You are on page 1of 127

TECDOC-01 SEPTEMBER 2008

TECHNICAL DOCUMENT ON
INSTRUMENTATION TUBING AND THEIR
CONNECTIONS

Instrumentation Technical Document Series By: Nirbhay Gupta


This Page is intentionally kept blank

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

23rd September, 2008

Mumbai

iii
This Page is intentionally kept blank

iv
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

v
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

vi
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

vii
This Page is intentionally kept blank

viii
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 
 
 

 
Nirbhay Gupta                                                                                                                                  1 
 
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. 
 
 
Nirbhay Gupta                                                                                                                                  2 
 
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) 

 
Nirbhay Gupta                                                                                                                                  3 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 

 
Figure­1­3: Galvanic Series chart 

 
Nirbhay Gupta                                                                                                                                  4 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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: 

 
   

 
Nirbhay Gupta                                                                                                                                  5 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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. 

 
Nirbhay Gupta                                                                                                                                  6 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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 

 
Nirbhay Gupta                                                                                                                                  7 
 
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) 

   

 
Nirbhay Gupta                                                                                                                                  8 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
Table­1­4: Fractional 316 or 304 STAINLESS STEEL (Welded & Drawn)  

Table­1­5: Seamless Stainless Steel metric tubing 

 
   

 
Nirbhay Gupta                                                                                                                                  9 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 

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 

 
Nirbhay Gupta                                                                                                                                  
10 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
   

 
Nirbhay Gupta                                                                                                                                  
11 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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. 
 

 
Nirbhay Gupta                                                                                                                                  
12 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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 
 
   

 
Nirbhay Gupta                                                                                                                                  
13 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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 

   

 
Nirbhay Gupta                                                                                                                                  
14 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 

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. 

 
Nirbhay Gupta                                                                                                                                  
15 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
 
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. 
 

 
Nirbhay Gupta                                                                                                                                  
16 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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 

     Do   = Nominal outside diameter of tube/pipe 


  Dmax  = the maximum outside diameter after bending or forming 
  Dmin   = the minimum outside diameter after bending or forming 

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. 

a. CONSIDERATION  OF  DESIGN  CONDITIONS  (STRESS  DUE  TO  SUSTAINED 


LOADS)(Refer NC 3652) 
The effects of pressure, weight and other sustained mechanical loads must meet the 
requirements of following eq. (4). 

         1.5                                                              …………………… (4) 

 
Nirbhay Gupta                                                                                                                                  
17 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
  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). 

1   2 1.8                                 ………. (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                 ………(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) 

 
Nirbhay Gupta                                                                                                                                  
18 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
= 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) 

             2                     …… (8) 


Where  
C2 and K2 are stress indices for class‐1 piping products or joints from NB 3681 (a)‐1. For 
straight pipe/tube the value of C2 and k2 are 1. 
 
For curved pipe/tube or welded elbows ‘I’ can be computed as per equation (9) below (refer 
NB 3681) 
.
                                                                             …… (9) 

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  
 

 
Nirbhay Gupta                                                                                                                                  
19 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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. 

 
Nirbhay Gupta                                                                                                                                  
20 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 

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) 

6  0.55 0.69 1.2


10  0.92 1.15 1.2
12  1.1 1.38 1.5
16  1.47 1.83 1.8(See note below)
20  1.83 2.29 2.5
25  2.29 2.86 3.0
Note: It can be seen from Tables – 2­2 & 2­3 that specified wall thickness of all sizes of tubing as per PB­M­
17  is  more  than  required  wall  thickness  as  per  ASME  Section  III  except  for  16  mm  size.    As 
maximum pressure and temperature may not be simultaneous so 1.8 mm wall thickness instead for 
1.83 mm of 16 mm size will be adequate from pressure rating considerations. 

“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 
 
Nirbhay Gupta                                                                                                                                  
21 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
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: 

     1   2 1.8            

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

 
Nirbhay Gupta                                                                                                                                  
22 
 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 
 
 
(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) 
   

 
Nirbhay Gupta                                                                                                                                  
23 
 
 
 
 
 

 
23  20  16  12  10  6  Tube size OD (Do) mm 

24 

3  2.5  1.8  1.5  1.2  1.2  Wall Thickness (t) (mm) 
.
Calculated B2  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) 


1.0  1.0  1.03  1.0  1.0  1.0 

Z (mm3) 


1022.21  536.89  257.06  115.97  65.42  18.46  – 
         
32

WL (wt. of 1m of tube filled with D2O) kg/m 


1.971  1.293  0.775  0.466  0.315  0.156 

WF (wt. of fitting) (kg) 


0.8  0.64  0.512  0.384  0.32  0.192 

Ma(kg/mm)   } 


446.37  321.62  224.87  154.25  119.37  67.5 
TABLE­2­4 

Ssl (kg/cm2) 
B1PDo B2Ma

310.27  310.5  383.4  383.7  449.07  475.34 
      
2tn Z

1.5Sh (kg/cm2) 

