2. Introduction
• All potential causes of seal failure must be controlled.
• Any of the following scenarios, if overlooked, can cause
premature seal failure:
– Incorrect seal design; I.e., the environmental stresses exceed
the limits of the material.
– Loss of strength due to shelf-aging
• Improper seal installation.
• Improper choice of elastomer for the environment to be
sealed.
• Poor quality assurance in manufacturing.
3. Introduction
Material selection is
based on service
conditions
(temperature, pressure,
and environment),
customer requirements,
and involves the total
seal system.
4. Introduction - Continued
• Two basic categories of seals
• Static
• Dynamic
• Static seals should be zero-leakage
• Seal must be resilient enough to flow and fill any small
irregularities on surface being sealed
• Resist extrusion into gap between sealing surfaces
• Both requirements must be long term
• Dynamic requirements are somewhat conflicting and call
for a compromise
• Good contact pressure with minimum friction
5. Basic Seal Mechanics
Prone To Extrusion Or Overstressing
•O-rings — simplest and most versatile type of seal
Wide range of applications both static and dynamic
Some of the basic mechanics of seal design using o-
rings are illustrated in the next slides.
6. Basic Seal Mechanics
Extrusion / Overstress / Prevention - Static Seal
Extrusion /
Overstress / Roll
Prevention -
Dynamic &
Pressure Reverse
Seal
Shaped Back-
Up Ring
7. Working Pressure and Groove Design
Notes:
Basically controlled by
clearance gap, temperature
of system, and hardness of
the ring.
Clearance gap can change
in working environment
due to expansion and
contraction of metal parts.
Extrusion of 95 Shore A O-
ring
9000
9500
10000
10500
11000
11500
12000
12500
13000
13500
14000
150 200 250 300 350 400
6 MILS
8 MILS
10 MILS
12 MILS
(66) (93) (121) (149) (177) (204)
(97)
(93)
(90)
(86)
(83)
(79)
(76)
(72)
(69)
(66)
(62)
Test Conducted
w/o Back Rings
Under Status
Conditions
Temperature (°F)
(°C)
Pressure(PSI)
(MPa)
8. Working Pressure and Groove
Design - Continued
• Low-temperature operation can use a shallow groove,
whereas high-temperature uses a deeper groove to allow
for expansion.
• Typical o-ring groove design should have :
– A radius of 0.50 to 0.75 mm (0.020 to 0.030 inches) in the bottom
corners.
– Top edge 0.12 mm to 0.25 mm (0.005 to 0.10 inches) to eliminate a
cutting edge.
• Groove finish is important as it affects the wear and life of
the seal.
• A finish of better than :
– 0.75 m (37 inches) is recommended for static
– and 0.4 m (16 inches) is recommended for dynamic
9. Working Pressure and Groove
Design - Continued
Notes to Remember
1. Remember - Elastomers are
incompressible
2. In general, the compression for static o-
ring should be 15 to 30%, depending on
the cross-section
10. Working Pressure and Groove
Design - Continued
Reduction in
cross-section
due to stretch
Squeeze
should never
be below 5%
Diametral Stretch, %
ReductioninCrossSection
Squeeze%
11. Vee-Packing
Also known as “chevron” rings.
Used in both static and dynamic applications.
Pressure rating and low temperature sealing capability can
be increased by using two or more rings together.
Failure Mode: Extrusion into clearance gap.
Fiber filler gives a very slight improvement in extrusion
resistance.
DOUBLE MALE ADAPTER
METAL
RING
SOFT
RING
HARD
RING
BACKUP
RING
12. Back-Up Ring
Hard Ring
Soft Ring
Retainer Wire
Double Male Adapter
Mandrel
CN01508
Seal Assembly
Variety of seal types are
needed
HP/HT designed to move
Vee-rings designed to
have initial interface with
seal bore
Pre-loaded seal-Retainer
Wire
13. Seal Failures
Compression Set
Probably the most common cause of o-ring failure
• A continuous “Seal Line” between sealed
surfaces must be maintained to prevent leakage
• Proper selection of gland or groove design and
cross-section of the ring will give correct
squeeze or compression
• Compression set is reported as the percent of
deflection by which the elastomer fails to recover
after a fixed time under a specified squeeze and
temperature.
