PRESSURE AND FLOW

FITTINGS TUTORIAL

this tutorial, pressure ratings will be given for

The purpose of this document is to serve as a tutorial on
recommended typical applications.
pressure and vacuum fittings commonly used with
FLUKE CALIBRATION products. The scope of this
tutorial is limited to applications commonly encountered. PRESSURES UP TO 10 MPa
This tutorial should not be used as an engineering
technical note but rather as a general guide applying to ®
Swagelok fittings or compression type tube fittings
flow and pressure calibration applications. As with any are common throughout the industry. We use this type
pressurized system, it is the operator’s responsibility for of fitting on the inside of products that see pressures of
following safe use practices. 10 MPa (1 500 psi) or less. Two common sizes are 1/4
inch and 1/8 inch (4T and 2T). These are convenient to
use and leak tight, but are not good for multiple make-
There are six basic types of fittings commonly used with and-break connections. After several uses, the
FLUKE CALIBRATION products and hardware: tendency is for the body to “flare out” and lose the ability
to seal.
• Tapered pipe thread (NPT, PT, BSPT, ISO-T)

• Straight thread or O-Seal (ISO-S, BSPP, SAE-S) CONNECTION / INTERFACE TO EXTERNAL

FITTINGS, PRESSURE ABOVE 10 MPa
• Flare Fittings (AN (JIS) 37º)
DH200 / DH500 are high pressure “gland and collar”
® ®
• Compression fittings (Swagelok / Gyrolok ) connections used both inside and outside as
interconnection hardware. This fitting is unique in that it
• Coned-and-threaded (DH200 / 500, Autoclave, HIP) is used with a 1/4 inch diameter tube which has a coned
and threaded tip. These are less common throughout
• Face seal (VCR, VCO) industry simply due to the fewer number of high pressure
applications. Some people may refer to these as
“Autoclave fittings” see http://www.snap-
These fittings are available in different sizes and are tite.com/Snaptite_AED/AED_VFT/products/technical_inf
used in a variety if different applications and industries. ormation/coned_threaded_connections/index.html for
details. They are very good for multiple make-and-break
In our products we have a general scheme of using a connections. DH500 has a larger gland and collar (as
type of fitting for a given type of application. compared to DH200) and is rated for pressures to 400
MPa (60 000 psi). The smaller version DH200 is rated
CONNECTION / INTERFACE TO EXTERNAL for pressures to 140 MPa (20 000 psi).
FITTINGS, PRESSURE UP TO 10 MPa
CONNECTION / INTERFACE TO EXTERNAL
Tapered pipe thread (or NPT – National Pipe Tapered) FITTINGS, FLOW
is the most common pressure fitting used throughout the
industry. We use this fitting on the majority of our The VCR Metal gasket face seal fitting is used with
pressure products up to 20 MPa (3 000 psi) to connect flow products (molbloc/molbox) to interconnect with
with devices outside of the instrument (i.e.: supply gas other flow hardware. It is widely used in the
inlet, test port, exhaust port, vent port). There are a few semiconductor industry, offering high purity and leak free
exceptions where we use smaller size NPT fittings up to connections for applications involving critical vacuum
70 MPa (10 000 psi). It is very common to use an and positive pressure. A soft Viton o-ring is typically
adaptor to go from NPT to some other type of fitting; used in place of the metal face seal to facilitate frequent
these are readily available from most local suppliers. make-and-break connections. However, this is not
NPT fittings require use of a thread sealer such as applicable for high purity applications – a metal gasket
®
Teflon tape. A note on pressure ratings: NPT fittings must be used.
are capable of much higher pressures given that certain
engineering considerations are applied. For purposes of
APPLICATION CONSIDERATIONS Pressure ratings for fittings and tubing are highly
dependant upon the mechanical integrity of the tubing and
When designing or assembling a system, it is the number of engaged threads and torque on a fitting.
recommended practice to minimize the number of The pressure capability of a component is based on
connections and to be consistent with the type and size calculated stress for new, undamaged materials.
of fittings as much as possible. Each connection point Capability is the maximum pressure that the system or a
represents a potential source for a leak. Using fittings of component can withstand. The component must maintain
varying inside diameters could create a flow restriction an established safety factor of 2 or 3 in comparison with the
and resulting pressure drop. burst pressure and yield strength of the material. The
pressure values given in the following pages are guidelines
Cleanliness requirements of the test system should also only and NOT intended for engineering or design purposes.
be considered. Fittings and interconnections used in As with any pressurized system, it is the operator’s
one fluid media should typically not be used with another responsibility to follow established safety practices.
system until they are thoroughly cleaned. This can be
especially critical in “oxygen clean” applications, or when
using liquid contaminated fittings with a gas system.
Consider the material properties of the connections;
brass is typically not recommended for high purity
applications.

