Case Studies Archives - Hi-Tech Seals

Name: High-Pressure T-Seal (35,000 PSI)
Brand: Hi-Tech Seals
Availability: InStock

Spring Energized Seals for Downhole Oilfield Telemetry

Client Web3 — Wed, 10 Jun 2026 18:51:20 +0000

Reviewed by Brian Benkendorf, Director of Design & Development This case study outlines how Hi-Tech Seals specified a PTFE spring energized seal for a downhole telemetry tool, resolving low-pressure leakage and reducing friction on mating metal components in a harsh wellbore environment.

Customer Profile

The client is an industry leader in oilfield telemetry, based in North America. Their work involves downhole telemetry tools deployed into wellbore environments exposed to high pressure, elevated temperatures, aggressive fluids, and abrasive particles.

Application

Downhole telemetry tools transmit measurement data from instruments near the bottom of the drill string to surface monitoring equipment during drilling. These tools are commonly used in measurement-while-drilling (MWD) applications to provide directional survey data, including wellbore inclination and azimuth. The sealing component requires both static and dynamic sealing. The seal isolates the tool’s internal clean fluid from the wellbore environment, including oil, hydrocarbons, H₂S, sand, and Lost Circulation Material (LCM), at temperatures up to 175°C and high pressures. The tool runs on battery power for the duration of a drilling run.

The Challenge

The final sealing component must seal out the harsh wellbore environment from the tool’s clean fluids while keeping friction low enough to avoid affecting battery life. The existing design used a thermoplastic copolyester elastomer (TPC-ET) such as Hytrel®. Although it sealed effectively at higher pressures, it experienced leakage at lower pressures, and its high friction contributed to wear on the metal components.

Hi-Tech Seals Solution

After reviewing several potential sealing solutions, including designs that posed challenges with installation and friction, our team determined that a PTFE spring energized seal proved to be the best solution. Spring energized seals are lip seals that incorporate a metal or composite spring into the seal design. The spring energizes the seal lip against the mating hardware, creating a seal capable of compensating for movement in a dynamic application. The spring energized seal used a helical wound spring providing highly engineered lip loading on the sealing surfaces. The spring maintains sealing force at the lip independent of system pressure, which addresses the low-pressure leakage. The final material design used carbon-reinforced PTFE for the seal jacket. PTFE’s low coefficient of friction helped reduce friction against mating metal components, and its excellent chemical resistance properties made it well-suited to the harsh wellbore environment. Carbon reinforcement improves the wear resistance and mechanical stability under load of the PTFE at elevated temperatures. A KasPex™ PEEK backup ring is added to the gland, blocking the extrusion path and resisting PTFE cold flow to maintain sealing integrity at high pressure.

The Results

The spring energized seal significantly reduced friction and eliminated the wear patterns previously seen on the tool’s metal components. The low-friction properties of the PTFE jacket did not impose a friction load that would contribute to the reduction of battery life. The seal also held pressure across the full operating range, resolving the low-pressure leakage seen with the previous thermoplastic design.

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Extending Slurry Pump Service Life with Custom HNBR Rubber & Fabric Reinforced Diaphragms

Client Web3 — Fri, 01 May 2026 17:01:40 +0000

By Josh Kelly, Sales Engineer The diaphragm is a critical component of a diaphragm slurry pump, a type of positive displacement pump used to transport dense and abrasive mixtures of liquids and suspended solid particles, often known as slurry. The diaphragm is a flexible membrane that flexes back and forth to draw slurry into the pump chamber and push it out, while isolating the slurry from the pump’s mechanical components. This case study outlines how Hi-Tech Seals provided specialized HNBR diaphragms to reduce costly downtime and maintenance, all while improving the pump’s service life.

Customer Profile

The customer provides millwright and on-site machining services for industries such as oil and gas, mining, power generation, pulp and paper, plastics, food, and steelmaking.

Application

This diaphragm slurry pump used two flexible diaphragms positioned on either side of a central drive mechanism. The diaphragms flex in opposite directions: one chamber draws slurry through its inlet check valve while the other discharges through its outlet check valve. This isolates the slurry from the pump’s mechanical components.

The pump operates in cobalt and copper leaching, transferring saltwater slurry with abrasive coral particles.

The Challenge

The diaphragms from previous suppliers could not withstand the abrasive nature of coral slurry. The material used was hydrogenated nitrile butadiene rubber (HNBR), and the reinforced fabric layer was not thick enough, wearing out within only 25 days. This drastically increased their operational costs as replacement diaphragms had to be ordered frequently. The supplier lead time was also a constraint, extending to nearly eleven months.

Hi-Tech Seals Solution

Our engineering team worked closely with the customer to design and engineer diaphragms with a longer service life. The revised design doubled the thickness of the reinforced fabric layer and used an optimized HNBR compound selected to improve durability in the customer’s abrasive slurry conditions.

