As part of our Special Topic for this issue, we address advanced sealing technologies, solutions, and proper protocols for optimal performance in high-pressure, chemically aggressive, and demanding operational offshore environments.
By Steve Fennell
Offshore oil and gas resources are integral to the U.S. energy supply. According to the Bureau of Ocean Energy Management (BOEM), which oversees the development of the National Outer Continental Shelf (OCS) Oil and Gas Leasing Program, offshore production on the OCS reached approximately 667.5 million barrels in fiscal year 2024 alone.
In addition, approximately 700 billion cubic feet of natural gas were produced, which combine to account for 14% of the nation’s crude oil production and 2% of its natural gas output. The actions, efforts and successes of oil & gas companies — from independents focusing on exploration and production (E&P) to “big oil” titans — do not come without maintenance and equipment challenges.
Staying current with environmental compliances, mitigating risk, ensuring continued maintenance of operations, and utilizing current technologies (to name a few criteria) are essential to these reported figures.
Sealing technology is fundamental to the inner workings of any industrial operation. While they may be out of sight, they are certainly not out of mind for end users and manufacturers in the offshore oil & gas environment.
For maintenance teams and design engineers, sealant technology must be able to withstand extreme conditions and most importantly, be properly utilized for the specific application in oil & gas. Constant operating pressures of up to 20,000 Psi, abrasive chemicals, and intense temperatures can all potentially combat the best sealing tech when its not properly implemented.
“It’s essential to ensure that sealants for the applications are always understood,” says Evan Sohodski, Technical Service & Development Engineer for Qnity, DuPont Electronics, the manufacturer of the Kalrez® perfluoroelastomer solutions for several industries.
“End users need to look at their situation from three main pillars of their application drivers. This includes the chemical compatibility, thermal resistance, and the mechanics of the application. In the offshore environment, pressures are very aggressive with the addition of exotic chemistries both on the process side and environmental side. So, we look at those three aspects to determine what makes the most sense from a product type standpoint and from a geometry standpoint.”
Kalrez® is just one specialty sealant and valve packing manufacturer with a commitment to the flow control industry. Its Kalrez parts can effectively withstand more than 1,800 chemicals, sustain high-temperature stabilities, and provide predictable lifespans.
End-to-End Collaboration
Sohodski explained that sealants must be robust to withstand both extrusion and rapid gas decompression, given the extreme conditions in which the equipment functions. These are often two big phenomena that affect sealant materials. “We work with the end user to determine the appropriate form factors,” says Sohodski. “We assess whether backup rings or if a spring-energized seal are required to avoid high-pressure failures while still providing optimal service life. Downtime is always very costly, even more so offshore.”
Sohodski explained that rather than just sharing basic temperature, pressure, or chemical data, users need an “end-to-end” approach when installing or upgrading new sealants on equipment. Making informed decisions by establishing the full context of information sourced from component drawings, groove designs, and/ or dimensional data is also key to determine the most effective sealant solution.
For specific applications, in-house finite element analysis (FEA) is available from select sealant providers. This can ideally establish how a sealant will perform under mechanical stress, extreme temperature fluctuations, and pressure variations.
An FEA also tests how a specific seal will perform when a valve is off or on, when it’s actuating, and when it’s at its highest and lowest pressures. This enables engineers to identify potential failure points and when to refine designs to ensure optimal safety and long-term reliability.
“It’s always important to know what the full mode of operation is, including how a sealant will perform during the maximum temperatures or pressures and even when its operating under standard flow conditions,” said Sohodski.
Resisting Extreme Chemical Conditions
Subsea and offshore environments expose sealants to a range of abrasive chemicals in some of the harshest operating conditions. These challenges become even more demanding during enhanced oil recovery (EOR) operations, particularly when carbon dioxide (CO2) is in production streams. The elevated CO2 can significantly impact the performance and durability of the sealant materials.
In fact, solutions that were used one or two decades ago were sufficient. Today, however, the excessive CO2 content can result in excessive swelling, which can compromise a sealant’s performance, potentially causing rapid gas decompression (RGD). Given these risks, end users need to maintain open communication with sealant manufacturers or parts distributors.
“We’re always making sure our customers are aware of our most up-to-date portfolio as its extremely important to their operations,” says Sohodski. “I’ve seen instances where some end users still want to use the same grade they have been using for 20-30 years.”
Sealants and Fugitive Emissions
As the forces of elements evolve and valve and sealant manufacturers successfully adapt, the challenge of mitigating fugitive emissions and meeting compliance remain constant.
In offshore oil & gas, sealants play a paramount role in addressing emissions. The solution is selecting the right valve sealants from the outset. There are a number of manufacturers in the flow control industry who provide API 622-certified valve packing, which is the American Petroleum Institute’s standard for fugitive emissions.
Yet, regular emissions testing, strict routine maintenance and repairs ultimately reveal the necessity for low-emission-designed sealants and further upgrades. Adhering to these procedures can significantly reduce long-term maintenance costs and downtime while supporting compliance with environmental and industry requirements.
“These packing solutions are engineered to increase service life, reduce maintenance and ensure the valve doesn’t need an oversized actuator to function properly. All of this adds up to a sealing system that’s reliable from day one — keeping fugitive emissions in check and supporting long-term environmental compliance,” said Sohodski.
E&P’s and the major operators continue to drill deeper — and further — with recent success. Operating in harsher conditions very much dictates the requirement for manufacturers and end users to test, innovate, and use new sealant technologies to ensure productivity, reliability and safety.
As a result, end users in this segment, as well as throughout the flow control industry, are provided with the available products, support, and effective sealing solutions from a variety of sealing manufacturers to ensure efficient and reliable operations.