G. R.

Murtagian1
e-mail: gte444q@prism.gatech.edu Sealability of Stationary
V. Fanelli2 Metal-to-Metal Seals
J. A. Villasante
The effectiveness of stationary metal-to-metal seals is investigated with respect to contact
D. H. Johnson pressure and length, load history, and the use of sealing compounds. Laboratory cup and
cone tests were carried out, and experimental results were used to develop a sealability
H. A. Ernst criterion. A sealability parameter is proposed and a critical value for it was obtained from
experiments. The criterion was validated through full-scale tests of tubular connections
and FEA. This criterion can be used for the comparison, qualification and future perfor-
Mechanical Technology Department, mance improvements of different metal-to-metal seals, in particular those used in the
TENARIS-Siderca Center for Industrial Research, petroleum industry. 关DOI: 10.1115/1.1715103兴
Dr. Simini 250, 2804, Campana, Buenos Aires,
Argentina Keywords: Sealability, Seal, Metal-to-Metal Seal, Sealing Compound, Cup and Cone

1 Introduction 2 Experimental Procedure

Petroleum reservoirs generally produce a mix of gas and oil and
in many cases contain sulfidric gas, which is toxic even at low
concentrations. Therefore, for safety and environmental reasons
well string joints have a seal to contain pressurized fluids. The
metal-to-metal seal has been increasingly used in the petroleum
industry since its market introduction as ‘‘Premium Connections’’
and has demonstrated an effective performance in sealing high-
pressure and high-temperature gases. This seal is generally estab-
lished by radial interference between the tube end and the cou-
pling 共Fig. 1兲.
Sealability refers to the ability of a seal to contain a fluid with-
out significant leakage. In tubular connections admissible leakage
flow rates are typically set at less than 2 ml/hr 关1兴. Numerous
types of metal-to-metal seals have been developed by different
manufacturers. Their differences are mainly in the connection ge-
ometry and its deformation response to the applied loads, with the
consequent changes in their P(l) and L. These two parameters are
of great relevance for seal performance, but given two different
P(l), it is not always possible to know which of them performs
better. Seal design and seal performance evaluation require
knowledge of the characteristics that increase seal efficiency: L,
Pc, the existence of P(l) peaks, the area under the P(l) curve, or
some other relationship between them.
Other variables also affect the seal performance. Among them
are seal material properties, use or not of SC, and surface topog-
raphy; the latter being dependent on the manufacturing process
and the mechanical history of the seal, in particular of the sliding
that takes place during assemblies and disassemblies.
The present work establishes a sealability criterion for the
metal-to-metal seal. Cup and cone specimens were used in labo-
ratory tests. Surface topography was characterized and P(l) and L
were modeled for this specimen geometry. A sealability parameter
is proposed and a way to obtain this parameter from a generic seal
is detailed. From the comparison of this parameter value with a
limiting or critical value given from experiments, it is possible to
obtain the sealability performance of the generic seal. This crite-
rion can be used for the comparison and qualification of different
seals and also for future seal design improvements.
1
Present address: The George W. Woodruff School of Mechanical Engineering,
Georgia Institute of Technology, Atlanta.
2
Present address: Laboratorio de Fı́sica del Sólido, Universidad Nacional de Tu-
cumán, Tucumán, Argentina.
Contributed by the Tribology Division for publication in the ASME JOURNAL OF
TRIBOLOGY. Manuscript received by the Tribology Division February 13, 2003;
revised manuscript received October 24, 2003. Associate Editor: S. Wu.
2.1 Specimen Geometry. The cup and cone specimen ge-
ometry was adopted because of its advantages with respect to the
widely used ring on disk specimen. Its main advantage is the low
sensitivity to cup and cone setup angular misalignments and also a
smooth contact stress profile along L. As a disadvantage there is a
dependency between P(l) and L, which needs to be modeled.
Different cone radii and cup angles were machined in order to
obtain a set of different contact pressure versus length profile for
the tests.
2.2 Apparatus. Test apparatus consists of the cup and cone
sample, a tubular transparent acrylic wall to form a space to col-
lect gas that leaks from the sample, a set of graduated pipettes, a
hose to connect the chamber to the pipette, a 100 kN hydraulic
clamp to hold both parts of the sample together, a 140 MPa pneu-
matic pump to supply pressurized N 2 to the sample chamber and
a load cell for measuring clamping force. The chamber formed by
the cup and cone is filled with pressurized N 2 . The chamber
formed by the acrylic wall and the sample is filled with water. Any
gas leaking from the pressurized chamber through the seal zone to
the acrylic chamber will produce visible bubbling in the water
chamber. The displaced water from the chamber travels through
the hose to the pipette and, taking time into account, the leak rate
can be measured. Figure 2 shows the experimental setup.
2.3 Test Variables
2.3.1 Test Input Variables.
R⫽discrete values from 12 to 310 mm
␣⫽discrete values from 30° to 45°
SC⫽Metal doped-Environmentally friendly
Fn⫽from 10 to 60 kN
P gas⫽up to 140 MPa
Ra⫽0.25⫾0.08 ␮m
␴ y ⬎550 MPa
2.3.2 Test Output Variables.
LR: 0.1–130 ml/hr
Number, position and relative size of leakage sites along seal
perimeter. This is obtained by observing the bubbles produced in
the water chamber.
2.4 Test Procedure. Once test variables are selected, cup
and cone are put into contact with a Fa⫽Fn. Part of this force is
distributed over the seal area, producing the Pc. Loading is
switched from force to displacement control, and the relative po-
sition of both parts of the sample is maintained constant during
the gas pressurization/depressurization cycles. Nitrogen pressure
is applied to the gas chamber and due to the displacement control,

