INTERNATIONAL

TRAINING MANUAL T-03

THE MECHANICS OF
HIGH PERFORMANCE TUBULARS
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Document Title High Performance Tubulars Training Manual

INTRODUCTION

It is Frank’s objective to provide equipment familiarisation training in the following subjects,

to enable trainee technicians and others attending the courses for inter-company training to

carry out their specific tasks in a safe and efficient manner.

The training is facilitated by the training officer, department managers, supervisors, delegated

competent employees or external specialists. This is done through classroom lectures, open

discussions and practical demonstrations.

The effectiveness of this training is monitored by feedback from Crew Supervisors and

recorded as part of our competency analysis system. Competence analysis identifies additional

training requirements regarding equipment and attitudes towards the work, work environment

and work colleagues.

PROPRIETARY NOTICE

Information contained in this manual is confidential and proprietary and is disclosed in

confidence.
The information contained therein may not be duplicated in full or in part by any
employee of Frank's International without prior permission from the Management of
Frank's International Ltd.

This document and the material contained herein are only for use by Frank's
International personnel in relation to the business of Frank's International. Any other
use or the disclosure to third parties of this material is specifically PROHIBITED.
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Running Guide-lines

It is the responsibility of the Frank's Operators to see that procedures are followed properly,
even though they may not be directly engaged in all work concerning the tubulars.
There is repetition between manufacturers' Guidelines, as they are based upon the API Bulletin
5A1 Procedures and Specific Requirements for Certain Products.

The intention here is to highlight particular methods or practices as laid down by the pipe
manufacturer that may be of use on the rig floor. The actual literature referred to should be
read and understood in any case.

The following is written using extracts from five Manufacturers' guidelines.

References

1. VAM Catalogue 870. British Steel Tubes 1988

2. HYDRIL Catalogue 861

3. NKK Premium-Connections Running Book NKK (UK) Ltd.

4. The Design & Testing of the FOX Premium Connection.

5. Kawasaki Technical Report No. 47 Dec. ’02.

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SECTION 1 - VAM

The Vallourec NEW VAM threaded connection employs a metal to metal seal and modified
buttress thread.
In essence, the VAM sealing principle relies upon a reverse flank arrangement, which ensures
that forces from internal or external pressure will re-enforce either primary or secondary seals.

o o
10 30
Coupling I.D.
o o
15 20

5 thds/in. 8 thds/in. (2.3/8 - 2.7/8)

(5.0 - 13.3/8) 6 thds/in. (3.1/2 - 4.1/2)

CASING TUBING
NEW VAM
Fig.1

Note the difference between Casing and Tubing stop shoulder and seal angles (Fig. 1) and the
different primary seal areas (Fig. 3). With the increased wall thickness of Casing, primary seal
pressure can be exerted against the coupling inner surface at a bearing pressure determined by
the 10° seal taper. The thinner walled Tubing seal relies more upon vertical energisation (note
the small seal area). This [tubing] design however is not very tolerant to over-torque.
Note also the internal contour of the pin wall that is designed to match the coupling I.D. to
prevent flow disturbances. (Resistance to liquid flow starts eddy current erosion that can
provide a foothold for pressure points and corrosion).
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3°
upper flank

Pin Thread crest area

Stabbing flank 10°

1:16
taper
Fig. 2 Modified Buttress Thread

Pin Pin

Primary Seal
Area
Primary Seal

Stop shoulder Stop shoulder Coupling

Coupling

VAM Casing VAM Tubing

Fig. 3 VAM Pin end (Seal)
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The thread angles have been chosen to provide ease of engagement using the 10 stabbing
flank whilst the 3 upper flank ensures maximum pullout strength of the connection. Note that
these angles are relative to the horizontal axis.
The choice of this thread form however provides a greater helical leak path at the thread crests
(Fig. 2) compared to round thread. Although this area is primarily filled with the dope
compound solids, the connection relies heavily on the integrity of the metal to metal seal to
prevent dope extrusion by service pressures.