14. Seal Failures - Continued
Compression Set - Continued
Causes of compression set
– Some materials inherently have poor compression set
– Excessive temperature
– Incomplete curing
– Fluid incompatibility
• Desirable to have low compression set values
15. Seal Failures - Continued
Spiral Failure
• O-Rings are not
particularly suitable
for slow speed
reciprocating seals
• The amount of
squeeze is very
important - too much
promotes spiral
failure
• Spiral failure usually
caused by conditions
which allows some
part of the ring to
slide and the other to
roll
16. Explosive Decompression
• Rubber is not 100% dense material.
• Molecular void or air space make up 3-4% of a seal’s
volume.
• Gases under pressure enter these void sites.
• Three problems can occur
• Blistering
• Rupture or fracture
• Explosion
• Blistering is characteristic of materials having
• Low Hardness
• Low Cross-link Density
• High Elongation
• Rupture is characteristic of materials having
• High Durometer
• High Cross-link Density
• Low Elongation
• Undersized O-Ring Groove
17. • In the past, explosive decompression was characteristic of high
performance materials such as:
• Chemraz
• Kalrez
But improvements in compounding and the base polymer has
greatly improved their resistance to explosive decompression.
• Preventing Explosive Decompression
• Avoid Testing with Gas - CO2 is probably the most destructive
• All gases will cause some problems
• Very slow bleed-down is recommended
• Below 1500 psi
• 20 psi per minute
• or 100 psi; wait 10 minutes; another 100 psi
• Continue to atmospheric pressure
• Testing on surface with gas can cause damage to seals before
equipment is placed in service if bleed-down procedure is not
followed.
Explosive Decompression - Cont’d
20. Where
G = shear modulus
v = Poisson’s ration 0.5
Cannot change critical pressure and flaw size easily.
Shear modulus can be altered by changing the cross-link density
or adding reinforcing filler to the rubber.
• Three major factors controlling seal resistance to these
types of failures:
• Critical Pressure is defined as
5E
6
• Flaw Size: 3-4% of Volume of Seal
• Shear modulus of rigidity is defined as
G = E/2(1+v)
where E = Young’s modulus
E = Tensile Stress (σ)/Tensile Strain ()
shear stress
shear strain
s
s
21. Causes Of Seal Failure
Maintenance
Glass
Transition
Temp Too
High
Slow
Elastomer
Recovery
O-ring Not
Lubricated
At
Assembly
Abrasion
Too Rough/Too
Smooth Surface
Finish
Poor
Lubrication
High
Temperature
Fluid
Contamination
Misc
Causes
Weather
Ozone
Cracking
Plastigizer
Extraction
Gas Expansion
Rupture
Failure of
Back-up Ring
Pressure
Surges
Extrusion
of Back-
Up Rings
Thermal
Charge
Spiral
Failure
Proper Cross
Section Not Used
Effects Of
Stroke Speeds
Uneven
Dispension
of Lubricant
Uneven
Surface Finishes
Side
Loads
Installation
Damage
Manufacturing
Defects
Difficult
Access
ID Too Large
On Piston Seal
Too Little
Elongation
Rod Seals
OD Too Small
On Piston Seal
Sharp Corners
Threads
Insufficient
Lead In Chamfer
Out Of
Dimensions
Excessive
Flash
Poor Knit
Lines
Inadequate
Q.C.