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 Fig. 1 Schematic of a stationary metal-to metal seal on a
tubular connection
the Fa increases proportionally to P gas , while Pc is maintained
approximately constant at its initial value 共with P gas⫽0). The LR
is measured at intervals of increasing P gas . When LR exceeds
approximately 30 ml/hr or when the maximum equipment P gas is
reached, the chamber is gradually depressurized. The LR is also
measured in the depressurization process at several values of
P gas . After this complete cycle in pressure is obtained, Fn is
increased to the following setup value and another pressurization/
depressurization LR curve is obtained. Usually 4 or 5 Fn setup
values are used before the equipment P gas limit is reached. All the
data obtained to this point is called data from the initial test 共on a
given sample兲. After this initial test, Fn is decreased to the mini-
mum setup value and the complete procedure described above can
be repeated up to 4 times. Figure 3 shows the pressurization and
depressurization curves for different Fn values on a first repetition
test. For the repetitions cup and cone may be relatively rotated, or
they may be kept in their former relative angular position. This is
done to obtain seal surfaces mismatch or match, respectively.
As an outlier criterion, localized vs. homogeneous leakage
through the seal perimeter is utilized. If leakage is observed in a
localized zone of the seal perimeter through a small amount of
leakage points, typically ⬍5 leakage points for 30 ml/hr leak, the
test is discarded. Surface localized imperfections such as cracks
and scratches may be the cause of this behavior.
3 Results
A total of 15 samples were tested at 4 to 5 Fn values, and an
average of 15 leakage points were obtained for each pressuriza-
tion cycle. Due to their strong behavioral differences, tests were
divided according to whether SC was used in them or not. Only
representative data is presented; a complete set of experimental
results can be found in 关2,3兴.
Fig. 2 Experimental set-up
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Fig. 3 Typical pressurization „solid…Õdepressurization „hollow…
LR curves for different Fn values. First test repetition.
3.1 Tests Without Sealing Compounds. Figure 3 is a typi-
cal plot for a test without use of SC. As can be expected, the
necessary P gas to obtain a leakage threshold of 0.1 ml/hr increases
with Fn, and the LR increases with P gas . Physically the total LR
as a function of P gas is due to the following two facts: 共i兲 the
nucleation of leakage sites along the seal perimeter, and 共ii兲 the
growth of leakage flow rate by site. It was observed that usually
increasing P gas the leakage begins from 1 to 3 leakage sites at 0.1
ml/hr and may reach 30 to 40 sites at 30 ml/hr. It was observed
that in samples prepared with surface scratches, leakage sites typi-
cally did not exceed 5, even at high LRs. A pattern observed in the
leakage plots was the hysteresis loop with respect to P gas . In the
depressurization, for the same P gas value, the LR was greater than
in the pressurization process. This LR loop was more pronounced
with increasing Fn values. If the P gas cycle is repeated, the LR is
the same within test uncertainties. The depressurization curve de-
pends on the LR obtained in the pressurization process. For this
reason, and also because the triggering of leakage is relevant for
these seals, only pressurizing curves are taken as representative of
sample behavior. Figure 4 shows the effect of surface load history
on the sealability. Iso-leakage curves are presented in an Fn ver-
sus P gas plot for two LR levels. It shows the shift in the leakage
curves due to surface load history for a leakage threshold level of
0.1 ml/hr, and for a LR of 30 ml/hr. It can be seen that for the
Fig. 4 Iso-leakage curves in an Fn vs. Pgas plot for a leakage
threshold level of 0.1 mlÕhr, and leakage level of 30 mlÕhr. Shift
in the leakage curves due to surface load history.
Transactions of the ASME
 Fig. 5 Seal surface aspect. Before test „left… and after