It has been shown that the rapid build-up of torque to a VAM connection can cause entrapment
of thread compound at the seal area. Any pressurised dope can be considered part of the
stored energy created with the application of torque. However, being fluid, it has been
proposed that this could dissipate over a period of time and produce a reduction in that stored
energy. Some customers therefore require a torque hold facility to enable any rapidly
compressed dope to leach out for a few seconds whilst final torque is maintained.

It is important to remember that the integrity of the connection in providing a leak proof joint
relies principally on the stored energy accumulated, from the torque exerted, at the seal and
shoulder contact area during make up. The torque range of the seal energisation region
corresponds to the seal/shoulder contact up to the maximum recommended torque.
The level at which the shoulder point must have commenced [to achieve the required seal
energisation] is called the Maximum Shoulder Torque (MST) point as shown in a the VAM
Torque/Turn profile shown (Fig. 4).

TORQUE
MAXIMUM +10 %
OPTIMUM
MINIMUM -10 %

MST Shoulder Torque 5% - 70%

60+ %

Thread interference

Seal contact

REFERENCE 3% - 10% 10 %

Fig. 4 MINIMUM MAXIMUM TURNS

Torque Turn Graph

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Inspection

Scratches and minor dents on threads are not significant. Burrs on threads, which may affect
make-up torque or result in galling, may be removed by the use of a fine triangular file.

Seal areas should never be ground or filed.

Minor damage can be defined as less than 0.3mm deep with metal displacement only, not with
metal missing.

Do not use wire brushes.

Do not use diesel oil to clean threads.

Make-up Tongs

The torque gauge should be regularly calibrated.

When a strain gauge or torque gauge is in the back-up line, it is imperative that the tong arm
form an angle of 90 to the line, or that appropriate compensation is made.

Thread Compound

 It is recommended that a thread compound complying with API Bul 5A2 and having a
friction correction factor of 1.0 be used.

 Compound should be well mixed by stirring before use.

 Compound should be spread evenly by brush or dispenser over the thread and seal areas
of pin and coupling.

 The minimum quantity requires to attain antigalling performance and sealing properties is
10 x Pipe O.D. in grammes

e.g. 4 1/2" = 45 grams, 7" = 70 grammes.

Running

Make-up rotation should ideally not exceed 15 RPM in high gear, whilst seals and shouldering
should be brought into contact in low gear.

Especially when running chromium steel or nickel alloy connections ensure that not too much
energy is absorbed by the connection during make-up.

N.B. When running stands, speed must be reduced by 50%.

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SECTION 2 - HYDRIL

A common example of Hydril tubing seen is PH-4/PH-6 that differs significantly from most
other Premium connections by utilising an integral upset pipe.

Connection strength of the Hydril is greater than coupled pipe. Internal and external profiles
are also streamlined enabling Hydril tubulars to be used in demanding test strings etc. Its form
is designed to withstand high bending loads and multiple make and breaks.

Additionally the threads are machined parallel to the pipe wall and give a traditional ease of
stabbing and low running-in torque. This can present a problem for the CAM Operator as the
detected shoulder point occurs at quite low torque, especially with used pipe. A Reference
torque no higher than 5% Optimum should be used to alleviate this problem.

The primary seal is situated at the pin end outer surface (14) but Hydril makes use of three
stop shoulders seen at the top (30 reverse angle), middle (90) and bottom (90) of the
threaded portion.
Note that there is no exit for entrapped Dope compound. It is therefore energised within the
connection - effectively resisting external pressure ingress.

Hydril PH - 4 / PH - 6

Fig. 5
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Running Guide-lines

Procedures for Hydril follow the same as those for most other premium tubulars. The
following are extracts from Hydril's General Visual Inspection Guidelines.

When an end area inspection is to be performed, the connection should be cleaned with a
suitable solvent or cleaning agent and a bristle brush. Do not use wire brushes.