NPT (NATIONAL PIPE TAPERED) FITTINGS

COMMON NAMES NPT, Tapered Pipe Thread, Pipe Thread
SIZES 4NPTF = 1/4 in. female, 2NPTM = 1/8 in. male. These are the
two common sizes used products. (“F” denotes Female, “M”
denotes Male)
KEY FEATURES Shaft is slightly tapered from the base narrowing towards the
end. This taper is exaggerated and noted with the dashed
lines on the picture.
HOW IT SEALS Seal is made by an interference fit on the leading edges of the
first few rows of threads. Requires use of a thread sealant
®
such as Teflon tape or Teflon paste.
DESIGN BENEFITS A common industrial fitting with a wide variety of adaptors
available. Rugged and good for multiple make and break
NPTM connections. However, incorrect use can lead to galling or
other damage of mating threads.
PRESSURE LIMITATIONS (Ratings based on 316 SS)
4NPT Some Manufacturers rate it at 55 MPa (8 000 psi), but
we typically use up to 20 MPa (3 000 psi)
2NPT Some manufacturers rate it at 70 MPa (10 000 psi),
but we typically use up to 40 MPa (6 000 psi) with
some special applications to 70 MPa (10 000 psi).

ASSEMBLY Screw in until tight. This is the only fitting where you must use
INSTRUCTIONS a thread sealer such as Teflon tape to prevent leaks. Do not
confuse or try to use with SAE straight thread fittings
COMPRESSION FITTINGS
® ®
COMMON NAMES “Tube fittings”, “Compression fittings”, Swagelok , Gyrolok ,
®
CPI, A-LOK
SIZES 4T = 1/4 in.; 2T = 1/8 in.; 1T = 1/16 in. These are the common
sizes used with our products. Many other sizes are available.
KEY FEATURES Front and rear ferrules are “swaged” (compressed into) to the
tube, deforming it slightly, making a permanent hold to the
tube. Some manufacturers use a single ferrule design.
HOW IT SEALS Seals by compressing the sloped portion of the front ferrule
NUT against the machined shoulder of the mating body, and also
seals along the outer surface of tube extending below the
REAR FERRULE
ferrules.
TUBE END FRONT FERRULE
DESIGN BENEFITS Good for leak-free pressure and medium vacuum applications.
Quick to assemble; widely available. Recommended for
permanent installations. Multiple make-and-breaks operations
often deform the mating body due to over torque leading to
leaks.
PRESSURE LIMITATIONS Pressure limitations are primarily a function of tube size and
wall thickness. See manufacturers’ specifications.
ASSEMBLY After initial assembly is complete, finger-tighten the nut and
INSTRUCTIONS turn with a wrench. Tighten 3/4 turn for quarter inch tube or
larger. Tighten 1-1/4 turn for eighth inch tube or smaller.
CAUTION: Front and rear ferrules must be of same manufacturer
– mixed ferrules may not properly “swage” to the tube making it
possible for the tube to pull out and cause injury.

