Kalsi Seals Handbook

Chapter E4
Using Kalsi Seals in high pressure washpipe assemblies

Revision 3 September 23, 2015

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Using Kalsi Seals in high pressure washpipe assemblies

1.

Chapter E4 Page 1

Introduction

Washpipe assemblies for oilfield drilling swivels and top drives conduct high pressure,
abrasive-laden drilling fluid from the stationary gooseneck to the rotary shaft. This chapter
describes what we believe to be the best mechanical arrangement for using Kalsi Seals in
a high pressure washpipe assembly. The basic design uses a floating washpipe,1 floating
backup rings, and pressure staging, and is covered by issued and pending patents. The
backup rings are hydraulically force balanced in the axial direction, so that they are free to
translate laterally in concert with washpipe runout. The backup rings are also radially
pressure balanced, to minimize pressure-related dimensional changes.
The design is robust, simple to manufacture, and easy to assemble and disassemble.
The design eliminates all radial O-rings, which are difficult to deal with during assembly,
and are also potential failure points. The design also eliminates all custom threads used in
earlier designs, and minimizes the number of precision machined surfaces, making it
economical to manufacture.
Licensing information

Kalsi Engineering prefers to license the patented and patent pending features of the
washpipe assembly with a simple unilateral license, granting permission to a specific
manufacturer to manufacture, use, and sell the design, provided that it is used with rotary
seals that are purchased from Kalsi Engineering. When this type of license arrangement is
used, the licensing fee can be included in the price of the seals, or as a per-seal or perswivel licensing line item, or for a part number representing a combination that includes
the seal and the hardware technology license. Bidirectional licenses are also possible, but
less economical, because they inevitably involve extended and expensive interaction
between legal departments, which consumes time and resources, delays project
completion, and inflates the licensing cost.
2.

Overview of the swivel figures

Figures 1 through 5 are section views of a high pressure washpipe assembly taken at
different angles to show various internal details. Figure 1 is a section view taken through
the internal porting. Figures 2 and 3 are enlargements that show details of the internal
porting. Figure 4 is a section view taken through the bulkhead bolts. Figure 5 is a section
view taken through the angular alignment features and the anti-rotation features.

The floating washpipe concept dates to 1946; see expired U.S. Patent 2,472,061, "Rotary swivel for
drilling rigs".

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 2

The washpipe assembly shown in Figure 1 was engineered by Kalsi Engineering, and
is designed for 10,000 psi operation. It has a 3 inch washpipe bore and a 4.5 inch sealing
diameter.2 The basic design can be adapted to other sizes and types of swivels.
3.

How the washpipe assembly operates

General arrangement of the washpipe assembly

The lower end of the washpipe is rotationally driven by, and retained to, a rotary shaft
(not shown). A spline drive is shown, but other drive arrangements are possible. The
sealing diameter of the articulation seal is the same as the sealing diameter of the Kalsi
Seals. This makes the washpipe hydraulically force-balanced in the axial direction, which
makes it free to articulate in response to misalignment and runout of the rotary shaft. The
lower end of the washpipe is guided by the bore that defines the extrusion gap for the
articulating seal. The upper end of the washpipe is guided by the journal bearing bore that
is defined by the upper housing. The surfaces that retain and guide the washpipe establish
clearances that are sized to accommodate the anticipated range of washpipe articulation
that may occur due to misalignment and runout. Information on designing journal bearing
clearance is provided in the engineering section of this rotary seal handbook. Optimally,
the journal bearing bore that is defined by the upper housing is produced by a bushing (not
shown) that is formed from an appropriate bearing material.
The pressure housing is retained to the gooseneck by any suitable means. Figure 1
shows a bolt flange with the bolts inserted from the bottom into the gooseneck adapter.
Other arrangements, such as bolting from the top, may be preferable. The illustrated
gooseneck adapter has eight spanner wrench holes that are used when tightening the
adapter to the gooseneck.
The pressure housing consists of the upper housing, first stage bulkhead, and second
stage bulkhead which are bolted together as shown in Figure 4. The stacked housing, when
assembled, defines three Kalsi Seal glands and two pressures stages. The upper housing
contains a seal groove for the partitioning seal, which separates the drilling fluid from the
first stage seal lubricant. Each pressure stage region contains a patent-pending3 high
pressure metal floating backup ring arrangement and a pressure retaining Kalsi Seal.
2