Adequate lighting should be provided to ensure a uniform and thorough inspection.

Check seal surfaces for:

Longitudinal cuts and scratches.

Out of roundness, that would preclude stabbing.

Excessive corrosion pits, rust and/or scale.

Dents and mashed areas.

Excessive galling or wear.

Check primary (external) torque shoulder for:

Radial cuts and scratches.

Flared shoulder pins and ballooned boxes due to excess torque.

Excessive torque on the connection can permanently nose-in the pin end. Its surface is at an
angle of 90 with the pipe axis, except for Supreme products that have a reverse angle.

Check pin end, pin ID and box bore shoulder for:

Excessive scale and plastic coating.

Excessive pin nosing.

Galling or wear indicates contact and possible overtorque.

Box OD and transition area.

The OD of the box on all Hydril, including couplings, should be inspected for severe
discontinuity. This could be caused by such things as tongs, slips, excessive pressure in the
thread area. Tong marks could result in reduced internal pressure rating. Slips or tongs set
on the upset of a swaged box could produce an out-of-round box, preventing an internal
pressure seal.
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Check OD for:

Tong and wrench grooves

Slip grooves

Hammer marks

Out-of-roundness that would preclude stabbing.

Expanded box, particularly over the large diameter thread step due to excessive torque.

CB Feature

The CB (corrosion barrier) feature consists of a CB ring placed into a specially machined
groove in the box.

Check CB ring for:

Proper placement in groove.

Looping or protrusion into the ID after installation.

Cuts.

Installation and final inspection of CB ring should be performed by a Hydril representative.

Specially designed tools are necessary to perform installation and inspection properly.

Handling and Running

Further extracts from Hydril are highlighted below:

1. If a wire brush was used inadvertently to clean the connection, an additional inspection
is required. Rub down the connection with a rag to pick up any stray bristles.

2. For aluminium, chrome and stainless steel connections, a pick-up machine (if available)
should be used to hoist the pipe into the V-door.

3. Before stabbing, apply a thin even coating of thread compound to the entire pin thread
and seal areas.

NOTE: For Casing - do not dope box. For Tubing - doping of the box is optional.
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For aluminium, chrome and stainless steel connections:

Prior to doping or stabbing, vertically mark connection OD opposite thread starts, on pin and
box. (Align both marks when stabbing the connections; this will allow threads to start
immediately, thus reducing the chances of galling).

Makeup

1. Do not latch rig tongs on the upsets on box ends

2. Using power tongs, make up all connections at 5-25 RPM. Under no circumstances
should 25 RPM be exceeded.

3. Power tongs should be engaged in low gear at approximately one turn prior to
connection shouldering.

Breakout

1. Do not hammer connections to assist breakout as this may damage Upset or

connections.

2. For aluminium, chrome and stainless steel connections: During breakout, record the
number of turns to disengage the threads and use this recorded information for the
remaining joints.

NOTE: Even connections that are damaged require protection, because the damage may be
minimal and can be repaired. If protectors or dope is left off, by the time they are
shipped to a machine shop, the connection ends may be beyond repair.

Adverse Weather Conditions

Freezing weather

Attempts to make up any Hydril connection with ice on any of the threads, torque shoulders
and/or sealing surfaces may cause premature torque build-up resulting in improperly made up
connections.

WARNING: Compound should be maintained at a temperature above 0 C to prevent ice

formation, resulting from possible condensation.

Recommended make-up torque actions differ according to temperature. Below freezing,

maximum torque should be used.

Connections with 30 external torque shoulders can be checked for proper make-up by
gauging shoulder standoff.
At 40% of the make-up torque, there should be no standoff at the shoulder. Any standoff at the
30 should is an indication of inadequate makeup and a possible indication of foreign and/or
frozen particle entrapment.
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SECTION 3 - NKK

NKK has been manufacturing tubular goods since 1912 and produces high quality tubing and
casing. A popular choice in present use is NK 3SB, which is discussed in detail here.

