AED-Resistant Seals – Anti-Explosive Decompression

AED-resistant seals provide reliable and effective protection in high-pressure environments where sudden pressure loss occurs, particularly in the oil and gas industry. O-rings designed to prevent explosive decompression (AED – Anti-Explosive Decompression) are specially engineered sealing components crucial for applications involving pressurised gases. These seals help prevent explosive decompression, protecting both personnel and equipment from serious damage or injury.

In this article, we explain what explosive decompression is, where AED-resistant seals are used, what materials they’re made from, and how they impact the oil and gas sector.

What Is Explosive Decompression (ED)?

Explosive decompression – also referred to as rapid gas decompression (RGD) – is structural damage to elastomer seals and O-rings caused by a sudden drop in pressure in a gaseous environment. This phenomenon often occurs when an elastomeric seal is exposed to high-pressure gas. Gases can saturate the seal material, filling molecular gaps and causing the seal to swell. While swelling alone may not damage the seal, a rapid pressure drop can result in explosive decompression. The gas trapped within the seal expands rapidly, causing fissures, cracks, and voids, which may lead to total seal failure. This rapid internal pressure change is what defines AED (anti-explosive decompression).

Explosive decompression can have severe consequences – a ruptured or exploded seal may injure staff and result in costly equipment failures.

High-Pressure Resistant AED Materials

AED O-rings are made from materials designed to withstand high-pressure gas environments. They are engineered from premium elastomers that retain elasticity and shape even under extreme pressure. These seals can endure rapid decompression without deformation or rupture.

Common materials used for AED seals and O-rings include:

• FKM (Viton®) – offers excellent resistance to explosive decompression, fuels, oils, and chlorinated solvents. Suitable for oil and gas drilling applications. Certified to NORSOK M710 Rev. 2 and NACE TM0297.

• FEPM (Alfas®) – resistant to acids, bases, water, and amines. Ideal for high-pressure and pressure-cycle environments. Often used in oil and gas extraction.

• FFKM (Kalrez®) – provides exceptional resistance to both explosive decompression and aggressive chemicals.

• HNBR – combines excellent resistance to explosive decompression with durability against oil, heat, CO₂, and corrosion inhibitors. Suitable where standard nitrile is insufficient, but FKM is not necessary. Also compliant with NORSOK M710 Rev.2.

How to Choose the Right AED Elastomer?

When selecting a material for high-pressure sealing applications, consider:

• Pressure level – damage typically increases with pressure.

• Hardness – higher hardness improves RGD resistance.

• Temperature – gas permeability increases with temperature; AED materials must withstand extreme thermal ranges.

• Chemical resistance – seals must resist hydrocarbons, methane, CO₂, hydrogen sulphide, and hydraulic fluids common in oil and gas applications.

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Where Are AED-Resistant Seals Used?

AED elastomeric seals are ideal for high-risk environments where explosive decompression is a major concern. AED O-rings are commonly used in high-pressure systems in the oil and gas industry.

Key benefits:

• Prevent explosive decompression events

• Help avoid costly failures and equipment damage

• Improve safety for workers

• Enhance operational efficiency

• Reduce costly downtime

• Support safe handling of pressurised systems

AED Certification

An AED certificate verifies that a seal meets stringent safety standards for industries like oil and gas, aerospace, and chemical processing.

Global testing standards for AED-resistant elastomers include:

• NORSOK M710 Rev.2 Section 7.3 Annex B – Qualification of non-metallic sealing materials and manufacturers.

• NACE TM0297 – Effects of CO₂ decompression at high temp and pressure.

• ISO 23936-2 – Non-metallic materials in contact with oil and gas production media.

• TOTAL GS PVV 142 Annex 8 – AED testing procedure for O-ring seals.

As discussed, AED-resistant seals and O-rings are critical for preventing failures caused by trapped gases expanding during sudden pressure drops. Designed specifically for extreme environments, these seals provide long-lasting protection and peace of mind in high-pressure applications.

To learn more about our premium rubber sealing solutions or to discuss your technical requirements, please contact us by phone: +48 22 292 40 24 or +48 505 16 03 03, via email at Power@PowerRubber.com, or through our contact form.