DH200/DH500 CONNECTIONS
1 EXPOSED COMMON NAMES DH200 / 500 equivalent to:
THREAD
Autoclave Engineers SF250CX / F250C and HiP LF4 / HF4
SIZES Both fittings are used with 1/4 in. OD tube, but with different
wall thickness and thread length.
DH200: Gland has 1/2 in. hex head
DH500: Gland has 5/8 in. hex head
KEY FEATURES Uses a gland and collar assembly to thrust the coned tip of a
1/4 in. nipple against a machined mating surface. Threaded
nipple is a left-hand thread. Female fittings always have a
weep hole to check for leaks and to prevent threaded area
from becoming pressurized.
GLAND CONED TIP
COLLAR HOW IT SEALS The pressure seal is made on the small coned surface of the
tube tip. The collar allows the gland to thrust the coned tip
against the sealing surface. These two surfaces have slightly
different angles.
DESIGN BENEFITS Excellent choice for high pressure gas or oil applications. Very
good for multiple make-and-break connections due to minimal
deformation of the coned sealing surface.
PRESSURE LIMITATIONS Regardless of the tube wall thickness, DH200 / DH500 end
connections are limited to:
DH200: 140 MPa (20 000 psi)
DH500: 400 MPa (60 000 psi)
CAUTION: Pressure rating for an assembly is limited by the
weakest component. Tube weld assemblies use smaller
diameter tubing. In these assemblies the pressure rating is
lower than the end connection.
ASSEMBLY Using a prepared coned and threaded tube (nipple), first slide
INSTRUCTIONS on the gland, then thread a collar onto the tube until one
thread is visible between coned tip and collar. This will ensure
adequate engagement of the gland with the mating body.
Tighten gland with wrench until snug. Our recommendation is
10 Nm for DH200 and 15 Nm for DH500 in standard
applications.
DH200/500 NIPPLES
SIZES Only available in 1/4 in. outside diameter (OD) stainless steel
(SS) tube – lengths available from 2.75 to 24 in. Custom sizes
are available.
KEY FEATURES Prepared lengths of tube by the manufacturer with coned and
threaded tips. DH500 has a longer threaded tip than DH200.
DESIGN BENEFITS Commonly used for interconnections between high pressure
devices.
PRESSURE LIMITATIONS Regardless of the tube wall thickness, DH200 / DH500 end
connections are limited to:
DH200: 140 MPa (20 000 psi)
DH500 DH500: 400 MPa (60 000 psi)
CAUTION: Pressure rating for an assembly is limited by the
weakest component. 1/4 in. OD SS tubing is available with
varying inside diameters (ID). The ID determines the pressure
rating of the tube. Tube weld assemblies use smaller diameter
tubing. In these assemblies the pressure rating is lower than
the end connection.

DH200
ASSEMBLY Thread is a left-hand (“reverse”) thread. Not recommended to
INSTRUCTIONS use DH200 collars and glands on DH500 nipples.