The design principle seen below incorporates several unique features to provide the properties
described: -

1. Although NK3SB uses a standard tapered connection (1:16), good pullout strength (in
excess of the pipe body) is achieved by utilising a flank thread at 90 to the pipe body.

2. Stabbing problems are eliminated with the 45 stabbing flank and thread crests parallel
to the pipe surface.

3. Primary sealing is achieved by an interference fit at the pin end OD and the secondary
seal at the internal stop shoulder. The thread design also provides an efficient sealing
effect due to precision tolerances coupled with the dope action.

DESIGN PRINCIPLE OF
NK 3SB T UBING

1. Threaded and Coupled Connection applied

Thread to non-upset Pipe.

2. Two metal to metal seals:

Sliding type seal with Tangent Point
Contact with Internal Shoulder

3. Positive Torque stop at Internal Shoulder

Tangent Point
Main Seal
4. Internal flush - smooth bore

5. Flat crested thread parallel to Pipe axis

8 threads per inch
Internal Shoulder
Seal
6. Load flank zero degrees
Stabbing flank 45 degrees

7. Tapered and runout type thread

Taper 1/16

8. Precision machining

Fig.6

Tubing and Casing designs are identical except for the number of threads per inch
(Tubing - 8 tpi, Casing - 5 tpi).

The pin seal OD is machined slightly greater than the box seal ID. This provides the contact
force at the metal-to-metal seal. This area is designed to give a circumferential contact of
2-3 mm at 5 mm from the pin end. As the primary seal uses hoop stress for energisation,
applied final torque is not critical. Similarly, tension and compression forces do not
compromise the sealing principle.
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As the stop shoulder is 90 to the pipe, over-torque conditions will not cause early
deformation. (NKK quote a maximum allowable 30% above Optimum).

Internal pressure exerted on a connection causes reinforcement of the seal.

Note especially the gap introduced above the seal area. Provided the correct dope quantity has
been used, this area provides an air chamber, which acts as a buffer against the hydraulic
action of the dope parting the seal during external pressurisation.
It is critical however that dope application is controlled to produce this requirement. (Dope
pressures of 2-2500 psi are normal but 12-18000 psi has been recorded with application of too
much dope). (See Running Procedures).

Inspection Procedures

Visual Inspection guidelines follow the same procedures as all premium connections -
cleaning, use of protectors, etc. and will not be repeated here. A few extracts however, are
given from NKK Running Guidelines: -

Thread inspection should include the following:

Relatively even thread surface. Full crest threads shall be free from burrs, tears, cuts,
shoulders or any other imperfection, which could break the continuity of the thread. Threads
found to have slight imperfections or rust may be field repaired using a fine file or emery
cloth. Minor surface irregularities on the thread root, crest and stabbing flanks do not
necessarily offer an operational detriment.

No mash is allowed on pin or box.

Seal inspection should include the following:

Longitudinal cuts and/or scratches on the tangent point main seal shall be rejected.

Excessive transverse cuts and/or scratches on the tangent point main seal shall be rejected.

Rusting and/or pitting shall be rejected. Minor surface imperfections such as discolouration
of the seal may be repaired using emery cloth.

Minor imperfections beyond the pin tangent seal area may be repaired.

Any imperfections that do not extend across the full width of the shoulder seal may be allowed
by filing the protrusion.

Dented and mashed seals shall be rejected.

Used tubulars - Visible roll and flare due to overtorque shall be rejected.
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Running Procedures

Again procedures follow normal practice and previous comments should be followed. The
extracts below are taken from NKK Running Practices: -

Make-up

Pipe wrenches, Rig tongs or chain are not recommended for connection make-up, but may be
required to make up accessories (due to various shapes and sizes).

Use power tongs close to upset or coupling and make up to recommended torque.

Start threads by hand or by power tong at low speed.

Tubular wobble will result in connection damage. Tong speed should be reduced or, with
assistance of stabber, tubular should remain vertical throughout make up.

Application of thread compound

Pin and box connections shall be cleaned and dried before application of dope.

API 5A2 modified thread compound shall be applied to the coupling for low carbon material
and to pin and box for high alloy material over CR9. See tables for dope quantities but note a
rule of thumb of:-

Dope required (grammes) = OD x 7 e.g. 7" x 7 = 49g

(Note this is 70% of that required for VAM).

Torque application

Torque/turn/time monitoring system shall be utilised.

Connections in excess of the recommended Maximum (120% of Optimum) should be backed

out for inspection. Provided the connection has not exceeded 130% of Optimum, it should be
visually inspected and if not damaged, re-made up.

Connections less than 80% of Optimum (or the recommended Minimum torque) should be
further made up to Optimum.

A connection showing no shoulder torque shall be broken out and visually inspected.
If no damage observed, it can be re-make after re-doping.

A connection showing a high shoulder torque more than the recommended Minimum (80%
Optimum) shall be backed off, cleaned, inspected and re-made after re-doping.

A torque curve showing a pressure wave below 80% Optimum is acceptable.

(Pressure waves occurring before shoulder engagement is often an indication of excessive

dope).
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Pulling

Use power tong with torque adjustment adequate for break-out without damaging pipe.

After breaking loose, rotate out by hand or with power tong. Do not overspin after connection
has parted.

If excessive torque is indicated during spinout, rotation should be stopped until the cause is
determined.

Recommended Dope Weight for NK3SB

ITEM PIPE OD OPTIMUM WEIGHT

Tubing 2 3/8" 9g +2g (4.9cc)

2 7/8" 11g +2g (5.9cc)
3 1/2" 13g +2g (7.0cc)
4.0" 14g +2g (7.6cc)
4 1/2" 16g +2g (8.6cc)

Casing 5.0" 30g +5g (16.2cc)

5 1/2" 35g +5g (18.9cc)
6 5/8" 40g +5g (21.6cc)
7.0" 45g +5g (24.3cc)
7 5/8" 45g +5g (24.3cc)
8 5/8" 50g +5g (27.0cc)
9 5/8" 60g +10g (32.4cc)
10 3/4" 60g +10g (32.4cc)
11 3/4" 70g +10g (37.8cc)
13 3/8" 80g +10g (43.2cc)

NOTE:

1. API 5A2 modified thread compound shall be applied with a gentle brush.

2. Recommended Dope weight based on dope gravity of 1.85.

3. For low carbon steel, dope shall be applied to the box with non-metallic gentle brush.

4. For high alloy material above CR9, dope shall be applied to pin and box with a non-
metallic gentle brush.
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SECTION 4 - FOX

Hunting Oilfield together with Kawasaki Steel produce a product with a unique thread design;
the FOX connection. The primary feature is its thread form that, although recognisably
modified Buttress, incorporates a changing thread pitch along its length designed to equalise
tensile loading of the thread flanks.

Consider a typical premium joint incorporating a stop shoulder. As the final torque is applied,
the compressive stresses of the pin are mostly concentrated in the first two or three threads of
the pin end. When subjected to tension, strain is also concentrated at the top two or three
threads of the box, which in extreme circumstances could 'bell out' the box and/or unzip the
connector.

To even out these high points of tooth load the FOX thread is cut to achieve a reduced pitch
angle at each end of the threaded section.

The following diagrams show this comparison:

TYPICAL PREMIUM JOINTS

FOX PREMIUM THREADED CONNECTION

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THE FOX PITCH CHANGE CONCEPT

A B C

A The gap between load flanks B The standard pitch area acts C The gap between load flanks
closes as the joint is made up to concentrate loads in the on initial assembly closes as the
to torque condition. centre section of the thread. joint is axially loaded in tension.

