Sect 9

10K PRESSURE CONTROL SCHOOL
SECTION 9 - PRESSURE TIGHT SEALS AND FITTINGS

Obviously our pressure equipment requires pressure tight connections. One way of
achieving this is to use threaded connections with a metal-to-metal seal. Another
method is to use a seal or 'O' ring. A third method is to use a flanged connection and a
fourth method is to use a grease seal as is done in the GIH. A quick summary of the
different methods is given below.
9.1 THREADED METAL TO METAL SEAL
Figure 9-1 shows a butted connection where the seal is made on the shoulder of
the pin connection. High torque is required to make the seal. This method is not
very satisfactory as any imperfection in the surface of the shoulder can easily
lead to a leaky joint, especially if insufficient torque has been applied. Drill pipes
tool joints use this type of seal.
Figure 9-2 shows an alternative method. The threads of the pin and box section
are tapered. When screwed together the threads themselves make the seal.
This has the advantage over the previous method of having a larger sealing area
and thus less chance of a leak - even if one thread happened to be damaged.
As an emergency procedure (and only in emergency!) the threads could be
coated with Teflon tape or a thick grease (e.g. pipe dope). This method also
requires high torque to make up the joint.
The tapered thread is used on casing, tubing and line pipe connections.
Standard thread profiles are defined by API and these threaded connections are
generally called “API Threads”. Line pipe threads have a sharp “V” profile,
while casing and tubing threads have rounded crests and troughs. (See Figure
9-3).
Butted Connection Figure 9-1
Seal at Shoulder
Commercial Confidential Copyright © Elmar 2001, not to be copied without permission
July 2002 Revision: 2 Section 9 - Page 1

Tapered Thread Joint
Figure 9-2
Seal on Threads
These seals will only seal if made-up tight
Figure 9-3
Line Pipe, V THD Form
Casing and Tubing, 8RD THD Form

Maximum acceptable working pressure for API threaded connections depend on

the pipe size, as specified in Table 9-1.
TABLE 9-1: PRESSURE RATING FOR API THREADED CONNECTIONS
Size range Max. Working Pressure

API Thread Type Inches psi
1/2 10,000
3/4 to 2 5,000
Line pipe
2 1/2 to 6 3,000
Tubing Round Thread 1.050 to 4 1/2 5,000
4 1/2 to 10 3/4 5,000
Casing, 8 Round 11 3/4 to 13 3/8 3,000

and Buttress Thread 16 to 20 2,000
Remember that API tubing connections rely on torque to seal properly. API
values of torque are given in Table 9-2.
TABLE 9-2: RECOMMENDED TORQUE FOR TUBING CONNECTIONS
Tubing Size Grade API Thread Torque

2 3/8” J-55 8 RD 1200 lbs.ft
2 3/8” N-80 8 RD 1500 lbs.ft
2 7/8” J-55 8 RD 1500 lbs.ft
2 7/8” N-80 8 RD 1800 lbs.ft
Tapered threads are also used to join the pieces which make-up BOP manifolds
of the equalising hose type. In this case NPT (National Pipe Taper) threads are
used. NPT threads are also used extensively for nipples and fittings in the
petroleum industry, and have a profile similar to Line Pipe. The half inch threads
are easily damaged, and time consuming to make up.
In all API Threaded connections the threads have a dual function: they ensure
the mechanical connection (therefore bear the loads), and make the seal. API
threads used in a well completion or in WHE are therefore partially exposed to
the well fluids. They can suffer corrosion and H2S attack, and therefore cause
catastrophic failures. For this reason API Threads are banned by most users of
Pressure Control Equipment, except for 1/2” NPT fittings.

9.2 PREMIUM SEAL CONNECTIONS
“Premium Seal” connections have a thread-independent sealing mechanism,

either a metal-to-metal seal or an O-Ring seal. The threads are not exposed to
well fluid, but only ensure the mechanical connection.
“Premium” threaded connections with metal-to-metal seal have been developed
for tubing and casing and are certified to seal in gas under pressures as high as
15,000 psi. (Vallourec VAM, Mannesman TDS, Hydril PH, CFJ, CS, etc). These
connections have special thread and shoulder profiles and specified torque
values for sealing.
ACME threads are rugged and easy to make-up. They are extensively used in
oilfield equipment for any connection that is to be made up and broken out
quickly and repetitively. ACME threads do not seal and must be coupled with an
O-ring type seal. (See Figure 9-4).
Figure 9-4: Acme Threads
o
29
Elmar Light Weight Lubricators use a proprietary improved Premium Seal

connection between the tube and the unions. The primary seal is a metal-to-
metal seal designed to be effective at low torque (500 lbs.ft). This is backed-up
by an O-Ring. The O-Ring and the connecting threads sees pressure and well
fluids only in case the primary metal-to-metal seal fails. Therefore the O-Ring
requires replacement only once a year or whenever the metal-to-metal seal is
broken.

9.3 O-RING SEALS
9.3.1 END FACE O-RING SEALS
This type of seal was used to connect up the obsolete Yale (Wing) Union of WHE
and is used for grease hose unions. The O-Ring is seated in the face of one half
of the joint. The force needed to keep the two halves of the joint against each
other is provided by means of a nut (Figure 9-5). The joint needs to be made up
fairly tightly to keep the O-Ring compressed, ensuring a seal. A small amount of
‘unscrewing’ will reduce the sealing ability. Does not require as much torque as a
metal-to-metal type seal.
“O” Ring Seal - End Face Figure 9-5
Ring Seal
Thread Seal
9.3.2 INTERNAL O-RING SEAL
This type of seal, shown in (Figures 9-6 & 9-7) has the advantage that the
connection does not need to be tightly joined: The threads are used only to keep
the two ends together, and not to compress the O-Ring - therefore these type of
connections need to be only hand tight. It is used in situations where relative
movement of the two components is necessary, e.g. between the ram stems and
the body of the Wireline Valves. It is also employed in connections requiring fast
and easy coupling such as the quick unions used to join the major WHE
components (Lubricators, Wireline Valves, etc).

Internal seal - “O” Ring in Pin
Figure 9-6
Internal seal - “O” Ring in Box
Figure 9-7
Will seal even if thread is loose

9.3.3 PROBLEMS WITH O-RING TYPE SEALS
The immediate problem faced in the field is that of keeping the 'O' rings and the
sealing surfaces free from dirt. The very nature of the WHE, with its grease seal
mechanism, means that everything is invariably coated with a sticky layer of
grease. Particles of dirt, sand, grit, etc, are easily trapped in the grease and can
prevent an effective seal and damage the rings. All 'O' rings should be cleaned
before making up a joint. A thin layer of grease is useful for helping to maintain
the seal.
A longer-term problem is damage or corrosion of the sealing surfaces. These

need to be smooth to perform their required function. If they are scored or
heavily corroded, a seal cannot be maintained. Hence it is very important to
remove all 'O' rings at the scheduled maintenance intervals, and inspect the
seats. 'O' rings exposed to a corrosive environment, e.g. drilling mud, should be
removed frequently so that the seats can be properly cleaned. A thin layer of
grease will help to prevent the corrosive elements coming in contact with the
seat.
9.3.4 THE THREE RING SYSTEM
O-Ring seals provide a way of making a rapid, pressure tight connection.

However, there are limitations to the conditions in which the O-Ring can retain
the seal.
The old style WHE risers used a connection of the type shown in Figure 9-6.
These connections can be made and broken repeatedly. In addition risers often
have to be connected when not perfectly aligned. To allow the joints to be made
up easily the difference between the pin OD and box ID is relatively large. This
means that the seal ring must be elastic and extend a long way beyond the seat.
When stabbing the pin into the box the 'O' rings become deformed especially if
the risers are not aligned, the O-Ring is also deformed when the system is
pressurised. Moderate deformation (Figure 9-8a) occurs at low pressures (this is
the "normal way for an O-Ring to seal) and severe deformation (Figure 9-8b)
occurs at high pressures.

The constant mechanical stress imposed on the 'O' rings either during the
connection of the joint or when under pressure, can weaken the 'O' ring,
particularly if the ring is in contact with a corrosive environment (drilling mud, gas,
etc). In severe cases the O-Ring will no longer seal and can rupture under very
high pressures (Figure 9-8c).
a) Low Pressure - Moderate Deformation

"O" Ring
P Seal Protector
b) High Pressure - Severe Deformation Anti-Extrusion Ring
FIGURE 9-9
!!!! The Three Ring System
!!
!!
RUPTURE
P
P
c) "O" Ring Stressed - Damage Occurs
“O” Ring Rupturing Under Stress The Three Ring System Sealing Against
Pressure
Figure 9-8 Figure 9-10
"O" Ring Moves