Key features of the washpipe assembly have been tested in the lab using a 4.5" test fixture. This fixture
uses the same seals and backup rings as the washpipe assembly. The pressure housings of the 4.5 test
fixture replicate the critical aspects of the internal geometry of the housings used in the washpipe
assembly. In addition to allowing us to evaluate the performance of the 4.5 rotary seals and backup rings,
this fixture has allowed us to collect hydrodynamic pumping related leakage data at various speed,
pressure and temperature combinations. This allows us to provide better input to customers regarding
design of the lubricant supply.
The washpipe assembly is also covered by U.S. Patent 6,007,105 and A.U. Pat. 746,508. Contact Kalsi
Engineering for licensing information.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 3

Floating backup rings allow the minimum possible extrusion gap clearance

The key to the high pressure performance of the washpipe assembly is the use of our
patent pending floating backup rings. These rings, which are axially force balanced and
radially pressure balanced, are guided radially by a journal bearing-type fit with the
washpipe. This fit, and the radial pressure balance, allow the minimum possible extrusion
gap to be used, thereby achieving maximum seal extrusion resistance. The axial force
balance allows the backup ring to move laterally to accommodate runout and misalignment
of the washpipe, while avoiding heavily loaded metal-to-metal contact at the extrusion gap,
and the seal-damaging heat that such contact would produce.
First stage seal lubricant pressurization

The first stage seal lubricant is pressurized to a value equal to or greater than the
pressure of the fluid being conducted by the swivel. The lubricant pressurization system
must react quickly, so that the pressure of the first stage lubricant is never less than the
pressure of the conducted fluid.
In the simplest embodiment, the pressure of the first stage seal lubricant is balanced
to the pressure of the conducted fluid by a diaphragm or bladder that also serves as a
lubricant reservoir. When this method is used, the partitioning seal has to be axially spring
loaded (not shown) using the method described in chapter D9, or has to be an Axially
Constrained Kalsi Seal. A 0.020 (0.51mm) radial extrusion gap clearance is recommended
for both of these partitioning seal options. The housing for the diaphragm or bladder can
be installed in the wireline port.
In lieu of using a diaphragm or bladder arrangement, the first stage lubricant pressure
can be provided at a pressure greater than the pressure of the conducted fluid using a piston
based pressure amplification-type lubricant reservoir or a computer-controlled lubricant
supply system, as described in chapter D11. In our experience, a first stage lubricant
pressure that is about 160 to 300 psi (1.10 to 2.07 MPa) greater than the nominal pressure
of the conducted fluid is satisfactory, and suitable for use with a 0.010 (0.25mm) radial
extrusion gap clearance for the partitioning seal. This lubricant overpressure orients the
partitioning seal against the upper wall of the seal groove, for optimum abrasion resistance.
The magnitude of the lubricant overpressure is selected to ensure that the pressure of the
first stage lubricant is always greater than the fluctuating pressure of the conducted fluid.
Laboratory testing indicates that the partitioning seal will function reliably if the first stage
lubricant pressure is more than 500 psi greater than the nominal pressure of the conducted
fluid.
With piston based reservoirs, it may be desirable to include an auto-refill function, and
to mount the first stage reservoir on the wireline port. Whatever the lubricant supply
system, it must be immune to inadvertent blockage by the conducted fluid.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 4

Pressure staging

In the two stage arrangement illustrated in this chapter, the second stage seal lubricant
pressure is provided at a pressure that is one half the pressure of the first stage seal
lubricant. This allows the first stage pressure to be shared by the first and second stage
pressure retaining seals, with each seal being exposed to one half of the differential
pressure. When two pressure stages are used, one stage should use a male quick connect
fitting, and the other should use a female quick connect fitting, to ensure that the lubricant
supply hoses are connected properly.
If desired, more than two pressure stages can be used. Washpipe assemblies with three
pressure stages are practical, and fit within the typical space provided by the gooseneck
support of many drilling swivels and top drives.
4.

