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SEALS AND SEALING
TECHNOLOGY
By
Thomas W. Ray
T W R CONSULTANTS
Education Symposium
July 2015
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.
Introduction
Material selection is
based on service
conditions
(temperature, pressure,
and environment),
customer requirements,
and involves the total
seal system.
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
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.
Basic Seal Mechanics
Extrusion / Overstress / Prevention - Static Seal
Extrusion /
Overstress / Roll
Prevention -
Dynamic &
Pressure Reverse
Seal
Shaped Back-
Up Ring
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)
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
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
Working Pressure and Groove
Design - Continued
 Reduction in
cross-section
due to stretch
 Squeeze
should never
be below 5%
Diametral Stretch, %
ReductioninCrossSection
Squeeze%
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
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
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.
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
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
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
• 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
Explosive Decompression
Example of surface cracks caused by explosive decompression.
Explosive Decompression
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 
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
• Mechanical properties should be examined in terms of
temperature
• Illustrates change in shear modulus on cooling
Mechanical Properties
• 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
NITRILE (NBR)
ELASTOMERS
Used in Completion Products and
Completion Service Tools
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 -20F (-29C) to 275F (135C) in
standard service
• Good explosive decompression resistance if
compounded correctly
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
NITRILE (NBR) ELASTOMERS
Temperature Range:
• From -20F (-29C) to 275F (135C) long term
application and where seal movement is
required
• Up to 325F (163C) short term application and
where no seal movement is required
• Peroxide cured material should be used for
higher temperature
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 225F (107C) and 3000 psi
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
HNBR
(Highly Saturated Nitrile Elastomers)
Used in Completion Products and
Completion Service Tools
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
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%
HNBR
(Highly Saturated Nitrile Elastomers)
Temperature Range:
• From -20F (-29C) to 325F (163C) with sulfur
cured material and 350F (177C) with peroxide
cured material
• Up to 350F (177C) with sulfur cured material if
no seal movement is required
Note: The specification for HNBR should state
“if material is sulfur or peroxide cured.”
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.
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
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
VITON® & FLUOREL®
Fluorocarbon Elastomers
Used in Completion Products and
Completion Service Tools
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
VITON® & FLUOREL®
Fluorocarbon Elastomers
Suitable for Use In:
• Sour Service
• Standard Service
• Some Drilling Muds (Testing is Advised)
• Aromatic Solvents
• Zinc and Calcium Bromide
VITON® & FLUOREL®
Fluorocarbon Elastomers
Temperature Range:
• Viton from -20F (-29C) to 325F (163C)
for long term application or where seal
movement is required
• Fluorel -20F (-29C) to 400F (204C) for
long term application or where seal
movement is required
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 250F (121C) and 5000 psi.
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)
COMPOUNDED
WITH LEAD OXIDE
COMPOUNDED
WITHOUT LEAD OXIDE
FLEXIBLE
BRITTLE
VITON® & FLUOREL®
Fluorocarbon Elastomers
VITON® & FLUOREL®
Fluorocarbon Elastomers
COMP: C
Time: 24 hr
Sol: Amine w/Diesel
Press: 6000 psi
Temp: 330°F
VITON - ETP
Used in Completion Products and
Completion Service Tools
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
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.
VITON - ETP
Temperature Range:
• From -20F (-29C) to 400F
(204C)
• Vee-Packing tested to 400F
(204C) and 15,000 psi
VITON - ETP
Cautions / Limitations:
• Back-Up Rings are recommended as with
all Fluorocarbon Elastomers
• This material now has field history with
outstanding results
AFLAS ® -
FLUOROCARBON
ELASTOMER
Used in Completion Products and
Completion Service Tools
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 450F (232C) and 13,000 psi
differential
• Held temperature and pressure for 20 hours
• Test completed - No Leaks
• Temperature Range 100F (38C) to 450F (232C)
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
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 250F and
6000 psi.
Note: Aflas® seals should not be used below 100F (38C)
because of the glass transition temperature.