Inclusion Of
Elastomer
Contaminants
No Back-Up
Rings
Pressure
Too High
O-ring “Bonds”
To Mating
Surface
Low
Temperature
Contraction
Should Not Be
Using Elastomer
Seal
Low
Temperature
Brittleness
Improper
Elastomer
Improper
Design
Glass
Transition
Temp Too
High
Slow
Elastomer
Recovery
Insufficient
Elongation
Improper
Compounding
Compressive
Modulus Too Low
Tensil Modulus
Too Low
Inadequate
Squeeze
Excessive
Stretch
Retrofit
Constraints
Improper
Surface Finish
Improper Volume
Increase Allowance
Extrusion /
Nibbling
O-Ring Softened/
Swelled by fluid
O-ring
Too Soft
Clearance
Too Large
Clearance Decreases
Under Pressure
Corners
Too Sharp
Pressure
Surges
Excessive
Swell
Ref Fluids Not
Representative
Of Service Fluid
Service Fluid /
Rubber
Incompatibility
Preservation
Fluid Effect
Aggressive
Additive
Compression Set
(Stress Relaxation)
Improper High
Set Compound
Inadequate
Cure
Hardening
Time
Effect
Temp Too
High
Excessive
Squeeze
Too Small
Cross Section
22. • Mechanical properties should be examined in terms of
temperature
• Illustrates change in shear modulus on cooling
Mechanical Properties
23. • Note the transition region is arbitrarily taken at 100 MPa
shear modulus
• Material no longer has any rubbery properties - now stiff
and brittle
• Hardness of 95 Shore A gives a shear modulus of 10 MPa
• Very little rubbery properties left
Mechanical Properties –
(Cont’d)
SHEAR MODULUS vs. HARDNESS
Shear
Modulus-G
MPa
10
3
1
0.3
0.1
0 20 40 60 80 100
Durometer
SHORE A
IRHD
26. NITRILE (NBR) ELASTOMERS
• Polymer of Butadiene and Acrylonitrile
• Workhorse elastomer of the oilfield
• Good resistance to oil swell
• Nitrile seals (all types) are used in the majority of
wells worldwide
• Useable from -20F (-29C) to 275F (135C) in
standard service
• Good explosive decompression resistance if
compounded correctly
27. NITRILE (NBR) ELASTOMERS
Suitable for Use In:
• Crude Oil
• Brines
• Sweet Gas
• Most Water-Base Drilling Muds (Testing is
advised before use in oil-base mud.)
• Methanol Injection
• Water Injection
• Water Base Inhibitors
• CO2 Injection
28. NITRILE (NBR) ELASTOMERS
Temperature Range:
• From -20F (-29C) to 275F (135C) long term
application and where seal movement is
required
• Up to 325F (163C) short term application and
where no seal movement is required
• Peroxide cured material should be used for
higher temperature
29. NITRILE (NBR) ELASTOMERS
Cautions / Limitations:
DO NOT USE IN:
• Sour service
• Oil based organic amine corrosion inhibitors
• Zinc and Calcium Bromide (contact elastomer
group)
• Aromatic Solvents
• Explosive decompression can be controlled with
proper bleed-off if procedure is followed
• Back-up rings are suggested for o-rings if
temperature exceeds 225F (107C) and 3000 psi
30. NITRILE (NBR) ELASTOMERS
Nitrile / Buna-N - Continued
Types of Seals Temperature Range
• Elements Retrievable 275°F (135°C)
• Permanent 350°F (176.7°C)
• O-Rings 275°F (135°C)
• Molded Seals 275°F (135°C)
• Vee-Packing 275°F (135°C)
Not recommended
• H2S
• Zinc Bromide
• Calcium Bromide
• Xylene
• Inhibitors –Oil Soluble
• Hydrochloric/
Hydrofluoric Acids
• Calcium Hypochlorite
(Packer Fluid)
• CO2 – Some Swell
• Methane – Some Swell
• Alcohols – OK
• Inhibitors – Water
Soluble – OK
• Diesel – Some Swell
• Brine – OK
• Sweet Oil & Gas – OK
Environments
32. HNBR
(Highly Saturated Nitrile Elastomers)
• Polymer of standard nitrile (butadiene and
acrylonitrile) with added chemistry.
• Better resistance to H2S than standard
nitrile
• Higher temperature use than standard
nitrile
• Not as good in explosive decompression as
standard nitrile
33. HNBR
(Highly Saturated Nitrile Elastomers)
Suitable for Use In:
• Crude Oil
• Brines
• Methane
• Methanol Injection
• Water Injection
• Water Base Inhibitors
• CO2 Injection
• Ethylene Glycol Fluids
• Sour Service, H2S less than 5%
34. HNBR
(Highly Saturated Nitrile Elastomers)
Temperature Range:
• From -20F (-29C) to 325F (163C) with sulfur
cured material and 350F (177C) with peroxide
cured material
• Up to 350F (177C) with sulfur cured material if
no seal movement is required
Note: The specification for HNBR should state
“if material is sulfur or peroxide cured.”
