By Emily Newton, www.revolutionized.com
Engineers in many process industries must manage the storage and transportation of volatile chemicals and need to know how to design effective seals. They understand the importance of hydraulic valve seals and when to choose those versus other types. These professionals also plan risk assessments to evaluate whether proposed designs will meet minimum standards. What should they do to get the best results?
Understand the relevant chemical’s properties
Designers should begin by confirming the characteristics of the chemical exposed to the sealing system. This evaluation provides a valuable framework for the work to come because it saves time by eliminating the unsuitable options and highlighting those most worth pursuing.
The characteristics to consider range from corrosivity to concentration. If the chemical’s temperature differs during storage versus use, that detail helps the design team create versatile sealing systems that continue functioning as intended regardless of handling.
Keeping the relevant information in a cloud-based storage tool allows authorised parties to access it any time. This benefit removes geographical barriers and enables designers to get support from remotely-located experts.
Consider the operating conditions
Creating a fail-safe sealing system means understanding the likely exposures through everyday use. Professionals developing designs can then counteract the potential adverse effects with thoughtful decisions.
The sealing system’s temperature range is a top concern, especially if regular usage will cause variations. Fluctuations may affect a seal on a chemical vessel, especially if it is a design for a container used in transport and then stored internally. Design professionals should similarly assess the expected operating pressure and the typical lifespan of the seals they might use.
Designers must also plan for environmental factors and reduce the associated issues when possible. One 2025 example occurred when a cargo ship collided with a moored oil tanker. The struck vessel had 18,000 tonnes of jet fuel on board when the incident occurred.
Although early reports suggested the ship carried highly toxic and volatile sodium cyanide, later information said there were only empty containers that usually held it. Some jet fuels are also highly volatile. These circumstances could have become catastrophic if sealing systems could not tolerate shocks and caused leaks.
Find the optimal materials
Materials-discovery activities help people find the most appropriate possibilities that fit the previously identified chemical characteristics. Project management tools increase accountability by detailing the work completed or material options proposed and the responsible parties.
Some teams have also developed artificial intelligence-powered tools that help users find material candidates faster. One recently created example centres on robotic platforms that blend machine learning with chemical and material sciences. This combination results in labs that gather 10 times more data than previous methods and do it at record-setting speeds. Those involved with this innovation say it will help people discover options in days rather than years.
Once engineers find several possible materials, they can consider creating prototypes to see how incorporating those options into sealing systems might work in controlled conditions. Successful experiments in labs are strong indicators of future real-world success.
Select the seal type
When engineers choose the seal type, they should consider operational concerns that may necessitate using a specific kind. A hydrodynamic lubrication-based rubber seal is a good option for situations where people need to reduce friction and the likelihood of overheating. It features a thin film made of fluid between the two seal faces. Alternatively, applications characterised by high pressures or temperatures benefit from springs incorporated into the design because they apply a firm, constant force regardless of those inherent aspects.
Designers evaluating the potential seal types should also consider looking at commercially available products featuring seals. Product descriptions that detail hydraulic control valve benefits may also discuss the seal type and the associated advantages. One product suited for loading liquid petroleum products into ships, railcars and trucks has a positive O-ring seal that remains reliable despite pressure drops or fluid viscosity.
If leaks around the seal housing are concerns, professionals can enhance durability by ensuring their designs include secondary seals or elastomers. Double mechanical seals are also practical options for more robust protection against hazardous chemicals because they involve a barrier fluid. Packing seals include braided fibres, making them reliable against high pressures.
Conduct thorough tests
Examining a seal’s performance in the laboratory under simulated conditions is a dependable way to study how it will perform in the real world. Engineers should partner with specialist providers that can run nondestructive tests on the seals.
One of the most common examinations is the air test, which involves attaching a compressed air supply to the item under test and pressurising the seal cavity. After testers gradually increase the pressure until they reach the target value, they should apply a leak-detection spray or soap solution to the seal’s joints, connection and other areas where leaks may occur. Bubbles indicate leaks.
Hydrostatic tests similarly evaluate whether the seal can handle the specified operating pressure without leaking. Examiners maintain that force for a specified duration and watch the seal face and gland area for leakage. Besides running the appropriate tests, the involved parties should keep thorough documentation, which regulators or other authorities may request if unexpected performance occurs later.
Supplement good design with monitoring
Even seals that meet performance requirements in labs and the real world can fail prematurely or for unexpected reasons. Connected sensors can give real-time alerts of abnormalities, allowing people to respond quickly and prevent dangerous consequences.
In one example, researchers created two monitoring stations for volatile organic compounds. The sensors continuously gathered temperature, pressure and relative humidity data in 90-second intervals, and this system included automatic sampling capabilities.
This oversight is ideal for professionals concerned about operating within regulations to prevent fines or excessive scrutiny. Because connected monitors are so readily available and affordable, decision-makers can often implement them without considerable expenses. Many options also send data to centralised dashboards, allowing authorised individuals to check the feeds at any time, regardless of location. Although designers should feel confident in their work if they follow best practices, real-time data provides an additional safeguard.
Learn from previous efforts
Besides following these tips, designers should document their processes and outcomes. Maintaining a database of prototypes, test results and other details will verify which approaches work best, saving them time when developing future seal-related projects.
