High-Performance Downhole Sealing

Overview

Well completions demand sealing solutions that can withstand some of the harshest downhole environments in the oilfield. From extreme pressures and temperatures to exposure to aggressive chemicals, every component must perform flawlessly to ensure well integrity, tool reliability, and efficient operations.

At KC Seals, we specialize in engineered sealing systems for a wide range of completion tools—supporting plug-and-perf systems, liner hangers, production packers, flow control devices, degradable frac plugs, and more. Our expertise in elastomers, thermoplastics, and thermosets ensures reliable performance in even the most demanding HPHT environments.

Key Applications

Plug & Perf Systems
Seals for reliable zonal isolation during hydraulic fracturing operations.

Liner Hangers
High-pressure, tight-clearance sealing using innovative packer designs for efficient wellbore anchoring.

Production Packers
Durable elastomeric seals that isolate production zones and prevent fluid migration.

Flow Control Devices
High-performance seals for sliding sleeves and other flow control components to maintain consistent pressure and flow rates.

Degradable Frac Plugs
Dissolvable elastomers that eliminate the need for milling or retrieval, reducing completion time and cost.

Featured Products

HPT Stack – Engineered for HPHT

Our proprietary HPT Stack is purpose-built for high-pressure, high-temperature applications, offering:

• Easier, damage-free installation

• Enhanced sealing performance in dynamic tools like sliding sleeves

• Improved longevity and reliability in challenging conditions

API 11D1-Certified Packer Elements

We manufacture API 11D1 V3/V0 approved packer element stacks designed for high-expansion and extrusion resistance. Key features include:

• Operation across wide temperature ranges (–35°C to 160°C)

• Pressure ratings up to 5,000 psi

• Resistance to corrosive environments, including H₂S

• High-performance elastomers for long-term reliability

Material Expertise

We select and formulate materials specifically for the challenges of completions:

Elastomers
HNBR, FKM, EPDM, and proprietary blends—offering excellent resistance to extrusion, compression set, and thermal cycling.

Thermoplastics
Ideal for wear rings, backup rings, and fluid-compatible barriers—delivering corrosion resistance and dimensional stability.

Thermosets
Reinforced composites offering exceptional mechanical strength and chemical resistance, especially in HPHT settings.

Addressing Critical Downhole Challenges

• Temperature Extremes: Withstand –45°C to 315°C

• High Pressures: Performance above 2,000 bar

• Chemical Exposure: Compatible with aggressive fluids (e.g., steam, base oils, H₂S)

• Rapid Gas Decompression (RGD): Prevents blistering and failure after sudden pressure drops

Certifications & Compliance

Our products are manufactured to meet or exceed key industry standards:

• API 11D1 V3/V0 for packer elements

• NORSOK M-710 for elastomers in H₂S-rich environments

• ISO 14310 for downhole sealing equipment

Below is a list of some of our most popular sealing products for completion tool equipment: