SPE 100220
Tightness Testing of Environmentally Friendly Thread Compounds
S. Hoenig and M. Oberndorfer, OMV E&P GmbH
Copyright 2006, Society of Petroleum Engineers
This paper was prepared for presentation at the SPE Europec/EAGE Annual Conference and
Exhibition held in Vienna, Austria, 12–15 June 2006.
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Abstract
In its most simple case the tapered round thread of casing or
tubing is sealed by a thread compound i.e. a special kind of
grease containing solids. To date, dopes that contain lead and
other heavy metals, so called API-modified thread
compounds, have found widespread use. This is surprising
since metal free or even biodegradable thread compounds are
available. OMV decided to initiate a project evaluating
environmentally friendly thread compounds.
To find out which of the non toxic products have a good
sealing performance, laboratory tests were carried out. Due to
the lack of a standardised sealing tightness test for thread
compounds a new benchmark test method was developed.
In the past, there have been two approaches for testing the
"tightness" of the various thread compounds: the simplified
grooved plate tests and the full scale tests on high pressurized
and mechanically loaded pipes. Unfortunately, the plate tests
do not provide reliable results, and the full scale tests are very
expensive.
For the test described in this paper threaded pipes in small
standard dimensions were used; relatively low testing
pressures and no mechanical load were applied. Two
parameters were implemented in a new way: temperature load
and test duration. Temperature load was applied for the whole
duration of the tests. The usual test duration was
approximately two weeks but during the development phase
some tests were run for several months.
This new combination of test equipment allowed
inexpensive testing of many different thread compounds
simultaneously. Not only performance differences between
thread compounds could be examined, but also other relevant
parameters such as varying temperature, pressure, torque etc.
could be easily recorded.
After this new method had been refined seven
environmentally friendly thread compounds were selected for
testing, two of them being universal compounds. For reference
purposes API-modified thread compounds from two different
manufacturers were tested. Enormous differences in the
sealing abilities of the products were found.
Life cycle costs can actually be reduced through the use of
an inexpensive and effective thread sealing compound.
Savings are possible due to a reduction in the number of
workovers, of expensive down time and lost production.
It was clearly shown that some of the environmentally
friendly thread compounds perform better and are cheaper
than the old fashioned toxic API-modified compounds.
Introduction
A thread compound is a special type of grease used for making
up drill pipe, casing, and tubing. The subject of this paper is
specially focused on thread compounds for casing and tubing
connections. The thread compound is brushed onto the threads
while running casing and tubing into the well. The main
functions of the thread compound are to lubricate the thread
and to guarantee a tightly sealed connection. The threads most
commonly used for completion equipment of oil wells are API
standard round threads. These threads achieve their sealing
ability from the thread compound only. For many years, so-
called API-modified thread compounds were almost
exclusively used. In recent years, a huge number of other
thread compounds have become available, mostly for
environmental reasons. In general, only little attention is given
to the selection of a thread compound although the use of a
compound with poor properties may lead to an expensive
workover. How a cheap measure can finally become
expensive can be shown with the example of a car: A spark
plug of a car engine is a cheap part but with an incorrect spark
plug, the engine does not work properly or even sustains a
damage. It is similar with the thread compound. Given that the
cost of thread compound is small compared to the total cost of
a drilling and completion operation it should be borne in mind
that if the compound fails, this may lead to an expensive
workover operation that would not be necessary with the use
of a more suitable thread compound.
Composition of Thread Compounds1. A common thread
compound consists of a base grease containing dispersed
particles. In most cases, the grease is a standard lubricating
grease made of mineral oil with a metal soap as thickener.
Many types of grease contain additives to provide a better
lubrication of surfaces under high loads, e.g. EP-additive
(extreme pressure additive), AW-additive (anti wear additive).
The base grease is mixed with particles which provide the
anti-galling and sealing properties of the thread compound.
2 SPE 100220

Powdered metals and non-metallic particles are used for this

purpose. The metals are usually malleable ones such as lead,
zinc or copper which are typical ingredients of thread
compounds. The non-metallic particles can be divided in two
main groups; first the organic components like plastics and
second the inorganic components like graphite, ceramics, and
others. It can easily be seen that the environmentally
friendliness of a thread compound is a function of its
composition only.
The classical standard thread compound is the API-
modified thread compound as defined in the API 5A3
“Recommended Practice on Thread Compounds for Casing, Helical leak paths
Tubing, and Linepipe”2. The standardised composition is
shown in Table 1. Beside the conventional composition with Figure 1 – API round thread3
grease and powders, some alternative compositions are
available as e.g. biodegradable thread compounds or anaerobic A helical leak path can be blocked by the solid particles in the
hardening polymer thread sealants. Regardless of the thread compound. These particles are pressed together, and so
composition, all thread sealants / lubricants within this paper they form a seal. The lubricating function of the thread
are called “thread compounds”. compound is only needed for a few seconds during make-up of
the pipes. But the seal performed by the thread compound
Table 1 – Composition of API-modified thread compound2 should last for the whole lifetime of a well. This circumstance
All values percent by weight:
shows the importance of the sealing abilities of a thread
Pass compound.
No.325
Constituent Solids Compound Sieve Classification of Thread Compounds. Two supplementary
Grease Base - 36.0 - classification schemes for thread compounds need to be
Amorphous Graphite 28.0 18.0 30 - 80 introduced.
Lead Powder 47.5 30.5 30 - 92 The environmental compatibility of a thread compound is
Zinc Dust 19.3 12.2 90 - 100 mainly based on its solid ingredients. The most toxic thread
Copper Flake 5.2 3.3 99 - 100 compounds are the lead containing ones. The API-modified
Total 100.0 100.0 thread compounds are placed within this group. Lead free, or
lead and zinc free thread compounds are less toxic. Metal free
Functions of Thread Compounds. The main functions of thread compounds are more environmentally friendly than
thread compounds are metal containing ones. The most environmentally friendly
thread compounds are the biodegradable ones.
• To lubricate the threads during make-up to prevent A second useful classification of thread compounds is
galling according to their use.
• To seal the gap between the male and female threads 1. There are “standard” thread compounds, for example
to get a tight connection the API-modified thread compounds, which are used
• And to protect the threads from corrosion. for conventional casing and tubing strings.
2. There are so-called “universal” thread compounds
This paper focuses on the sealing function. The standard API (laid down by the authorities in special cases4) that
round threads do not achieve a tight seal without thread can be used for all threaded connections at the rig.
compound contrary to “premium connections” with their metal 3. Some more special types of thread compounds are:
to metal seal. The API round thread, defined in the API 5B high friction compounds or hardening, glue-like
“Specification for Threading, Gauging, and Thread Inspection compounds which are used to prevent the threads
of Casing, Tubing, and Line Pipe Threads.”3, has two spiral from unscrewing.
gaps between the roots and crests of the male and female 4. Finally, there are special thread compounds available
thread, the so-called helical leak paths (see Figure 1). that are used for premium connections only.
For a better understanding, in Table 2 the two
classification schemes are plotted with some common thread
compounds highlighted.
SPE 100220
Table 2 - Classification schemes of thread compounds - it can
easily be seen that the more special thread compounds are at
the same time the more environmentally friendly ones
more environmentally friendly
lead containing
more special use
universal
standard API
high friction *)
hardening
premium
connection
*) no data available
Tightness Testing – Why? The importance of the seal
tightness of casing and tubing is unquestionable. In the case of
round type (and buttress type) threads, this tightness depends
on the sealing performance of the thread compound. A leaking
tubing connection may lead to an expensive workover and to a
loss of production. The use of a thread compound with good
sealing abilities will help to reduce tubing leaks caused by
threaded connections that do not form a tight seal.
A simple, standardised test method to find out if a thread
compound has an acceptable sealing performance does not
exist yet. Even the two relevant standards, API 5A3
“Recommended Practice on Thread Compounds for Casing,
Tubing, and Linepipe”2 and the equivalent ISO/DIS 13678
“Petroleum and natural gas industries – Evaluation and testing
of thread compound systems for casing, tubing and linepipe”5
express the requirement for a seal tightness testing device for
thread compounds: (quote) Since industry consensus has not
been achieved, manufacturers and users are encouraged to
further develop sealing test methods until such acceptance
occurs. (unquote)
A second important aspect of seal tightness testing of
thread compounds is quality control. Usually, neither during
the manufacturing process nor after the delivery of a thread
compound to the customer, tightness testing of the thread
compound is performed. The API RP 5A32 / ISO DIS 136785
states that (quote) the thread compound manufacturer is
responsible for the fluid sealing performance of the thread
compound. (unquote) This gives rise to the question as to how
a manufacturer can guarantee the sealing performance of his
product as long as no adequate equipment and method for seal
tightness testing of thread compounds exist?
Definitions
Explanations and Definitions in alphabetical order
• API-modified (thread) compound: a widely used but
heavy metal containing thread compound.
3
• Helical leak path: a spiral shaped gap between roots
and crests of a thread.
• Premium connection: a thread for casing or tubing
using an integrated metal to metal seal to achieve the
seal tightness of the connection without an additional
sealant.
biodegradable
• Test pipe assembly: one unit of the test apparatus
metal-free
lead-free
zinc-free
consisting of two capped pipes connected by a
coupling made up with the thread compound to be
tested.
• Thread compound: any kind of thread lubricant and
X sealant
X X X X
Background of Tightness Testing
Clearly, the best method of testing the sealing abilities of
X thread compounds is a full-scale test. Full-scale tests are
performed using pipes with standard (round) threads having
X
the thread compound to be tested applied and with the
coupling being made-up using power tongs. The pipes are
pressurised with nitrogen or water up to 700 bars (~10150 psi).
In some special cases, the pressurised pipes are mounted in
huge tensile testing machines. This kind of test is standardised
in the API 5C5 “Recommended Practice for Evaluation
Procedures for Casing and Tubing Connections”6 and in the
similar ISO/DIS 13679.2 “Petroleum and natural gas
industries – Testing procedures for casing and tubing
connections”7. The test methods described in these standards
were developed to prove the performance of new thread
geometries and not for testing thread compounds.
To test a large number of thread compounds, it was
necessary to have a simplified test method. In the 1960s,
Grenawalt et al. “Relative Sealing Characteristics of Thread
Compounds”8 gave the description of a so-called plate test.
The thread compound was pressed between two steel plates
with parallel thread-shaped grooves. Water at high pressure
was used as testing fluid. The testing pressure where water
drops permeated through the gap was the classification
number for the thread compound under test.
In the 1980s, in an API research project described by
McDonalds “Overview of API Research Projects on Thread
Compounds Performance Properties”9 and the Oil and Gas
Journal “Thread Compounds Test Procedures Being
Developed”10, a plate with a spiral groove looking similar to a
music record was used. Thread compound was spread onto
this plate, a flat counter plate was pressed against it, and
nitrogen at high pressures was used as test fluid. A simple
bubble trap indicated the pressure at which the system became
untight.
To date, no simplified plate test has been internationally
standardised.
Requirement for a Seal Tightness Test. The reason for the
development of a new seal tightness test for thread compounds
was the need to increase the time between workovers of oil
and gas wells. Field application showed that even threads that
had been pressure tested while running the tubing into the well
started leaking within some weeks or months. A thread
compound with good sealing abilities should prevent such
4 SPE 100220