same load conditions the initial test presents greater LR than the
following ones. This difference is greater at lower Fn values.
After the initial test these curves remain almost invariant either
with or without angular repositioning, and for this reason leakage
points from the repetitions are taken for modeling. Samples pre-
Fig. 7 Modeled Pc vs. normal applied force. R is a parameter.
sented better sealability after the initial test. During the experi-
ments the bulk of the sample was subjected to elastic stresses,
nevertheless at the asperity level plastic deformation took place.
Figure 5 shows the seal surface of a sample before and after the
tests. It can be seen that after testing, the seal surface presents a must be reduced to P atm in order to stop leakage. Specimens were
smoother aspect, which is reflected in slightly decreasing values disassembled, cleaned and a new layer of SC should be delivered
of Ra 共0.25⫾0.08 ␮m versus 0.21⫾0.07 ␮m for the complete set to re-test them.
of samples兲. It was observed that results were repetitive and consistent. No
appreciable difference was observed between the compounds here
3.2 Tests With Sealing Compounds. Tests with SC were utilized, and for this reason results from both SCs are merged for
carried out on some of the samples already pre-tested without SC. modeling 关4兴.
Because LR do not show significant changes after the 1st repeti-
tion either for cases with or without angular repositioning in tests
without use of SC, studying the behavior of these samples with
use of SC eliminates variability in results due to sample differ- 4 Modeling
ences. Six samples were re-tested with two different SCs. One In order to model the seal performance, Pc and L must be
typically utilized in oil wells for connections, which is metal obtained. Here they are found by modifying the Hertz expressions
doped with Cu, Zn, and Pb, and the other a metal-free SC. for the elastic contact between two cylinders 关5兴. As a result the
Figure 6 is a typical plot of these tests. One fundamental dif- following expressions are obtained:

冑*
ference observed with respect to the tests conducted without SC,
is that in these cases leakage appeared suddenly. The leakage rate 2 2FnR
L⫽ (1)
rose from zero to the maximum value 共could not be measured兲 in ␲ E rc共Sin ␣ ⫹ ␮ e Cos ␣ )
P gas intervals smaller than 500 kPa. Also, under the same Fn
and
samples showed better sealability than in tests without SC; i.e.,
the use of SC improves the sealability of samples. This effect was
consistently observed in all samples.
Another singularity of these tests is that leakage showed an
PC⫽
1
4
冑 E * Fn
2RrC共Sin ␣ ⫹ ␮ e Cos ␣ )
(2)