Washpipe design considerations

Washpipe diameters

The first step in washpipe design is selection of the bore diameter that is required to
accommodate the desired volumetric flow rate of the conducted fluid. The second step is
selecting the seal diameter. For optimum results, the wall thickness should be designed to
minimize pressure-induced washpipe deflection at the extrusion gap locations. This is best
accomplished through the use of finite element analysis. The analysis must include the
pressures acting along the interior and exterior of the washpipe, including pressure changes
associated with failure of any of the rotary seals.
In order to properly design the backup rings, a complete understanding of the
dimensional effect pressure has on the sealing diameter is necessary. The designer should
confirm that stress levels are at acceptable values for normal operating pressure and for
proof testing.
As shown in Figure 1, the washpipe diameter at the articulation seal is the same as the
washpipe diameter at the rotary seals. This eliminates axial hydraulic thrust on the
washpipe, allowing it to freely articulate in response to lateral misalignment and runout.
Seal running surface and installation path

The washpipe surfaces contacted by the rotary seals and the backup rings are protected
by a ground and polished tungsten carbide surface, per the normal practices described in
chapter D2. The installation paths for the Kalsi Seals and the articulation seal include an
installation chamfer, to avoid cutting the seals during installation, as described in chapter
D3. These washpipe features are preferably protected from corrosion to avoid corrosion
related seal damage, as described in chapter D3.

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Using Kalsi Seals in high pressure washpipe assemblies

5.

Chapter E4 Page 5

Upper housing design considerations

Overall size of the upper housing

The upper housing is sized to provide adequate wall thickness to accommodate the
necessary bulkhead bolt size and keep the stress levels within the design limits when
exposed to operating pressure, and proof pressure loads.
The groove for the partitioning seal

The groove for the partitioning seal is designed in accordance with chapter D5. If the
partitioning seal is axially spring loaded, also refer to chapter D9. The extrusion gap that
faces the conducted fluid is designed in accordance with the abrasive exclusion guidelines
in chapter D7. Extrusion gap details are most clearly visible in Figures 2 and 3.
The recess for the first stage pressure retaining seal

The cylindrical bore and lubricant side wall of the recess for the first stage pressure
retaining seal are designed in accordance with the instructions for the comparable seal
gland surfaces in chapter D5.
Pressure communication porting

Referring to Figure 1 for an overall view of the pressure porting, the first stage
lubricant pressure is communicated to a pressure distribution groove that is located near
the groove for the partitioning seal. The axial length between the distribution groove and
the seal groove should be minimized, as described and illustrated in chapter D11. In
conditions when the pressure of the conducted fluid is increasing rapidly, the pressure
distribution groove, in close proximity to the partitioning seal groove, helps to minimize
pressure lag, preventing conditions where the pressure of the conducted fluid is
momentarily greater than the pressure of the first stage seal lubricant. Field experience
shows that reducing pressure lag significantly increases the life of the rotary seals.
Porting details are best understood by referencing the enlarged details of Figures 2 and
3. The pressure porting includes axial ports communicating balancing pressure to the
undersides of the backup rings, to provide axial force balance. This pressure is
communicated through the housing interfaces via small diameter local O-rings. The use of
small local O-rings minimizes hydraulic thrust area, and thereby minimizes the pressure
load acting on the bulkhead screws.
Radial pressure balance is communicated to the backup ring diameters primarily by
radial vent passages through the backup ring as shown in Figures 1-3. An additional radial
pressure balance port for the second stage backup ring is shown in Figures 1 and 3. A port
venting to atmosphere can be included for the stage 2 backup ring.

