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TECHNICAL DOCUMENT ON
INSTRUMENTATION TUBING AND THEIR
CONNECTIONS
ii
PREFACE
Instrumentation design and construction is a very interesting proposition. One is supposed to
know the electronics and electrical aspects as well as the mechanical aspects too.
Instrumentation tubing is one such field where an instrumentation engineer has to don the
robes of a mechanical engineer. In NPCIL, for a long time, it was felt that there is no single
document that can cater to the needs of budding as well as practicing engineers when they
want to search some information on instrumentation tubing and connections.
Instrumentation tubing covers both Impulse tubes (sensing lines) as well as pneumatic tubes.
Connections include tapping points, root valves and tube fittings. Usually one has to refer to
myriad technical documents, codes and standards to s earch for a specific aspect of tubing
design or construction. This technical note is an attempt to put all the information at one
place. The efforts have been put to expose the reader to all the aspects of tubing and make
him aware of all the developments in the world. A comprehensive list of all the reference
documents is given at the end and they have been liberally used while preparation of this note
was underway. Effort has been made to represent all the relevant information here however,
enterprising readers will benefit even more if they peruse the reference documents directly.
Attempt has been made to demonstrate analytically that if the design and installation
practices are followed as per this note then the sensing line will meet the intent of class -I
tubing. Readers may note that the word tube/tubing used here should be inferred as
instrumentation tubing only limited to maximum 1” size.
It may be noted that various tubing practices have not been discussed in this note. The
detailed installation practices for various process measurements will be discussed in respective
process measurement/field installation technical notes. However, salient issues common to all
installations have been discussed in detail.
Author is grateful to a large number of engineers with whom they had an opportunity to work
with during their long career in NPCIL and on the way a lot of design aspects were concluded.
Nirbhay Gupta
Mumbai
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TABLE OF CONTENT
Section TITLE Page
No.
1.0 INTRODUCTION 1
1.1 DIFFERENCE BETWEEN A PIPE AND A TUBE 1
1.2 MAJOR ADVANTAGES OF TUBING OVER PIPING SYSTEMS 2
1.3 TYPES OF TUBES 3
1.4 GUIDELINES FOR SELECTION OF INSTRUMENTATION TUBES 3
1.5 DIFFERENT SIZES OF TUBES 5
1.6 CRITERIA FOR SELECTING THE SIZE OF A TUBE 5
1.7 SELECTION AND DESIGN CRITERIA 6
2.0 DESIGN OF TUBING AND TUBING SYSTEMS 13
2.1 CLASS-I INSTRUMENTATION TUBING DESIGN 13
2.2 REQUIREMENTS OF MATERIAL FOR INSTRUMENT TUBING/PIPING AS PER NB-2000 13
2.3 DESIGN REQUIREMENTS OF INSTRUMENT PIPING/TUBING AS PER SUBSECTION NC (NC 13
3600)
2.4 PRESSURE DESIGN (INTERNAL PRESSURE) OF INSTRUMENT TUBING/ PIPING 14
2.5 ANALYSIS CRITERION OF TUBING/PIPING SYSTEM 15
2.6 ANALYSIS OF SS TUBES USED IN NPCIL 18
2.6.1 WALL THICKNESS AND PRESSURE RATING OF DIFFERENT SIZES OF INSTRUMENT TUBING 18
2.6.2 STRESS ANALYSIS OF TUBING SYSTEMS 19
2.6.2.1 ANALYSIS FOR SUSTAINED MECHANICAL LOADS 19
2.6.2.2 ANALYSIS FOR OCCASIONAL LOADS (LEVEL A&B SERVICE LIMITS) 19
2.6.2.3 ANALYSIS FOR STRESS DUE TO THERMAL EXPANSION AND OTHER SUSTAINED LOADS 20
2.7 CONSIDERATION FOR VARIOUS FORCES 23
2.8 TUBE BENDING CONSIDERATIONS 23
2.9 SPECIAL DESIGN ASPECTS TO MEET THE REQUIREMENTS OF CLASS-I TUBING AND 23
TUBING SYSTEMS
2.10 CONCLUSION 24
3.0 TECHNICAL REQUIREMENTS OF SS TUBES 25
4.0 PNEUMATIC TUBING 27
4.1 ADVANTAGES OF USING COPPER TUBES 27
4.2 DIFFERENT TYPES OF COPPER TUBES 28
4.3 RECOMMENDATIONS FOR SELECTION OF A TYPE OF COPPER TUBE 29
4.4 TECHNICAL REQUIREMENTS OF COPPER TUBE 34
4.5 APPLICABLE INTERNATIONAL STANDARDS FOR COPPER TUBES 35
5.0 ASTM TUBING SPECIFICATIONS OUTSIDE DIAMETER/WALL THICKNESS 36
6.0 EMBEDDED PENETRATIONS 38
7.0 METHODS OF CONNECTION OF INSTRUMENTATION TUBES 39
7.1 WELDED JOINTS 39
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7.2 FLARED, FLARELESS AND COMPRESSION JOINTS 39
7.3 THREADED JOINTS 40
8.0 GUIDELINES FOR TAKE OFF C ONNECTIONS FOR SENSING LINES 41
8.1 LOCATION OF PRESSURE TAPS 41
8.2 CONSIDERATIONS FOR PRESSURE TAP DESIGN 42
8.3 RECOMMENDATIONS FOR PRESSURE TAP DESIGN 43
9.0 GUIDELINES FOR ROOT VALVES 44
10.0 INSTALLATION OF INSTRUMENTATION TUBING 45
10.1 BEST PRACTICES FOR IMPULSE TUBE INSTALLATION 45
10.2 SOME PRACTICAL GUIDELINES FOR TUBE LAYING AND BENDING 48
10.3 TUBE BENDING CHECK LIST 50
10.4 CHARACTERISTICS OF A WELL-MADE TUBING CIRCUIT 54
10.5 COMMON CAUSES OF IMPERFECT BENDS 55
10.6 ROUTING OF BENDS 57
10.7 GUIDELINES FOR C OPPER TUBE INSTALLATION 60
10.8 GUIDELINES FOR C OPPER TUBE BENDING 60
10.9 COPPER TUBE JOINTS 61
11.0 IMPULSE TUBE/SENSING LINE SUPPORT 62
12.0 IMPULSE TUBE INSTALLATION THROUGH EPS 64
13.0 TUBE FITTINGS 65
13.1 REQUIREMENTS OF A TUBE FITTING 65
13.2 CONSTRUCTION OF A TUBE FITTING 67
13.3 TYPES OF TUBE FITTINGS 68
13.4 FLARED FITTING 68
13.5 FLARELESS BITE TYPE TUBE FITTING 69
13.6 FLARELESS C OMPRESSION TYPE TUBE FITTING 69
13.7 SINGLE FERRULE FLARELESS COMPRESSION TYPE TUBE FITTING 70
13.8 TWIN FERRULE FLARELESS COMPRESSION TYPE TUBE FITTING 71
13.8.1 FERRULE AND ITS PURPOSE 72
13.8.2 SWAGING 73
13.8.3 OPERATION OF A TWIN FERRULE TUBE FITTING 74
13.8.4 EFFECT OF TUBE THICKNESS ON SWAGING 78
13.8.5 SAFETY PRECAUTIONS FOR TUBE FITTING INSTALLATION 80
13.9 REPEATED ASSEMBLY AND DISASSEMBLY OF TUBE FITTING 82
13.10 SPECIFICATION FOR SS TUBE FITTINGS 83
13.11 SPECIFICATION FOR BRASS TUBE FITTINGS 85
14.0 THREADS USED FOR TUBE FITTINGS 87
14.1 EVOLUTION OF THREADS 87
14.2 TYPE OF THREADS 87
14.3 SIZES 88
14.4 TAPER/PARALLEL THREADED JOINTS 89
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14.5 DRY SEAL NPTF THREADS 93
15.0 WELDING METHODS 96
15.1 300 SERIES STAINLESS STEELS 96
15.2 C1018 FITTINGS 96
15.3 TIG WELDING 97
15.4 ORBITAL TUBE WELDING 98
15.4.1 ORBITAL WELDING EQUIPMENT 99
15.4.2 REASONS FOR USING ORBITAL WELDING EQUIPMENT 99
15.4.3 INDUSTRIAL APPLICATIONS FOR ORBITAL WELDING 100
15.4.4 GENERAL GUIDELINES FOR ORBITAL TUBE WELDING 101
15.4.5 THE PHYSICS OF THE GTAW PROCESS 102
15.4.6 MATERIAL WELDABILITY 102
15.4.7 WELD JOINT FIT-UP 103
15.4.8 SHIELD GAS (ES) 104
15.4.9 TUNGSTEN ELECTRODE 105
15.4.10 WELDING BASICS AND SET-UP 106
15.4.11 WELDING PARAMETER DEVELOPMENT 109
16.0 References and Suggested Reading 116
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
1.0 Introduction
Impulse sensing lines are the lines containing process fluid which run between the
sensing instruments and process tapping points, and are usually made of
tubing/piping, valves and tube fittings.
1.1 Difference between a pipe and a tube
The fundamental difference between pipe and tube is the dimensional standard to
which each is manufactured.
A tube is a hollow product of round or any other cross section having a continuous
periphery. Round tube size may be specified with respect to any two, but not all
three, of the following: Outside diameter, inside diameter, wall thickness; type K, L
and M copper tube (See section6 for details) may also be specified by nominal size and
type only. Dimensions and permissible variations (tolerances) are specified in the
appropriate ASTM or ASME standard specifications.
Generally tubing is specified by giving O.D. and wall thickness whereas pipes are
specified by giving nominal diameter & wall thickness (NB and Schedule).
A pipe is a tube with a round cross section conforming to the dimensional
requirements for nominal pipe size as tabulated in ANSI B36.10, Table 2 and 4, and
ANSI B36.19, Table 1. For special pipe having a diameter not listed in these tables,
and also for round tube, the nominal diameter corresponds with the outside
diameter.
Pipe versus Tubes
Standard fluid line systems, whether for simple household use or for
the more exacting requirements of industry, were for many years
constructed from threaded pipe of assorted materials and were
assembled with various standard pipe fitting shapes, unions and
nipples. Such systems under high pressures were plagued with
leakage problems besides being cumbersome, inefficient and costly to
assemble and maintain. Therefore, the use of pipe in these systems
has largely been replaced by tubing because of the many advantages it
offers.
Figure 11 Tubing provides simplified, free flow system
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Old Method Each connection is threaded ‐ requires numerous fittings – system not
flexible or easy to install and service connections not smooth inside ‐ pockets obstruct flow.
Modern Method ‐ Bendable tubing needs fewer fittings ‐ no threading required ‐ system
light and compact ‐ easy to install and service ‐ no internal pockets or obstructions to free
flow.
1.2 Major Advantages of Tubing over Piping Systems
1. Bending Quality ‐ Tubing has strong but relatively thinner walls; is easy to bend.
Tube fabrication is simple.
2. Greater Strength ‐ Tubing is stronger as no threads are required for connection. No
weakened sections from reduction of wall thickness by threading.
Figure 12: With no threading necessary, tubing does not require extra wall thickness
3. Less Turbulence ‐ Smooth bends result in streamlined flow passage and less
pressure drop.
4. Economy of Space and Weight ‐ With its better bending qualities and a smaller
outside diameter, tubing saves space and permits working in close quarters. Tube
fittings are smaller and also weigh less.
5. Flexibility ‐ Tubing is less rigid, has less tendency to transmit vibration from one
connection to another.
6. Fewer Fittings ‐ Tubing bends substitute for elbows. Fewer fittings mean fewer
joints, fewer leak paths.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
7. Tighter Joints ‐ Quality tube fittings, correctly assembled, give better assurance of
leak‐free systems.
8. Better Appearance ‐ Tubing permits smoother contours with fewer fittings for a
professional look to tubing systems.
9. Cleaner Fabrication ‐ No sealing compounds on tube connections. Again no
threading; minimum chance of scale, metal chips, foreign particles in system.
10. Easier Assembly and Disassembly ‐ Every tube connection serves as a union. Tube
connections can be reassembled repeatedly with easy wrench action.
11. Less Maintenance ‐ Advantages of tubing and tube fittings add up to dependable,
trouble‐free installations.
1.3 Types of tubes
Tubes can be categorized in different ways.
1. Categorization based on tube dimensional specifications: Tubes can be classified as
a. Metric tubes, where dimensions are specified in mm units e.g. 10mm, 20 mm
etc.
b. Fractional tubes, where dimensions are specified in inch units e.g. ½”, ¾”, 1”
etc.
2. Categorization based on material of tubes e.g. carbon steel tubes, PVC Tubes, Copper
tubes, SS tubes, Inconel tubes, etc.
3. Categorization based on method of tube drawing i.e. welded and drawn, seamless
etc.
1.4 Guidelines for selection of instrumentation tubes
Proper Tubing Selection
1. Always Match Materials –
S.S. Tubing should be used only with S.S. Fittings. The only exception to this rule is
copper tubing with brass fittings. Mixing materials can cause galvanic corrosion.
Galvanic Corrosion (Electrochemical)
All metals have a specific relative electrical potential. When dissimilar metals come
in contact in the presence of moisture (electrolyte), a low intensity electric current
flows from the metal having the higher potential to the metal having the lower
potential. The result of this galvanic action is the corrosion of the metal with the
higher potential (more anodic). (See Galvanic Series Chart)
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Figure13: Galvanic Series chart
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2. Select proper tubing hardness –
Remember instrumentation tube Fittings are designed to work within specific
hardness ranges. RB 90 maximum for S.S., RB 80 recommended. For proper swaging
the hardness of the tube should be less than the hardness of the fitting.
3. Select proper tubing wall thickness –
Proper wall thickness is necessary to accommodate accepted safety factors relative
to desired working pressures.
4. Tubing surface finish –
Always select tubing free of visible draw marks or surface scratches. If possible, cut
off any undesirable sections. These “deep” scratches can cause leaks when
attempting to seal low‐density gases such as argon, nitrogen, or helium. Proper
surface finish ensures leak‐proof compression joint with fitting.
1.5 Different sizes of tubes
Following tube sizes have been used in NPCIL NPPs
SS Tubes (metric): 6 mm, 10mm, 12mm, 20mm and 25mm.
SS tube (Fractional): ¼”, 3/8”, ½”, ¾” and 1”.
Copper tubes (metric): 6mm, 10mm, 12mm, 20mm and 25mm.
Copper tubes (Fractional): ¼”, 3/8”, ½”, ¾” and 1”.
1.6 Criteria for selecting the size of a tube
The selection criteria for sizing the tube are as follows:
• The O.D. of the tubes/impulse tubes should be the same and not smaller than
6 mm even with clean liquids and non corrosive piping, owing to the chance
of blockage after long service.
• If condensation is likely to occur or if gas bubbles are likely to be liberated,
the O.D. should not be smaller than 10 mm.
• When long runs cannot be avoided, the internal diameter of impulse
tubing/piping may be selected as per the following table‐1‐1:
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TABLE – 11
Pressure signal Inside Dia. in mm of impulse tubing/piping for different process
transmission fluids
distance Water/steam Wet air or gas Oil of low to Very dirty
(meter) Dry air/gas med. viscosity liquid or gas
0 ‐ 16 7 to 9 13 13 25
16 ‐ 45 10 13 19 25
45 ‐ 90 13 13 25 38
As very long runs of impulse tubing/piping are not expected in our systems
and also process fluid is expected to be clean, 10 mm OD tubing having I.D.
of 7.6 mm has been found to be adequate, for pressure/ ΔP measurement
except for some cases for level measurement in tanks/vessels using ΔP
principle.
• Based on hold up, installation and material cost, radiation streaming
considerations, higher size (>10 mm OD) tubing is not recommended for
pressure/∆P measurement in primary/nuclear system in general.
1.7 Selection and Design criteria
Following requirements should be met for impulse tubing for sensing the
pressure/differential pressure signal for all types of process systems including for
safety and safety related systems.
The most important consideration in the selection of suitable tubing for any
application is the compatibility of the tubing material with the media to be
contained. Table 1‐2 lists common materials and their associated general
application. Table 1‐2 also lists the maximum and minimum operating
temperature for the various tubing materials. Properly designed tubing/piping
based on service conditions, should only be used for sensing lines.
The practice of mixing materials should be strongly discouraged. The only
exception is brass fittings with copper tubing. Dissimilar materials in contact may
be susceptible to galvanic corrosion. Further, different materials have different
levels of hardness, and can adversely affect the fittings ability to seal on the tubing.
The use of a particular type of tube for a specific usage depends on the application
and the process condition. The following table briefly describes the application
guidelines for a specific tube material.
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Table12
1. For operating temperatures above 800 °F (425 °C), consideration should be given to media. 300 Series
Stainless Steels are susceptible to carbide precipitation which may lead to intergranular corrosion at
elevated temperatures.
2. All temperature ratings based on temperatures as per ASME/ANSI B313 Chemical Plant and Petroleum
Refinery Piping Code, 1999 Edition.
Gas Service
Special care must be taken when selecting tubing for gas service. In order to achieve a gas‐
tight seal, ferrules in instrument fittings must seal any surface imperfections. This is
accomplished by the ferrules penetrating the surface of the tubing. Penetration can only be
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
achieved if the tubing provides radial resistance and if the tubing material is softer than the
ferrules.
Thick walled tubing helps to provide resistance. Tables‐1‐3 to 1‐10 below indicate the
minimum acceptable wall thickness for various materials in gas service. The ratings in
white indicate combinations of diameter and wall thickness which are suitable for gas
service. Acceptable tubing hardness for general application is listed in Table 1‐12.
These values are the maximum allowed by the ASTM. For gas service, better results can be
obtained by using tubing well below this maximum hardness. For example, a desirable
hardness of 80 RB is suitable for stainless steel. The maximum allowed by ASTM is 90 RB.
System Pressure
The system operating pressure is another important factor in determining the type, and
more importantly, the size of tubing to be used. In general, high pressure installations
require strong materials such as steel or stainless steel. Heavy walled softer tubing such as
copper may be used if chemical compatibility exists with the media. However, the higher
strength of steel or stainless steel permits the use of thinner tubes without reducing the
ultimate rating of the system. In any event, tube fitting assemblies should never be
pressurized beyond the recommended working pressure.
The following tables (1‐3 to 1‐10) list by material the maximum suggested working
pressure (in psi) of various tubing sizes. Acceptable tubing diameters and wall thicknesses
are those for which a rating is listed. Combinations which do not have a pressure rating are
not recommended for use with instrument fittings.
Table13: Fractional 316 or 304 STAINLESS STEEL (Seamless)
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Table14: Fractional 316 or 304 STAINLESS STEEL (Welded & Drawn)
Table15: Seamless Stainless Steel metric tubing
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Table16: Fractional Carbon Steel (Seamless)
Tube Wall Thickness, in.
Tube 0.09 0.10
0.028 0.035 0.049 0.065 0.083 0.120 0.134 0.148 0.165 0.180 0.220
OD 5 9
in. Working Pressure, psig
Note: For gas service, select a tube wall thickness outside of the shaded area.
1/8 8000 10 200
3/16 5100 6 600 9600
1/4 3700 4 800 7000 9600
5/16 3 700 5500 7500
3/8 3 100 4500 6200
1/2 2 300 3200 4500 5900
5/8 1 800 2600 3500 4600 5300
510
3/4
2100 2900 3700 4300 0
430
7/8
1800 2400 3200 3700 0
370
1
1500 2100 2700 3200 0 4100
1 290
1/4 1600 2100 2500 0 3200 3600 4000 4600 5000
1 240
1/2 1800 2000 0 2600 2900 3300 3700 4100 5100
170
2 1500 1900 2100 2400 2700 3000 3700
0
Table17: Carbon Steel Metric tubing
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Table18: ALUMINIUM (SEAMLESS) Table19: COPPER (SEAMLESS)
Table110: MONEL 400 (SEAMLESS)
Note:
• All working pressures have been calculated using the maximum allowable stress levels in
accordance with ASME/ANSI B31.3, Chemical Plant and Petroleum Refinery Piping or
ASME/ANSI B31.1 Power Piping.
• All calculations are based on maximum outside diameter and minimum wall thickness.
• All working pressures are at ambient (72°F) temperature.
• Ratings in gray are not suitable for gas services.
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Systems Temperature
Operating temperature is another factor in determining the proper tubing material. Copper
and aluminum tubing are suitable for low temperature media. Stainless steel and carbon
steel tubing are suitable for higher temperature media. Special alloys such as Alloy 600 are
recommended for extremely high temperature (see Table 1‐2). Table 1‐11 lists de‐rating
factors which should be applied to the working pressures listed in Table 1‐3 to 1‐10 for
elevated temperature (see Table 1‐2). Simply locate the correct factor in Table 1‐11 and
multiply this by the appropriate value in Tables 1‐3 to 1‐10 for the elevated temperature
working pressure.
Table-1-11
Temperature Derating Factors
Temperature Monel
°F (°C) Copper Aluminum 316 304 Steel 400
SS SS
100 (38) 1.00 1.00 1.00 1.00 1.00 1.00
200 (93) .80 1.00 1.00 1.00 .96 .88
300 (149) .78 .81 1.00 1.00 .90 .82
400 (204) .50 .40 .97 .94 .86 .79
500 (260) .90 .88 .82 .79
600 (316) .85 .82 .77 .79
700 (371) .82 .80 .73 .79
800 (427) .80 .76 .59 .76
900 (486) .78 .73
1000 (538) .77 .69
1100 (593) .62 .49
1200 (649) .37 .30
EXAMPLE: 1/2 inch x .049 wall seamless stainless steel tubing has a working pressure of 3700
psi @ room temperature. If the system were to operate @ 800°F (425°C), a factor of 80% (or
.80) would apply (see Table 111 above) and the “at temperature” system pressure would be
3700 psi x .80 = 2960 psi
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Table‐1‐12
Material Type ASTM Tubing Spec. Condition Max.
Recommended
Hardness
Stainless 304, 316, ASTM‐A‐269, A‐249, A‐ Fully Annealed 90 RB
Steel 316L 213, A632
Copper K or L ASTM‐B75 B68, B88* Soft Annealed Temper 0 60 Max. Rockwell
(K or L) 15T
Carbon 1010 SAE‐J524b, J525b Fully Annealed 72 RB
Steel
ASTM‐A‐179
Aluminum Alloy 6061 ASTM B‐210 T6 Temper 56 RB
Monel™ 400 ASTM B‐165 Fully Annealed 75 RB
Alloy C‐ C‐276 ASTM‐B‐622, B‐626 Fully Annealed 90 RB
276
Alloy 600 600 ASTM B‐167 Fully Annealed 90 RB
Carpenter 20CB‐3 ASTM B‐468 Fully Annealed 90 RB
20™
Titanium Commercially ASTM B‐338 Fully Annealed 99 RB 200 Brinell
Pure Grade 2 Typical
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2.0 DESIGN OF TUBING AND TUBING SYSTEMS
2.1 CLASSI INSTRUMENTATION TUBING DESIGN
In ASME Section III‐Division‐I sub‐section NB (Class I components), the design
criterion/design requirements for instrument tubing has not been covered separately.
Thus design guidelines given for small size of piping is being followed for Class I instrument
tubing also. Also as the outside diameter of instrument tubing is being limited to 1” (25
mm); so any design concession permitted for lower size piping (<1”) will also be applicable
to instrument tubing.
As per NB 3630 (Piping design and analysis criteria) the piping of 1” NB or less, which have
been classified as class I in design specification, may be designed and analyzed as per
subsection NC.
Thus for instrument tubing, the material & testing requirements shall be as per subsection
NB whereas the design and analysis will be as per subsection NC.
2.2 REQUIREMENTS OF MATERIAL FOR INSTRUMENT TUBING/PIPING
AS PER NB2000
a. Pressure retaining material should confirm to the requirements of one of the
specifications for material given in NB‐2121.
b. Impact testing for austenitic stainless steel is not required. Also impact testing is not
required for a pipe/tube with a nominal pipe size less than 6”, irrespective of wall
thickness.
c. Seamless pipes, tubes and fittings need not be examined by the rule of NB‐2510
(examination of pressure retaining material).
d. Wrought seamless and welded (without filler metal) pipes and tubes shall be
examined and may be repaired in accordance with the requirements of class‐I
seamless and welded (without filler metal) piping and tubing of SA‐655 (specification
for special requirements for pipe and tubing for nuclear and other applications).
2.3 DESIGN REQUIREMENTS OF INSTRUMENT PIPING/TUBING AS PER
SUBSECTION NC (NC 3600)
i. MAXIMUM ALLOWABLE STRESS
For design/calculating minimum wall thickness of instrument tubing/piping, the
maximum allowable stress for the material at design temperature shall be used as
given in ANSI/ASME B36.19.
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ii. PRESSURE AND TEMPERATURE RATINGS
The pressure ratings at the corresponding temperature given in ANSI/ASME B36.19
shall not be exceeded and piping/tubing product shall not be used at temperature in
excess of those given in ANSI/ASME B36.19 for all the materials of which the tubing
is made.
iii. ALLOWANCES
Increased wall thickness of tubing shall be taken for providing allowances for
corrosion or erosion, mechanical strength & bending etc.
iv. DYNAMIC EFFECTS
Impact forces caused by either external or internal loads shall be considered in the
piping/tubing design. Also the effect of earthquake and non‐seismic vibration shall
be considered in the tubing design.
2.4 PRESSURE DESIGN (INTERNAL PRESSURE) OF INSTRUMENT
TUBING/ PIPNG (Ref. NC3640)
a) Minimum Wall Thickness of straight tube/pipe:
The minimum wall thickness of straight tube/pipe shall not be less than that determined
by eq. (I) as follows:
Do
tm=P* +A …….. (1)
2 S+PY
tm = minimum required wall thickness, mm
P = Internal design pressure, kPag
DO = Outside diameter of tube/pipe, mm
S = Maximum allowable stress in the material due to internal pressure and joint
efficiency at design temperature, kPa
A = Additional thickness, to provide for material removed in threading, corrosion
and erosion allowances and allowance for structural strength needed during
erection.
Y = a coefficient having a value of 0.4. For pipe/tube with a ratio less than 6, the
value of ‘Y’ for ferritic and austenitic steels designed for temperature of 480 oC
and below should be taken as per eq. (2) below
………. (2)
Where
d = Inside diameter of tube/pipe.
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b) Wherever bending of tubing/piping is likely to be involved in installations, the minimum
wall thickness after bending shall not be less than the minimum wall thickness calculated
as per eq. (1) for straight tube/pipe. To meet this requirement, actual wall thickness of
tubing/piping is to be increased as per following Table –2‐1 (This is based on NC 3000):
TABLE – 21
Bend Radius Minimum thickness recommended Prior to
bending
6 tube/pipe diameter or greater 1.06 tm
5 tube/pipe diameter 1.08 tm
4 tube/pipe diameter 1.16 tm1
3 tube/pipe diameter 1.25 tm
1 As per ANSI/ASME B31.1 this value is 1.14. However NC3000 is more conservative.
tm = minimum wall thickness required as per eq. (1) above.
c) Also, unless otherwise justified by the design calculation the ovality of tubing/piping after
bending should not exceed 8% as determined by following eq. (3).
% 100 ……….. (3)
Where
2.5 ANALYSIS CRITERION OF TUBING/PIPING SYSTEM
Analysis requirements for tubing/piping systems as per NC‐3650 are given below.
“The design of complete piping system shall be analyzed between anchors for the effects of
thermal expansion, weight and other sustained and occasional loads.”
The detail requirements/analysis criteria are given in following sub‐sections.
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Ssl = Stress due to sustained loads, kPa
P = Internal design pressure, mm
Do = Outside diameter of tube/pipe, mm
B1, B2 = Primary stress indices for the pipe/tube (As per Figure below) NC 3673.2 (b)1
MA = Resultant moment loading on cross section due to weight and other sustained
loads, kN‐m. NC 3653.3
Z = Sectional modulus of pipe/tube, mm3
Sh = Basic material allowable stress at design temperature consistent with loading
under consideration.
tn = Nominal wall thickness, mm
b. CONSIDERATION OF LEVEL A AND B SERVICE LIMITS (REF. NC3653)
i. STRESS DUE TO SUSTAINED PLUS OCCASIONAL LOADS
The effect of pressure, weight, other sustained loads and occasional loads including
earthquake, for which level B service limits are designated, must meat the requirements of
following eq. (5).
But not greater than 1.5 Sy
Where
Mb = resultant moment loading on cross section due to non reversing dynamic loads e.g.
occasional loads such as thrust from relief and safety valves loads from pressure
and flow transients and earthquake.
Sy = material yield strength at temperature consistent with the loading under
consideration, kPa.
Sol = stress due to occasional loads, kPa.
Pmax = Peak pressure, kPa
ii. SUSTAINED PLUS THERMAL EXPANSION STRESSES
The effects of pressure, weight, other sustained loads and thermal expansion for which level
A and B service limits are designated, shall meet the requirements of following eq. (6).
0.75 i shall not be less than 1.0
Where
Ste = Sustained plus thermal expansion stresses.
MC = range of resultant moments due to thermal expansion
SA = Allowable stress range for expansion stresses.
i = Stress intensification factor (refer NC‐3673.2)
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= ratio of bending moment producing fatigue in a given number of cycles in a
straight pipe/tube with girth butt weld to that producing failure in the
same number of cycles in the fitting or joint under consideration.
Other terms are same as of eq. (4)
Allowable stress range for expansion stresses (SA) can be calculated using following equation
S A = f (1.25 SC + 0.25 Sh) ……. (7)
SC = Basic material allowable stress at minimum (cold) temperature.
Sh = Basic material allowable stress at maximum (hot) temperature.
f = stress range reduction factor for cyclic conditions for total number N of full
temperature cycles over total number of years during which system is
expected to be in service from table‐2‐1A below NC 3611.2 (e)‐1
TABLE: 21A
Number of equivalent full Stress range
temperature cycles (N) reduction factor (f)
7000 and less 1.0
7000 to 14000 0.9
14000 to 22000 0.8
22000 to 45000 0.7
45000 to 100000 0.6
100000 and over 0.5
Stress intensification factor ‘i’ can be calculated using following equation (8)
where
…… (10)
tn = nominal wall thickness of tube/pipe
R = bend radius
r = mean radius of tube/pipe
iii. CONSIDERATION OF LEVEL C SERVICE LIMITS
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In section II in calculating the resultant moment MB, moment due to SEE conditions is
proposed to be used which is more conservative, thus separate analysis for level C service
limits is not required.
iv. TESTING REQUIREMENTS AS PER SUBSECTION – NB
Requirements of material testing as per subsection NB is briefly mentioned above. In
addition to examination/testing requirements as per SA‐655, tubing should be
hydrostatically tested at not less than 1.25 times the design pressure with minimum holding
time of 10 min.
2.6 ANALYSIS OF SS TUBES USED IN NPCIL
2.6.1 WALL THICKNESS AND PRESSURE RATING OF DIFFERENT SIZES OF INSTRUMENT TUBING
The maximum design pressure and temperature are taken as 195 kg/cm2 and 310oC
respectively. Though the above pressure and temperature may not exist simultaneously in
any system, still to be on conservative side, all the sizes of tubing will be designed for
above ratings.
Using eq. (1) in the analysis criteria above, the minimum wall thickness of straight tubing
can be calculated.
Thus following equation can be used
Do
tm=P* +A
2 S+PY
We can make following assumptions
• There will be no threading on the tubes
• Corrosion, erosion is negligible (hence allowance for corrosion and erosion may
be neglected)
• Bend radius is not less than 3Do. The actual wall thickness is to be increased as
per Table‐2‐1 above.
Following data may be used
P = design pressure (= 195 kg/cm2)
S = maximum allowable stress of S.S. 304L material at 310oC temp. (= 986 kg/cm2)
Y = 0.4
By putting the above variables, the minimum wall thickness for different sizes (Do) of
straight tubing is tabulated in following Table‐2‐2.
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TABLE – 22
Tube O.D. Required minimum wall Minimum recommended Specified wall
(Do) mm thickness of straight wall thickness (mm) thickness as per (PB‐
instrument tubing (tm) in prior to bending (1.25 M‐17) in mm
mm (for design pressure of 195 tm )
kg/cm2 and design temp. of
310oC)
“For example, the maximum pressure & temperature in PHT system will be 125 kg/cm2 and 310oC
respectively. For this application, the required minimum wall thickness for 16mm OD tube,
including the bending allowance, should be 1.3 mm, which is less than specified wall thickness of
1.8 mm. Similarly, in some applications like F/M supply circuit, the maximum pressure and
temperature may be 195 kg/cm2 and 40oC respectively. For this service also, the minimum
required wall thickness including the bending allowance for 16mm OD tube should be 1.62mm
which is less than specified wall thickness of 1.8 mm”.
2.6.2 STRESS ANALYSIS OF TUBING SYSTEMS (TUBING CONFORMING TO PBM17)
2.6.2.1 ANALYSIS FOR SUSTAINED MECHANICAL LOADS
When the tubing is installed in the field, the effects of pressure, weights and other
sustained mechanical loads must meet the requirements of eq. (4) i.e.
Stress due to Sustained load = Ssl < 1.5 Sh
The above equation may be verified for different sizes of tubing having wall thickness as
given in Table‐2‐2 and other constants to be calculated/taken as below:
B1 = 0.5 (as per NB – 3680)
.
2 / and
2
Where
tn = nominal wall thickness of tube
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R = Bend radius
r = (Do – t)/2 = mean radius of tubing
–
32
Thus for different sizes of tubing systems Ssl value is tabulated in Table‐2‐4
2.6.2.2 ANALYSIS FOR OCCASIONAL LOADS (LEVEL A&B SERVICE LIMITS)
As per requirement of ASME – Section III installed tubing system should satisfy the
equation (5) of Section 4.2.1 as given below:
Based on the seismic analysis carried out for different tubing layouts, the recommended
conservative value of Mb is 200 kg mm for all sizes of tubing systems for SSE level of
earthquake. Thus for different sizes of tubing systems Sol value is tabulated in Table‐2‐4.
This can be seen that Sol is less than 1.8 Sh for all the sizes of tubing thus satisfying the
above equation.
2.6.2.3 ANALYSIS FOR STRESS DUE TO THERMAL EXPANSION AND OTHER SUSTAINED
LOADS
As per requirement of ASME Section III installed tubing system should satisfy the
following equation
0.75
4
The maximum value of stress (iMc/Z) due to thermal loading (temperature variation
from 25oC to 310oC) for different tubing systems comes out to be 1600 kg/cm2 provided
that tubing system is supported as per recommended practices. Based on the above data
and other parameters/constants, Ste has been calculated & tabulated in TABLE‐2‐3 for
different sizes of tubing.
This may be seen from the table that Ste value for different sizes of tubing is less than the
value of Sh + SA (viz. 2615 kg/cm2).
TABLE 23
Tube Size Nominal Wall Calculated value to be STE Sh + SA
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(OD) mm Thickness (tn) (mm) (See note2) used for analysis (kg/cm2)
6 1.2 0.42
1.33 2164.94
10 1.2 0.67
1.33 2169.92
12 1.5 0.65
1.33 2205.82 2615
16 1.8 0.71
1.33 2112.3
20 2.5 0.65
1.33 2043.24
25 3 0.67
1.33 2045.4
Note:
1. The values of MA, Z, P, Sh used for calculation of STE are same as given in Table24.
2. The value of used is based on requirement such that 0.75 should not be less than 1.0
3. SA = f (1.25 Sc + 0.25 Sh) where f = 1 & Sc = 1106 (kg/cm2)
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23 20 16 12 10 6 Tube size OD (Do) mm
24
1
3 2.5 1.8 1.5 1.2 1.2 Wall Thickness (t) (mm)
.
Calculated B2 2
2
0.94 0.93 1.03 0.94 0.97 0.61
B2 value to be used for analysis (as B2 cannot be less than 1)
3
1.0 1.0 1.03 1.0 1.0 1.0
Z (mm3)
4
1022.21 536.89 257.06 115.97 65.42 18.46 –
32
WL (wt. of 1m of tube filled with D2O) kg/m
5
1.971 1.293 0.775 0.466 0.315 0.156
WF (wt. of fitting) (kg)
6
0.8 0.64 0.512 0.384 0.32 0.192
Ma(kg/mm) }
7
446.37 321.62 224.87 154.25 119.37 67.5
TABLE24
Ssl (kg/cm2)
B1PDo B2Ma
8
310.27 310.5 383.4 383.7 449.07 475.34
2tn Z
1.5Sh (kg/cm2)
9
1479
200 Mb (Kg mm)
1.8 Sh
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Where –
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For seismic classification the instrument sensing lines should be of SSE Category
for safety and safety-related instrumentation systems.
A single instrument sensing line should not be used to perform both a safety-
related function and a non safety-related function unless the following can be
shown:
a. The failure of the common sensing line would not simultaneously
1. cause an action in a non-safety-related system that results in a plant
condition requiring protective action and
2. also prevent proper action of a protection system channel designed
to protect against the condition.
Tubing system should be such that the failure of non safety impulse line/tubing
should not affect the reading of safety system.
2.10 CONCLUSION
1) MATERIAL SELECTION
a. Based on the requirements of corrosion resistance, tensile strength,
hardness and weldability, austenitic stainless steel grade SS-304L material
as per ASTM A-213/SA655 has been selected and specified for instrument
tubing. Also the instrument SS tubing should be seamless, cold finished and
full annealed. From welding consideration the tubing should have delta
ferrite of 5 to 10%.
b. Based on the requirements of different applications the tubing in different
sizes have been specified i.e. OD of 6mm, 10mm, 12mm, 16mm, 20mm and
25mm.
2) NON-DESTRUCTIVE INSPECTION
3) Based on the analysis of tubing systems carried out above for our installations the
stress values for different loading (service limits) are well within the required
limits.
4) Thus, if SS 304L instrument tubing are supplied as per specification above and
installation of tubing systems is done as per recommended practices(see
section-10) then instrument impulse tubing systems will be meeting the intent
of ASME Section III-Sub-Section NB-Class I components.