VCR – METAL GASKET FACE SEAL FITTING

COMMON NAMES “Face seal”, “VacuSeal™”
SIZES 1/2 in., 1/4 in. These are the two common sizes used with our
flow products. Other sizes industrially available.
KEY FEATURES Standard fitting for our flow products – commonly used in high
purity applications.
HOW IT SEALS Seal is made when a gasket or o-ring is compressed between
opposing polished annular beads. The metal gasket can only
be used once to ensure leak free operations. Teflon gaskets
are also available.
DESIGN BENEFITS Offers high purity when using a metal gasket; provides leak
free operation from vacuum to positive pressure. Unlimited life
cycle with disposable gaskets.
PRESSURE LIMITATIONS Limit to 100 psi or less when using o-rings.
ASSEMBLY A Viton o-ring is typically used in place of a metal gasket to
INSTRUCTIONS provide a quick, convenient, finger-tight assembly. The o-ring
is reusable. Tightening with a wrench is not recommended
with o-rings. O-rings not recommended for high purity
applications.
®
MANUFACTURERS Parker, Swagelok (Cajon)
37° FLARE FITTINGS / ADAPTORS
COMMON NAMES “AN4”, 37° Flare Tips, Triple-Lok 37°
SIZES Industrially available in 1/16 in. increments. Most common
size is ¼ inch.
KEY FEATURES Straight threaded body with a 37° tapered nose. These are
the predominant fitting within the US military and aerospace
industry. Also commonly used in the automotive industry.
HOW IT SEALS Seal occurs on the tapered nose of the fitting and mates with a
37° flared tube end. Gaskets are often used.
DESIGN BENEFITS Quick and easy to assemble / disassemble. Not as prone to
wear as compared with compression type fittings.
PRESSURE LIMITATIONS See manufacturer data.
SPECIAL NOTES Not used as a standard fitting on our products, but is offered
as an adaptor as shown in the first picture and some lines and
fittings kit include these fittings.

4NPT X DH200F ADAPTOR

SIZES Adaptor available from with either a 1/4 inch or 1/8 inch NPT
end. A similar adaptor is available for use with DH500.
KEY FEATURES A weep hole on the high pressure end indicates that the
adaptor is designed to accept a gland and collar type fitting
and not an SAE straight or an NPT fitting.
PRESSURE LIMITATIONS Limiting factor is the pipe thread. See ratings for NPT fittings.

DH200 X 4T ADAPTOR
SIZES Available in ¼ inch or 1/8 inch (4T / 2T) male tube ends.
PRESSURE LIMITATIONS Pressure rating is dependant on the attached tube thickness
and integrity of the swaged assembly. With all things equal,
typical pressure rating is 11 000 psi for use with 1/8 inch size.
MANUFACTURER Fluke Calibration
KF25 VACUUM FITTINGS
SIZES 40 mm, 25 mm, 16 mm. Used for vacuum and flow
applications. Commonly referred to as “KF__” fittings.
KEY FEATURES Large diameter flanged connections.. The number indicates
inside diameter in millimeters (mm).
HOW IT SEALS A metal centering ring with an o-ring on the periphery is used
to align flanges with each other. A clamp is then used to press
the faces of each flange against the o-ring where the seal is
made.
DESIGN BENEFITS Provides for a high conductance (low resistance to flow)
vacuum path.
PRESSURE LIMITATIONS Recommended for use with vacuum applications; generally not
recommended for positive pressures above 1 MPa without
special clamps.
ASSEMBLY Align centering ring between opposing flanges; apply clamp
INSTRUCTIONS over lips of both flanges and tighten the wing nut or latch.
Special adaptive centering rings for transitioning between
various flange sizes are available.
MANUFACTURER Leybold, Nor-Cal, Varian, Pfeifer, BOC Edwards

PORT CONNECTORS
SIZES ¼ inch and 1/8 inch (4P / 2P) are typically used.
KEY FEATURES Port connector is a female-female union.
PRESSURE LIMITATIONS Follow same guidelines as with tube fittings.
ASSEMBLY When a port connector is ordered or included with an
INSTRUCTIONS interconnections kit, it arrives as unassembled stem along with
one nut and pair of ferrules. User must assemble the pieces
to look like the picture at left.

SAE “STRAIGHT”
KEY FEATURES Straight threads and seals with an o-ring. Unlike an NPT
there is NO taper.
HOW IT SEALS O-ring used to form seal.
ASSEMBLY Looks similar to NPT in size – very easy to confuse if o-ring
INSTRUCTIONS is missing. Do not attempt to use an SAE fitting with an
NPT body.

Fluke Calibration
Pressure and Flow Products Tel 877.355.3225
4765 East Beautiful Lane www.flukecal.com
Phoenix AZ 85044-5318
USA © 2012 Fluke Calibration