The oil and gas industry constantly pushes seal materials to their limits with high-pressure gas systems. Every cycle adds mechanical and thermal stress. Rapid decompression can pull trapped gas through the seal body, forming cracks that grow until the part fails. Joint seams and poor vulcanization only accelerate the problem.
The Challenge
A leading manufacturer in the oil and gas industry came to Marco Rubber & Plastics after critical seal failures in one of their high-pressure systems. Their existing seals were cracking along the joint line and separating under decompression.
They needed a replacement that could handle high pressure, gas exposure, and rapid decompression without losing integrity. The goal was longer service life and fewer unplanned shutdowns.
Marco’s engineering team reviewed the failed seals and identified two root causes: an FKM compound that was not rated for explosive decompression and a molding process that left a weak seam through the part.
Marco’s Engineering Approach
Our engineering team began by inspecting the failed seals. Two issues were clear: poor vulcanization caused weak joints, and explosive decompression caused cracking. Under repeated pressure cycles, the seam acted as a stress point where cracks formed and spread until complete failure.
With the root cause confirmed, Marco selected a 90-durometer FKM compound with verified resistance to explosive decompression, per NORSOK M-710 standards. The material’s strength and low gas permeability maintained sealing performance through repeated decompression cycles.
The team then used a continuous molding process to produce a seamless part with consistent density and no joint line. The structural weak point, which caused cracking in the original seal, was eliminated. Long-term resilience was improved.
The new design was validated through high-pressure and rapid-decompression testing. The seals maintained flexibility, surface integrity, and sealing force after multiple cycles with no damage present.
Proven Results from Marco
The new design met every performance target:
- Service life increased fivefold over the original seal
- Joint cracking and separation eliminated
- Maintenance frequency and downtime significantly reduced
By combining material science and precise molding, Marco delivered a reliable sealing solution that restored uptime and reduced total operating costs for the customer.
Reliable Sealing for Harsh Oil and Gas Environments
Marco Rubber & Plastics provides engineered sealing solutions that hold up in the toughest oil and gas systems. Through controlled testing and material validation, Marco ensures every seal delivers consistent performance under demanding field conditions.
Related Materials for Extreme Conditions
For environments with higher chemical or temperature exposure, Marco also recommends Markez® FFKM compounds such as Z1352 and Z1400. These materials maintain strength and elasticity in sour gas, amine, and high-temperature service where standard FKM can begin to degrade.
Learn more about related solutions:
- O-Ring material specifications
- Continuous molded seals and custom manufacturing
- Markez FFKM compounds for extreme service
- Chemical compatibility guide
Talk to Marco Rubber & Plastics for your high-pressure and decompression-resistant sealing solutions.