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Using Kalsi Seals in high pressure washpipe assemblies

6.

Chapter E4 Page 6

Backup ring and bulkhead design

Detailed instructions for designing the backup rings are provided in chapter D17. As
shown by Figure 5 of this chapter, the anti-rotation pin can be a loose pin that is inserted
from the ID of the backup ring, and retained by the washpipe.
As a general overview, the axial depth of the bulkhead recess that receives the backup
ring is critical, because it controls the face-type extrusion gap clearance that the outer
portion of the rotary seal is exposed to. The axial length of the backup ring and the depth
of the recess are tightly toleranced, assuring that the backup ring is just a few thousandths
of an inch shorter than the recess depth. These are two of the most critical dimensions of
the assembly. The other two critical dimensions are the sealing diameter of the washpipe
and the inner diameter (ID) of the backup ring.
The ID of the backup ring is designed to be as tight of a fit as possible while still
assuring freedom of relative rotation between the washpipe and the backup ring. Design of
this fit requires the designer to consider tolerances, differential thermal expansion, and
pressure induced deformation. The outer diameter (OD) of the backup ring is designed to
always extend beyond the OD of the outer force balancing O-ring gland, considering the
maximum anticipated lateral motion of the backup ring and the tolerance stackup of the
backup ring and the O-ring gland.
The ID of the bulkhead is designed to accommodate the maximum anticipated runout
and misalignment of the washpipe. The ID gland dimension for the inner force balancing
O-ring should be sized and toleranced so the minimum wall thickness between the seal
gland and the bulkhead bore is adequate to keep the stress levels within the design limits
when exposed to operating pressure, and proof pressure loads. The OD gland dimension
for the outer force balancing O-ring should be sized and dimensioned to define a projected
area with the ID of the inner O-ring that is substantially the same as the projected area
defined by the washpipe diameter and the OD of the pressure retaining Kalsi Seal gland.
When sizing the force balancing area include tolerance stackup to ensure the force
balancing area is never larger than area defined by the Kalsi Seal. We recommend having
the force balancing area always smaller and in a range that results in an axial load sufficient
to compress the force balancing O-rings.
The diameter of the recess that receives the backup ring OD is designed to
accommodate the maximum anticipated lateral motion of the backup ring, in MMC
tolerance conditions.
7.

Housing interface design

Several of the housing end surfaces are sealing surfaces for face seals, and must have
a suitably smooth surface finisha 32 micro-inch AA or better surface finish is
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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 7

recommended. The end surfaces impact overall alignment of the housings, and must be
machined parallel to one another, and square with critical bore surfaces.
The housings are aligned to one another by overlapping piloting surfaces near the OD
of the housings. The MMC fit of the pilots should correspond to the MMC RC 3 class of
fit, however the LMC fit can be looser than the LMC RC 3 class of fit, so that tolerances
can be looser than RC 3 tolerances. The axial length of the overlap of the piloting surfaces
should be kept short, to prevent the possibility of misalignment-related binding due to the
sticky drawer effect. A concentricity tolerance should be provided between the housing
pilots and critical interior surfaces, such as the extrusion gap bore of the upper housing, the
recess bores that receive the backup rings, and the smallest inside diameters of the bulkhead
housings.
Preferably, the upper housing and the bulkhead housings incorporate an indexing
feature, to ensure that they are assembled in proper angular alignment. One practical
indexing feature is the use of axially oriented indexing pins, and corresponding recesses in
the mating parts. Another practical indexing feature is to use a slightly uneven angular
spacing of the hole pattern for the bulkhead screws, so that the holes only line up when the
housings are in the correct angular orientation. In the example shown, the indexing pins
are formed by socket head cap screws.
8.

