Uses of rubber in the oil and gas industry

In the UK, domestic production of oil and gas is a critical element of the energy mix, with offshore rigs predominantly concentrated in the North Sea, east of Scotland and north east of England. The rigs located in the Central North Sea (east of Aberdeen) and the West of Shetland (the new, large-scale Rosebank development) remain pivotal to the oil and gas industry. While there is increasing competition from the UK renewables sector, the oil and gas industry supports around 200,000 UK jobs.

At Aquaseal Rubber, we provide oil and gas products made from a range of rubber materials. This guide to the uses of rubber in the oil and gas industry will highlight the three different core operational segments within oil and gas (upstream, midstream and downstream), what rubber materials are used and where, and the best ways to maintain rubber for oil and gas.

What is the oil and gas industry?

The oil and gas industry is the global sector involved in the exploration, extraction, refining, transportation and distribution of petroleum products and natural gas. As one of the world’s most economically influential sectors, the industry powers modern transportation, generates electricity and manufactures essential everyday materials like plastics, fertilisers and pharmaceuticals.

Since the primary focus of the oil and gas industry is to safely extract and transport hazardous fluids, certain rubber materials are used to provide essential sealing and flexibility under extreme conditions. Nitrile, EPDM and viton rubber are commonly used to manufacture o-rings, rubber gaskets and high-pressure hoses to ensure safe operations and optimal performance of oil and gas applications.

In the UK, notable companies operating in the oil and gas industry include Shell UK, BP and TotalEnergies. These companies all require rubber materials in some form to enhance their operations whilst maintaining health and safety standards.

Where is rubber used in the oil and gas industry?

Because operations in the oil and gas industry involve harsh chemicals, high pressures and extreme temperatures, specialised synthetic rubber materials are used across drilling equipment, pipeline systems and refinery applications. Rubber is primarily used in this industry to create heavy-duty rubber seals, gaskets and o-rings.

Operations in the industry are split into three main segments, with varied rubber for oil and gas components required for each one.

Upstream

Upstream operations include exploration and drilling, where rubber is used in seals, packers, blowout preventers, hoses, gaskets, drilling equipment and vibration-dampening components. These applications are exposed to extreme pressures, fluctuating temperatures, drilling fluids, crude oil and abrasive materials, meaning rubber materials must be used to prevent leaks and equipment failure.

Rubber is used in upstream operations because of its excellent sealing performance, ability to absorb vibration, resist wear and maintain flexibility under harsh operating conditions. Therefore, the preferred material for many upstream applications is nitrile rubber because of its excellent resistance to oil, fuels and hydraulic fluids. For applications operating in higher temperatures or with aggressive chemicals, hydrogenated nitrile (HNBR) is often used because it offers improved heat, pressure and abrasion resistance.

Midstream

Since midstream operations focus on the storage, processing and transport of fuels, rubber is relied on for pipelines, valves, pumps, expansion joints, storage tanks, transfer hoses and pipeline sealing systems. These components must withstand continuous contact with hydrocarbons whilst accommodating pressure changes, vibration and movement over long distances.

Rubber materials are used to create leak-proof seals, protect infrastructure from wear, absorb mechanical stress and maintain flexibility in dynamic systems, with its durability helping to ensure the safe and efficient transportation and storage of oil and gas products. Like in upstream operations, nitrile is widely used for pipeline seals, hoses and gaskets because of its oil resistance and durability, whilst HNBR is preferred for higher temperatures because it provides enhanced mechanical strength and a longer service life.

Downstream

Downstream oil and gas operations use rubber in pumps, valves, seals, gaskets, chemical transfer hoses, expansion joints and processing equipment. In refining and petrochemical environments, materials are exposed to high temperatures, aggressive chemicals, steam, fuels and refined petroleum products.