irreversible pattern. Once leakage was produced, gas pressure being

E
E *⫽ (3)
2 共 1⫺ ␷ 2 兲
Figure 7 shows the Pc versus Fn curves for several conditions.
Because of the geometry of the contact a parabolic P(l) on L is
obtained.
In Figs. 8 and 9 leakage threshold points are shown for the
same P gas in a seal Pc versus L plot for the case of tests with and
without SC, respectively. The following three important points
can be observed:
1兲 Regardless of the differences between leakage physical phe-
nomena, in both cases the leakage threshold showed the
same relationship with respect to L and Pc.
2兲 For the same applied gas pressure, tests with SC showed
better sealing properties than tests without SC.
3兲 Data variability was substantially reduced by the use of SC.
Differences in sealing behavior observed in tests without use
of SC between geometrically similar samples, mainly due to
seal surface topographic differences, were strongly
smoothed by the use of sealing compounds. The use of SC
allows the study of sealing properties with respect to L and
Pc disregarding topography differences in the range studied
Fig. 6 Typical leakage curves obtained for test with use of SC here.

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 Fig. 11 Family of Wac leakage threshold curves as a function
Fig. 8 Leakage threshold data for a given Pgas on samples of Pgas. Tests with SC.
with use of SC. R indicated in „ ….

In these plots for a given P gas , a L versus Pc limit curve can be

modeled to separate regions of leakage and no-leakage, below and ␩ ↓with P gas
f

above the curve, respectively. Based on a series of these plots a ␩ ↓with P C

sealability model is developed.
␩ ↓with L
4.1 Development of a Sealability Model. Four hypotheses
are taken The following functional relationship is proposed

冉 冊
1兲 The parabolic profile P(l) in the sample seal area is replaced i m
by an equivalent rectangular one of the same seal length L, and a P gas
␩⫽ exp⫺ 关 bL P nc 兴 (4)
mean contact pressure Pc. f
P gas
2兲 The seal length is divided into cells, as shown in the ex-
ample of Fig. 10, and these seal cells are additive. b, m, n⫽parameters
3兲 Seal cells are commutative. defining
4兲 There is no leakage for an infinite L value. Wa⫽L P Cn (5)
A leakage or transmission factor ‘‘␩’’ is postulated. This param-
eter allows assessment of the effectiveness of each elementary It is readily apparent that the proposed form of ␩ met hypoth-
seal cell and from the experimental observations it is proposed eses 2 and 3. For a seal continuous function P共l兲, Eq. 5 becomes

冕
that ␩ has the following dependencies L

␩ ↑with P gas
i Wa⫽ P nc 共 l 兲 dl (6)
0

4.2 Sealability Criterion. A sealability criterion is pro-

posed as follows
Wa⬍Wac⇒Leakage
(7)
Wa⬎Wac⇒No Leakage
There is a required Wa value, Wac, to seal fluid at a given
pressure. The exponent n is obtained by fitting the experimental
leak threshold data for different gas pressures. Two different val-
ues of n were obtained, according to the use or non-use of SC.
Figure 11 shows a family of Wac required for different P gas for
the case of tests with SC. Note that 1/L is used on the ordinate
axis, and according to hypothesis four the origin of this plot be-
longs to the fitted curve. Then
L ⫺1 ⫽A C P Cn (8)
and
Fig. 9 Leakage threshold data for a given Pgas on samples 1
without use of SC. R indicated in „ …. Wac⫽ (9)
AC
The exponent n increases slightly with gas pressure. For tests
without SC the mean n value is found to be 1.4; meanwhile in test
with SC it is 1.2.
According to the experimental results, Wac depends on the
P gas as shown in Fig. 11. The following dependence is proposed:

Fig. 10 Example of a seal composed of three seal cells

Wac⫽B 冉 冊 P gas
P atm
m
(10)