failures. Additionally there is the demand to use more Drying

environmentally friendly products in the oil and gas fields. Cabinet
As shown above, no standardised test method was
available to rank thread compounds according to their sealing
properties. For this reason an appropriate OMV internal
research project was initiated to develop a method for seal
tightness testing of thread compounds. This project was
successfully concluded in 2004. R

New Test Method11. The plate tests described above are too
simplified with respect to the complicated geometry of the
helical leak paths of a real thread. On the other side full-scale
tests require large machines and are very expensive to
perform. The new approach endeavours to use the advantages
of both test methods and takes into consideration the field
conditions.
Real threads were used to get a real helical leak path
comparable to a full-scale test. Testing at high pressures as Figure 2 – Simplified Process Flow Diagram
common in other tests necessitates expensive safety measures.
To avoid these problems, the test pressure was kept relatively The test pipe assemblies were mounted in a simple rack and
low (below 60 bars ~870 psi). To compensate for this low the whole unit could be placed in a drying cabinet where the
pressure, helium was used as the test medium because this test pipe assemblies complete with the thread compounds were
noble gas is much more volatile than water or nitrogen which heated up to a maximum of 300°C (572 °F). The whole setup
are usually used for seal tightness testing. is shown in Figure 3. For safety reasons and to achieve a
Two important parameters were implemented in a new faster pressure drop in the event of a leak the volume inside
way: Temperature load was applied for the whole duration of the test pipes was reduced by inserting aluminium filler bars.
the tests. Most other tests were performed at ambient
temperatures although in a well the thread compound is
exposed to higher temperatures. Many seal tightening tests
used in the past were short-term tests lasting from ten seconds
to a few hours. The new test method was designed as a long-
term test. The usual test duration was about two weeks, but
during the development phase some tests were run for several
months.
The only mechanical load applied to the test pipes was the
internal pressure. Because the ends of the pipes were closed,
this resulted in a slight axial load.
The characteristics of the new test could be summarised as
follows: The new method used two threaded pipes with
capped ends connected by a coupling. Volatile helium gas at
moderate pressures was used as testing fluid. Each test was
carried out over a period of several weeks at elevated
temperatures but without applying tensile load.
12
Test Equipment and Procedure
On a piece of 2 7/8” tubing, a tapered API 10-round thread
was cut. The other end of the pipe was sealed by welding on a
standard pipe cap. Two such pipes as described above were
connected by a coupling. This setup constitutes the “test pipe
assembly”. Using readily available stainless steel instrument
piping and fittings the test pipe assemblies were connected to a
manifold. Within this manifold each pipe assembly was
permanently connected to a pressure gauge and could be
connected to a gas inlet or outlet by opening a valve. The gas
source used was a conventional gas cylinder filled with helium
at 200 bars (~2900 psi).
Figure 3 – Setup of Test Apparatus
The setup described above is shown in a simplified process
flow diagram in Figure 2.
SPE 100220
Execution of Tests. The first step before testing was
commenced was the cleaning of the pipe and coupling threads.
All threads were cleaned mechanically and chemically. After
brushing and washing the threads the pipes and couplings
were dried using compressed air. It turned out to be important
to perform a short visual inspection of all threads before
continuing.
The thread compound under test was applied manually in a
field like manner. The compound was brushed onto the pin
threads shortly before makeup. The coupling was made up