35. HNBR
(Highly Saturated Nitrile Elastomers)
Cautions/Limitations
DO NOT USE IN:
• Oil base inhibitors
• Aromatic solvents
• Zinc or calcium bromide (contact elastomer group)
• Sulfur cured compounds have better extrusion
resistance than peroxide cured materials.
36. HNBR
(Highly Saturated Nitrile Elastomers)
Cautions/Limitations
DO NOT USE IN:
• Sour service when the H2S content exceeds 5%.
• With oil based inhibitors, zinc or calcium
bromide, or with aromatic or halogenated
solvents.
Harder compounds (90+ Duro) will not have as much
swell in CO2 as softer compounds. This also applies
to explosive decompression situations.
The sulfur-cured materials have better extrusion
resistance than peroxide-cured ones.
Notes
37. HNBR
(Highly Saturated Nitrile Elastomers)
Highly Saturated Nitrile
Type Of Seals
• C02 - Some Swell
• Alcohols - OK
• Sweet Oil & Gas -
OK
• Brine - OK
• Inhibitors - Water
Soluble - OK
• No Molded Seals Or Vee-Packing
Tested At This Time
• Elements
Retrievable
Permanent
355°F (176.7°C)
375°F (190.6°C)
Not Recommended
• H2S — Fair
• Zinc Bromide
• Aromatic Solvents
(Xylene)
• Inhibitors - Oil
Soluble
Temperature Range
Environments
39. VITON® & FLUOREL®
Fluorocarbon Elastomers
• Polymer of Vinylidene Fluoride and
Hexafluoropropylene
• Improved temperature rating over standard nitrile
• Resistant to acids (HCL and HF) if compounded
correctly
• Good resistance to aromatic solvents
• Fluorel has good explosive decompression
resistance
40. VITON® & FLUOREL®
Fluorocarbon Elastomers
Suitable for Use In:
• Sour Service
• Standard Service
• Some Drilling Muds (Testing is Advised)
• Aromatic Solvents
• Zinc and Calcium Bromide
41. VITON® & FLUOREL®
Fluorocarbon Elastomers
Temperature Range:
• Viton from -20F (-29C) to 325F (163C)
for long term application or where seal
movement is required
• Fluorel -20F (-29C) to 400F (204C) for
long term application or where seal
movement is required
42. VITON® & FLUOREL®
Fluorocarbon Elastomers
Cautions / Limitations:
DO NOT USE IN:
• Steam
• Organic Acids (such as Acetic or Formic)
• Methanol Injection
• Organic Amine Corrosive Inhibitors
• High pH Fluids (pH 8 or greater)
Note: Back-up rings are recommended at temperatures
above 250F (121C) and 5000 psi.
43. VITON® & FLUOREL®
Fluorocarbon Elastomers
Fluorocarbon Elastomers
Environments Types Of Seals Temperature Range
• Glutaraldehyde
(Biocide)
Not Recommended
• Organic Amines
(Inhibitors)
• Methanol Injection
• Steam
• Formic & Acetic
Acids
• Dimethyl / Disulfide
(DMDS)
• High pH Fluids
(Xylene) - OK
(Usually < 10%)
Acid (Caution) - OK
• H2S - OK
• Zinc Bromide - OK
• Calcium Bromide - OK
• Aromatic Solvents
• C02 - Some Swell
• Hydrochloric / Hydrofluoric
• Sweet Oil & Gas - OK
• Retrievable (Viton)
(Fluorel)
• O-Rings
(Fluorel)
(Viton)
• Molded Seals
(Fluorel)
• Vee-Packing
(Filled)
(UnFilled)
• T - Seals
350°F (176.7°C)
400°F (204°C)
325°F (162.8°C)
400°F (204°C)
400°F (204°C)
350°F (176.6°C)
325°F (162.8°C)
400°F (204°C)
46. VITON - ETP
Used in Completion Products and
Completion Service Tools
47. VITON - ETP
• A premium fluorocarbon elastomer being
investigated for long-term downhole
applications
• Polymer of ethylene, tetrafluoroethylene
and perfluoromethylvinyl ether
• Good resistance to high pH fluids
• Good resistance to most oil-base drilling
muds
• This compound is now available for seals
48. VITON - ETP
Suitable for Use In:
• Sour Crude
• Oil-Base Drilling Muds
• Potassium / Cesium Formate Fluids
• High pH Fluids
• Brine Solutions
• Zinc and Calcium Bromide
• Hot Diesel with Inhibitors
• Aromatic Solvents
Note: In all the above tests, Viton-ETP gave outstanding results.