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b. EXPANSION TEST : On one sample piece of each size and each batch as per
relevant ASTM standard
c. TENSILE TEST : On one sample piece of each size and each batch as per
relevant ASTM standard
d. FLATTENING AND DOUBLING OVER TEST : On one sample piece of
each size and each batch as per relevant ASTM standard
e. CHEMICAL ANALYSIS : One sample of each batch as per relevant ASTM
standard
12. ROUTINE TESTS
a. DIMENSIONAL TEST : Required to be done on 10 % of the lot
2
b. HYDROSTATIC TEST : At pressure of 300 kg/cm (g) for 10 min. required to
be done on each sizes of each batch
13. LENGTH OF EACH TUBE: 6 meters
4. ASTM A 370 Standard test method and definitions for mechanical testing
of steel products.
5. ASME SEC. III Examination & Repair Of seam less and welded (without
NB 2550 filler metal) tubular products and fittings
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Table 4-1 below identifies the six standard types of copper tube and their most
common applications2. The table also shows the ASTM Standard appropriate to the
use of each type along with a listing of its commercially available lengths, sizes and
tempers.
Types K, L, M, DWV and Medical Gas tube are designated by ASTM standard sizes,
with the actual outside diameter always 1/8-inch larger than the standard size
designation. Each type represents a series of sizes with different wall thicknesses.
Type K tube has thicker walls than Type L tube, and Type L walls are thicker than
Type M, for any given diameter. All inside diameters depend on tube size and wall
thickness.
Copper tube for air-conditioning and refrigeration field service (ACR) is designated
by actual outside diameter.
“Temper” describes the strength and hardness of the tube. In the piping trades,
drawn temper tube is often referred to as “hard” tube and annealed as “soft” tube.
Tube in the hard temper condition is usually joined by soldering or brazing, using
capillary fittings or
by welding. Tube in the soft temper can be joined by the same techniques and is also
commonly joined by the use of flare-type and compression fittings.
It is also possible to expand the end of one tube so that it can be joined to another by
soldering or brazing without a capillary fitting—a procedure that can be efficient
and economical in many installations.
Tube in both the hard and soft tempers can also be joined by a variety of
“mechanical” joints that can be assembled without the use of the heat source
required for soldering and brazing.
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Tabl e-4- 1
1. There are many other copper and copper alloy tubes and pipes available for specialized applications.
2. Individual manufacturers may have commercially available lengths in addition to those shown in this table.
3. Tube made to other ASTM standards is also intended for plumbing applications, although ASTM B 88 is by far the
most widely used. ASTM Standard Classification B 698 lists six plumbing tube standards including B 88.
4. Available as special order only.
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choice can be made, it is helpful to know which type of copper tube has and can
serve successfully and economically in the following applications:
a. Underground Water Service: Use Type M hard for straight lengths joined
with fittings, and Type L soft where coils are more convenient.
b. Water Distribution Systems: Use Type M for above and below ground.
d. Drainage and Vent System: Use Type DWV for above- and below-ground
waste, soil and vent lines, roof and building drains and sewers.
e. Heating: For radiant panel and hydronic heating and for snow melting
systems, use Type L soft temper where coils are formed in place or
prefabricated, Type M where straight lengths are used. For water heating and
low-pressure steam, use Type M for all sizes. For condensate return lines,
Type L is successfully used.
g. Fuel Oil, L.P. and Natural Gas Services: Use Type L or Type ACR tube with
flared joints in accessible locations and brazed joints made using AWS A5.8
BAg series brazing filler metals in concealed locations.
j. Ground Source Heat Pump Systems: Use Types L or ACR where the ground
coils are formed in place or prefabricated, or as specified.
k. Fire Sprinkler Systems: Use Type M hard. Where bending is required, Types
K or L is recommended. Types K, L and M are all accepted by NFPA.
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Table-4-2: Rated Internal Working Pressures for Copper Tube: TYPE DWV*
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Table-4-6: Rated Internal Working Pressures for Copper Tube: TYPE ACR*
NOTE: * Based on ‘S’, the maximum allowab le stress in tension (psi) for the indicated temperatures (°F).
** When b razing or welding is used to join drawn tube, the corresponding annealed rating must be used.
***Types M and DWV are not normally available in the annealed temper. Shaded values are provided for
guidance when drawn temper tube is b razed or welded.
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11. Tests
11.1 Type Tests
a. Hardness Test: On one test piece of each size and each batch as per
ASTM-E-18
b. Expansion Test: On one sample piece of each size and each batch as per
ASTM-B-153
c. Tensile Test: On one sample piece Of Each Size And Each Batch As Per
ASTM-E-8M
d. Flattening And Doubling Over Test: On One sample piece Of Each
Size and Each Batch As Per BS-2871 & ASTM-E-255
e. Chemical Analysis: one sample of each batch as per ASTM-E-53 & ASTM-
B-55M
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Table-C: Permissible Variations in Wall Thickness for ASTM B68 and ASTM B75 cold
drawn copper tubes
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Table-C: Permissible Variations in Wall Thickness for ASTM B68 and ASTM
B75 cold drawn copper tubes
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(a) There should be enough space between two penetrations so that tube fittings
(bore-through connector) can be installed easily using spanner or a suitable
tool.
(b) Lead shielding balls are filled in the floor penetration EPs.
(c) In floor penetration EPs bore through connector is installed only on the top
opening of the EP. Bottom opening is left as it is. This allows thermal
expansion of the tube through the EP and no additional stress is caused on
the EP.
(d) In the top plate of a floor EP a hole is made and a suitable plug is installed in
it. This hole is used to fill the Steel/lead shielding balls in the EP.
(e) In the bottom plate of a floor EP a hole is made and a suitable plug is installed
in it. This hole is used to take off the Steel/lead shielding balls from the EP.
Note: For further details on the EP installation refer section 12. 0 of this
technical note.
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c) Socket welds should not be used where the existence of crevices could
accelerate corrosion.
Flareless and compression type tube fittings may be used in instrument sensing
lines for the tube sizes not exceeding 25mm (1”) O.D. provided following
conditions are met.
a) Fittings and their joints should be of compatible material with the tubing or
pipe material with which they are used and should conform to the range of
wall thickness and method of assembly recommended by the
manufacturers.
c) Wherever compression type flareless tube fittings are used, they should be
made of design in which the gripping members or sleeve shall grip or bite
into the outer surface of the tube hold the tube against pressure (to prevent
blow out) but, without seriously deforming the inside diameter. The
gripping member or sleeve should form a pressure seal against a fitting
body.
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e) The fitting parts of the original flareless tube fittings should be designed and
manufactured by same company. Replacement parts from different
manufacturers should be qualified to meet and seal properly at the design
service conditions, or the complete fittings should be replaced when needed.
f) The fittings selected should not degrade the inherent strength of the tubing
specified.
h) Metal tubing material should be softer than fitting material. For example,
stainless steel tubing should not be used with brass fittings.
i) When tubing and fittings are made of the same material, tubing must be
fully annealed and ferrule of fittings should have more hardness than tubing
material.
Threaded joints in which the threads provide the only seal may be avoided as far
as possible. Threaded joints should not be used between the process taps and
accessible isolating valves. However, threaded joints between accessible isolating
valve and instrument may be used within the limitations specified below:
c) Threaded joints should not be used when severe erosion, crevice corrosion,
shock or vibrations are expected to occur.
d) In case of steam or hot water if service temperature is more than 100 oC,
threaded connections should be used only if process pressure is less than
100 kg/cm2.
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Following aspects should be kept in mind while designing the pressure taps for
take off connections.
I. MATERIAL CONSIDERATIONS:
Take of connections at the source together with attaching bosses or adapters
should be made of material at least equivalent to material of process
pipes/vessels to which they are attached. They should be designed to
withstand full line pressure, temperature and stresses.
The turbulence error is also a function of edge condition of pressure tap hole.
With the burrs up stream, flow is diverted away from the hole and the
pressure sensed at the hole is less than the true static pressure. Conversely,
if the burr is on downstream edge of the hole, the pressure at the hole will
have a positive velocity effect and the pressure at the hole will be greater
than the true static pressure.
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velocity is low, the size and workmanship of the tap hole are not so
important.
During fast transients, measurement errors may be more as the nozzle drop
(take off connection losses) is proportional to the square of the velocity.
However during steady state this loss can be neglected. Thus, in the system
where fast transients are expected this requirement is more crucial.
Thus based on above considerations the size of pressure tap holes should be
decided depending upon the process fluid condition, reliability of measurement,
accuracy, response time and requirement of physical strength.
a. In venturi tubes/orifice plates as the low pressure tap holes are to be located
in high velocity region, it is recommended to use small size of pressure tap
holes uniformly for HP & LP connections as recommended in ASME/PTC-9.5
(Flow measurement).
b. In all other applications where turbulence error does not come in picture, it is
recommended to use 20 mm NB pressure tap holes from the consideration of
reliable measurement/minimizing possibility of plugging/choking fast
response and mechanical/physical strength.
c. Workmanship of pressure taps holes plays an important role in
accurate/reliable measurement of pressure signals. Proper care should be
taken while machining the pressure tap holes. There should be no burrs, wire
edges or other irregularities on the inside of pipe/vessel at pressure tap
connections or along the edge of the hole through the pipe/vessel wall.
d. In no case shall any fittings project beyond the inner surface of the pipe/vessel
wall.
e. Also there should be no change in the pressure tap hole diameter for at least a
distance of 2.5 d as measured from the inner surface of the pipe/vessels ( d =
inside dia. of pressure tap hole).
f. Redundant taps should be located a distance apart such that the failure of one
tap does not adversely affect the reading through the other taps.
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Isolating root valves are provided at take off connections to isolate the entire
measurement system from the main pipe line/vessel when necessary. Following
recommendations should be followed.
a. Root valves should not affect the pressure signal during normal operation.
b. Root valves should be capable of withstanding the maximum working
pressure and temperature of the piping/vessel system to which the take off
adapters or nipples are attached.
c. Isolating/root valves should be located immediately following the tapping
point.
d. It is preferred to use gate valves for root valves in order to:
i) Avoid trapping gas bubbles in the valve structure, in case of liquid flow
ii) Avoid trapping liquid in the valve structure, in case of gas flow.
e. Root valve bore/should not be less than the inside diameter of impulse
tubing/piping.
f. It is recommended that the root valves be ¾ inch unless special requirements
necessitate a different size.
g. The root valves may or may not perform the function of the accessible
isolation valve, dependent on its location.
h. Root valves should be of the same material as that of the pipe they are
connected to.
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reviewed to ensure that the seal does not anchor the sensing line when a
guide is required.
All sensing lines including trays, supports, instrumentation, valves, and other
in-line devices should be installed to avoid contact interferences caused by
relative motion between the sensing line and other adjacent equipment or
devices. Sources of relative motion that should be considered are thermal
expansion, seismic motions, vibrations, and design-basis accidents or events.
The Code classification of the sensing line will determine the requirements for
relative motion that shall be considered.
Routing of the nuclear safety-related sensing lines shall ensure that the
function of these lines is not affected by thermal motions due to “hot blow
down” of the sensing lines. One of the following methods should be used to
ensure that the sensing-line function is not affected:
1. Demonstrate by documented analysis or calculations that the majority
of the sensing line routing is at ambient temperature, and “hot blow
down” is not a design loading.
Or
2. Design the sensing line routing using the process design temperature
as the temperature value used in the design analysis.
Routing of the nuclear safety-related sensing lines shall ensure that the
function of these lines is not affected by the movement of the main process
(piping, ductwork, equipment, etc.) to which the sensing line is connected.
One of the following methods should be used to ensure that the sensing line
function is not affected:
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Tubing Handling
Imperfection on the tube OD can be potential source of problems in a tubing
system. Handling of the tube shall be done very carefully to avoid scratches
and protect the finish of the tubes.
Dragging the tube across any surface that could scratch the surface can
cause seal corrosion and sealing problems. On offshore facilities
scratches on tube may lead to corrosion of SS tubing from salt water
pitting.
It is a good practice to visually inspect tubing to ensure it is free from
scratches and other damage.
When cutting the tubing hacksaw must not be used, the correct tool is a
tube cutter with a sharp blade.
Correct deburring tool shall be used for deburring both inside and
outside edge of tube ends.
It is good practice to clean the tubing with dry instrument air. If the
surface requires higher degree of cleanliness then a cleaning agent
should be used.
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EXACT MEASUREMENT is required to insure that you obtain the desired distance
between bends. If you do not measure exactly, the tube line will not fit. (See
Figure-10-2 below)
ACCURATE BENDING is necessary to achieve the exact angles required for the
tube line. If you do not bend accurately, the tube line will not fit. (See Figure 10-3
below)
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is measured from the end of the tube. On most benders, the edge of the radius
block is at the centerline of the tube.