Fig. 7

There are two methods of achieving this concept of pitch variation: -

Single Pitch Change

Pin and box both have standard pitch section followed by a reduced pitch section. After make-
up, this produces a centre section which is fully matched and inner and outer regions in which
the variation causes a reduced load on the flanks of the thread teeth.

Double Pitch Change

The pin has a standard pitch over its full length whilst the box incorporates three sections:
increased pitch at the box end, standard pitch at the centre section and reduced pitch at the
inner section. This produces exactly the same effect as the Single Pitch method.

The end result ensures that the thread flanks are preferentially loaded at the centre of the
connection.
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The FOX Seal

Whereas the conventional tubing seal can be considered to consist of one or two sharply
defined areas with consequent high pressure points, the 'Triple Radius' seal of the FOX
connector is effectively a bullet nose design blending the lateral primary seal with the reverse
flank stop shoulder. The seal is claimed to provide a greater cumulative stored energy than
other typical joints.

THE TRIPLE RADIUS CONTOUR SEAL

Initial assembly
1 Pipe brings contact
2 Coupling 2 between pin and
3 Primary radius box at 3
metal to metal 3 Application of
seal make-up torque
4 Secondary induces shouldering
radius torque 1
4 out - closing the
shoulder
gap at 4 and pre-
loading the
connection.

Fig. 8
Comparison of seal stored energy

160
Pipe
140 Typical
Coupling
FOX 120 Premium Joint
100
Cumulative Pipe Cumulative
80
strain energy Coupling Strain energy
60 in typical
in FOX joint
40 premium thread
(axial)
20 (axial)
0
Thread tooth number Thread tooth number

The characteristics of the FOX connection are summarised as follows:

1. Lower thread tooth loads after make-up (about 30% lower than with conventional
connections).

2. Higher metal to metal seal energy (about 80% greater than with conventional
connections).

3. More efficient load distribution within the connection.

4. Superior sealing performance and overtorque resistance resulting from contoured seal
shape.
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Running Guide-lines

Guidelines similar to other Premium tubulars. Additional areas of interest are reproduced here
and are taken from the Operating Procedure booklet provided by Hunting Oilfield Services.

Protectors

Protectors may be of metal or plastic moulded construction.

Premium connections require adequate protection in the threaded area, particularly at the
extremity of the pin seal.

A minimum of 15mm is recommended between the bottom of the torque bar groove and the
position of the pin seal extremity when the connector is fully tightened.

Protectors should be manufactured to allow an even thickness of thread compound to cover

threads and seals when in fully made up position.

Protectors made of moulded plastic should be reinforced with metal plates for sizes 5" and
larger. The reinforcing material should be extended to include the extremity of the pin seal
member.

Running

If drifting is required, carefully remove closed end protector; replace with clean open-end
type, and drift. Do not use a metallic drift with the box seal unprotected, as damage may
occur to this critical area.
Replace the closed end protector to ensure pipe debris cannot contaminate the seal area.

Stab pin into box carefully. Avoid dropping pin into box to cause damage to thread crests.
Ensure alignment is true. Engage threads by hand until proper mating has occurred.

Place make-up tong on upper joint within 6" of coupling edge, and back-up on lower joint at
the same distance.

Rotate pin at 5-15 RPM until abutment of seal takes place.

Continue make-up until Optimum recommended torque has been reached.

NOTE: Couplings are made up to Maximum recommended torque (generally 10% greater
than Optimum).
Rig make-up should not exceed Maximum, as couplings will possibly breakout at the mill end
when work-overs take place.

When using Torque/turn equipment, settings should allow for approximately 1/4 to 1/2 turn from
onset of power torque to final seating.

Always ensure that tong dies and elevators are the correct diameter for the pipe being run.
Coupling O.D.'s are not always standard.
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Make-up Torque

Torsion Energy is applied to pins and couplings in order to create high compression at the
sealing profile face (approaching yield stress limits).
This is known as pre-load.

