Scientists from North Caucasus Federal University (NCFU) have developed an innovative leak-prevention compound for oil and gas wells. This breakthrough enables the use of more cost-effective metal-plastic pipes instead of traditional metal ones. A patent has already been granted for this development, according to the university`s press service.
During oil and gas extraction, downhole tubing is constantly subjected to extreme stress, corrosion, and significant temperature fluctuations. For instance, processes like hot steam injection for enhanced oil recovery or hydraulic fracturing can cause rapid temperature spikes within the pipes.
Such temperature swings often cause traditional threaded pipe connections to lose their seal, leading to leaks and reduced extraction efficiency, explained NCFU researchers.
“The challenge lies in the differential expansion of pipes and connections when heated, which weakens the contact pressure in the threads. Existing solutions either lack sufficient reliability or significantly complicate the design,” explained Ivan Kovalenko, a second-year master`s student in Oil and Gas Engineering at NCFU.
The university`s scientists proposed an innovative solution: a threaded connection equipped with fluoroplastic seals.
Kovalenko highlighted: “The key feature of this development is the use of fluoroplastic. This material possesses a unique property: when heated, it expands more than metal, automatically compensating for thermal deformations and maintaining the connection`s integrity.”
This new threaded connection developed by the researchers enables the use of more affordable metal-plastic pipes instead of metal ones, significantly reducing equipment procurement and maintenance costs, according to the authors of the study.
Kovalenko stated: “Our solution is unprecedented. It not only enhances operational reliability but is also economically advantageous: metal-plastic pipes are cheaper, lighter, and more corrosion-resistant.”
According to him, the previous use of metal-plastic pipes in oil and gas wells was limited due to the need for metal connecting elements that could provide sufficient strength and sealing.
Tests confirmed that the new connection can withstand pressures up to 12 MPa without deformation or leaks. University scientists reported that the results showed no defects, such as leaks or cracks, either on the main metal or in the detachable connections.
NCFU specialists assert that their proposed invention will significantly enhance the reliability and economic efficiency of both gas and oil well operations.
These achievements were recognized in the 2025 digest `Promising Scientific and Technical Developments for the Fuel and Energy Complex` by the Russian Energy Agency (REA) under the Ministry of Energy of Russia.
A patent, RU2825910C1, has been granted for this development.
Rupert Blackwood 
Clement Ashworth