49. VITON - ETP
Temperature Range:
• From -20F (-29C) to 400F
(204C)
• Vee-Packing tested to 400F
(204C) and 15,000 psi
50. VITON - ETP
Cautions / Limitations:
• Back-Up Rings are recommended as with
all Fluorocarbon Elastomers
• This material now has field history with
outstanding results
52. AFLAS® - FLUOROCARBON
ELASTOMER
• Polymer of Tetrafluoroethylene and Propylene
• A 100 H Polymer has been used successfully in
downhole applications
• First used in South Texas in deep hot well in mid
1980’s
• Packers are still in the holes with no problems
• Packers tested to 450F (232C) and 13,000 psi
differential
• Held temperature and pressure for 20 hours
• Test completed - No Leaks
• Temperature Range 100F (38C) to 450F (232C)
53. Suitable for Use In:
• Standard Service
• Sour Service (H2S)
• Zinc and Calcium Bromide
• High pH Fluids
• Organic Amine Corrosion Inhibitors
• Organic Acids
AFLAS® - FLUOROCARBON
ELASTOMER
54. Cautions / Limitations:
DO NOT USE IN:
• Aromatic Solvents
• Oil-Base Drilling Mud - Testing is advised
• Hot Diesel Completions
Note: Back-up rings are recommended above 250F and
6000 psi.
Note: Aflas® seals should not be used below 100F (38C)
because of the glass transition temperature.
AFLAS® - FLUOROCARBON
ELASTOMER
55. Aflas®
• CO2
• H2S RESISTANCE
• Zinc Bromide
• Calcium Bromide
• Corrosion Inhibitor
( All Types)
• Sweet Oil & Gas Production
• Brines
• Dimethyl Disulfide
( DMDS )
Some Swell ( Usually < 10% )
Good
Very Good
Very Good
Very Good
Good
Very Good
Very Good
Environments Types Of Seals Temperature Range
• Packer Elements
Retrievable
Permanent
400 O F (204 O C)
450 O F (232 O C)
• O-Rings
• Vee-Rings
( ATR )
• Molded Seals
400 O F (204 O C)
450 O F (232 O C)
400 O F (204 O C)
AFLAS® - FLUOROCARBON
ELASTOMER
56. Physical Property vs Temperature
1000
100
10
1.0
0.1
Hard Glass
Glass Transition
Transition (Leathery)
Regions
Rubbery
Viscous
Shear
Modulus, G
MPa
Temperature
Aflas® seals are good in explosive decompression if
they have been compounded correctly.
AFLAS® - FLUOROCARBON
ELASTOMER
58. Perfluoroelastomers
KALREZ & CHEMRAZ
• Perfluoroelastomer
• Chemically very stable
• Can be reinforced with fibers
• KTR (Kalrez, Teflon, Ryton) Seals were used
in hot sour well in late 1970’s. Some of these
same seals are still in producing wells.
• In the early use of this material it was poor in
explosive decompression resistance, but
advances in compounding has improved its
resistance to explosive decompression.
59. Perfluoroelastomers
KALREZ & CHEMRAZ
• Standard Service
• Sour Service
• Aromatic Solvents
• High pH Fluids
• Acidizing Solutions
• Sulfur Solvents
Suitable For Use In:
60. Perfluoroelastomers
KALREZ & CHEMRAZ
Temperature Range:
• Kalrez from 100F (38C) to 450F (232C) as o-
rings and up to 450F (232C) as vee-packing
with a proper back-up system
• Chemraz from 40F (4C) to 450F (232C) as o-
rings and up to 450F (232C) as vee-packing
with a proper back-up system
61. Perfluoroelastomers –
KALREZ & CHEMRAZ
Cautions / Limitations:
• Proper bleed-down must be used in order
to avoid explosive decompression with
both Kalrez and Chemraz.