High pressure washpipe seals

Pressure retaining seals for washpipe assemblies

Plastic Lined Kalsi Seals constructed of -3034 material are the most pressure capable
rotary seals we offer. These seals have been tested for 1,000 hours on a floating washpipe
rotating at 240 feet/minute with 7,500 to 7,800 psi lubricant pressure using an ISO 150
viscosity grade lubricant maintained at 130F. The seals were in excellent condition at the
conclusion of the 1,000 hour test (Figure 6), and could have kept running for much longer.
A conventional washpipe packing only lasts a few hours under such extreme conditions,
and an entire set may only last a day or two.
Dual Durometer Kalsi Seals in the -107, -114, and -115 material also provide high
pressure capability. A pair of Kalsi Seals (PN 655-4-114) have been tested for 950 hours
on a washpipe rotating at 252 feet/minute with 5,000 psi lubricant pressure using an ISO
320 VG lubricant maintained at 130F. The seals were in good condition at the conclusion
of the 950 hour test (Figure 7) and could have continued running for much longer.
Partitioning seals for lubricant overpressure-type washpipe assemblies
4

We use the traditional dash numbering system to identify seal materials within seal part numbers. The
part number includes the seal drawing number and the material dash number. At Kalsi Engineering, "303" is spoken as "dash 303".

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 8

We recommend single durometer Kalsi Seals for partitioning seals in lubricant

overpressure type washpipe arrangements, where the seal lubricant is maintained at a value
greater than the process fluid that is conducted through the washpipe. Extra Wide Enhanced
Lubrication Seals offer the most sacrificial material to accommodate wear, are compatible
with relatively low viscosity lubricants, and are good choices with suitably sized lubricant
reservoirs. Because of their ability to resist pressure reversals in the 500 psi range, we
believe that Chamfered Enhanced Lubrication Seals may offer an advantage in lubricant
overpressure systems that experience pressure lag. Axially Constrained Kalsi Seals are also
appropriate for use as washpipe partitioning seals.
Partitioning seals for flush-type washpipe assemblies

Another method, covered by Kalsi Engineerings U.S. Patent 7,798,496, is to use lip
seals as the partitioning seals, and supply lubricant at a regulated flow rate through the
dynamic interfaces of the lip seals, generating a lubricant pressure that is greater than the
process fluid. This can be accomplished by use of a positive displacement lubricant supply
pump.
The lip seals need to be selected for their pressure venting characteristics. This
typically means that the inner lip is shorter than the outer lip, so that it does not contact the
extrusion gap clearance on the process fluid side of the lip seal. Contact Kalsi Engineering
for patent licensing information.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 9

Figure 1
Washpipe assembly with floating washpipe and floating backup rings
In this drilling swivel washpipe assembly, the pressure is divided between two rotary seals mounted
in high pressure bulkheads. These bulkheads incorporate laterally floating metal backup rings that
minimize size of the high pressure extrusion gaps. The illustrated assembly has a three inch bore
and is engineered for 10,000 psi service.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 10

Figure 2
Enlargement of the rotary seal area of washpipe assembly
This view shows the cross-drilled hole arrangement that provides first stage lubricant pressure to
the underside of the first stage backup ring. Each backup ring is hydraulically force-balanced in the
axial direction. This leaves the backup rings free to float laterally as the washpipe articulates in
response to misalignment and runout of the rotary shaft. The backup rings are also radially
pressure-balanced to minimize pressure-responsive diameter changes.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 11

Figure 3
Enlargement of the rotary seal area of washpipe assembly
This view shows the cross-drilled hole arrangement that provides second stage lubricant pressure
to the back side of the second stage backup ring. It also shows the porting that assures radial
pressure balance of the first stage backup ring.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 12

Figure 4
Washpipe seal assembly with floating washpipe and floating backup rings
This view is taken through two of the socket head cap screws that retain the bulkhead housings to
the upper housing. The bulkhead bolts are sized to withstand both the hydraulic force generated
by the first stage pressure acting over the sealed area between the upper housing and the first
stage bulkhead, and the preload necessary to resist separation due to the hydraulic force. Other
critical fasteners for the washpipe assembly are also shown and need to be sized according to their
specific loading.
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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 13