hand tight before the filler bar was inserted. The final step in
preparation of the test assemblies was to complete the test
assembly with the second capped and threaded pipe. The
connections were made up using a hand operated torque
wrench. After removal of excessive dope from the ends of the
coupling the test pipe assemblies were installed in the drying
cabinet. They were connected to the manifold and pressurised
at room temperature. A good but simple leak testing of the test
assemblies was carried out with a snooper-spray.
The pressure at the beginning of the test was recorded. The
heater was turned on and off in regular intervals. Pressure was
logged at room temperature after each heating cycle. At the
end of a given test series the test assemblies were removed
from the drying cabinet. After unscrewing the couplings the
assemblies were prepared for the next test series.
Test Parameters. Variations of the following parameters were
tested during the development of the apparatus:
• The pressure at room temperature was set to 20 bar
(~290 psi) or 40 bar (~580 psi) for testing. As would
be expected the higher pressure led to a greater
number of leaking connections.
• The most severe condition was cycling temperature
as shown in Figure 4. The high temperature led to an
expansion of the steel and the gas both resulting in a
movement of the threads. Furthermore the high
temperature had an ageing effect on the thread
compound similar to real well conditions.
• Two possibilities were exploited in order to influence
the helical leak path. One variation was to truncate
the couplings to shorten the helical leak path. The
other variation was to truncate the thread crests of the
coupling threads to enlarge the cross sectional area of
the helical leak paths.
• Extended testing with durations of up to several
months was performed. From these tests it was
derived that the optimum test duration was
approximately two weeks.
• In field operations torque is the most important
parameter which can be varied. As there was no axial
load applied during testing it was not necessary to use
torques as high as those applied at the rig for the test
pipes.
• Different gases (carbon dioxide, nitrogen, helium and
argon) were used for developing the test apparatus.
5
Test Temperature
180 356
150 302
Temperature [°C]
Temperature [°F]
120 248
90 194
60 140
30 86
32
0
0 3 6 9 12 15 18 21 24
Time [h]
Figure 4 – Characteristics of the Test Temperature
A considerable number of tests trying variations of the
parameters listed above were carried out. The results of the
tests complied with the anticipated theoretically expected
behaviour (e.g.: “damaged“ threads led to leaks, using
nitrogen instead of helium reduced the gas losses). This was
the proof that the new test method was working fine and could
be used for benchmarking thread compounds.
Results
After the test apparatus had been fully developed the
evaluation of the thread compounds was commenced. Seven
environmentally friendly thread compounds were selected for
testing, two of them being universal thread compounds. For
reference purposes API-modified thread compounds from two
different manufacturers were also tested.
For each test run four different thread compounds were
tested. Using each of these compounds on four test pipe
assemblies enabled it to be shown that the results were
statistically reliable. To carry out all the testing three test
series each lasting two weeks and the usual secondary
processing time were necessary.
The average pressure at the end of the tests was calculated
as percentage of the pressure at the beginning of a test. This
percentage was used as performance figure for the seal
tightness of a thread compound. A value of 100% end pressure
meant that all four test pipe assemblies stayed tight. A value of
0% end pressure was taken to indicate that all four test pipe
assemblies had leaked and lost all their gas.
The end pressures of the compounds under test are plotted
on the Y-axis in Figure 5. Each column represents one thread
compound. On the X-axis a simplified description of the
composition/type of the thread compound is given.
6 SPE 100220