    1479       
 

Yes  Yes  Yes  Yes  Yes  Yes  Whether  Ssl < 1.5 Sh 


 

      200         Mb  (Kg mm) 
 

329.83  347.75  463.54  556.17  754.78  1558.76  1   2  


2

1.8 Sh 
 

      1774.8     
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS  2008 

Nirbhay Gupta                                                                                                                                  
 

Yes  Yes  Yes  Yes  Yes  Yes  Whether  Sol < 1.8 Sh 

 
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

2.7 Consideration for various forces


The design of tubing/piping systems for sensing lines should take account of all
the forces and moments resulting from thermal expansion and contraction and
from the effects of expansion joints if any.

2.8 Tube Bending Considerations


Bend radius in instrument tubing/piping should be subject to following
limitations;
i) Minimum wall thickness at any point in the completed bends should not be
less than required minimum wall thickness for the design pressure.
ii) The ovality of instrument tubing/piping after bending should not exceed
8% as calculated below:

Ovality (%) = 100 (D max – D min)/Do

Where –

Do = Nominal O.D. of tube/pipe

Dmin = The min. outside diameter of tube/pipe after bending

Dmax = The max. outside diameter after bending

The above requirements are met if bend radius is more than 3D o.

2.9 Special design aspects to meet the requirements of class-I tubing


and tubing systems
In addition to the general requirements of impulse connections as mentioned
above, the following requirements should also be met for impulse connections for
pressure/differential pressure measurement in safety and safety related systems.

For safety and safety-related systems the safety classification of instrument


sensing lines including the first accessible isolating valves should at least remain
the same as that of process systems, and from the valves up to instruments they
should meet at least the requirements of ANSI-B-31.1.
SS tubes should meet the design intent of ASME Section III sub-section NB/NC.

Nirbhay Gupta 23
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

All finished tubing should be inspected by ultrasonic or eddy current methods


or any combination of these methods in accordance with the requirements of
NB-2550.

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.

Nirbhay Gupta 24
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

3.0 Technical Requirements of SS tubes


Following design requirements should be specified while ordering SS tubes.

1. TYPE : SEAMLESS, AS PER ASTM-A213


2. MATERIAL : SS 304L
3. SIZE & THICKNESS : As per the Table below
Out side Wall thickness [min] Tolerances on O.D. Length of tube
dia. [mm] and tolerance [mm] [mm] Pieces

6 1.2 + 15%; -0% -00 + 0.10

10 1.2 + 15%; -0% -00 + 0.10

12 1.5 + 10%; -0% -00 +0. 10


6 meters
16 1.8 + 10%, -0% -00 +0. 12

20 2.5 + 10%, -0% -00+ 0. 12


25 3.0 + 10%; -0% -00 + 0.12

4. FLUID : Water/Steam/Lube oil


5. MAX. PRESSURE: 200 kg/cm2(g)
6. MAXIMUM TEMPERATURE : 320ºC
7. OVALITY VARIATION: < 8.0% OF O.D.
8. HARDNESS : > ROCKWELL B-65 & < ROCKWELL B-80
9. SURFACE FINISH: BETTER THAN 8.2 microns FOR O.D. & I.D.
10. MECHANICAL PROPERTIES :
2
a. TENSILE STRENGTH : ≥ 4920 kg/cm (g)
2
b. YIELD POINT : ≥1760 kg/cm (g)
c. ELONGATION % IN 50MM GAUGE LENGTH : ≥ 35 %
11. TYPE TESTS
a. HARDNESS TEST : On one test piece of each size and each batch as per
relevant ASTM standard

Nirbhay Gupta 25
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

Relevant standards for SS tubes


Following standards should be followed while specifying or testing SS tubes.

Sr. Code/Standard Description


No.

1. ASTM-A-213 Seamless Ferritic & Austenitic Alloy Steel Boiler , Super


heater & Heat Exchanger Tubes

2. ASTM-A-450 General requirement for carbon, Ferritic & Austenitic Alloy


steel Tubes.

3. ASTM A 262 Standard Practices for Detecting susceptibility to inter-


granular attack in stainless steel .

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

6. PB-M-17 Specifications for Seamless Austenitic SS tubes

Nirbhay Gupta 26
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

4.0 Pneumatic Tubing


Copper tubes are primarily used for pneumatic connections. Earlier pneumatic
instruments were more popular and used (controllers, transmitters, indicators etc.). Thus
pneumatic tubing was used widely. However now-a-days most of the instruments that
are used are electronic instruments, thus the use of pneumatic tubing is limited. Still, at
present this is used to connect the pneumatic actuator and its accessories viz. positioners,
I/P converters, solenoid valves etc. which are quite important from plant operation point
of view. Pneumatic instruments are still prevalent in hazardous areas. Even though the
pneumatic instruments are passé, they still provide a very reliable alternative to
electronic instruments.