• Kalrez should never be used below 100F
(38C) because of the glass transition
temperature.
62. Chemraz – Registered Trademarks of Green-Tweed Co.
Kalrez – Registered Trademarks of DuPont Co.
Chemraz
• Minimum Use Temperature 40 F (5 C)
• Maximum Use Temperature 450 F (232 C)
• Corrosion Inhibitor Resistance – Good
• Solvent Resistance - Good
• Gas Resistance (CO2, Methane, H2S) – Some Swell
• Explosive Decompression Resistance – Good
• Acid Resistance – Good
• Backup Rings must be used
Type of Seal
• O-Rings
• Vee-Rings
• CTP
Temperature Range
• 40 F 450 F
(5 C 204 C)
• 40 F 450 F
(5 C 232 C)
• 40 F 450 F
(5 C 232 C)
Kalrez
• Minimum Use Temperature 100 F (38 C)
• Maximum Use Temperature 450 F (232 C)
• Corrosion Inhibitor Resistance – Good
• Solvent Resistance – Good
• Gas Resistance (CO2, Methane, H2S) – Some Swell
• Explosive Decompression Resistance – Fair
• Acid Resistance – Good
• Backup Rings must be used
Type of Seal
• O-Rings
• Vee-Rings
• KTR
Temperature Range
• 100 F 450 F
(38 C 204 C)
• 100 F 450 F
(38 C 204 C)
• 100 F 450 F
(38 C 232 C)
Perfluoroelastomers
KALREZ & CHEMRAZ
63. Elastomers vs. Plastics in Seals
Elastomers
Resistant to Creep
Resilient / Compliant in Seals
Flexible for Easy Fitting into Grooves etc.
Capable of Recovery/Good Stress Relaxation
Plastics and Thermoplastic Elastomers
Creep (Cold)
Temperature Dependent
Lower Extensibility Making Fitting Difficult
Poor Compression Set Under Constant Deformation
Shaft Fretting in Mechanical Seals
Poor Compliance to Imperfect Finishes
65. Thermoplastic Materials
Ryton
• RTR Seal Unit — 200° F (98 C) 350 F (177 C)
at 15,000 psi
• RTR Seal Unit — 200 F (98 C) 450 F (232 C)
at 10,000 psi
• Chemical Resistance — Good
• Broad Temperature Range
• Blends well with Glass and Teflon
• Good Mechanical Properties
• Impact Strength — Poor
• Elongation — Poor
PEEK
• PTP Seal Unit — 200 F (98 C) 450 F (232 C)
at 20,000 psi
• PTP Seal Unit for Steam injection—
200ÞF (98 C) 550 F (288 C) at 3000 psi
• Chemical Resistance — Good
• Blends well with Glass and Teflon
• Broad Temperature Range
• Outstanding Thermal Resistance
• Good Elongation (up to 30%)
• Impact Strength — Good
• Retention of Properties at Temperature
Seals have been tested to 600 F and 2000 psi
• Excellent Back-up Material for O-Rings
and Vee-Packing
High Performance
Thermoplastics
66. Teflons
25% Glass Filled
• Standard Material in Packer Seal Unit
• Chemical Resistance — Good
• Elongation — Good
• Recommended for Standard or Corrosive Service
• Hard Back-up Rings must be used with Teflon Vee-Packing
• Can be used as Back-up Rings for O-Rings
40% Glass Filled
• Used in PTP Seal Units for Steam Injection
• Chemical Resistance — Good
• Elongation — Good
• Can be used as Back-up Rings for O-Rings
• Recommended for Standard or Corrosive Service
Teflon Containing Molybdenum Disulfide
• Back-Up Rings Must Be Used With This Material Under All Conditions
• Chemical Resistance — Good
• Impact Strength — Good
• Extrusion Resistance — Poor
High Performance
Thermoplastics
68. Storage (To Obtain Maximum Shelf-Life)
Ambient Temperature Should Not Exceed 120F
(49C).
Protect from UV light such as the sun and
fluorescent lights.
Do not store near electrical equipment or welding
machine. These produce ozone.
Store in opaque package materials.