3. Control Accuracy
Remember only you can control the accuracy of your work. Use good, careful
workmanship at all times.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
(See Figure 10-5 above)Put the mark on the side opposite the direction in which you wish
to bend. When you put the tube in the bender, center the mark face up in the groove of
the radius block. (See Figure 10-
6)This will insure that you bend
in the correct direction. It also
gives you a reference mark in
case you must leave your work
unfinished.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
90° angles - tangent flush with length mark (refer to dotted line xy
tangent to radius block @ 90° fig. 10-8 (above).
Angles more than 90° - position for a 90° bend and continue on to
desired angle, i.e. 135°, 145°. (i.e. Length mark @ 90° on link member)
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
if you unknowingly make a reverse bend of 90°, you will trap the gain, in table 10-1
(approximately one tube O.D.) and increase your length between bends by that amount. If
bend direction for either 45° or 90° bend must be reversed, subtract the “gain” amount
listed in table 10-1.
While our rule of thumb is approximately correct, the amount of stretch is related to the
diameter of the radius block used. This chart (Figure 10-11) gives the accurate increase in
length that occurs with the most commonly used sizes of radius blocks. As long as you
measure and bend with the tube inserted from the left, and measure centerline, “pickup”
will not affect your actual center-to- center measurement.
NOTE:
1. Some radius blocks
may differ. Cons ult individual
radius block manufacturers for
details on other radius
diameters.
2. For metric tubes the
size and radius can be
computed in the similar way.
Table-10-1
Radius of
Pre-Measuring Tube size
You may pre-measure a series (in Size Bender Gain Gain
of bends. Measure the first inches)
bend from the end of the tube, (in inches) 90° 45°
the correct length. Compensate
for each bend after the first by 1/8 2 3/8 .16 .02
subtracting the amount of gain 3/16 3 7/16 .19 .02
from your chart for each 90° of 1/4 4 9/16 .24 .02
bend to allow for stretch 5/16 5 11/16 .30 .03
(Figure 4-11). Always custom 3/8 6 15/16 .40 .04
measure for the last bend. 1/2 8 1-1/2 .64 .06
5/8 10 1-7/8 .80 .08
3/4 12 2-1/4 .97 .10
“Rule of Thumb” Method 7/8 14 2-5/8 1.13 .11
Compensate each 1 16 3 1.29 .13
measurement after the first by 1-1/4 20 3-3/4 1.61 .16
subtracting the gain listed in 1-1/2 24 4-1/2 1.93 .19
table 10-1. Best Way to 2 32 8 3.43 .34
Measure For maximum
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Remember too, that length magnifies bend angles errors. If the leg following the bend is
fairly long, an error of 1° may result in the tube line missing the desired point completely.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Table: 10-2
TUBE O.D.
inches
1-1/4
1-1/2
1/16
3/16
5/16
1/8
1/4
3/8
1/2
5/8
3/4
7/8
2
of Strai ght
(inches)
Tubing
Length
Free
1.19
1.25
1.25
1.31
1.50
1.94
2.41
3.25
.50
.70
.75
.80
.88
.94
“L”
“D” Tube
Insertion
(inches)
Depth
1.05
1.22
1.61
1.96
2.65
.38
.52
.56
.61
.66
.69
.94
.98
.98
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Offset Bends
To form a tube offset, it is obviously necessary to make two bends. With the tube benders,
it is easy to make double 45° bends. To make an offset bend simply follow the “Offset
Bend Allowance” steps below to determine the proper distance between the two 45°
bends. Here’s the procedure.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Figure-10-17
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Figure-10-18
Allow for expansion and contraction - Use a “U” bend in long lines to allow for expansion
and contraction.
Allow for motion under load - Even some apparently rigid systems do move under load.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Generally long runs of copper tubes are not used because of slow response.
Therefore, extension of tube length is not required. However, if it is needed union
is used (instead of brazing and welding).
Separation is being maintained between the pneumatic tubing used for redundant
valves/instruments.
Because of response time considerations 6 mm tubes are for short distances
whereas 10 mm tubes are used for air supply connections.
Pneumatic tubing for redundant instruments should be taken from different
supply headers.
Considering the strength and hardness of copper tubing, brass tube fitting
becomes the preferred choice. The tube fitting that is used is Brass compression
type single ferrule tube fitting.
The installation procedure of brass tube fitting is more or less similar to that of SS
tube fitting. However galling problem of straight threads is not there to that extent
as that of SS tube fittings.
Moisture free instrument air is recommended from the consideration of corrosion
of tubing.
Tubing should not be laid at a place where human or machine movements are
expected. As these tubes are soft they may get damaged.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Mechanical joints are used frequently for underground tubing, for joints where the
use of heat is impractical and for joints that may have to be disconnected from time
to time.
Copper tube may also be joined by butt-welding without the use of fittings. Care
must be taken to use proper welding procedures.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Hanger, support and clamps design should include provision for seismic, pipe
whip and thermal expansion of process taps and instrument sensing lines to which
the hangers, supports or clamps may be subjected during normal operation,
seismic or other credible events.
Material for hanger, clamps, pads and spacers in contact with sensing lines should
be compatible to avoid corrosion.
From the consideration of seismic qualification the following supporting criterion
should be followed:
b) Supports should be placed at a distance of about 150 mm from each end of
tube fittings as well as bends in the tubing layout.
c) Instrument isolating valves or other instrumentation valves coming in the
sensing lines should be supported with suitable clamps.
d) In the intermediate tubing runs supports should be located in such a way
that the maximum unsupported span is not more than 1m.
From the consideration of thermal loading, tube fittings and bends coming in the
sensing lines should not be supported. This criterion will be applicable for sensing
lines/tubing where temperature cycling is expected.
Tube Clamping
Once you’ve taken the time to make good bends and installed them, it’s not enough to just
let them lay suspended in mid-air. When tubing is left unsupported, shock and vibration
will cause the tubing to shake, and in turn, cause the fitting to loosen and leak or even
allow tube to fall through fatigue.
Tube support and clamping is a necessary
requirement in the fluid power industry.
Tubing can be clamped individually, in sets,
and can also be stacked. The most
important part of any clamping system is
having enough
clamps to attain the final result. That being,
a well supported, vibration and noise free
system.
Also, most manufacturers specify SAE and
JIC approved components on their
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
equipment. The best way to meet these specs concerning clamps is to utilize a clamp that
employs both an upper and lower unit made of metal and a rubber split bushing which
surrounds the tube or pipe and fits on the inside of the clamping units.
Parker Hannifin offers a tube clamp support system by the name of “ParKlamp”. ParKlamp can clamp and
support tube fro m 1/4” to 2” and pipe or hose fro m 1/4” to 1-1/2”. It comes standard in steel and uses a rubber
grommet around the tube for vibration dampening.
Alongside Table-11-1 is
Table-11-1
showing maximum
FOOT SPACING permissible spacing
EQUIVALENT SPACING IN between clamps. It is
TUBE TUBE BETWEEN METE RS recommended to clamp
O.D.” (mm) SUPPORTS (Approx.)
as close to each bend of
1/4” - 1/2” 6 - 13 mm 3 ft. .9 m the tube as possible; and
3/8” - 7/8” 14 - 22 mm 4 ft. 1.2 m one must clamp each
1” 23 - 30 mm 5 ft. 1.5 m side. This eliminates
1-1/4” & up 31 & up mm 7 ft. 2.1
thrust in all directions.
The tube should be
clamped at 1 m distance preferably. (See class-1 Tubing design)
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Figure-12-1
sleeve and the sensing lines should be filled with the suitable radiation absorbing
material. Sensing lines (tubing/piping) should pass the E.P. through seal plate and
suitable sealing arrangement should be
provided on the seal plate using suitable
fittings/bore through tube fittings etc.
Figure-12-2
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Any tube fitting must accomplish two important functions within the pressure,
temperature and vibration criteria that the tube fitting is designed to meet. First, the tube
fitting must grip the tube end so as to prevent loss of seal or tube blow out. Secondly, the
tube fitting must maintain a primary seal against leakage.
The requirement that a tube fitting accomplish these two functions has been the driving
factor in tube fitting design for decades. A multitude of factors influence the design of a
tube fitting to meet a desired grip and seal performance criteria, but basic to any tube
fitting design will be:
1.0 The characteristics of the tubing that the fitting must work with, including
the material, outside diameter and wall thickness; and
2.0 The tube grip and seal performance level required of the tube fitting for its
intended applications.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
unreliable. (This may be noted that NAPS onwards welded tubes have
replaced by Seamless annealed tubing in all NPCIL plants/projects)
The term "pull-up" simply refers to the operation of tightening the tube fitting
assembly so as to complete the assembly of the fitting onto the tube end with the
desired tube grip and seal.
Usually a stainless steel tube fitting is first assembled in a "finger tight" condition
and then a wrench or other suitable tool is used to tighten or "pull up" the fitting
to its final initial and complete assembled condition. In some cases, especially for
larger tube sizes, a swaging tool is used to pre-install a ferrule onto the tubing. The
pull up mechanism most commonly used is a threaded connection of a female
threaded nut component and a male threaded body component, with the tube
gripping device being acted upon by these two components as they are threaded
and tightened together. The body includes a tube end receiving bore with an
angled camming surface at the outer portion of that bore. The most commonly
used camming surfaces are frusto-conical such that the term "camming angle"
refers to the cone angle of the camming surface relative to the tube end
longitudinal axis or outer surface. The tube end is axially inser ted into the body
bore and extends past the frusto-conical camming surface. The gripping device is
slipped onto the tube end and the nut is partially threaded onto the body to the
finger tight position such that the tube gripping device captured axially between
the camming surface and the nut. The nut typically includes an inward shoulder
that drives the tube gripping device into engagement with the angled camming
surface on the body as the nut and body components are threadably tightened
together. The angled camming surface imparts a radial compression to the tube
gripping device, forcing the tube gripping device into a gripping engagement with
the tube end.
The tube gripping device typically is to form a seal against the outer surface of the
tubing and also against the angled camming surface.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
A flareless tube fitting generally refers to a type of tube fitting in which the tube
end remains substantially tubular, in contrast to a flared tube fitting in which the
tube end is outwardly flared over a fitting component. Flared tube ends are
commonly encountered in use with plastic tubing and plastic tube fittings.
The present note is not directed to plastic tubing or tube fittings because such
fittings have significantly different challenges and material properties that affect
the ability of the fitting to both grip the tube and provide an adequate seal.
Operating pressures and temperatures are also typically substantially lower in the
plastics tubing systems. In other words, with respect to tube grip and seal,
whatever works in a plastic tube fitting provides little or no guidance for a non -
plastic tube fitting.
Among the above, the recommended fitting is flareless compression type twin
ferrule tube fitting. Because of its ease of installation and higher reliability this
type of fitting is most commonly used.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
As compared to ordinary compression joints, the ferrule holds the pipe in its place
to give a proper seal when the nut is screwed on to the body. When it is fully
tightened, the case hardened ferrule is pushed slightly in the middle where it acts
as a spring. This maintains a continuous friction between the body and nut and
which help prevent the nut from loosening under stress and repeated vibration.
Bite-type fittings are typically single ferrule in design. This requires the nose of the
ferrule to perform two functions: to bite into the tube to hold it, and to provide a
sealing element for the coupling body, an action that can easily compromise on e or
both functions. A two-ferrule separation of functions (the first to seal, the second
to hold the tube) would solve this problem, as the separation would permit each of
the elements to be designed specifically for the task.
The most common commercially available stainless steel tube fittings especially
for high pressure applications have historically been of two radically distinct
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
designs of the tube gripping device--single ferrule tube fittings and two ferrule
tube fittings.
The front end of the ferrule is driven against the angled camming surface of the
body by the nut pushing against the back end of the ferrule. The bowing action
helps direct the front end of the single ferrule into the tube end. The bowing action
is also used to cause the back end of the ferrule to likewise engage and grip the
tube end. This is accomplished usually by providing an angled drive surface on the
nut shoulder that engages the back end of the single ferrule so as to radially
compress the back end of the ferrule into a gripping action on the tube end. In
some single ferrule designs, the back end of the ferrule apparently is intended to
bite into the tube end.
This back end tube grip is sometimes used with the single ferrule in order to
attempt to improve the tube fitting's performance under vibration because the
back end grip attempts to isolate down-tube vibration from affecting the front end
tube bite.
