temperature (HPHT) Testing

Our comprehensive suite of HPHT testing gives you complete insight into how your materials will perform under extreme conditions, with specialized capabilities for both sour (H₂S-containing) and sweet (non-H₂S) environments. We subject your materials to specific combinations of liquids and gases, including H₂S, H₂, acids, bases, hydrocarbons, and custom mixtures while simultaneously applying relevant temperature variations and pressure fluctuations to replicate your exact operating conditions. 

• Compatibility testing for polymers, elastomers, and composites 

• Rapid Gas Decompression (RGD) testing in both sour and sweet environments 

• Stress Corrosion Cracking (SCC) and pitting/crevice resistance evaluation 

• Autoclave Slow Strain Rate (SSR) and Rippled Slow Strain Rate (RSSR) testing  

• Cyclic pressure and temperature testing 

• Accelerated aging for lifespan prediction 

• Custom exposure programs for material evaluation/qualification, and functional testing 

• Custom exposure programs for client-specific applications 

• Comprehensive pre- and post-exposure analysis 

From critical sealing components to structural materials, we test a comprehensive range of items that must withstand extreme environments. Our testing capabilities cover elastomeric seals, gaskets, O-rings, flowlines, pipe liners, metal alloys, and composite materials used in high-stress applications. Whether you need qualification testing for a new material or investigating the cause of an unexpected failure, our experts deliver accurate, actionable results that help you select and validate materials for your most demanding applications. 

• Polymer components: seals, gaskets, O-rings, flowlines, pipe liners 

• Metals and alloys: pipes, connections, vessels, wellhead components 

• Composite materials for structural applications 

• Thermal insulation systems and coatings 

• Critical components for subsea and downhole applications 

Our experts work with you to advise on the most suitable testing methods for your materials, develop testing protocols that meet your specific project requirements, and build custom R&D programs to evaluate components and systems. We optimize resource allocation by using adaptable testing platforms with multiple large vessels and smaller units, enabling simultaneous testing and faster results. For polymer testing, we offer specialized capabilities for both sour (H₂S-containing) and sweet (non-H₂S) environments with test durations ranging from standard protocols to extended exposure studies. 

• Qualification testing to industry standards 

• Custom testing programs for specific applications 

• Accelerated aging to predict long-term material performance 

• Rapid Gas Decompression (RGD) evaluation in both sour and sweet environments 

• Sour and sweet fluid compatibility testing 

• Failure analysis for in-service components 

• Comprehensive material characterization before and after exposure 

Post-Exposure Services: 

Following HPHT testing, Element provides a comprehensive suite of post-exposure services to assess material properties and identify potential degradation mechanisms: 

• Chemical Analysis (FTIR): Identify before and post-test material composition and degradation products. 

• Thermal Analysis (TGA/DSC): Assess thermal stability, decomposition behavior, glass transition, crystallinity  through combined weight and heat flow measurements. 

• Thermo-Mechanical Properties (DMA): Measure changes in material properties such as stiffness, modulus, and damping characteristics as a function of temperature, time, and frequency before and after HPHT exposure. 

• Thermal conductivity measurement: Assess the impact of HPHT exposure on a material's thermal conductivity, a critical factor for heat transfer applications. 

• Electrical Properties: Evaluate changes in electrical conductivity and other electrical properties after HPHT exposure, relevant for electrical components. 

• Microscopic Analysis: Employ optical and electron microscopy to examine the microstructure of the material and identify any microstructural changes induced by HPHT exposure. 

• In-Situ Friction Testing: Assess the tribological properties of materials under simulated downhole or service conditions. This test replicates the specific temperature, pressure, environment, media, force, and speed experienced by the material in real-world applications. By measuring the coefficient of friction and mass losses of materials under these conditions, you gain valuable insights into the material's ability to perform reliably in terms of wear and tear. 

• Mechanical Testing: Evaluate changes in material properties like flexural, tear, tensile strength, yield strength, and elongation after HPHT exposure. 

Our state-of-the-art facilities are equipped with specialized testing vessels and analytical equipment to simulate the most demanding service environments and accurately measure how materials respond to these challenges. We operate multiple large HPHT vessels, allowing for simultaneous testing and faster turnaround times. Our specialized equipment includes vessels capable of extreme conditions (up to 2000 bar, 320°C), dedicated facilities for sour service testing, and comprehensive analytical capabilities for post-exposure evaluation. 

• Multiple large HPHT vessels for simultaneous testing up to 2,000 bar and 300°C 

• Specialized vessels for testing up to 320°C 

• Dedicated facilities for sour service testing with mixtures containing up to 30% H₂S, performed in sealed areas with fast extraction systems to ensure safety 

• Pressure labs with over 100 test stations for sweet environment testing 

• Comprehensive analytical equipment for post-exposure evaluation 

• Simulated Service Test (SST) vessel for pipeline insulation testing 

Element uses a fully instrumented 0.8 m diameter SST (Simulated Service Test) vessel for two 5 m insulated pipes capable of being heated to 200°C internally with up to 250 bar external water pressure at 4°C for tests lasting up to 12 months. Our experts can thoroughly assess subsea wet insulation coatings for changes in mechanical and thermal properties caused by the simulated service conditions. 

• Low-temperature seal performance rigs 

Our sour fluid exposure capabilities 

• World-class scale sour fluid exposure facilities in the UK and the US. 

• Routine exposure to 340 bar and 250 °C with mixtures containing up to 30% H₂S 

• Exposure temperatures to 320 °C in special vessels. 

• Customer-specific services; consultancy, material and functional testing programs. 

• Rapid Gas Decompression (RGD) tests with sour gas mixtures. 

Our sweet fluid exposure capabilities 

• Pressure labs with over 100 test stations 

• Our standard vessels operate up to 230°C and 1000 bar 

• Special vessels are used for temperatures to 315°C and pressures to 1,400 bar 

• Pressure labs with over 100 test stations 

• Low-temperature seal performance rig 

• Dedicated rigs for umbilical pressure cycling and permeation (ISO 8308) 

• Dedicated lab for gas permeation 

• Many ovens for vapor pressure tests 

• Simulated Service Test (SST) vessel, for  pipeline insulation 

• Customer-specific services; consultancy, material, and functional testing programs 

Element operates world-class HPHT testing facilities strategically located to serve global clients, with specialized capabilities at each location. Our extensive network provides convenient access to testing services regardless of your location, with consistent methodologies and documentation across all facilities. Our technical staff have contributed to both ISO and NORSOK standards development and are members of the relevant ISO Working Group committee. Element has also run two internationally supported Joint Industry Projects (JIPs) in the area of oilfield polymers: SOUR and SOUR2. With laboratories in the UK, US, and Europe, we offer localized support with global expertise, ensuring you receive the same high-quality service and reliable results wherever you are based. 

• UK: Advanced polymer testing facilities including sour service exposure capabilities 

• US: Global Corrosion and Materials Technology Center in Houston specializing in metals and polymers 

• Europe: Specialized testing facilities supporting the energy sector 

• Additional support from our global network of laboratories for comprehensive materials evaluation