By John C.

Cox Swagelok Company

In Search of the Ideal Fitting? Ten Different Types of Tube and Pipe Fittings Examined System leakage most often occurs at the connections in a system, where fittings under stress can fail. Selecting, installing and maintaining a systems fitting connections is therefore an important component of successfully operating and maintaining a plant, as leakage can pose huge costs in the form of higher operating expenditures, increased downtime and potentially negative effects on product quality. In energy costs alone, a few small leaks in a facility using air at 100 pounds per square inch gauge, with an electric consumption cost of approximately 6 cents/kilowatt-hour, can waste more than $22,000 annually. Does there exist an ideal fitting connection one that offers 100-percent, leakfree operation under every system parameter requirement? In short, the answer is no; any type of tube or pipe fitting is prone to leakage under certain conditions, especially if mechanical vibration is present. However, certain fitting designs and technologies offer greater reliability than others. And if properly installed, quality fittings can reduce leakage to less than 3 percent. Two critical considerations for preventing leakage are the types of connecting devices used in joining process piping throughout the system, and the level of knowledge and practical experience of those installing and maintaining the application. Learning some important design, installation and maintenance tips and warnings for different types of tube and pipe fittings can help you improve fluid handling systems in a manner that minimizes potential problems and enhances overall performance. First, well begin with tube fittings.

TUBE FITTINGS Compression fittings. The compression fitting was the first tube fitting to be developed. It is made up of three components: nut, body and gasket ring or ferrule. This design uses a friction grip on the tube. See Figure 1.

Figure 1. Compression Fittings

No special tools are required to assemble compression fittings.

One benefit of compression fittings is that no special tools are required in assembly, unlike pipe connections, which require thread chasers and dies to make up the threads. Furthermore, the seals can be (but are not always) line-type, creating a dominant force in one small area and providing one of the most effective metal-to-metal seals available. However, this type of connection can only withstand minimal pressure as a result of the friction grip, is available in just a few materials (mostly brass), and often

does not function well in systems having vibration, thermal cycling and other dynamic forces.

Flare fittings. The flare fitting is made up of three components: nut, sleeve and body with a flare or coned end. In some instances, the sleeve is used as a self-flaring option, usually on thinner wall or softer tubing materials. Compared to the original compression fitting, the flare fitting can handle higher pressures and wider system parameters, is available in a larger variety of materials and has a larger seal area, which provides remake capabilities in maintenance applications. However, special flaring tools are required to prepare the tubing for installation. Additionally, flaring of the tubing can cause stress risers at the base of the flare or cause axial cracks on thin or brittle tubing. Uneven tube cuts with poorly designed rotational tube cutters or ineffective hacksaws will create an uneven sealing surface.

Bite-type fittings. Bite-type fittings need no special tools for assembly and accommodate higher pressure ratings than those of the original compression design. This design is composed of a fitting with a nut, body and ferrule(s) having a sharp leading edge, which bites into the skin of the tubing to achieve holding ability. A second seal is made on the long, deep surface between the ferrule and internal body taper. Bite-type fittings are typically single ferrule in design. This requires the nose of the ferrule to perform two functions: to bite into the tube to hold it and to provide a sealing element for the coupling body, an action that too easily can compromise one or both functions. A two-ferrule separation of functions (the first to seal, the second to hold the tube) would solve this problem, as the separation would permit each of the elements to be designed specifically for the task it is required to address.

Mechanical grip-type fittings. Mechanical grip-type fittings typically are two-ferrule in design. These fittings also might use a live-loaded seal characteristic, which pertains to the spring action of the ferrules during sealing. Fitting pull-up spring loads the front ferrule as it seals, thereby coining the surfaces of the tubing and coupling body. A radial colleting or holding action of the back ferrule grips the tube for a distance just outside the tube holding point of the ferrule nose to enhance vibration resistance. Break and remake of the fitting after installation can be accomplished successfully without damaging either the fitting components or the tubing. In addition,

some manufacturers offer a gauge to ensure proper and sufficient pull-up on initial installation. Under-tightening of tube fittings, especially in harder materials such as stainless steel, is considered a major cause of leakage.

PIPE FITTINGS Pipe butt weld. The fitting connection most resistant to both vibration and fatigue is a pipe butt weld fitting. Its ability to resist vibration and fatigue is determined by the strength and integrity of the connection made. However, pipe butt weld fitting connections do have some disadvantages. The welding equipment and specialized training required to make the connection can be costly. Additionally, the amount of time required to install pipe butt weld fittings into a system is greater than that required for other fitting installation options. The degree of knowledge required by the installer should be factored into the equation as well. Thorough training is essential to ensure quality weld connections are achieved. Finally, accessibility for maintenance in fluid system piping is minimal, unless maintenance people are prepared to carry a torch or hacksaw to cut their way into a system line.