The use of a back end tube grip actually works against the effort to grip the tube
end at the front end of the single ferrule. Ideally, the single ferrule should be
completely in three dimensional compression between the nut and the camming
surface of the body. Providing a back end grip actually places a counter acting
tension to the single ferrule that works against the front end compression being
used to provide the tube grip. Additionally, the outward bowing action tends to
work against the effort to grip the tube at the front end of the single ferrule
because, in order to enable the outward bowing action, the single ferrule requires
a lessened mass that is adjacent the tube gripping "bite". The outward bowing
action radially displaces ferrule mass from central of the ferrule body to away
from the tube end. Consequently, an outwardly bowed single ferrule fitting could
be more susceptible to ferrule collapse, loss of seal and possibly tube blow out at
higher pressures.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
In order to achieve an adequate tube grip on stainless steel tubing, single ferrule
stainless steel tube fittings have historically used a rather shallow camming angle
of between 10o and 20o. This range of angles is referred to herein as "shallow" only
as a term of convenience in that the angle is rather small. The shallow camming
angle has been used in single ferrule fittings to obtain a mechanical advantage
because the shallow angle provides an axially elongated camming surface against
which to slide and radially compress the single ferrule front end to bite into the
tube end outer surface. Hard stainless steel tubing material necessitated this
elongated sliding camming action in order to be able to get the single ferrule to
create an adequate bite for tube grip. Over the years, the single ferrule has been
‘through hardened’ or ‘case hardened’ so as to be significantly harder than the
stainless steel tubing, however, the shallow camming angle is still used today in
such single ferrule fittings to obtain a mechanical advantage from the ferrule
sliding along the camming surface to produce the "bite" so as to assure an
adequate tube grip. An example of a commercially available single ferrule tube
fitting that uses a case hardened ferrule and a shallow camming angle of about
twenty degrees is the CPI fitting line available from Parker-Hannifin Corporation.
Another example is the EO fitting line available from Ermeto GmbH that uses a
through hardened single ferrule and a twelve degree camming angle.
In some single ferrule designs, a non-conical camming surface has been tried
whereby an attempt is made to simply press the ferrule against the outer surface
of the tube end, thereby not creating a bite. The result in such cases however is a
low grip or low-pressure-only fitting that are not well suited to stainless steel
fittings.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
ferrule to come into contact with the camming surface against which it is being
driven. The result necessarily is a larger seal surface area between the outer
surface of the single ferrule and the camming surface. This enlarged seal area
causes an unwanted distribution of the sealing force between the single ferrule
and the camming surface, and also creates a larger area for surface imperfections
to allow leaks to occur. This is particularly a metal to metal seal issue (as
contrasted to non-metal to non-metal seals: for example, in a plastic fitting it is
usually desirable to provide an enlarged seal contact area because the more highly
ductile plastic material can better form a seal between the two surfaces.)
One result of this situation is that some single ferrule tube fittings have been
designed with additional components and techniques to achieve an adequate seal.
Less than optimum seal performance is particularly noted in single ferrule fittings
that attempt to seal against gas, and especially high pressure gas. Single ferrule
tube fittings thus are usually more suited to lower pressure liquid applications
such as hydraulics, however, even in such lower pressure applications single
ferrule seal performance remains less than desired.
The double ferrule fitting has the ability to lock onto the tube with a 'double bite'
feature. Each ring bites in to the tube giving two separate sealing areas. This style
of fitting does so without transmitting torque or twisting the tube ensuring that
the tube does not become 'stressed'. Therefore, the mechanical properties of the
tube are maintained. A further sealing point occurs at the bottom of the tube
abutment. The abutment has an angle which the tube is forced into when the rings
bite and drive the tube forward.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
production processes must consistently turn out defect-free ferrules that hold
tight tolerances and maintain metallurgical specifications.
Back and front ferrules are designed to provide leak resistant, secure and tight
connections for operations at high pressures. These fittings provide a tight
pressure seal and have a long thread area for improved resistance to pressure
and load on ferrules. Long support area of back ferrules improves resistance to
vibration and line loads.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Swaging can be further expanded by placing a mandrel inside the tube and
applying radial compressive forces on the outer diameter. Thus, through the
swage process, the inner tube diameter can be a different shape, for example a
hexagon, and the outer is still circular. Flared piece of pipes are sometimes
known as "swage nipples," "pipe swages," "swedge nipples," or "reducing
nipples".
In the two ferrule fitting, the tube grip and seal functions also are separately
achieved by the use of two ferrules. The forward or front ferrule provides an
excellent seal even against gas, and the back or rear ferrule provides an excellent
tube grip.
The front ferrule achieves an excellent seal by camming against a shallow
camming surface angle such as twenty degrees. This is because the front ferrule
does not need to slide excessively on the camming surface in order to achieve a
tube grip function. Likewise, the front ferrule is not case hardened because the
primary purpose of the front ferrule is to seal and is not to bite into the tube end.
Thus the relatively "softer" front ferrule achieves an excellent seal, particularly
against gas, even though the body conical camming surface presents a camming
angle of about twenty degrees.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
the tube end as a function of a radially inward hinging action. As used herein, the
term "hinging" refers to a controlled deformation of the ferrule such that a central
region or mid-portion of the ferrule body undergoes an inwardly radial
compression, as distinctly contrasted to a bowing or radially outward
displacement. Thus, the effective shallow camming angle not only does not
compromise the fitting seal capability, it actually substantially enhances the
overall performance of the tube fitting especially for stainless steel tubing.
By using separate ferrules for each to achiev e primaril y only one of the
key tube fitting functions, the two ferrule tube fitting achieves
tremendous tube grip and seal functions.
The back ferrule also swages the tube to provide the grip needed to keep the
fitting and tubing firmly in place. To swage and grip the tube properly, the back
ferrule’s leading edge must be sufficiently harder than the tube. Two methods of
producing this differential hardness may be employed—
The improved engineered hinging action of the back ferrule (Figure 4, next
page) provides several benefits:
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
An important aspect of the cho ice of material s is that the ferrule preferably
should be cas e or through hardened to a ratio of at least about 3.3 and
preferably 4 or more times harder than the hardest tubing material that the
fitting will be used with. Therefore, the ferrule need not be made of the
same material as the tubing itself. For example, the ferrule may b e s elected
from the stainless stee l material s or other suitab le materi als that can be
case hardened, such as magnesium, titanium and aluminum, to name some
add itional examples.
The elements of the fitting are depicted in cross-section prior to make-up: the fitting nut (top), the
advanced geometry back ferrule (left), the front ferrule (center), and the fitting body (right). The
tube wall section is shown belo w the ferrules and body.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
During make-up, the front ferrule (center) is driven into the body of the fitting (right) and the
tube (botto m) to create primary seals (tube and body), while the bac k ferrule (left) hinges
inward to create a strong grip on the tube. The back ferrule geo metry allo ws for an improved
engineering hinging action that translates axial (forward) mo tion into radial swaging ac tion on
the tube, yet operates with a low input force (torque) requirement. The improved radial
colleting ac tion of the back ferrule (the area to the left of the swage point) isolates and pro tects
the swaged area of the tube, preventing the exposed vibration stress riser that is typical of bite-
type fittings.
A distinct advantage of the contoured back ferrule is that pull up forces
between the nut drive surface and the contoured face of the Back ferrule are
more uniformly distributed across the surface of the back ferrule, thus
reducing and substantially eliminating force concentrations. This further
reduction of force concentrations on the drive nut reduces pull up torque and
reduces galling, thus facilitating re-make of the fitting.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
For swaging over thickness may lead to unreliable joint and in very thin tube it
may lead to distortion of tube leading to leakage. Thus considering all the above
factors, optimal thickness should be selected when use of compression type of
tube fittings is envisaged.
A heavy wall tube resists ferrule action more than a thin wall tube, allowing the
ferrules to coin out minor surface imperfections. If the wall is too heavy the rings
will not bite.
A thin wall tube offers less resistance to ferrule action during installation,
reducing the chance of coining out surface defects, such as scratches. When the
tube wall is too thin, the tube will collapse rather than allow the rings to bite fully.
Within the applicable suggested allowable working pressure table, select a tube
wall thickness whose working pressure is outside of the shaded areas. Reference
to the manufacturers' product information should be made in all instances. The
tube should generally have a hardness of no more than 80 on the Rockwell 'B'
scale.
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TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008
Wi der Targ et for Pr oper Ins tal l ati on: The e ngi ne ered hi ngi ng actio n of t he back f errul e d eliv ers en ergy
to not only s eal t he f ront f errul e, bu t als o to de liv er grea ter s w agin g actio n thro ugho ut th e pu ll -up
proces s . As a r es ult, this f ittin g red uces th e pot ent ial f or im prop er ins tall atio n an d s y s tem leakage , ev e n in
cas es w here the f itti ng w as les s than prop erly tighte ne d.
E nhanced Gas Seal : The b ack f errul e h ing e d eliv ers s teady f orce to s eal t he f ront f err ule c ons is ten tly on a
w ide ran ge of tu bin g. B eca us e th e adv a nce d back f err ule c an hin ge a nd a bs orb m ore e nergy th an a
conv ent iona l hard en ed b ack f errul e, th is des ign r edu ces th e pot enti al f or ov erdriv ing t he f ront f errul e,
there by ens urin g relia ble op erati on an d gas s eal f or repeat ed rem akes .
Vi brati on Fati g ue R esi s tance: T he e ngi ne ered back f errul e h ing ing act ion de liv ers a m or e co ns is tent
radial col let ing ac tion to giv e im prov e d s upport to th e tub e beh ind t he poi nt of grip. This coll etin g prote cts
the s w aged ar ea of the tub e m ore ef f ectiv ely f rom s y s tem v ibration and f atig ue .
Greate r Marg i n of Performan ce on C omme rci al Tubi ng : Textbook calc ula tions , s uc h as Lam e’ s f orm ula
f or determ ini ng m inim um ru ptur e pres s ure of a tu be , us e th e m inim um al low abl e ult im ate t ens il e s treng th,
m inim um allow abl e w all t hick nes s , an d m axim um al low abl e out er diam eter f or tub e burs t c alcu latio ns —as
they s hould. How ev er , thes e c alcu latio ns of f er a cons erv ativ e es tim ate of the tube’ s pres s ure -cont ain ing
ability . In r eali ty , s tain les s s tee l tu bin g m an uf actur ers do not a lw ay s run t heir proc es s es f or the m in im um
requir ed m at erial s tre ngth v al ues ci ted by AS TM and other s ta ndar ds f or determ ini ng t he ru ptur e pres s ure
of a tube. Th e res ul t is s tronger, h arder t ubi ng w ith b urs t pres s ures of ten s ign if ican tl y high er tha n w hat
occurs und er leas t c as e cond itio ns . The adv a nce d S w agelok t ube f itti ng is robus t e noug h to grip a nd e xc eed
the b urs t pres s ure of th es e s trong er, av ailab le t ubi ng m at erials . I n ad ditio n, t he unif orm s urf ace -har de ned
des ign of the ba ck f er rule of f ers high corros ion res is tanc e.
C ompati bi l i ty wi th Ori g i nal Desi g n Swag el ok Tube Fi tti ng s: Th e adv an ced S w ag elok f itti ng p ulls up
us ing th e s am e one-an d-one-q uart er - turn proc ed ure as the origi nal d es ign S w age lok tube f itti ng. In
addit ion, t he adv anc ed S w ag elok f ittin g us es th e s am e ins tall atio n ins p ectio n ga uges as bef ore . How ev er,
w hat ev ery ins tall er w il l no tic e is a m ore cons is te nt f e el, f rom a m ore c ons is ten t ra nge of torq ue on ev ery
pull-u p to an ev e n m ore cons is tent , leak f ree co nn ectio n.
Appl i cabi li ty to New Al l oys: The adv an ced S w ag elok f ittin g dem ons trat es it is practic al to dev el op an
eas y -to ins tall, hig h- perf orm anc e tu be f itti ng t hat c an b e bu ilt us i ng a dv ance d all oy s , s uch as s uper d upl ex
s teel, d es pit e their i ncre as ed s trengt h an d adv anc ed m ech anic al prop erti es .
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Following safety precautions should be taken while installing the tube fitting1
Do not bleed the system by loosening the fitting nut or fitting plug.
Do not make up and tighten fittings when the system is pressurized.
Make sure that the tubing rests firmly on the shoulder of the tube fitting body
before tightening the nut.
Use the gap inspection gauge to ensure sufficient pull-up upon initial
installation.
Never allow problems to go unreported.
Always use proper thread sealants on tapered pipe threads. In NPCIL a Nickel
compound based sealant is used (Never Siege compound) to avoid galling
Do not mix materials or fitting components from various manufacturers—
tubing, ferrules, nuts, and fitting bodies.
Never turn the fitting body. Instead, hold the fitting body and turn the nut.
Avoid unnecessary disassembly of unused fittings.
LUBRICATION
Stainless-steel parts that rub together under high pressure have a strong
tendency to cold weld and seize. And to form high-integrity, leak-free tubing
connections, ferrules must only slide forward during assembly and not rotate
with the nut. To prevent seizing and ensure only linear ferrule movement,
surface conditions and lubrication at the nut/ferrule and nut/body interfaces
should be precisely controlled..
All mating surfaces must be smooth and free of defects, which exacerbate
seizing. A bonded molybdenum-disulfide coating is the recommended
lubricant for many compression fittings.
