Kalrez® 0090 Packing Element Downhole Completion Tool


DuPont Kalrez® 0090 perfluoroelastomer parts, with its high pressure, high temperature (HPHT) properties, chemical resistance and  superior rapid gas decompression (RGD) resistance, has reached a milestone in extremely aggressive environments when used in the development of a downhole completion tool.

DuPont, in collaboration with multiple customer engineering groups and a year in development, has successfully used Kalrez® 0090 parts in a permanent packer completion tool that can be used in ultra HPHT conditions of over 500°F and 25,000 psi.

The unique and innovative packer completion tool employed Kalrez® 0090 parts have excellent properties in aggressive high temperature conditions.  During the process, a proprietary rubber processing method was utilized to manufacture a large part that could withstand and seal successfully in extreme environments.

During development, various methods of bonding Kalrez® 0090 parts to a metal substrate were examined. Due to its perfluorinated molecular structure, Kalrez® parts will not easily react with common adhesives. This represented a significant challenge with the design of the completion tool. Ultimately, a proprietary bonding method with the required strength for the application was achieved.

This development has helped advance the long term HPHT range in the use of elastomers for downhole exploration tools.  The end result will contribute to extended life service, reduced unplanned maintenance and reliable production.

Take Your Design to the Next Level with DuPont Kalrez® Parts 

DuPont is advancing collaboration with customers to make difficult parts a reality.  Even with very large and “exotic” high end metals, Kalrez® high performance materials and proprietary technology opens up molding options that allows DuPont to help with your most challenging designs.

Kalrez® Parts for HPHT

Kalrez® perfluoroelastomer (FFKM) parts are resistant to 1,800 chemicals and solvents and even resist sour multi-phase fluids. They retain high levels of elasticity and recovery, even after long-term exposure to elevated temperatures.

In rigorous third-party laboratory testing for rapid gas decompression (RGD) resistance, Kalrez® 0090 K312 "A" O-rings received the best possible rating of 0000 per the *NORSOK M-710 Rev 2 standard.

To achieve a “0000” rating, the seal must have no internal cracks, holes or blisters, of any size, after rapid gas decompression testing. Some competitive seals developed multiple internal cracks during test cycling.

What is your HPHT challenge?  Collaborating with our customers leads to helping solve problems using subject matter resources that can help support extending life service and reducing unplanned maintenance.  Contact us to find out how we can help you with your toughest downhole challenges.

*NORSOK M-710 Rev 2 conditions: Test gas: 90/10 mol% CH4/ CO₂; Test temperature: 100°C; Test pressure: 150 bar; Decompression rate: 20 bar/minute


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