Selection Guidelines for Elastomers

Scope

This document serves as a means to inform Field Operations about current elastomer
recommendations for downhole tools applications. “HT-3” o-rings field test has been
completed. “HT-3” o-rings have been commercialized and will be used for the entire
temperature range up to 425oF. It replaces V-25 o-rings for H2S Service.

Recommended Elastomer Compounds

There are three o-ring compounds recommended for use in downhole equipment;

Standard Service: C-67 90 durometer nitrile compound

new> High Temp H2S Service: HT-3 95 durometer Viton compound
Severe Service: 90-95 durometer Aflas

The C-67 nitrile can be used when all of the following conditions are met:
• No H2S is present.
• Neither Zinc Bromide (ZnBr) or Calcium Bromide (CaBr) is used.
• Downhole temperature is less than 300oF

The HT-3 Viton should be used when any of the following conditions are expected:
• H2S is present or suspected.
• ZnBr or CaBr is used.
• Downhole temperature is less than 425oF.
• Produced fluids contain higher levels (typically > 10%) of low molecular weight
aromatic hydrocarbons such as Benzene, Toluene, or Xylene.
• Provided low levels of amines are present. Amines are corrosion inhibitors commonly
found in stimulation fluids and in some mud systems.

Aflas should be considered when any of the following conditions are expected:
• High concentrations (typically > 40%) of H2S are present.
• High concentrations (typically > 35%) of CO2 are expected.
• High volumes or concentrations of stimulation acids will be pumped.
Provided
• Downhole temperature is greater than 100oF and less than 440oF
• Produced fluids contain less than 10% of low molecular weight aromatic
hydrocarbons such as Benzene, Toluene, or Xylene.
Downhole Environment

The downhole testing environment is very tough on elastomers because of the variety of
fluids and gases present along with the added effects of time, pressure cycling, and
temperature. Many of these factors tend to “age or overcure” the elastomer and can lead
to possible failures. To choose the best o-ring material for any particular downhole
environment, the main contributors to seal failure must be examined:

Extrusion Resistance

This is the ability of the o-ring to withstand being forced through a gap between two
mating parts. The majority of our tools today use back-up rings to prevent extrusion on
moving parts, and use double o-rings in one groove on static seals. The only exception to
this norm is the requirement for back-up rings on most static seals when using Aflas o-
rings. One of the characteristics of Aflas is its poor extrusion resistance when compared
with C-67 or V-25. Relative extrusion resistance for our elastomers is as follows (best to
worst): HT-3 (~V-25) > C-67 >> Aflas

Explosive Decompression

When gas permeates into an o-ring and the pressure is reduced (such as bleeding off
tubing pressure after shut-in), the gas in the o-ring will try to expand and leave the o-ring.
This results in blisters and cuts in the o-ring. Upon inspection many of the cuts in an o-ring
due to explosive decompression first appear as manufacturing flaws or defects in the
seal, because of their proximity to the parting line of the seal and the smooth nature of the
cut.

Chemical Attack and the Resulting Loss of Mechanical Properties

Almost all oilfield chemicals such as brines, inhibitors, and acids all serve to damage any
o-rings’ mechanical properties. The key to determining the proper o-ring material for
downhole use is to determine the amount and time of exposure to any of the offending
chemicals and select the compound that is least affected. The following chart provides a
quick look at the relative impact of some common oilfield chemicals on our approved
elastomers.
Notes: Rating system; 5 is excellent, 1 is not recommended.
1 Amine based inhibitor systems are used in most oilfield acid and some mud systems
3 Concentrations of light aromatics (such as Benzene, Toluene, and Xylene) above 10%
greatly soften Aflas o-rings and can lead to eventual extrusion failures.

Aflas o-rings

This material is usable up to 440oF, has high resistance to explosive decompression (CO2)
and hostile chemical attack. However, along with these benefits the Aflas has reduced
extrusion resistance (as compared with HT-3 or V-25) and poor low temperature sealing
properties. The compound has been tested in a seal test device and on full scale tools in
the SRC Autoclave test vessel.

Low Temperature Pressure Testing

Aflas is similar to the Teflon family of materials, and like Teflon it is stiff at low
temperatures. This stiffness allows the seals to leak at cold temperatures, this
phenomenon is related to the “Glass Transition” Temperature. The Glass Transition
Temperature changes with pressure.

Because of “Glass Transition”, pressure testing tools dressed with Aflas o-rings require
reductions to the maximum surface pressure test. Pressure testing above the
recommended value for the temperature can lead to flooding atmospheric chambers or
external leakage. Follow the attached chart to determine the maximum pressure test
without exceeding the low temperature seal of the o-rings.
With Aflas seals installed and if pressure testing is required above the limits as defined
above, the tool should be heated (to +125oF) to prevent seal leaks and flooding
atmospheric chambers.

O-Ring Extrusion Resistance

Aflas o-rings have lower extrusion resistance than the HT-3 Viton series o-rings. For this
reason Aflas o-rings are not recommended for small diameter applications such as drain
plugs and drain valves.

Breakout Friction (Initial Mandrel motion)

Break-out friction is the force required to move the mandrel from its stationary position
after an extended time period. Break-out friction of Aflas vs. HT-3 Viton tends to be higher
after sitting at long periods downhole.

Conclusions

Prior versions of this publication had only 4 types of o-rings; C-67 (nitrile), V-25 (Viton), HT-
3 (Viton) and Aflas. The HT-3 o-ring has now been tested and qualified and replaces the V-
25 Oring for all applications. The HT-3 fills the entire temperature range up to 425oF, with
similar chemical resistance to V-25 Viton.

All locations are advised to implement the introduction of HT-3 compound immediately.
The chemical resistance and mechanical properties of the HT-3 make this material an
excellent choice for a large range of applications.

There are multiple different types of elastomers that seal manufactures are touting for
HPHT service but in reality few are well suited for the downhole environment and have
not been qualified. The introduction of new elastomers into the marketplace is very slow
and infrequent, thus there are only a limited number of “new” elastomers out there to
evaluate. We will continue to monitor the performance of High Fluorine Content Viton’s,
and use this information in future decision making.