4.1 Advantages of using copper tubes


Strong, corrosion resistant, copper tube is the leading choice for pneumatic piping. There
are seven primary reasons for this:

1. Copper is economical. Easy handling, forming and joining permits savings


in installation time, material and overall costs. Long-term performance and
reliability mean fewer callbacks, and that makes copper the ideal cost-
effective tubing material.
2. Copper is lightweight. Copper tube does not require the heavy thickness of
ferrous or threaded pipe of the same internal diameter. This means copper
costs less to transport, handles more easily and, when installed, takes less
space.
3. Copper is formable. Because copper tube can be bent and formed, it is
frequently possible to eliminate elbows and joints. Smooth bends permit the
tube to follow contours and corners of almost any angle. With soft temper
tube, particularly when used for renovation or modernization projects,
much less wall and ceiling space is needed.
4. Copper is easy to join. Copper tube can be joined with capillary fittings.
These fittings save material and make smooth, neat, strong and leak-proof
joints. No extra thickness or weight is necessary to compensate for material
removed by threading.
5. Copper is safe. Copper tube will not burn or support combustion and de-
compose to toxic gases. Therefore, it will not carry fire through floors, walls
and ceilings. Volatile organic compounds are not required for installation.

Nirbhay Gupta 27
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

6. Copper is dependable. Copper tube is manufactured to well-defined


composition standards and marked with permanent identification so you
know exactly what it is and who made it.
7. Copper resists corrosion. Excellent resistance to corrosion and scaling
assures long, trouble-free service, which means satisfied customers.

4.2 Different types of copper tubes

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.

Nirbhay Gupta 28
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

4.3 Recommendations for selection of a type of copper tube


It is up to the designer to select the type of copper tube for use in a particular
application. Strength, formability and other mechanical factors often determine the
choice. Plumbing and mechanical codes govern what types may be used. When a

Nirbhay Gupta 29
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

c. Chilled Water Main: Use Type M for all sizes.

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.

f. Solar Heating: See ‘Heating’ section above. For information on solar


installation and on solar collectors, write CDA.

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.

h. Nonflammable Medical Gas Systems: Use Medical Gas tube Types K or L,


suitably cleaned for oxygen service per NFPA Standard No. 99, Health Care
Facilities.

i. Air-Conditioning and Refrigeration Systems: Copper is the preferred


material for use with most refrigerants. Use Types L, ACR or as specified.

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.

l. Low Temperature Applications –


Use copper tube of Type determined by rated internal working pressures at
room temperature as shown in Tables below. Copper tube retains excellent
ductility at low temperatures to –452°F and yield strength and tensile
strength increase as temperature is reduced to this point. This plus its

Nirbhay Gupta 30
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

excellent thermal conductivity makes an unusual combination of properties


for heat exchangers, piping, and other components in cryogenic plants and
other low temperature applications.

m. Compressed Air—Use copper tube of Types K, L or M determined by the


rated internal working pressures as shown in tables 4-2 to 4-9 below. Brazed
joints are recommended.

Table-4-2: Rated Internal Working Pressures for Copper Tube: TYPE DWV*

Table-4-3: Rated Internal Working Pressures for Copper Tube: TYPE K*

Nirbhay Gupta 31
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Table-4-4: Rated Internal Working Pressures for Copper Tube: TYPE L*

Table-4-5: Rated Internal Working Pressures for Copper Tube: TYPE M*

Nirbhay Gupta 32
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

Nirbhay Gupta 33
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

4.4 Technical Requirements of Copper tube


Following parameters are to be specified while preparing the specifications for
copper tubes for pneumatic piping.

1. Type : Annealed Copper, Seamless copper tubes as per ASTM-B-68M.


2. Length: 15 m< L < 80 meters
3. Size (mm):
Out Side Tolerance On OD In mm Wall Thickness[In mm]
Dia. in mm And Tolerance
6 +0.1 1.2 + 0.16
-0 -0
10 +0.1 1.2 + 0.16
-0 -0
12 +0.1 1.2 + 0.16
-0 -0
20 +0.12 1.5 + 0.20
-0 -0
25 +012 1.5 + 0.20
-0 -0
Note: Though from pressure rating consideration the thickness requirement may
be less but while deciding the thickness due consideration is to be given to the
strength.