AFLAS® - FLUOROCARBON
ELASTOMER
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
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
Perfluoroelastomers
KALREZ® & CHEMRAZ®
Used in Completion Products and
Completion Service Tools
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.
Perfluoroelastomers
KALREZ & CHEMRAZ
• Standard Service
• Sour Service
• Aromatic Solvents
• High pH Fluids
• Acidizing Solutions
• Sulfur Solvents
Suitable For Use In:
Perfluoroelastomers
KALREZ & CHEMRAZ
Temperature Range:
• Kalrez from 100F (38C) to 450F (232C) as o-
rings and up to 450F (232C) as vee-packing
with a proper back-up system
• Chemraz from 40F (4C) to 450F (232C) as o-
rings and up to 450F (232C) as vee-packing
with a proper back-up system
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 100F
(38C) because of the glass transition
temperature.
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
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
High Performance
Thermoplastics
Used in Completion Products and
Completion Service Tools
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
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
Elastomer Storage
Used in Completion Products and
Completion Service Tools
Storage (To Obtain Maximum Shelf-Life)
 Ambient Temperature Should Not Exceed 120F
(49C).
 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.
The End

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Singapore Presentation 2015 new

  • 1. SEALS AND SEALING TECHNOLOGY By Thomas W. Ray T W R CONSULTANTS Education Symposium July 2015
  • 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
  • 18. Explosive Decompression Example of surface cracks caused by explosive decompression.
  • 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
  • 24.
  • 25. NITRILE (NBR) ELASTOMERS Used in Completion Products and Completion Service Tools
  • 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 -20F (-29C) to 275F (135C) 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 -20F (-29C) to 275F (135C) long term application and where seal movement is required • Up to 325F (163C) 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 225F (107C) 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
  • 31. HNBR (Highly Saturated Nitrile Elastomers) Used in Completion Products and Completion Service Tools
  • 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 -20F (-29C) to 325F (163C) with sulfur cured material and 350F (177C) with peroxide cured material • Up to 350F (177C) 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
  • 38. VITON® & FLUOREL® Fluorocarbon Elastomers Used in Completion Products and Completion Service Tools
  • 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 -20F (-29C) to 325F (163C) for long term application or where seal movement is required • Fluorel -20F (-29C) to 400F (204C) 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 250F (121C) 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)
  • 44. COMPOUNDED WITH LEAD OXIDE COMPOUNDED WITHOUT LEAD OXIDE FLEXIBLE BRITTLE VITON® & FLUOREL® Fluorocarbon Elastomers
  • 45. VITON® & FLUOREL® Fluorocarbon Elastomers COMP: C Time: 24 hr Sol: Amine w/Diesel Press: 6000 psi Temp: 330°F
  • 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 -20F (-29C) to 400F (204C) • Vee-Packing tested to 400F (204C) 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
  • 51. AFLAS ® - FLUOROCARBON ELASTOMER Used in Completion Products and Completion Service Tools
  • 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 450F (232C) and 13,000 psi differential • Held temperature and pressure for 20 hours • Test completed - No Leaks • Temperature Range 100F (38C) to 450F (232C)
  • 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 250F and 6000 psi. Note: Aflas® seals should not be used below 100F (38C) 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
  • 57. Perfluoroelastomers KALREZ® & CHEMRAZ® Used in Completion Products and Completion Service Tools
  • 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 100F (38C) to 450F (232C) as o- rings and up to 450F (232C) as vee-packing with a proper back-up system • Chemraz from 40F (4C) to 450F (232C) as o- rings and up to 450F (232C) 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 100F (38C) 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
  • 64. High Performance Thermoplastics Used in Completion Products and Completion Service Tools
  • 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
  • 67. Elastomer Storage Used in Completion Products and Completion Service Tools
  • 68. Storage (To Obtain Maximum Shelf-Life)  Ambient Temperature Should Not Exceed 120F (49C).  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.