NPT fittings. One of the most common types of connections found in process fluid handling systems is the threaded or screwed pipe fitting connection. Used as a workhorse in industry since the inception of joining pipe, National Pipe Thread (NPT) fittings have a tapered thread on both the male and female ends. The seal is actually a "crush seal" between the joining metal surfaces, and occurs on the flank, crest and root of the tapered thread. Because of the affinity metal has for itself, especially when mating carbon steel or stainless steel, galling and tearing of the metal will take place during the installation procedure. When joining NPT threaded connections, it is imperative for plants to apply lubricant or a sealant with a lubricating agent on the male threads to prevent damage to them. A popular thread sealant is polytetrafluoroethylene (PTFE) tape. When using tape to lubricate or fill voids in the thread crest, root and flanks, plant personnel must be sure to: Limit tape application to two to three wraps of the male threads, which is sufficient with most tapes. Never wrap tape over the end of the first thread, because the tape eventually will splinter and enter into the fluid-handling system and could damage the internals of

system components. Wrap tape in a clockwise direction when viewing the thread from the end of the fitting. If not wrapped in the correct direction, the tape will not properly lubricate, potentially resulting in leaks. Cut off excess tape and draw the free end of the tape around the threads tautly to conform to the thread. Then, press on the tape firmly with thumb and index finger at the overlay point. If the crests of the threads protrude through the tape, galling might occur, so additional tape will be required. Be sure to remove all excess tape and apply new tape prior to reassembling the threaded connections if the threads are disassembled for maintenance. Tape that has not been removed from initial installation could act as a leak point on subsequent assemblies. SAE straight thread fittings. Another thread type gaining popularity is the Society of Automotive Engineers (SAE) straight thread. The SAE straight threads are mechanical types, designed to hold only the fitting in place; SAE threads do not provide a seal. The sealing function is provided by an elastomer, typically located at the base of the male thread. See Fig. 2. The elastomer compresses against a boss or flat surface near the entrance to the female port. This type of threaded seal offers the advantages of an NPT connection in that maintenance, accessibility, and remake of the fitting are significantly easier for the installer.

Figure 2. SAE Straight-thread Fittings

SAE straight threads are mechanical types; they do not provide a seal.

Other types of threads found in fluid-handling systems include International Standards Organization (ISO) parallel and tapered threads, National Pipe Thread Fine (NPTF) dryseal threads and 37-degree Army-Navy (AN) flare fittings.

ISO parallel and tapered thread fittings. ISO thread fittings work similarly to NPT tapered thread fittings relying on threads to perform the sealing characteristics and SAE straight thread fittings, using either an elastomer, bonded metal washer or gasket as a backup seal.

NPTF national pipe tapered dryseal fittings. Dryseal threads have roots that are more truncated than the crests, so an interference fit causes the roots to crush the crests of the mating threads. The theory behind this thread is that when the crest, root and flank of the threads are engaged, mating contact always is achieved, creating a seal without lubrication. Unfortunately, inherent properties of some metals such as carbon steel and stainless steel cause galling to occur in this type of seal without lubrication, making initial installation difficult and remake impossible.

37-degree AN flare fittings. These fittings use straight mechanical threads similar to the SAE and ISO straight- or parallel-thread design. These straight threads are used only for holding, while a 37-degree male flared end, machined on the end of the fitting, mates with a female flared surface at the base of the female threaded port. This type of connection is found predominantly in hydraulic applications.

In sum, understanding the inherent benefits and pitfalls of different fitting designs and technologies, as well as being aware of installation and maintenance considerations for ensuring that connections perform optimally, can go a long way toward preventing the negative consequences of system leakage.

SIDEBAR: Calculating the Friction Factor It is important to note that both tube fittings and pipe fittings have their place in process systems, but a definitive argument can be made that tube fittings particularly the mechanical-grip design can bring reliability and provide the type of leak-tight connections that yield desired results in the long run.

Although threaded connections of all types have been popular fitting choices in industry, an inherent disadvantage is associated with pipe use in both process and instrumentation lines. Pressure drop or head loss resulting from friction from the internal surface of a piping system can prevent applications from achieving necessary flow characteristics. This pressure drop effect can be illustrated through application of the Reynolds Number, combined with internal geometry. The Reynolds Number (Re), shown below, is equal to the inside diameter of the tube or pipe, multiplied by average fluid velocity (V), multiplied by fluid density (p) and divided by kinetic viscosity ().

An internal friction factor is calculated by first determining the Reynolds Number for the fluid flow in the pipe. By combining the relative roughness of the pipe surface with the Reynolds Number, the friction factor can be determined. Tests conducted with this formula indicate that as a result of the internal surface roughness of pipe versus tube, flow in pipe typically will be more turbulent and will require greater pressure drop. Furthermore, to create a directional change with pipe, 45degree or 90-degree elbows must be used. Elbows impose abrupt inner diameter changes and rough edges, adding to turbulence and even greater pressure drop. Although directional elbows are available for tubing systems, the ability to bend tubing provides a smoother transition, reducing the pressure drop or turbulence created.

Mr. Cox is the business development manager for Swagelok Company, Solon, Ohio. Contact him at john.cox@swagelok.com.