Solid molybdenum disulfide readily adheres to surfaces, is noted for its
lubrication and anti-seizing properties, and the solid does not squeeze out like
liquid or soft, waxy lubricants under extreme pressure. The result is low
assembly torque and consistent performance, even with repeated remakes.
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Repeated assembly and disassembly of the tube fitting causes the reduction in the
distance between the two ferrules. As the distance between the two ferrules reduces over
a period of time the back ferrule’s spring action diminishes and a time comes when both
the ferrules touch each other and the leak tightness provided by this assembly is no
longer assured. Therefore it is necessary to keep this gap under check and whenever this
gap is found to be very little the new tube fitting and swaging should be used. The
figure:13-8 shows this type of action.
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8.0 Tests
8.1 Type Test
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ASME Boiler and As per section III, Division I, Sub section NB for Class I
Pressure vessel components.
code
ANSI-B-1.1 Unified inch screw threads (UN AND UNR thread form)
equivalent for tube end
ANSI-B.1.20.1 Pipe threads, general purpose
ANSI-B-1.20.2
ASTM-A-213 Standard specification for seamless ferritic & austenitic
alloy steel boiler super heater and Heat exchanger tubes
ASTM-A-262 Standard practice for detecting susceptibility to inter
granular attack in austenitic stainless Steels.
ASTM-A-276 Standard specification for stainless steels bars &shapes.
ASTM-A-314 Standard specification for stainless steels billets and
bars for forging.
ASTM-A-473 Standard specification for stainless steels forgings
SAE – J -514 Hydraulic tube fittings
ANSI-B-31.1
ASTM-A-269
ISOR-206
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8.0 Tests
8.1 Type Test
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ASTM-B-124 Copper and copper alloy forging rod bar and shapes
ANSI-B-1.1 Unified inch screw threads (UN AND UNR thread form)
equivalent for tube end
ANSI-B.1.20.1 Pipe threads, general purpose
ANSI-B-1.20.2
SAE J 514 Hydraulic Tube fittings
ASTM-B-16 Free cutting brass rod, bar and shapes for use in screw
machine.
Notes:
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Different types of screw threads have evolved for fastening, and hydraulic systems. Of
special concern are plastic-to-metal, taper/parallel threaded joints in hydraulic circuits. A
discussion and recommendations are provided to create an awareness of diff erent types of
threads and how they are used.
I. Jointing threads – are pipe threads for joints made pressure tight by sealing on the
threads and are taper external and parallel or taper internal threads. The sealing
effect is improved by using a jointing compound.
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II. Fastening threads – are pipe threads where pressure tight joints are not made on the
threads. Both threads are parallel and sealing is affected by compression of a soft
material onto the external thread, or a flat gasket.
14.3. Sizes
Pipe thread sizes are based on an inside diameter (ID) or flow size. For example, “1/2 –
14 NPT” identifies a pipe thread with a nominal inside diameter of 1/2 inch and 14
threads to the inch, made according to the NPT standard. If “LH” is added, the p ipe has
a left hand thread. The most common global pipe thread forms are:
Plastic injection molded thread forms are manufactured to ANSI B2.1 and SAE J476
standards. The word “tapered” in several of the above names points to the big
difference between many pipe threads and those on bolts and screws. Many pipe
threads must make not only a mechanical joint but also a leak proof hydraulic seal.
This is accomplished by the tapered thread form of the male matching the thread form
of the female tapered thread and the use of pipe sealant to fill any voids between the
two threads which could cause a spiral leak. The bottoms of the threads aren't on a
cylinder, but a cone; they taper. The taper is 1⁄16 inch in an inch, which is the same as
3/4 inch in a foot.
Because of the taper, a pipe thread can only screw into a fitting a certain distance
before it jams. The standard specifies this distance as the length of hand tight
engagement, the distance the pipe thread can be screwed in by hand. It also specifies
another distance – the effective thread, this is the length of the thread which makes the
seal on a conventional machined pipe thread. For workers, instead of these distances, it
is more convenient to know how many turns to make by hand and how many with a
wrench. A simple rule of thumb for installing tapered pipe threads, both metal and
plastic, is finger tight plus one to two turns with a wrench. Torque installation values
can be determined as per application, but due to the variations involved in pipe joints
such as dissimilar materials of male and female threads, type of sealants used, and
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This table shows the distances and number of turns called for in the standard. A
tolerance of plus or minus one turn is allowed, and in pract ice threads are often
routinely cut shorter than the standard specifies. All dimensions are in inches.
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Pipe threads were originally designed as machined thread forms. With the use of
thermoplastics and plastic injection molding in the manufacture of plastic pipe thread
forms, mold shrinkage and plastic sink make it difficult to insure leak free joints. For
this reason, the use of a Teflon based sealant is recommended on all plastic pipe
threads. The most common form of sealant is Teflon tape wrapped 2 to 3 turns around
the male thread before assembly. Liquid Teflon based sealants are also used
successfully to ensure a pressure tight seal. It is always important to use care when
applying sealants to avoid introducing the sealant material into the system flow path.
The following sections show examples of how different threads are used and issues
that can arise in attempting to create a leak free connection.
When a BSP tapered male thread is tightened into a straight female thread (BSPP) the
seal can only be made at the base of the female port with 1 or 2 threads. See figure -14-
1. Sealing is compromised by the lack of thread form control in BSP specifications.
Variation in crests and roots may cause a mismatch in the thread and create a spiral
leak. Thread sealant is required to seal this combination.
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Figure 14-5 shows a male NPT tightened into a BSPP. Because of the smaller size of the
BSPP and the pitch difference, the NPT tightens with only a few turns.
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Figure 14-6 shows an NPT tightened into a BSPT. The NPT thread to engage further, but
pitch difference eventually causes a binding of the threads. Pitch and thread angle
differences will allow spiral leakage.
The 1/2” and 3/4” sizes in the NPT and BSP are all 14 threads per inch, and the NPT will
engage the BSP fairly well.
Although these threads are the same pitch and engage well there are still issues with the
tread form. The thread angles and the crest and root tolerances being different will allow
spiral leakage as shown in figure 14-6. These threads might be used effectively together if
Over tightening of any plastic pipe thread will have adverse affects on the function of the
joint. The major difference between plastics and metals is the behavior of polymers.
Injection-molded plastic parts continue to deform if they are held under a constant load e.g.
creep. Creep is the continued extension or deformation of a plastic part under continuous
load. Typically the plastic material in an injection-molded plastic pipe thread form will
creep from being over tightened into a female tapered port. The deformation of the part’s
internal features can lead to part failure.
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The roots of both external and internal threads are truncated slightly more than the
crest, i.e. roots have wider flats than the crests, so that metal to metal contact occurs
as the crests and the roots coincident with or prior to flank contact, see figure -14-7.
Thus as the threads are assembled wrenching, the roots of the threads crush the
sharper +crests of the mating threads .This sealing action at both the major and
minor diameters tends to prevent spiral leakage and pressure tight without the
necessity of using sealing compounds, provided that the mating threads are in
accordance with standard specification and tolerance and are damaged by galling in
the assembly. The control of crest and root truncation is simplified by
the use of properly designed threading tools. Also it is desirable that both for the
length. However, where not functionally objectionable, the use of a compatible
lubricant or sealant may be used to minimize the possibility of galling. This is
desirable in assembling dryseal pipe threads in refrigeration and other systems to
affect a pressure tight seal.
In order to obtain a pressure tight seal using dryseal pipe threads without a sealer, it
is necessary to hold crest and truncation of both internal and e xternal threads
within the limits specified. Unless this is done by use of threading tools with the
crest and root truncation controlled so assure reproduction on the product of
threads, it is necessary to use a system of measuring or a system of gauging and
measuring to determine conformance.
There are two classes of Dryseal pipe threads viz. Class-I and Class-II Dryseal pipe
threads. The classes differ only in inspection requirements. For class -I threads,
inspection of roots and crest is not required while for class-Ii threads these
inspections are required.
External Dryseal threads are tapered only while internal Dryseal threads may be
either straight or tapered. Also, the thread lengths may be either standard or short
depending on the requirement of the application. Short threads are obtained by
shortening the length of the standard thread by one pitch.
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The minimum material condition as shown at the left is established by having the mating
crests and roots of equal truncation so as to assure metal to metal contact at these points
coincident with flank contact. The condition is established at the sharpest root and the
flattest crest and gives no clearance. Tolerances at the crests and the roots are established
in the direction of interference only, therefore the maximum material condition shown at
the right is established by having the extreme combination of sharpest crests and flattest
roots, which provide the maximum interference.
When threaded joints are made wrench tight, it is intended that the flanks and crests and
roots shall be in contact.
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As this process runs “hotter” than the stick process, the use of a backing gas is
mandatory. It should be noted that in welding the relatively small fitting sizes, filler
deposition rate economies are not a factor and therefore the MIG method is not
commonly applied.
Carbide Precipitation
When un-stabilized stainless steels are heated to 800° - 1500° F during welding, the
chromium in the steel combines with the carbon to form chrome carbides which
tend to form along the grain boundaries of the metal (carbide precipitation). This
lowers the dissolved chromium content in these areas and thus lowers their
corrosion resistance, making them vulnerable to intergranular corrosion. Carbide
precipitation is reduced by holding the carbon content of the material to a very low
value. This limits the amount of carbon available to combine with the chromium.
The “L” series (extra low carbon) stainless steels are often used for this purpose, but
their use reduces system design stress by approximately 15%. Weld fittings are
made from a select 316 series with carbon content in the low range of 0.04 to 0.07
percent. This results in a welded fitting with good corrosion resistance and a high
strength factor. All weld fittings in stainless steel are supplied in the solution-
treated condition, capable of passing ASTM-A-262 Tests for Detecting Susceptibility
to Intergranular Corrosion.
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TIG welding is akin to gas welding as far as welding technique in that the torch is
held in one hand and the filler rod is manipulated with the other hand. It is
considered more difficult than other arc welding processes because it requires the
use of both hands. Often times a foot pedal amperage control is also used which
adds another layer of difficulty.
A TIG torch can be either water cooled or air cooled and is designed to provide
shielding gas as well as welding current through a tungsten electrode. A ceramic
nozzle directs the shielding gas to the weld puddle and internal copper parts like the
collet and collet body hold the electrode in place. The tungsten electrode is
sharpened for applications where the arc needs to be pinpointed and for very low
amperage. The heat the melts the metal and makes the weld puddle comes from the
arc that is created between the tungsten electrode and the work piece. The arc is
shielded by argon, helium, or a mixture of the two. Sometimes for certain alloys,
hydrogen is added in small percentages to improve the way the puddle flows. The
arc is very smooth and quiet and clean when DC current is used. When the TIG
welding machine is set on Alternating current, it is slightly more noisy but still clean
and smooth.
Almost any metal can be welded with TIG. Carbon and low alloys steels like 1010
carbon steel and 4130 chromoly steel, Stainless steels like 304, 321, and 17-7ph,
Nickel alloys like inconel 718 and Hastelloy X, Aluminum alloys like 6061, 5052,
Magnesium alloys like az31b, Titanium alloys like commercially pure, and 6al4v,
Cobalt alloys like Stellite 6b and l605, copper alloys like Nibral bronze and pure
copper, All can be welding using the TIG welding process.
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In the orbital welding process, tubes/pipes are clamped in place and an orbital
weldhead rotates an electrode and electric arc around the weld joint to make the
required weld. An orbital welding system consists of a power supply and an orbital
weldhead.
Power Supply: The power supply/control system supplies and controls the welding
parameters according to the specific weld program created or recalled from
memory. The power supply provides the control parameters, the arc welding
current, the power to drive the motor in the weld head and switches the shield
gas(es) on/off as necessary.
Weld Head: Orbital weld heads are normally of the enclosed type and provide an
inert atmosphere chamber that surrounds the weld joint. Standard enclosed orbital
weld heads are practical in welding tube sizes from 1/16 inch (1.6mm) to 6 inches
(152mm) with wall thickness' of up to .154 inches (3.9mm) Larger diameters and
wall thickness' can be accommodated with open style weld heads.
There are many reasons for using orbital welding equipment. The ability to make
high quality, consistent welds repeatedly at a speed close to the maximum weld
speed offer many benefits to the user:
Quality. The quality of a weld created by an orbital welding system with the
correct weld program will be superior to that of manual welding. In
applications such as semiconductor or pharmaceutical tube welding, orbital
welding is the only means to reach the weld quality requirements.
Skill level. Certified welders are increasingly hard to find. With orbital
welding equipment you don't need a certified welding operator. All it takes is
a skilled mechanic with some weld training.
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Many other reasons exist for the use of orbital equipment over manual
welding. Examples are applications where inspection of the internal weld is
not practical for each weld created. By making a sample weld coupon that
passes certification, the logic holds that if the sample weld is acceptable, that
successive welds created by an automatic machine with the same input
parameters should also be sound.