Down Under Pressure
Seal Protector Ring "O" Ring

Deforms Slightly Due Seal Protector Ring
to Expansion
Split Ring with
Split Ring Opens and Bevelled Edge
Slides Up Bevelled
Edge of Seat
Three Ring System Three Ring System Sealing

Against Pressure
Figure 9-11a Figure 9-11b

To surmount this problem, a multiple ring system has been developed and is
extensively used throughout the pressure equipment manufactured. The three
rings are the 'O' ring, seal protector ring and anti-extrusion ring as shown in
Figure 9-9. The anti-extrusion ring is made of steel or a hard plastic material and
is chamfered on one side. The chamfered edge faces away from the 'O' ring.
When pushed back, due to the pressure acting on the 'O' ring, the anti-extrusion
ring is forced to expand as the chamfered edge slides up the matching bevelled
edge of the seat. The anti-extrusion ring is a split ring and the two ends overlap
as shown in Figure 9-11a. The seal protector ring is composed of elastomer. It
is used to protect the O-Ring from possible damage due to the expansion and
contraction of the anti-extrusion ring. Finally the O-Ring itself makes the seal
against pressure (Figures 9-10 & 9-11b).
Elmar equipment uses a two-ring system for "up to" 10,000 psi WP and a 3-ring
system (with Teflon non-extrusion ring) in 15,000 psi equipment. The Elmar
system uses a glass-filled PTFE back-up ring, maintain in place by a small O-
Ring (Figure 9-12). Elmar does not use the chamfered groove system due to
damage sometimes caused by the metal non-extrusion ring.
Figure 9-12
PTFE Back-Up Ring

"O" Ring
In some parts of the WHE, where the connection is never broken, e.g. the
internal seals of the Wireline Valve, the 3-ring system may be replaced by a one-
piece Buna plastic seal ring (Figure 9-13). This was done to try and prevent
damage to the equipment if steel rings were improperly installed.
Notice:
In a three-ring system, the seal protector and non-extrusion rings are always
installed on the low pressure side, with the O-Ring on the high pressure side
(Figure 9-9). If high pressure is on both sides a double set is required.

Integrated ring system
Figure 9-13
Non - Extrusion Ring Non - Extrusion Ring

(2 Req)
Seal Protector Ring Seal Protector Ring
(2 Req)
"O" Ring "O" Ring
o o
30 30
Buna N Ring "CP" Hard Plastic Split

Ring "TK" (2 Req)
Soft Buna N Double

Lip Seal "TL"
o o
30 30
BOP End Cap Seals Piston Seal

(Pressure on one side) (Pressure on both sides)

9.4 FLANGE SEAL
API flanges are sealed by means of a steel ring. The ring is placed between the
flanges and located in the seal ring grooves. A metal-to-metal seal is formed
(Figure 9-14). The pressure required to make the seal is supplied by means of a
series of bolts, distributed around the outer part of the flange. The number and
size of bolt and the size of the flange varies according to the pressure rating of
the equipment.
Flange connections tend to be time consuming to make up and are usually

employed for permanent or semi-permanent connections.
Flange connection
Figure 9-14
OUTSIDE DIAMETER
Inside
Bore
Seal
Ring
Groove

9.5 FITTINGS
There are different types of fittings rated for various pressures. Only forged steel
fittings are to be used and never cast iron. The most common with our pressure
control equipment are NPT, Autoclave Engineer, BSP, CPI and JIC. NPT
threaded fittings may be used up to 10,000 psi working pressure. Above 5,000
psi working pressure fittings shall be ½" nominal or smaller. Above 10,000 psi
working pressure only suitably rated Autoclave Engineer or similar fittings
corresponding to API 6A, section 100 should be used. Use only stamped
approved fittings, if its not stamped or you are in doubt, do not use it. Never use
cast iron fittings for oil and gas applications.
1) NPT (National Pipe Tapered) fittings (Figure 9-15): threads must be

machined from a conical shaped material, or a hole drilled with a twist drill.
Cheaper fittings are cut in cylindrical material and have less strength. Threads
are cut at 60° angle; taper is 1° 47'. There must be at least 7 perfectly cut
threads, not over-flattened. When assembling, the fitting should be hand-tight
after 4 to 4.5 turns. Normal wrench-tightening is another three turns, giving a
minimum of 7 turns for a good seal. Teflon tape (3 wraps max) or a liquid sealant
can be used on the male thread, but use sparingly. Do not use Teflon tape on
fittings connected to the input of hydraulic pumps: Teflon tape shreds can clog
the filters. In the range 1/16" to 1/2" the maximum acceptable flat is 1/10th mm;
this can be evaluated with the naked eye (Figure 9-16).
Figure 9-15
NPT Hex coupling NPT Hex nipple