Figure 5
Enlargement of the rotary seal area of washpipe assembly
This view is taken through the socket head cap screws that ensure the housing assembly is in the
correct angular orientation, aligning the pressure communication porting shown in previous figures.
This view also shows the backup ring anti-rotation pins, which are inserted from the inside of the
backup ring, and retained by the washpipe. The anti-rotation pins engage mating pockets in the
bulkhead housings. These pockets must be wide enough to allow pin insertion without compressing
the face seals that engage the backup ring. If the pockets are not wide enough, pin insertion will
locally compress the face seals, and cause the ring to cock, which complicates further assembly.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 14

Figure 6
The plastic lined seals were in excellent condition after 1,000 hours at 7,500 psi
These photos were taken at the conclusion of a 1,000 hour, 7,500 to 7,800 psi test of plastic lined
Kalsi Seals under simulated oilfield washpipe operating conditions. The speed was equivalent to a
4. 5 washpipe rotating at 200 rpm. The washpipe was guided by radially pressure balanced backup
rings. The rotary seals were in excellent condition at the conclusion of the test, as can be seen in
these photos. The upper test seal is shown in the upper photo, and the lower test seal is shown in
the lower photo. Both seals are shown with the exclusion edge up.

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Using Kalsi Seals in high pressure washpipe assemblies

Chapter E4 Page 15

Figure 7
The Dual Durometer seals were in good condition after 950 hours at 5,000 psi
These photos were taken at the conclusion of a 950 hour, 5,000 psi test of -114 Kalsi Seals under
simulated oilfield washpipe operating conditions. The speed was equivalent to a 4. 5 washpipe
rotating at 200 rpm. The washpipe was guided by radially pressure balanced backup rings. The
washpipe had an intentional 0.01 inch runout. The rotary seals were in good condition at the
conclusion of the test, as can be seen in these photos. Both seals are shown with the exclusion
edge down.

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Using Kalsi Seals in high pressure washpipe assemblies

9.

Chapter E4 Page 16

Miscellaneous observations on washpipe assemblies

Design the washpipe pressure housing to be square with the gooseneck

When determining the means of attaching the washpipe assembly to the gooseneck,
features that help ensure the installation results in the housing being square to the
gooseneck and rotating shaft are important.
For best results, align the gooseneck prior to installing the washpipe assembly

When installing the washpipe assembly in a shop setting, the gooseneck pilot and drive
shaft pilot should be carefully aligned. One way to align the gooseneck pilot with the drive
shaft pilot is magnetically mounting a dial indicator on the drive shaft and sweeping the
gooseneck pilot as the drive shaft slowly rotates. After the gooseneck is placed in good
alignment it is bolted to the gooseneck support. A top drive with well aligned gooseneck
and drive shaft pilots will outperform units with poor alignment.
Avoid trapped air when filling the washpipe with lubricant

Vacuum filling is desirable for this application for two reasons. It helps to prevent the
formation of an air pocket below the partitioning seal. If an air pocket is large enough, it
can cause lubricant starvation of the partitioning seal. Vacuum filling minimizes pressure
lag because entrained air and air pockets do not have to be collapsed, which takes some
time.
Installation procedure should address the weight of the washpipe assembly

In the oilfield, high pressure washpipe assemblies typically have large through bores,
to facilitate hole cleaning in deep wells. This can lead to relatively heavy washpipe
assemblies. The assembly shown in Figure 3 weighs 120 pounds. This weight should be
considered when developing a safe field installation procedure. For example, the flange of
the upper housing or the lower side of the second stage bulkhead could be tapped to attach
the washpipe assembly to a lifting tool.
Attach the rotating components to the housing assembly during installation

The articulation seal carrier should be connected to the housing assembly during
installation to prevent the washpipe and attached seal carrier from falling off. The method
should be strong enough to support the weight of the washpipe, articulation seal carrier,
and the spline drive plates. The two-piece construction of the illustrated articulation seal
carrier allows for easy extraction of the articulation seal. The two pieces are held together
with small socket head cap screws.

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