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Metal Seal Design 鈥� New Product Development for a Leading O&G Equipment Manufacturer

October 16, 2025
Metal Seal Design 鈥� New Product Development for a Leading O&G Equipment Manufacturer

Executive Summary

乐播传媒视频 partnered with a leading Oil & Gas equipment manufacturer to develop a next-generation metal seal for sour service. Leveraging advanced FEA, material optimization, and integrated project management, the team overcame complex design and validation challenges鈥攃ompressing the overall timeline by 25% while achieving API 6A and API TR8 qualification.

Business Challenge

  • Material selection complexity (For Sour Service, API, and NACE requirements)
  • FEA intensive design: The seal turns into a plastic zone during the sealing function, making it complex to validate
  • Highly non-linear FEA with plasticity involved, convergence challenges
  • Geometry sensitive design: Minor changes to the profile can alter the results to a great extent
  • Consideration of ease of installation and system-level components
  • Test fixture and Tooling design
  • Withstand 15 K pressures and qualify testing per API 6A and API TR8

Business Challenge

  • Material selection complexity (For Sour Service, API, and NACE requirements)
  • FEA intensive design: The seal turns into a plastic zone during the sealing function, making it complex to validate
  • Highly non-linear FEA with plasticity involved, convergence challenges
  • Geometry sensitive design: Minor changes to the profile can alter the results to a great extent
  • Consideration of ease of installation and system-level components
  • Test fixture and Tooling design
  • Withstand 15 K pressures and qualify testing per API 6A and API TR8

Our Solution

  • Collective consultation with internal SMEs based on the design challenges faced
  • Manufacturing Expert consultation on a need basis to address manufacturing issues
  • Managing overlapping activities to best utilize the resources and achieve efficient execution till Testing and Validation
  • Material review and suggestion of alternate material (approval sought from the BH material expert before finalization)
  • Test reporting and RCA for any failures, and corrective action with Final Test Report

Key Results and Benefits

  • Requirements analysis
  • Multiple Concept designs and shortlisting main and back-up concepts
  • Validating the concepts with Design calculations using MathCAD
  • Test procedure writing and conducting RCA on a need basis
  • Resolve test issues
  • Metal Seal that qualified 15K Pressure
  • Overall timeline compressed by 25% with Integrated Project Management
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About 乐播传媒视频

乐播传媒视频 is a leading global technology services and solutions provider, led by Business and Technology Consulting. 乐播传媒视频 provides business-friendly solutions to help clients succeed and be future-ready, by seamlessly bringing together digital expertise, strong industry specific alliances and the unique ability to leverage deep domain expertise from ITC Group businesses. 乐播传媒视频 is a wholly owned subsidiary of ITC Ltd., a 100-plus-year-old diversified conglomerate with businesses spanning Hotels, Consumer Goods, Paperboards & Packaging, Agri Business, and Information Technology. ITC Ltd. has been in the hospitality business for over 4 decades. It has over 100 properties across 70+ destinations. The hospitality practice at 乐播传媒视频 is 800+ people strong and most have experience in the hospitality domain leading to a high-quality IT service experience for its hospitality customers.

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