Investigation of Elastomeric Seal Systems in Oil and Gas Well Applications

The article provides a detailed review of literature, research findings, and industrial standards related to elastomer seal assemblies used in oil and gas wells. Elastomer-based seals are essential for maintaining well integrity. Advances in rubber chemistry and sealing technologies were critical in controlling pressure and fluid flow long before the 1901 Spindletop oil eruption in Texas. These materialsremain indispensable today, as the cost of constructing a single well can exceed one billion dollars. Almost all modern drilling and completion systems rely on elastomers and other sealing materials to ensure reliable operation throughout their service life. Research shows that seal malfunctions can cause blowouts or oil leaks, creating serious health, safety, and environmental risks. Because of these risks, regulators and industry experts stress the need for improved seal design and qualification, especially for high-pressure, high-temperature (HPHT) applications. This paper evaluates key studies and standards on elastomer sealing systems. It examines the main factors that influence seal performance and the major causes of failure. The review’s primaryaim isto identifygaps in current standards and propose priorityareas for future research to improve seal reliability. The analytical results show how elastomer geometry and material properties influence maximum sealing pressure. The study also analyzes different strain conditions to assess sealing efficiency. Current industry standards focus mainly on material-level testing and offer limited guidance for seal design within complete equipment assemblies. Existing qualification procedures are not well adapted to different seal shapes, sizes, or applications. More comprehensive research is needed on seal assembly design, including energization mechanisms, housing and support structures, and potential functional failures going beyond basic material evaluation. Furthermore, there is a pressing need for robust methodologies capable of translating laboratory-scale findings into field-level applications that ensure long-term operational reliability.