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Fig. 12 Sealability critical curve with use of SC
Figures 12 and 13 show the Wac curves for different relative
gas pressure values for tests with and without SC, respectively. B
and m are fitted parameters. Then the critical value Wac has the
following form:
Wac⫽1.843 10⫺3 冉 冊
P gas
P atm
1.177
(11)
for the case of tests with SC and
Wac⫽0.1036 冉 冊
P gas
P atm
0.838
(12)
for the case of test without SC.
4.3 Model Validation. The model is validated through full
scale testing on tubular connections of different seal geometries at
different load conditions 关6 – 8兴. As a geometric scaling factor the
relation between LR and seal perimeter is adopted. Similarity re-
quires that this value be the same for both full scale and laboratory
conditions. As an output from the full-scale tests three conditions
can be obtained: no leak, leak, and border line 共one of the two
ends of the connection leaks and the other end does not兲. A FEA
was performed on the connection geometry according to the load
applied, and P(l) was obtained for the different conditions, as
shown in the example of Fig. 14 关9–11兴. By applying Eq. 6, Wa
values were obtained. All this information is plotted in Fig. 15.
Superposed in the same plot is the leakage critical curve predic-
Fig. 13 Sealability critical curve without use of SC
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Fig. 14 Example of P„l… profiles obtained by FEA for actual
connections under different load cases
tion obtained from applying the model to the laboratory test re-
sults for the case of test with SC 共Fig. 12兲. It can be seen that a
close agreement exists between the fitted model using laboratory
data with full-scale tests, validating the model and obtained pa-
rameters as representative of the sealability performance of metal-
to-metal seal connections under different load conditions.
5 Discussion
In the experiments without SC it was observed that after the
initial test the sample shows improved sealing behavior. This can
be explained by the fact that the seal surface asperities were de-
formed up to a certain point at high Fn loads and seal surfaces
mean separation was decreased in the repetitions, this effect being
more pronounced for lower Fn values. Surface topography influ-
ences sealability behavior of samples but no single two-
dimensional roughness parameter can explain these differences
because they can not account for three-dimensional arrangements
of surface asperities.
One possible explanation for the observed leakage hysteresis
with the Pgas loading and unloading is that when compressing the
gas in the sealed chamber, the gas temperature increases. Given a
certain volumetric leakage rate, when gas reaches the bubbling
chamber it cools down by contact with the chamber water, de-
creasing its volume. When decompressing, the gas in the sealed
chamber is cooled down and the inverse effect takes place. Further
research is needed to corroborate this theory.
Fig. 15 Comparison between full-scale tests result and FEA
with sealability model prediction
JULY 2004, Vol. 126 Õ 595
 For the case of use of SC, the observed sudden leakage can be Ac ⫽ inverse of Wac
explained supposing that the compound is extruded at a deter- a, b, B, m, n ⫽ parameters
mined gas pressure from the seal interface. E ⫽ material elastic modulus 关MPa兴
The Wa takes into account the contribution of each of the pa- Fa ⫽ clamping force 关kN兴
rameters Pc and L to the sealability. The ‘‘area’’ generated by the Fn ⫽ clamping force with Pgas⫽0 关kN兴
product of both parameters gives a positive correlation with the L ⫽ total seal length in the direction of fluid leak
sealability, nevertheless the relevance of each factor is different 关mm兴
and is considered by weighting them. The Pc exponent n is an LR ⫽ leakage flow rate 关ml/hr兴