The pre-load is relieved by the weight of the suspended string and any tension applied to the
string by the travelling block. The correct pre-load prevents leakage of the connection under
internal or external fluid pressure.

Torsion Energy (T) = Friction torque

+ Interference torque
+ Pre-load torque (Shoulder torque)

i.e. T = TFI + TP
T.max

T.min

TORQUE TP
(60% T.min)

(Not more than

40% T.min) TFI

0 TURNS
Fig. 9

FOX Connection make-up specifies that:-

T shall be at least 60% of T.min in any given
P
production run.

Note: Fox make-up torques typically show that

over 90% of all connections exhibit pre-load
torques (TP ) of at least 75%.
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Revised: 27/06/06 Page : 21 of 26
Prepared by C. Fell
Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

Diagram Analysis

MAXIMUM
T ORQUE
OPT IMUM
MINIMUM

T URNS

0.03 T O 0.8 T URNS

FIRST PHASE
OVERCOMING FRICTION AND
PIN BOX
RADIAL THREAD INTERFERENCE

SECOND PHASE
INITIAL METAL-TO-METAL SEAL
PIN BOX CONTACT. BENDING OF PIN NIB
TO SHOULDER POSITION

T HIRD PHASE
PRE-LOADING OF SEAL
PIN BOX

Fig. 10

Torque

FOX is a relatively low interference connection and in order to record that interference before
the onset of pre-load torque recording, it is necessary to set the Reference Torque up to 4% of
Optimum Recommended Torque.

Turns

From initial stab to full make-up takes approximately 10 turns. FOX thread interference
begins to register after 7 to 8 turns.

If Company policy is to use power tongs from initial stab to full make-up, the Turns window
should be fixed at no less than 11 turns.
(Note that the Data-Trek has a maximum Turns window of 12 turns).

If policy is to make-up connections to the hand-tight position before applying power tongs, the
turns window should be fixed at 1 turn.
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Revised: 27/06/06 Page : 22 of 26
Prepared by C. Fell
Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

Speed

From initial stab to the hand-tight position, FOX may be assembled at 5 to 15 RPM.
After initial abutment of seal faces, reduce speed to 3 to 5 RPM until full make-up torque is
achieved.

Break-out

The following shows the expected breakout for FOX connections: -

Diameter TPI Turns

2 3/8 8 10.5
2 7/8 8 10.5
3 1/2 6 7.87
4 6 7.87
4 1/2-13 3/8 5 9.92
 Doc. Issue: 27/1/93 Rev : D
Revised: 27/06/06 Page : 23 of 26
Prepared by C. Fell
Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

Recognising FOX Connections

The general appearance of FOX connections is similar to a more familiar - but very different -
connection in common use in your area.

Use the following guide to identify FOX: -

- Measure the coupling length. FOX has one standard length per pipe O.D. regardless of
material grade. Other connections have couplings that are sometimes longer (high chrome
alloys); sometimes shorter (regular carbon grades) than FOX.

- "FEEL THE SEAL". The FOX seal is rounded at the end of the pin and feels quite smooth.
The others are machined with straight tapers that feel sharp at the end in comparison.

- FOX has a gradual taper on the I.D. of the pin and (5 on tubing, 15 on casing) running
from the seal shoulder into the pipe bore. Some other connections feature a parallel
counterbore before tapering into the pipe bore.

CAUTION

It is possible on all sizes (except 4 1/2") to make up FOX connections with other types because
the T.P.I. is identical. However the geometry of FOX and others are very different, and it is
probable that seals will jam and performance of both types would be seriously impaired.