Rubber materials are used because they provide dependable sealing, chemical resistance and flexibility while helping equipment withstand continuous operation. Viton rubber, or fluoroelastomers, is the best choice for downstream applications because of its outstanding resistance to fuels, oils, solvents and many aggressive chemicals, all whilst maintaining performance at high temperatures. For applications involving steam or certain polar chemicals, EPDM can be used as long as oil resistance is not the primary requirement. Choosing the right material for downstream operations reduces maintenance requirements, improves process reliability and protects against leaks.

What rubber materials are used in the oil and gas industry?

Different types of rubber materials are used across the oil and gas industry because each type of rubber for oil and gas boasts different properties, with some better suited to certain applications.

From leak-proof seals to maintain safety to resisting vibrations and wear to enhance longevity, bespoke rubber materials are crucial for use in the oil and gas industry. These materials include:

• Nitrile: one of the most widely used elastomers in the oil and gas industry, nitrile offers excellent resistance to petroleum-based oils, fuels and hydraulic fluids. It is often used in upstream and midstream operations due to its durability, abrasion resistance and cost-effectiveness.
• Hydrogenated Nitrile (HNBR): building on the oil resistance of standard nitrile, HNBR also provides superior resistance to heat, pressure, abrasion and mechanical wear. It is used in more demanding applications where longer service life is essential.
• Viton/Fluoroelastomers (FKM): valued for their exceptional resistance to high temperatures, aggressive chemicals, fuels and hydrocarbons, fluoroelastomers – often known by the brand name Viton), are widely used in downstream refining and petrochemical processing for seals, gaskets and o-rings exposed to harsh chemical environments.
• EPDM: since it offers excellent resistance to steam, hot water, weathering, ozone and many chemicals, EPDM is suitable for non-petroleum applications within oil and gas applications. It is commonly used in water treatment systems, cooling circuits and steam service, but is generally not recommended for prolonged contact with oils or hydrocarbon fuels.

Other types of rubber can be used in certain scenarios. For example, neoprene offers good weather, ozone and moderate oil resistance, making it suitable for outdoor sealing applications where environmental exposure is a concern. Silicone can be used where extreme high or low temperatures are encountered, with fluorosilicone often chosen for specialised rubber seals and rubber gaskets.

At Aquaseal Rubber, we are proud to work with clients operating in several industries worldwide, providing bespoke rubber solutions for their projects. A full list of rubber for oil and gas applications can be found on our wider oil and gas page.

What are the best ways to maintain rubber in the oil and gas industry?

Maintaining rubber components in oil and gas applications is vital for preventing catastrophic leaks, ensuring pressure integrity in harsh environments and avoiding environmental contamination.

Rubber for oil and gas can be maintained by:

• Conducting routine visual inspections: this helps to identify early signs of cracking, hardening, wear or chemical attack before they lead to component failure. Detecting any deterioration early reduces unplanned downtime and improves safety.
• Ensuring strict temperature control: by keeping rubber components within their recommended operating temperature range, you can prevent premature hardening, softening or loss of elasticity. This ensures seals, hoses and gaskets continue to perform reliably in demanding oil and gas environments.
• Protecting rubber from environmental exposure: limiting exposure to UV light, ozone, moisture and unnecessary contact with incompatible chemicals helps slow the ageing and degradation of rubber materials. Proper storage and shielding preserve the rubber’s physical properties.
• Choosing the right lubricants: using lubricants that are compatible with the specific rubber compound prevents swelling, cracking or chemical degradation that can compromise sealing performance. Selecting the correct lubricant also reduces friction during installation and operation.

Aquaseal Rubber can support your oil and gas industry applications

From helping you understand the role of nitrile watertight seals in the oil and gas industry to ensuring you are confident in selecting the best rubber gaskets for oil rigs, our team is here to support you in maximising the safety and performance of your oil and gas industry applications.

At Aquaseal Rubber, we are experts in manufacturing a range of bespoke products in rubber materials depending on your requirements. No matter the application, working with our team of expert rubber manufacturers UK and global businesses choose to meet performance and safety standards can ensure your oil and gas machinery is compliant and ready for use.

Contact us to discuss your requirements and see how we can support your operations in the oil and gas industry.