Enhancing Reliability of Subsea Hydraulic Systems: Metal Seal Solutions for Extending Coupling Service Life

Our Client specializes in designing and manufacturing advanced hydraulic distribution systems for offshore energy applications, supplying critical components that control subsea production systems worldwide. Their expertise ensures efficient and safe operations in some of the most challenging environments on earth.

The ApplicationThe client required a sealing solution for a series of dual-resistant hydraulic couplings designed to withstand make-and-break cycles under full system pressure. These couplings, available in three sizes with a uniform design, were integral to subsea equipment where reliability and longevity are paramount.

Previously, the client relied on a back-to-back elastomer O-ring configuration. However, they sought an upgraded sealing solution to increase the number of connect/disconnect cycles per coupling, thereby extending the overall lifespan of the equipment. The application posed significant challenges: operating at high pressures (15,000 psi) and requiring compatibility with well fluids and control fluids in subsea conditions. Additionally, the seals needed NACE approval to ensure resistance to corrosion and sulfide stress cracking.

Our Custom Sealing SolutionTo meet the client’s demands, our engineering team recommended a precision-engineered metal seal. This solution addressed both the extreme pressure requirements and compatibility with hydraulic fluids. The seal was designed to endure slight dynamic movements during coupling mating and demating, ensuring consistent performance over thousands of cycles.

The seal’s base alloy underwent NACE MR0175 heat treatment, a critical process for oil and gas applications to prevent catastrophic failure in H2S-rich environments. To further enhance performance in dynamic conditions, the seal was gold-plated, leveraging gold’s malleability and resistance to galling. Rigorous cycle testing confirmed the seal’s ability to maintain integrity under full pressure, with no leakage detected throughout the trials.

Client Success & ResultsThe new metal seal solution exceeded expectations, delivering a 100-cycle connect/disconnect lifespan before requiring replacement—a significant improvement over the original elastomer O-ring setup. This breakthrough not only enhanced the reliability of the client’s hydraulic couplings but also reduced maintenance costs and downtime for offshore operations.

Impressed by the results, the client approved the gold-plated metal seals for mass production. Today, our sealing solution is a standard component in their subsea hydraulic systems, trusted by energy companies worldwide for its durability, NACE-compliant performance, and ability to thrive in high-pressure, corrosive environments.

By combining advanced materials engineering with rigorous testing, we empowered our client to set new benchmarks in subsea equipment reliability. Explore how our metal sealing solutions can elevate your offshore energy applications—contact us today to discover tailored, SEO-optimized sealing innovations.