FOX - VAM Seal Recognition

Smooth radius

VAM
TUBING
25o
25°
o
1515°

o
3
VAM
o
55° CASING
o
1515°
FOX CASING & TUBING

COMPARITIVE SEAL PROFILES

Fig.11
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Revised: 27/06/06 Page : 24 of 26
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Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

Field Inspection

Threads

Check for: - mechanical denting

crushing (drift tube ends)
severe metal removal

Check thread load flanks for galling - simple "polishing" is permissible - but no deep scoring
or metal separation is allowed.

Local damage to threads crests is permissible providing that among the first 8 complete
threads, only 2 crests have suffered local damage.

Seal Areas

Inspect closely for serious denting or notch type damage. Minor, local notch-type damage
may be permissible, but do not perform any local filing of the defect, as this removes the local
ridge of metal surrounding the notch which can, if run back together, provide an effective
sealing surface.

Examine closely the outer section of the nose seal for evidence of dope scoring. This might
indicate galling and if present, is a serious defect. However, provided that actual metal
removal has not taken place, sealing may again be achieved. Only light dressing with emery
cloth is permissible to remove burrs or sharp minor slivers. No filing under any
circumstances is permitted. Radial damage is more serious in this region because it provides
a leak path, which will soon wash out.

Damaged couplings should be removed and replaced with new ones. Note that the make-up
torque for a coupling is the Maximum Recommended.

BASIC BUTTRESS
THREAD FORM LOAD FLANKS
AND PITCH
Primary Seal
Area

5 degrees Taper
Fig. 12
Torque Shoulder
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Revised: 27/06/06 Page : 25 of 26
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Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

SECTION 5 – KSBEAR

The previous FOX connection has shown evolvement of the modified Buttress threaded
connection, primarily to equalise internal stress points between the pin and coupling.

Further advances in drilling technology have pushed the design limit requirements even
further. As wells become even deeper, and directional and horizontal wells become more
common, the ability to maintain a leak-proof connection under intense bending and pressure
forces, has led to improved designs such as the BEAR connection developed by Kawasaki
Steel. Compare the modified Buttress thread to that of the KSBEAR below.

-5°
3°
Load flank
Load flank
Negative
25° Load Flank
Stabbing flank Angle
Stabbing flank
10°

Higher
Pin Stabbing
Pin Flank Angle

Increased
Corner
Radius

MODIFIED BUTTRESS KSBEAR

Fig. 13.

Bending Forces
When tensile load, bending load, and external pressure act on a connection that has a modified
buttress thread form, these loads generate a force that moves the pin thread and coupling
thread away from each other. The hooked thread form of the KSBEAR significantly reduces
this parting force.
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Revised: 27/06/06 Page : 26 of 26
Prepared by C. Fell
Reviewed by : C.Thatcher
Approved by J. Lethbridge
Document Title High Performance Tubulars Training Manual

Stabbing Flank contact

It has been seen that as a pin and coupling are made up to torque, the compressive stresses
accumulating within the seal area reduce the contact forces at the pin thread stabbing flanks.
In consequence, the [lower] seal area sustains the majority of stresses when subjected to down-
hole forces. This can cause deformation at the seal area and/or leakage when subject to
bending forces.
Design of the KSBEAR stabbing flanks is optimised to provide a stronger contact pressure at
these thread surfaces (19% of total compressive load) after make-up.

Load Flank contact Load Flank

Although this hooked thread design offers good leakage

resistance, the negative flank would tend to produce galling
during make-up. An increased radius of the upper load flank
has been incorporated to prevent stress concentration at that
point and shifted it towards the root of the pin thread where Pin
the strength is higher.

Fig. 14

Summary of KSBEAR Design Features

Feature Improvement

Negative load flank angle Increased tensile and bending capacity

Increased external pressure capacity

Optimised gap between stabbing flanks Increased resistance to compressive loads

on pin and coupling threads

Different corner radius on load flanks Increased resistance to galling

on pin and coupling threads

Different load flank angles on pin and Increased external pressure capacity
Coupling threads Increased resistance to galling

25° angle on thread stabbing flank Fast make-up and increased resistance to
cross threading