The Results

The improved diaphragms increased service life from 25 days to 45-60 days, reducing replacement frequency and associated downtime. Hi-Tech Seals was also able to cut lead time by more than half compared to the previous supplier. Together, the extended diaphragm life and shorter lead time reduced slurry pump maintenance, downtime, and operating costs.

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Rockatek Validates T-Seal Performance at 35,000 psi

Client Web3 — Wed, 01 Apr 2026 20:17:26 +0000

By Brian Benkendorf, Director of Design & Development Customer Profile: Rockatek is a professional engineering consultancy, specializing in design, analysis, and custom testing services across sectors including oil and gas, aerospace, defense, and renewable energy. They are known for rigorously testing components under extreme operating conditions.

Application

The T-Seals were installed in a controlled bench test setup to verify final suitability for operation within oil & gas. The seals were required to perform in both static and dynamic (sliding) conditions across approximately 10mm – 15mm of movement. Testing was conducted using ISO 32 hydraulic oil at +10^oC.

The Challenge

Rockatek required seals capable of withstanding hydraulic pressures up to 35,000 psi while fitting around their existing fixed metalwork dimensions, which ruled out off-the-shelf sealing options. A fast turnaround was also critical to align with their testing timeline.

Hi-Tech Seals Solution

We were able to rapidly design and deliver a batch of custom MH92 + MP89 T-Seals engineered to Rockatek’s existing metalwork specifications and operating requirements, delivered within the lead time required to keep their testing on schedule. MH92 is our high-quality hydrogenated nitrile (HNBR) compound used as the primary sealing material; MP89 is our KasPex™ compound, a high-performance virgin PEEK material exclusive to Hi-Tech Seals used as the back-ups.

The Results

The T-Seals were subjected to hydraulic pressures up to 35,000 psi and performed reliably in both static and sliding movements throughout the testing program. “The latest batch of T-Seals we ordered were chosen for the lead time matching our testing timeline and previous stellar results. The seals were designed around our fixed metalwork dimensions. We were very impressed by the performance of these seals… I would highly recommend Hi-Tech Seals for their outstanding products, knowledgeable staff, and commitment to deliver quality products quickly.” — Jim Crowley, CEng, Pet. Eng, Director at Rockatek

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Improved Engine Performance with Double Lip Oil Seals

Client Web3 — Wed, 17 Dec 2025 20:11:24 +0000

Reviewed by Brian Benkendorf In automotive engineering, every component plays a critical role in ensuring vehicle performance and reliability. This case study outlines how Hi-Tech Seals provided an effective solution to Formule ETS’ issue with elastomer seals that could not withstand the operational demands of their machinery. Customer Profile     The customer is Formule ETS, a team of engineering students from the École de technologie supérieure in Montreal. For over 36 years, Formule ETS has been designing and building racing prototypes with a performance-focused approach. Their prototypes have been recognized internationally as complex and accomplished vehicles, and the team itself as forward-thinking that pushes the limits of performance to a professional standard. They compete internationally every year at FSAE and Formula Student competitions. Application    The sealing ring is located between the rotor and the motor housing of their new electric prototype platform. The seal isolates the lubricant used in the transmission from the internal components of the motor. This vehicle model required a more rigorous design and manufacturing process to enhance quality, safety, and efficiency. The Challenge Formule ETS’ challenge was to look for seals capable of withstanding the high temperatures and speeds that were demanded by their electric race car. Previously used elastomers degraded under these operating conditions. Hi-Tech Seals’ Solution    We collaborated closely with Formule ETS to identify the right sealing solution. During this process, we found that the properties of the elastomer seals they were using did not meet the performance requirements of the vehicle, which led to premature degradation. We supplied them with Double Lip Oil Seals made from specialized materials with properties needed to withstand the vehicle’s high temperatures and speeds. A double lip oil seal is a rotary shaft seal with two sealing lips oriented in opposite directions along a rotating shaft. The primary lip faces inward to retain lubricant within the housing under continuous shaft rotation. The secondary lip faces outward as an excluder, preventing contaminants such as dust, moisture, and debris from reaching the bearing and internal components. In the Formule ETS engine, a double lip oil seal combined with a specialized high‑temperature resistant elastomer retained lubricant and increased sealing integrity under sustained high‑speed rotation and thermal cycling. The Results    Formule ETS received the Double Lip Oil Seals and delivered impressive results. This contributed significantly to the overall increase in speed and the success of the engine’s development.

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Carbide Drill Inserts: A Case Study on Wear Resistance with WolCar™

Client Web3 — Wed, 20 Aug 2025 19:53:25 +0000

Selecting the right material is imperative in demanding industrial environments as this can affect operational efficiency. This case study illustrates how Hi-Tech Seals provided a tailored solution for a customer who required better-performing drill bit inserts compared to the conventional ones in the market. Hi-Tech Seals introduced WolCar™ Carbide as the excellent solution for the customer’s application. WolCar™ Carbide [hyperlinked to WolCar webpage] is Hi-Tech Seals’ family of superior-performing cemented tungsten carbide materials. WolCar™ Carbide offers extreme strength, remarkable wear resistance, and versatility as it can be produced into virtually any shape and size, enabling customized solutions for different applications.

