Expansion of Subsea Research Infrastructure: The Hydraulic High-Pressure Testing System (HHPS)
With the funded project Hydraulic High-Pressure Testing System (HHPS), the Institute for High Integrity Mechatronic Systems (ZMS) at Aalen University is strategically expanding its research infrastructure in the fields of energy and subsea technology. The objective of the project is the development and implementation of a modular high-pressure test bench that enables realistic investigation of pump and valve systems under extreme conditions. The project is designed for a duration of 11 months. It is funded by the German Federal Ministry for Economic Affairs and Energy (BMWE), with Project Management Jülich (PTJ) acting as the project sponsor.
At the core of the project is a novel testing system that allows experiments with various fluids such as water, CO₂, and hydraulic fluids under partially multiphase conditions and at pressures of up to 1500 bar. This enables comprehensive testing of both active and passive subsea components. HHPS facilitates performance, leakage, and lifetime tests under conditions comparable to those encountered in real subsea applications.
Thanks to its modular architecture and intelligent interconnection of different process segments, the system offers a high degree of flexibility. It enables the verification and validation of complex electrohydraulic and electromechanical systems, including subsea high-pressure pumps, metering pumps, and safety-critical valves used in the offshore industry. A particular advantage of HHPS lies in its full compatibility with the existing ZMS research infrastructure. In particular, its integration with the subsea environmental simulator developed in the CHARISMA project opens up new possibilities for combined system testing under realistic environmental and pressure conditions. This results in a powerful overall system that allows a previously unattainable depth of analysis of mechatronic components.
The project addresses key scientific questions in the field of mechatronic high-pressure systems, including:
• the behavior of fluids in multiphase states under high-pressure conditions,
• the effects of phase transitions and impurities on materials and sealing systems,
• and the reliable control and regulation of complex fluid processes.
The insights gained make a significant contribution to improving the long-term stability and operational safety of components in subsea production systems. In addition, the testing system provides a valuable platform for teaching and training young researchers by enabling hands-on experiments and student research projects.
Technologically, HHPS serves as a development and qualification platform for innovative maritime systems. The ability to flexibly simulate different fluids and test conditions significantly reduces the effort required to develop specific test setups. With HHPS, ZMS strengthens its position as a high-performance research institute in the field of reliable mechatronic systems. The new infrastructure complements existing laboratory facilities such as engine test benches, valve simulators, and the subsea environmental simulator, creating a solid foundation for future third-party funded projects, doctoral research, and international collaborations.