indicator of the relative importance of Pc with respect to L for the P atm ⫽ atmospheric pressure 关MPa兴
sealability. Values of n⬎1, like those obtained here, indicate that Pc ⫽ mean seal contact pressure on L 关MPa兴
for seals of same Pc versus L area, those with higher Pc peaks in Pgas ⫽ N 2 gas pressure 关MPa兴
smaller L are more effective than those of smaller average Pc P(l) ⫽ seal contact pressure profile on L 关MPa兴
over a longer L. There is a required Wa value, Wac, to seal fluid R ⫽ cone curvature radius 关mm兴
at a given pressure. Ra ⫽ mean average roughness 关␮m兴
rc ⫽ mean seal radius 关mm兴
6 Summary and Conclusions SC ⫽ sealing compound
Laboratory sealability tests were carried out in order to assess SxxG ⫽ sample identification for tests with use of SC
the sealability behavior of metal-to metal seals, in particular seals Wa ⫽ weighted area
on tubular connections for the petroleum industry. Wac ⫽ critical value of Wa
Cup and cone contact was modeled and contact pressure and
length were obtained for this specimen geometry. References
A leakage or transmission factor was proposed and a way to
关1兴 ISO/DIS 13679 Norm, 2002, Petroleum and Natural Gas Industries—
obtain it was detailed. A sealability criterion is proposed through a Procedures for Testing Casing and Tubing Connections.
critical value of Wa. 关2兴 Villasante, J. A., Murtagian, G. R., Fanelli, V., Johnson, D., and Ernst, H. A.,
Sealability critical curves were obtained from laboratory tests 1998, ‘‘Ensayos de Sellabilidad en Probetas de Laboratorio Tipo Copa y
for seals with or without sealing compounds. Cono,’’ Informe CINI 1377/98.
关3兴 Fanelli, V., Villasante, J. A., Murtagian, G. R., and Ernst, H. A., 1999, ‘‘Análi-
The model was validated with full scale testing of tubular con- sis de Datos Experimentales de los Ensayos de Sellabilidad en Probetas de
nections and FEA, and a good leakage prediction is observed. Laboratorio Tipo Copa y Cono,’’ Informe CINI 1405/99.
This model is useful to compare different seal geometries 关4兴 Ernst, H. A., Fanelli, V., and Murtagian, G. R., 1998, ‘‘Modelo de Pérdidas
and/or load conditions, and it can also be applied to improve seal para los Ensayos de Sellabilidad,’’ Informe CINI 1380/98.
关5兴 Fanelli, V., 1999, ‘‘Criterio de Sellabilidad en Uniones de Tubos Petroleros,’’
design. Tesis de Maestria en Ciencia y Tecnologı́a de los Materiales, Instituto de
Tecnologı́a, UNSAM Argentina.
关6兴 Johnson, D. H., 1992, ‘‘API RP 5C5 Class Three Testings on Siderca SEC 3
Acknowledgment 1/2⬙, 9.2#, L80 Tubing,’’ CINI Internal Report.
This research was supported by Siderca SAIC. In addition, the 关7兴 Benedetto, F., and Johnson, D. H., 1993, ‘‘Ensayos con Strain Gauges de
Unión SEC 7⬙, L80, Cargas Combinadas,’’ CINI Internal Report.
authors would like to express their appreciation to M. Borgeaud 关8兴 Silva, C, Daubian, P., Perrone, G., Nakoneczny, M., Johnson, D. H., and Ernst,
and LEPE personnel for their valuable contributions. H. A., 1998, ‘‘Qualification Test Program on Dalmine Premium Connection
AMS 4 1/2⬙, 12.6# SD 95 According to SIPM Procedure 92-0147共EP2兲,’’ CINI
Nomenclature Internal Report
关9兴 Assanelli, A., Toscano, R., and Dvorkin, E., 1997, ‘‘Finite Element Analysis of
␣ ⫽ cup half angle 关°兴 the AMS 9 5/8⬙, 53.5# P110 Casing Connection,’’ CINI Report 1048/97.
␩ ⫽ leakage or transmission factor 关10兴 Dvorkin, E., Assanelli, A., R. Toscano, R., and Calo, V., 1997, ‘‘Finite Element
Analysis of the SEC 9 5/8⬙, 53.5 PC 110 Casing Connection,’’ CINI Report
␮e ⫽ static coefficient of friction 1091/97.
␴y ⫽ material yield strength 关MPa兴 关11兴 Assanelli, A., and Toscano, R., 1998, ‘‘Finite Element Analysis of the Antares
␷ ⫽ Poisson coefficient MS 3 1/2⬙, 12.7# P110 Connection,’’ CINI Report 1248/98.

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