High Pressure High Temperature (HPHT) Testing

As a world-leading testing partner for the Energy, Aerospace and Petrochemical industries, Element performs HPHT (high pressure, high temperature) testing, also known as autoclave testing, for many applications including metals, alloys, polymers, composites and coatings. Qualifying and assessing materials that can perform under extreme conditions for decades of useful service is a high priority for rapidly advancing industries.

HPHT testing, also known as Autoclave Testing, is carried out in an environment that recreates the high temperatures (HT) and high pressures (HP) which is commonly occurring in many processes of the subsea oil and gas production and Carbon Capture and Storage (CCS, CCUS). Combining significant experience in HPHT applications with our state-of-the-art testing facilities, Element can replicate a combination of extreme conditions of high pressure and high temperature safely to provide you with testing, analysis, and materials evaluation of equipment designed for harsh HPHT environments.

With HPHT autoclave facilities for testing of your materials, we are in a unique position to provide you with short lead times and fast turnaround. We understand the individual needs and challenges of HPHT projects and can help you meet your product safety and qualification requirements on time and on budget.

HPHT testing for polymers

HPHT testing is critical for polymers used as seals, gaskets, flowlines, and pipe liners in chemically aggressive environments including hydrogen, supercritical CO2, hydrogen sulfide and other sour gases. Element offers a wide range of testing for the characterization and compatibility of polymers, elastomers and composites, including exposure to production and sour fluids in HPHT environments. The testing services we offer include: 

• Polymer exposure in sour fluids, CO2, CH4 and multiphase mixtures
• Polymer exposure in sweet environment
• Customized sour Rapid Gas Decompression (RGD) 
• Accelerated thermal and chemical ageing 
• Service life estimation using Arrhenius approaches 
• XHPHT
• Pressures to 15,000 psig
• Temperatures to 320 °C
• Temperature and pressure cycling on seals
• Full datalogging
• Multiple large vessels capable of ageing several materials simultaneously
• Dozens of smaller vessels for ageing

The following post-exposure services assess material performance:

• Mechanical Testing 
• Differential Scanning Calorimetry (DSC)
• Dynamic Mechanical Analysis (DMA)
• Thermo Mechanical Analysis (TMA)
• Thermogravimetric Analysis (TGA)
• Thermal conductivity measurement 
• XHPHT

HPHT Testing for Polymers

Test standards:

• ISO 23936
• API 6A conditions EE/FF and GG/HH
• NORSOK M-710
• API TR 6J1
• API 17D

HPHT testing for metals 

HPHT testing is required to evaluate the Stress Corrosion Cracking (SCC), pitting and crevice resistance of Corrosion‐Resistant Alloys (CRAs) exposed to harsh sour service (H2S) and sweet service (CO2) environments in the Oil & Gas industry. Element performs HPHT testing to qualify materials to the requirements of NACE MR0175 / ISO 15156. Our HPHT testing includes autoclave facilities with the following capabilities: 

• World-class scale; HPHT laboratories in the UK, US and Europe
• Stress Corrosion Cracking (SCC), Pitting and Crevice tests up to 250° C and 300 bar 
• Autoclave Slow Strain Rate (SSR) and Rippled Slow Strain Rate (RSSR) testing 
• Customer-specific services; advice and guidance, consultancy and bespoke testing programs

HPHT testing for coatings 

HPHT testing for the evaluation of internal coatings and linings for tank and vessel applications are designed to simulate field conditions in a controlled, laboratory setting. Evaluations are conducted through exposing the coating or lining in question to a specific composition of liquids and gases (both sweet and sour) often in conjunction with temperature and pressure. Often this testing is utilized to qualify new coatings for a specific environment or to determine their resistance to process conditions such as steam out, gas pressure variations, rapid decompression etc. 

Test methods covered include NACE TM 0185 as well as client-specific standards and bespoke test methods. Element also offers a wide range of characterization tests for coatings both pre and post-exposure testing to evaluate the film performance.

Custom HPHT testing

Element has over 25 years of experience of implementing an array of features to accommodate your specific HPHT testing requirements. We can design, build and operate custom fixtures, rigs, pressure vessels, and other apparatus to achieve real-time conditions for your project.

Our Engaged Experts have developed a number of client-driven bespoke HPHT tests, including sour rapid gas decompression of elastomers and thermoplastics. Almost every set of circumstances is different, we can work with you to create a test plan that meets your specific needs in a single test program.

Complementary testing services 

Element’s HPHT testing services for testing of metals, polymers and coatings is complemented by our fully equipped facilities for mechanical testing, thermal analysis testing, chemical  analysis, fracture mechanics and fatigue. Our Engaged Experts characterize material behavior both pre-and post-exposure, to quantify the influence of exposure on material performance and provide you with the most accurate data possible. 

Contact our experts today to discuss your HPHT testing requirements.