Optimization of contact pressure profile for performance improvement of a rotary elastomeric seal operating in abrasive drilling environment

Abstract The magnitude and profile of seal-contact pressure are critical in the sealing performance of downhole equipment being operated in an abrasive drilling environment. Recently, a design analysis was conducted with the assistance of finite element software to visualize the seal contact pressure profile. A set of design criteria was followed to achieve the preferred contact pressure profile for sealing performance improvement. As per the prescribed optimization criteria, a new seal with a unique contact pressure profile was designed and then tested on a rotary seal tester against the benchmark o-ring design. Testing data indicated that the proposed design greatly extended the service life of the sealing system. Seal performance improvement was corroborated by the observation of lower frictional torque, surface temperature, and material loss. Surface wear scars also indicated that the proposed design was more effective in impeding the ingression of abrasive particles than the o-ring seal.