Customer Profile

The customer provides innovative and tailored hard-facing solutions across a range of industries. They specialize in creating product life extensions for commodity-type items.

Application

Drill inserts are replaceable cutting tips used in drill bits and machine tooling, playing a major role in cutting hard materials. The customer has been using profiled tungsten carbide drilling inserts for their equipment used in oil and gas mining operations. These are commonly used in applications where heavy-duty and high-precision drilling are required. They are used in extreme environments, from drilling hard rock formations to operating in applications exposed to highly aggressive chemicals.

The Challenge

Hi-Tech Seals was given the opportunity to enhance the performance of the customer’s drill inserts. The challenge was to provide tungsten carbide inserts that would surpass the capabilities of conventional inserts. The new inserts should also be reasonably priced with acceptable lead times to promote ease in the customer’s overall buying process.

Proposal and Testing

After assessing the customer’s requirements—with the help of our engineering department, we were able to choose the right WolCar™ Carbide material to help enhance the performance of various profiles. The customer then performed two controlled impact trials to validate the proposed solution. During the first trial, both the customer’s existing profiled tungsten carbide drill inserts and Hi-Tech Seals’ WolCar™ tungsten carbide drill inserts were subjected to heavy impact testing. The second trial employed the same techniques but with the involvement of heat.

The Results

In both tests, the WolCar™ carbide drill inserts outperformed the customer’s samples and proved to be the most suitable material for the customer’s application. The combination of successful results with WolCar™’s characteristics, cost-effectiveness, and quick delivery turnaround was key to the customer’s decision in choosing Hi-Tech Seals as their new provider of drill bit inserts.

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Reduce Downtime and Costly Maintenance with Viton™ O-Rings

Administrator — Tue, 22 Apr 2025 20:57:36 +0000

In the asphalt industry, selecting the appropriate sealing components is just as important as maintaining equipment reliability. In this case study, Hi-Tech Seals introduced Viton™ O-rings, offering a sealing solution engineered for the customer’s unique application to help reduce downtime and costly maintenance. Viton™ is a high-performance fluorocarbon (FKM) compound known for its exceptional resistance to heat, fluids, and aggressive chemicals while maintaining outstanding physical properties even in the most demanding environments. Customer Profile     The customer is an industry-leading company that specializes in mix design and manufacture of asphalt emulsions for construction, roadway, and municipal maintenance industries. Application    Hi-Tech Seals was consulted by the customer regarding a critical issue affecting a key piece of their production equipment, the centrifugal pump. The pump is used in transferring asphalt throughout the production process. During peak season, production runs 24 hours a day and 7 days a week. The pump’s service life is between 2.5 to 3 weeks. At this point, asphalt may breach the pump’s internal stator, leading to equipment failure. Such a breakdown could result in one to two days for transporting parts, followed by two to three days of equipment overhauling, and approximately $20,000 in repair costs per occurrence, excluding any associated profit losses. Sealing Challenges    Upon reviewing the application, the issue appeared to have originated from failed fluorocarbon (FKM) O-rings located in various ports of the pump. During operation, the seals experienced heavy compression set (the cross-section became triangle shaped), became hardened, cracked, and extremely brittle. Temperatures consistently reached 325°F (163°C) internally, and the pumping pressure was maintained at 50 psi. Hi-Tech Seals’ Solution    For further analysis, the customer submitted the failed seal samples to our engineering lab. After a thorough examination, we ruled out temperature and pressure as the primary causes of failure. This is because FKM’s temperature range exceeds the pump’s operating temperature. The pump’s operating pressure was also too low to cause a compression set or deterioration of this magnitude. We then changed our focus to chemical compatibility in conjunction with heat and pressure. Asphalt is comprised of a mixture of the following components:

Bitumen

Stoddard Solvent

Fatty Acids

Styrene

Butadiene

Water

Aggregate

Petroleum-based Binder

FKM is rated as having excellent compatibility with each component, except when directly exposed to water. Based on this assessment, we concluded that the original O-rings’ failure was due to their composition, specifically being a sub-quality elastomer with low fluorine content. The immediate solution was to replace the affected seals with our Viton™ O-rings. The Results    After implementing Viton™ O-rings, an end-of-season maintenance and evaluation confirmed that Viton™ exceeded the performance and service life of the original FKM O-rings exponentially, with no instances of failure observed. Viton™ O-rings exhibited only a minor compression set, minimal increase in hardness, and negligible bypass. As a result, the pump performed reliably and uninterrupted throughout the season.

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