Conclusions
Test Results 1. Successful development of a new sealing test method
100 for thread compounds.
2. The new test method fulfils the requirements of API
90 and ISO for a seal tightness test for thread
compounds.
80 3. Selection of the best sealing thread compound by
means of the newly developed benchmark test has
70
become possible.
End Pressure [%]

4. There are considerable differences in the sealing

60
properties of different brands of API-modified
50 compounds although the formulation of these
compounds is specified within close limits.
40 5. There are environmentally friendly thread compounds
available which are cheaper and provide better
30 sealing characteristics than API-modified
compounds.
20 6. Quality control of the sealing abilities of a thread
compound has become possible. Point three of the
10
conclusion stresses the need for quality control.
0
7. Life cycle costs can be substantially reduced through
the use of an inexpensive and effectively sealing
Metal Free - Universal

Metal Free - Universal

Zinc & Lead Free

Zink & Lead Free

Metal Free

Biodegradable

Lead - API -modified

Lead - API modified

Lead Free

thread compound. Savings are possible due to the

reduction in the number of workovers and of
expensive down time and lost production.

The next steps in the selection and optimisation process for

thread compounds are laboratory testing of the friction
Composition /Description of Compund properties and performance of field tests with selected thread
compounds. A further challenge could be to upgrade the test
Figure 5 – Results of the Tightness Tests method so that also compounds for premium connections or
drill pipes can be tested.
The results were somewhat surprising: Two of the three
best thread compounds are environmentally friendly, they are Selection of the most suitable thread compound will enhance
metal free or even biodegradable. The two API-modified the performance of the wells and at the same time lead to
thread compounds show different sealing performance substantial cost savings.
although there is hardly any range within the API formulation.
This remarkable finding agrees with the results of Grenawalt8 Acknowledgements
and confirms the necessity for a seal tightness test method for Support of this project by Voestalpine TUBULARS is greatly
thread compounds. The universal thread compounds also acknowledged. Sincere thanks are due to all companies for
showed only a poor sealing ability. It becomes apparent that it supplying us samples and information. In particular thanks are
is difficult to formulate a universal thread compound such as due to Herschel B. McDonald for his visit and the helpful
to accommodate the different requirements on casing and discussion.
tubing or drill pipe.
Literature
Economic Aspects. The most important technical benefit of 1. Hoenig, S.: “Dichtheit von Rohrverbindungen”, Master Thesis,
using a thread compound that forms an effective seal is that Technical University of Vienna (2000).
the number of leaking connections can be reduced. Less leaks 2. API RP 5A3: “Recommended Practice on Thread Compounds
for Casing, Tubing, and Line Pipe.” 1st Edition June 1996.
result in a reduction in the number of workovers required and 3. API STD 5B: “Specification for Threading, Gauging, and
less production losses due to downtime. Less workovers and Thread Inspection of Casing, Tubing, and Line Pipe Threads.”
uninterrupted production can be quantified as money saved. 12th Edition May 31, 1987.
The seal tightness test for thread compounds facilitates the 4. Stringfellow, W. D., Hendriks, R. V. and Jacobs, N. L.:
selection of an inexpensive and effective product. Some of the “Environmentally Acceptable Thread Compounds:
best sealing environmentally friendly thread compounds are Requirements Defined.” paper presented at 25th Offshore
even cheaper than API-modified thread compounds. One Technology Conference, Houston, USA, May 3-6, 1993.
reason for this is that the metal components used in API- 5. ISO/DIS 13678: “Petroleum and natural gas industries -
modified compounds are relatively expensive. Another Evaluation and testing of thread compound systems for use with
casing, tubing and line pipe.” 1999.
economic aspect is that the costs for the disposal of an
environmentally friendly thread compound are considerably
less than those of a heavy metal containing grease.
SPE 100220 7

6. API RP 5C5: “Recommended Practice for Evaluation

Procedures for Casing and Tubing Connections.” 2nd Edition
Nov. 1996.
7. ISO/DIS 13679.2: “Petroleum and natural gas industries -
Testing procedures for casing and tubing connections.” 2001.
8. Grenawalt, J. J., Pallant, N. L. and Roblin, M. J.: “Relative
Sealing characteristics of Thread Compounds.” paper presented
at the 22nd Annual ASME Petroleum Mech. Eng. Conference,
USA 1967.
9. McDonald, H. B.: “Overview of API Research Projects on
Thread Compound Performance Properties.” paper presented at
the 25th Offshore Technology Conference, Houston, USA, May
3-6, 1993.
10. N.N.: “Thread-compound test procedures being developed.”, Oil
& Gas Journal (Sep. 1990) 75.
11. Hoenig, S.: “Entwicklung einer Prüfeinrichtung”, PhD Thesis,
Technical University of Vienna (2004) 3.1.
12. Hoenig, S.: “Tightness Testing of Threaded Pipe Connections”
paper presented at the 10th ICPVT, Vienna, Jul. 7-10, 2003.