Aerospace: As noted earlier, the aerospace industry was the first industry to
recognize the requirement for orbital welding. The high pressure systems of a single
plane can have over 1,500 welded joints, all automatically created with orbital
equipment.
Boiler Tube: Boiler tube installation and repairs offer a perfect application for
orbital welding. Compact orbital weld heads can be clamped in place between rows
of heat exchanger tubing where a manual welder would experience severe difficulty
making repeatable welds.
Food, Dairy and Beverage Industries: The food, dairy and beverage industries
require consistent full penetration welds on all weld joints. Most of these
tubing/piping systems have schedules for cleaning and sterilization in place. For
maximum piping system efficiency the tubing must be as smooth as possible. Any
pit, crevice, crack or incomplete weld joint can form a place for the fluid inside the
tubing to be trapped and form a bacteria harbor.
Offshore Applications: Sub-sea hydraulic lines use materials whose properties can
be altered during the thermal changes that are normal with a weld cycle. Hydraulic
joints welded with orbital equipment offer superior corrosion resistance and
mechanical properties.
Tube/Pipe Fittings, Valves and Regulators: Hydraulic lines, and liquid and gas
delivery systems all require tubing with connector fittings. Orbital systems provide
a means to ensure high productivity of welding and improved weld quality.
Sometimes the tubing may be welded in place to a valve or regulator body. Here the
orbital weldhead provides the ability to produce high quality welds in applications
with restricted access to the weld joint.
For orbital welding in many precision or high purity applications, the base material
to be welded, the tube diameter(s), weld joint and part fit -up requirements, shield
gas type and purity, arc length, and tungsten electrode material, tip geometry and
surface condition may already be written into a specification covering the specific
application.
The orbital welding process uses the Gas Tungsten Arc Welding process (GTAW) as
the source of the electric arc that melts the base material and forms the weld. In the
GTAW process (also referred to as the Tungsten Inert Gas process - TIG) an electric
arc is established between a Tungsten electrode and the part to be welded. To start
the arc, an RF or high voltage signal (usually 3.5 to 7 KV) is used to break down
(ionize) the insulation properties of the shield gas and make it electrically
conductive in order to pass through a tiny amount of current. A capacitor dumps
current into this electrical path, which reduces the arc voltage to a level where the
power supply can then supply current for the arc. The power supply responds to the
demand and provides weld current to keep the arc established. The metal to be
welded is melted by the intense heat of the arc and fuses together. No additional
filler material is used in this process of welding.
The material selected varies according to the application and environment the
tubing must survive. The mechanical, thermal, stability, and corrosion resistance
requirements of the application will dictate the material chosen. For co mplex
applications a significant amount of testing will be necessary to ensure the long
term suitability of the chosen material from a functionality and cost viewpoint.
In general, the most commonly used 300 series stainless steels have a high degree of
weldability with the exception of 303/303SE which contain additives for ease of
machining. 400 series stainless steels are often weldable but may require post weld
heat treatment.
Tubing is produced according to tolerances that are rigid or loose according to the
application for which the tube was purchased. It is important that the wall
thickness is repeatabl e at the weld joint from part to part. Differences in
tube diameter or out -of-roundness will cause weld joint mismatch and arc
gap v ariations from one welding set up to another.
Tube and pipe end prep facing equipment is recommended in order to help ensure
end squareness and end flatness. Both the ID and OD should be burr free with no
chamfer.
When two tubes are butted together for welding, two of the main considerations are
mismatch and gaps. In general, the following rules apply:
Any gap should be less than 5% of the wall thickness. It is possible to weld
with gaps of up to 10% (or greater) of wall thickness, but the resultant
quality of weld will suffer greatly and repeatability will also become a
significant challenge.
Wall thickness variations at the weld zone should not be more than ± 5% of
nominal wall thickness. Again, the laws of physics will allow welding with
mismatch of up to 25% of wall thickness if this is the only challenge but
again, the resultant quality of weld will suffer greatly and repeatability will
also become a significant issue.
An inert gas is required on the tube OD and ID during welding to prevent the
molten material from combining with the oxygen in the ambient atmosphere. The
objective of the welder should be to create a weld which has zero tint at the weld
zone ID.
Argon is the most commonly used shield gas (for the OD of the tube)and the purge
gas (for the ID of the tube). Helium is often used for welding on copper material.
Mixed gases such as 98% Argon/2% Hydrogen, 95% Argon/5% Hydrogen, 90%
Argon/10% Hydrogen or 75% Helium/25% Argon my be used when the wall
thickness to be welded is heavy (.1" or above). Using mixtures of 95% Argon/5%
Hydrogen is incompatible with carbon steels and some exotic alloys, often causing
hydrogen embrittlement in the resultant weld. As a general rule use 100% argon
gas, for simplicity and reduction of shield gas cost.
Gas purity is dictated by the application. For high purity situations where the
concern for micro-contamination is paramount, such as semiconductor and
pharmaceutical applications, the shield and purge gases must minimize the heat
tint that could otherwise be undesirable. In these applications, ultra high purity gas
or gas with a local purifier are employed. For non-critical applications, commercial
grade argon gas may be used.
The tungsten welding electrode, the source of the welding arc, is one of the most
important elements of the welding system that is most commonly ignored by
welding systems users. While no one would refute the importance of the ignition
device on an automobile airbag, the rip cord for a parachute, or quality tires f or
automobiles, the importance of tungsten electrode for quality welding is often
overlooked. Users continue to manually grind and wonder why they produce
inconsistent results. Whether in manual or automatic welding, this is the area
where manufacturing organizations can improve the consistency of their welding
output with minor effort.
The objective for the choice of tungsten parameters is to balance the benefits of a
clean arc start and reduced arc wander with good weld penetration and a
satisfactory electrode life.
Electrode Materials: For quite some time, tungsten manufacturers have added an
oxide to pure tungsten to improve the arc starting characteristics and the longevity
of pure tungsten electrodes. In the orbital welding industry, the most commonly
used electrode materials are 2% thoriated tungsten and 2% ceriated tungsten.
Safety: The safety issues of tungsten electrode material are now being looked at
more closely. Many users of the TIG welding process do not realize that the welding
electrode they use contains Thorium, a radioactive element added to the tungsten.
While the radioactivity is of a low level, it brings an issue of danger especially with
the radioactive dust generated when grinding the electrodes to a point for welding.
Electrode Tip Geometry: Given the ever increasing weld quality requirements of the
final weld, more and more companies are looking for ways to ensure that their
To produce high consistent welds the Tungsten electrode must provide the
following:
A. Electrode Taper - This is usually called out in degrees of included angle (usually
anywhere between 14º and 60º). Below is a summary chart that illustrates how
different tapers offer different arc shapes and features:
In addition, to demonstrate graphically how the taper selection will affect the size of
the weld bead and the amount of penetration, below is a drawing that shows typical
representations of the arc shape and resultant weld profile for different tapers.
1. Improved arc starting, increased arc stability and more consistent weld
penetration.
4. A dedicated electrode grinder helps ensure that the welding electrodes will
not become contaminated by residue or material left on a standard shop
grinder wheel.
5. Tungsten electrode grinding equipment requires less skill to ensure that the
tungsten electrode is ground correctly and with more consistency.
Pre-Ground Electrodes: Rather than risk electrode radioactivity issues and also
constantly endure the variability of each operator grinding the electrodes with a
slightly different touch, many manufacturing organizations have chosen to
purchase electrodes pre-ground. In addition, since a small difference in the
dimensions of an orbital electrode can produce a big difference in the weld
results, pre-ground electrodes are the preferred electrode choice to maintain the
consistency of your welding. This low cost option ensures that the electrode
material quality, tip geometry and ground electrode surface input to the welding
process is constant.
Note: The "rules of thumb" noted below are general guidelines only and will not
apply to every welding application and mix of parameters chosen. Although the
welding parameters are often chosen and changed according to the specific needs
of the application, there are some industry standards that have been developed as
starting points. Experimentation and experience will determine the final weld
parameters.
Arc Length
The arc gap setting is dependent on weld current, arc stability and tube
concentricity/ovality. The objective of the welding engineer is to keep the
electrode at a constant distance from the tube surface with sufficient gap to avoid
stubbing out.
As a "rule of thumb" use a base arc gap of 0.010" and add to this half the
penetration required (usually the tube wall thickness) expressed in thousandths
of an inch. Thus if the tube wall is .030" then a good starting arc gap would be
0.010" + 0.015" = .025". For a wall thickness/penetration requirement of .154" the
arc gap would be 0.010" + .070" = 0.080"
Weld Speed
The weld speed is dependent on flow rate of material to be welded, and wall
thickness. The objective is to weld as fast as possible while still yielding a quality
output.
As a starting point the tungsten surface speed should be 4 - 10 inches per minute
with the faster welding speeds used for thinner wall materials and the slower
welding speeds used for heavy wall thickness. As a good starting point, use 5
inches per minute.
Welding Current
As a starting point use 1 ampere current per 0.001" wall thickness if the material
is stainless steel. Thus for a 0.030" wall tubing the average weld current will be 30
amps in the first level.
Orbital welding normally uses multiple levels of weld current to compensate for
heat building up in the tube during the welding process. If the weld current used
to initially penetrate the tubing was held at the same level for the complete weld,
the weld penetration would increase as the weld progressed around the tube,
producing too much penetration.
Figure15-8: A Typical Weld Program current Profile ( This weld profile shows
a single level of weld time). Orbital welding normally uses a minimum of 4
levels of weld time with each level decreasing in weld amperage as the tube
heats up during the welding process
Normally orbital welding uses a minimum of 4 levels of weld time with each level
decreasing in weld amperage
Starting parameters: Set weld level 4 to be at 80% of weld level 1 amperages. Set
weld level 2 and weld level 3 to gradually decrease the current from level 1 to
level 4.
Figures 15-9 and 15-10 depict a typical weld program current profile for a 10 mm
O.D. SS tube. It may be noted that in the weld program chosen by the welder, the
time for each level is same (Impulse rate) and the average current decreases with
each level.
Arc Pulsing
Arc pulsing involves using the welding power supply to rapidly alternate the weld
current from a high (peak current) to a low (background current) value. This
creates a seam of overlapping spot welds. This technique reduces the overall heat
input to the base material and can also allow for increases in weld speed. This
welding technique brings many benefits to the welding procedure, often
improving weld quality and repeatability. In some cases materials and weld joints
with poor fit-up that are difficult to successfully weld with a non-pulsed arc can
easily be welded with a pulsed arc technique. The result is impro ved weld quality
and increased output.
In orbital welding, arc pulsing also offers another advantage due to the fact that
the gravity pulls the weld puddle in different directions as the weld is created
around the tube. When pulsing at peak current the base material(s) melt and flow
together, at the lower background current the puddle can solidify before becoming
liquid at the next peak current pulse. This diminishes the effect of gravity on the
molten weld, minimizes the weld sagging at the 12 and 6 o clock positions, and
reduces the molten weld puddle running/slumping downhill at the 3 and 9 o'clock
positions and effectively alters the electrode to weld puddle distance. The arc
pulsing technique thus becomes more advantageous as the wall thickness
increases resulting in a larger weld puddle.
Arc Pulsing Parameters: Arc pulsing involves four welding parameters: peak
current, background current, pulse width (duty cycle), and pulse frequency. Here
again, opinions vary from one welding organization to another and indeed from
welder to welder. Many welders arrive at the same welding result having
somewhat different welding parameters.
The primary objective is to use the benefits of weld pulsation to improve weld
quality and output.
Pulse Frequency: The pulse frequency is dependent on spot overlap required. Good
starting parameters are to attempt for a 75% spot overlap. Pulse rate for thin wall
tube is often equal to the weld speed in ipm (5 ipm = 5 pps) {pps: pulse per
second}
Pulse Width: The pulse width (the percentage of time spent on the peak current) is
dependent on heat sensitivity of material and available current from power
supply. Higher heat sensitivity requires lower pulse width % on peak current.
Standard pulse widths are often 20% to 50%. A good starting parameters would
be to set a pulse width of 35%.
Background Current will be 1/3rd of peak current. Pulse width/duty cycle is 35%
The above data gives starting parameters. On completion of the first test weld, the
parameters will be modified to obtain the final result desired.
8. ISA-S 67.02.02(1996): Nuclear safety related instrument sensing line piping and tubing.
12. PB-E-146: Specifications for SS compression type twin ferrule (flareless)tube fittings.
13. PB-M-23: Specifications for Seamless Copper tubing for 500 MWe
18. BS-4368-Part-I-1972; Carbon and Stainless Steel Compression Couplings for Tubes
21. “Tools and Manufacturing Engineer’s Handbook: A Reference Book for Engineers,
Managers and Technicians”, Tom Drozda, Charles Wick.
24. “TIG Welding Basics-for TIG Welders, by a TIG Welder”, Jody Collier.