Figure 9-16: NPT Fittings
F Female
Male
F
Vanish Plugs
Threads +1
OK! Plain OK
"Vanish" Threads
GOOD
BAD
Female Male

Caution is needed when replacing high pressure NPT fittings with blind plugs.
Use only solid machined plugs, never a hollow plug. A few useful numbers are
given in Table 9.3.
TABLE 9.3
No of turns No of
Nominal Number Width of No of turns OD of
Wrench Vanish
Size of TPI Flat F Hand-tight Male thread
make-up threads
1/16 27 0.0014" to 0.3125"
1/8 27 0.0041" 0.405"
1/4 18 0.0021" to 4 to 4.5 3 3.5 0.540"
3/8 18 0.0057" 0.675"
1/2 14 0.0027" to 0.840"
3/4 14 0.0064" 1.050"
Be careful not to replace high pressure fittings with low-pressure water-pipe

fittings. A way to visually check is to measure the ID of the fittings. For a 5,000
psi rated fitting:
1/4" nominal size, the ID should be 7/32" maximum

2) Autoclave fittings are made up of three parts (Figure 9-17):
1) The piece of pipe or tubing you are going to make-up

2) The gland or nut, to allow the connection to be tightened
3) The collar.
The end of the tubing on an Autoclave engineer fitting has to be prepared with a
special tool. The tool threads the pipe and shapes the end into a cone. The seal
is made across the cone, which has been cut to 59°. Once the tubing is threaded
and cut, you slip over the gland and screw the collar on until 1 to 2 threads are
exposed. You then apply thread sealant onto the threads of the gland, make-up
connection by hand and tighten to a set torque specified by manufacturers.
3) JIC fittings (Figure 9-18): are also a cone type seal. The angle of the cone is
37° for both male and female connectors. Thread sealant should be used on
threads during make-up. For example, used on control module.

Figure 9-17
Assembled high pressure Autoclave fitting
Completed AE medium pressure Completed AE high pressure

connection connection
Figure 9-18: JIC Fittings
JIC 37° female swivel JIC 37° male

4) CPI Ultra Seal fittings (Figure 9-19): have an end to end O-Ring seal that is
designed for a system that needs regular removal and replacement, for example,
grease injection hoses.
CPI Ultra Seal
Figure 9-19
5) CPI single ferrule tube fitting: consist of three parts. Requires only two
metal-to-metal seal points to secure a pressure tight seal. These seals are to the
fitting body and to the tubing for example, the piping behind the panel of the
control module.
9.5.1 THREADS FOR FITTINGS
BSPP and BSP taper threads have a thread angle of 55°. BSPP - British
Standard Pipe Parallel threads are used for tubes and fittings where pressure-
tight joints are not made on the threads.
BSP Taper - British Standard Pipe Taper threads are used for tubes and fittings
where pressure-tight joints are made across the threads.
Almost all tube fittings and valves use screw threads for fittings, valve stems, lock
nuts, end threads etc. They are straight, not tapered threads.

Unified screw threads:

American Standard Unified Screw Thread (UN, UNC, UNF)
• 60° thread angle

• Pitch measured in inches
• Truncation of root and crest are flat
• Diameter measured in inches
Threads are named UN (standard) UNC (coarse) or UNF (fine) when describing
the relationship of threads per inch to thread diameter. For example UNF, ‘F’
stands for fine pitch.
Metric Screw Threads (ISO262):

International Organisation For Standards (ISO Metric)
• 60° Thread angle

• Pitch measured in millimetres
• Truncation of root and crest are flat and of a different width
• Diameter measured in millimetres
• Metric screw threads are straight and not tapered and use either a
gasket or O-Ring to seal male screw threaded components to a female
component.

9.6 VALVES
Various types of valves are used in wellhead equipment. The most commonly
used valves are needle valves, ball valves, check valves and metering valves.
Needle valves (Figures 9-20 & 9-21): used for controlling high pressures. The
valves are designed to shut-off pressure from 1 main direction. An arrow on the
valve body usually marks the direction, or you can tell by looking into the entry
ports of the valve. The high pressure should always enter the valve from below
the valve seat. Needle valves can be found on the end of the high pressure
grease return line, equalising hose type Wireline Valves manifolds and on the
pressure control grease injection module. Various pressure ratings are available
from 0 to 15,000 psi. Needle valves using a replaceable cartridge seat are used
in Elmar's integral manifolds; see Figure 9-22.
Regulating needle valve with CPI fitting
Figure 9-20
INLET OUTLET

Lorimer valve 10,000 psi Working Pressure Figure 9-21
Cartridge valve manifold block Figure 9-22
Teflon Seal
Valve Stem Valve Seat
Valve Gland
"O" Ring and

Stem Retaining Screw Back-Up Rings

Ball Valves (Figure 9-23): used in the control modules for directing the flow of
hydraulic fluid for line wiper and stuffing box etc. Also used for air supply shut off
on control module. Ball valves are available as 2 or 3 way valves with operating
pressures up to 10,000 psi.
3-way ball valve Figure 9-23
Bottom - Loaded,
Blowout - Proof Stem
Directional Handle Panel Mounting
Spring - Loaded
PEEK Seats
INLET

Check Valves (Figure 9-24): used in the grease injection line and in some of the
hydraulic lines. The check valve prevents back flow of the substance that is being
pumped. It is very important that the check valve on the grease injection line is
operating correctly to prevent well fluids from coming back to the grease tank and
contaminating the grease. It could also cause an explosion if the tank is filled
with high pressure gas. Always check the direction of flow on a check valve
when installing.
10,000 PSI check valve Figure 9-24
Direction
Of Flow
Metering Valves: used to control the hydraulic oil pressure being applied to the
WHE components, for example, line wiper, stuffing box etc. Working pressure
rating of up to 6,000 psi.

Sect 9

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10K PRESSURE CONTROL SCHOOL

SECTION 9 - PRESSURE TIGHT SEALS AND FITTINGS

9.1 THREADED METAL TO METAL SEAL

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 1

Tapered Thread Joint

These seals will only seal if made-up tight

Line Pipe, V THD Form

Casing and Tubing, 8RD THD Form

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 2

Maximum acceptable working pressure for API threaded connections depend on

TABLE 9-1: PRESSURE RATING FOR API THREADED CONNECTIONS

Size range Max. Working Pressure

Casing, 8 Round 11 3/4 to 13 3/8 3,000

TABLE 9-2: RECOMMENDED TORQUE FOR TUBING CONNECTIONS

Tubing Size Grade API Thread Torque

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 3

9.2 PREMIUM SEAL CONNECTIONS

“Premium Seal” connections have a thread-independent sealing mechanism,

Figure 9-4: Acme Threads

Elmar Light Weight Lubricators use a proprietary improved Premium Seal

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 4

9.3 O-RING SEALS

9.3.1 END FACE O-RING SEALS

“O” Ring Seal - End Face Figure 9-5

9.3.2 INTERNAL O-RING SEAL

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 5

Internal seal - “O” Ring in Pin

Internal seal - “O” Ring in Box

Will seal even if thread is loose

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 6

9.3.3 PROBLEMS WITH O-RING TYPE SEALS

A longer-term problem is damage or corrosion of the sealing surfaces. These

9.3.4 THE THREE RING SYSTEM

O-Ring seals provide a way of making a rapid, pressure tight connection.

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 7

a) Low Pressure - Moderate Deformation

b) High Pressure - Severe Deformation Anti-Extrusion Ring

Figure 9-8 Figure 9-10

"O" Ring Moves

Seal Protector Ring "O" Ring

Three Ring System Three Ring System Sealing

Figure 9-11a Figure 9-11b

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 8

PTFE Back-Up Ring

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 9

Integrated ring system

Non - Extrusion Ring Non - Extrusion Ring

Buna N Ring "CP" Hard Plastic Split

Soft Buna N Double

BOP End Cap Seals Piston Seal

Commercial Confidential Copyright © Elmar 2001, not to be copied without permission

July 2002 Revision: 2 Section 9 - Page 10

9.4 FLANGE SEAL

Flange connections tend to be time consuming to make up and are usually