4. Fluid: Air /oil / water


5. Max. Pressure: 8.5 kg/cm2(g)
6. Max. Temperature: up to 100oC
7. Hardness: Rockwell F50
8. Ovality Variation : < 0.7% Of O.D.
9. Surface Finish : Better than 8.2 Microns For O.D & I.D
10. Mechanical Properties:
a. Tensile Strength: 2200 kg/Cm2 (g)
b. Yield Point: 650 kg/cm2 (g)
c. Elongation (%) in 50 mm Gauge Length: 40%

Nirbhay Gupta 34
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

11.2 Routine Tests


a. Dimensional Test: Required to be done on 10% of the lot
b. Hydrostatic Test: At pressure of 50 kg/cm 2(g); for 10 min. Required to
be done on each size each batch
c. Pneumatic Test: At a pressure 8.5 kg/cm2 (g); for 10 min. Required to
be done on each size each batch.

4.5 Applicable international standards for copper tubes


Besides NPCIL specifications following international codes and standards may be
referred while specifying copper tubes.

ASTM-B-68M: Standard specification for seamless copper tube, bright Annealed


[metric]
ASTM-E-8M: Standard test Method for tension testing of metallic materials
[metric]
ASTM-E-18: Standard test method for Rockwell hardness and Rockwell
superficial hardness of metallic materials
ASTM-E-53: Method for chemical analysis of copper
ASTM-B-153: Standard test method for expansion [pin test] of copper and copper
alloy pipe and tubing
ASTM-E-243: Standard practice for electro-magnetic [eddy current] examination of
copper and copper alloy tubes.
ASTM-B-251M: Standard specification for general requirement for wrought
seamless copper and alloy tubes [metric]
ASTM-E-255: Practice for sampling copper and copper alloy for determination of
chemical composition.
BS-2871: Copper and copper alloys tubes

Nirbhay Gupta 35
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

5.0 ASTM Tubing Specifications outside


diameter/wall thickness
It is important to understand that both of the above can affect the ferrule(s) ability to seal
on the tubing. It is recommended to order tubing manufactured to the plus (+) side of the
outside diameter tolerance. Wall thickness variations can affect pressure ratings and flow
characteristics.

The following tables should explain the allowable variations.

ASTM Dimensional Specifications for Tubing


Table-A: Permissible Variations in Outside Diameter

Table-B: Permissible Variations in Wall Thickness

Table-C: Permissible Variations in Wall Thickness for ASTM B68 and ASTM B75 cold
drawn copper tubes

Table-A Permissible Variations in Outside Diameter

Nirbhay Gupta 36
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Table-B: Permissible Variations in Wall Thickness

Table-C: Permissible Variations in Wall Thickness for ASTM B68 and ASTM
B75 cold drawn copper tubes

Nirbhay Gupta 37
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

6.0 EMBEDDED PENETRATIONS


Whenever the tubes have to pass through some floor slab or a wall a n embedded
penetration is used. This serves two purposes viz.

a. Supporting the tube


b. Making a leak tight passage. This prevents streaming of radioactivity from an
active area to a non-active area

Guidelines for EP Design

Following general guidelines should be followed:

(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.

Nirbhay Gupta 38
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

7.0 METHODS OF CONNECTION OF INSTRUMENTATION


TUBES
Different types of connections/joints can be used in instrument sensing lines as discussed
below:

7.1 WELDED JOINTS

a) Butt-welded joints should be made wherever possible.

b) Socket-welded joints are permitted but limited to tube/pipe size of 50 mm


and less. Socket welded joints should conform to requirements of ANSI-B-
16.11. While performing socket-welding, approximately 1.6 mm should be
provided between the end of pipe/tube and bottom of socket, before
welding.

c) Socket welds should not be used where the existence of crevices could
accelerate corrosion.

7.2 FLARED, FLARELESS & COMPRESSION JOINTS

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.

b) Tube fittings should be used at pressure-temperature ratings, not exceeding


the recommendations of the manufacturer.

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.

Nirbhay Gupta 39
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

d) Tube fittings should be installed in accordance with manufacturer’s


recommended procedures.

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.

g) Service conditions such as vibration and thermal cycling should also be


considered in the application.

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.

7.3 THREADED JOINTS

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:

a) Thread size should not exceed ¾” (N.B.)

b) Pipe threads should be taper pipe threads in accordance with applicable


standard. Suitable sealant should be used on pipe threads depending upon
the type of threads.

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.

e) Threaded connections should not be used at temperature above 495oC.

Nirbhay Gupta 40
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

8.0 GUIDELINES FOR TAKE OFF CONNECTIONS


FOR SENSING LINES
Following guidelines pertaining to the take off connections (pressure taps) should be
followed.

8.1. LOCATION OF PRESSURE TAPS


a. In general the location of pressure taps in a pipe line having flowing fluid,
should be at a point where the flow is uniform.
b. Location of pressure taps should be at least 5 diameters downstream from
a symmetrical pipe fitting (as a reducer) and at least 10 diameters from any
unsymmetrical fitting (as a tee, elbow or valve). It should also be at least 2
diameters upstream from any fitting or irregularity.

c. LOCATION OF PRESSURE TAPS IN HORIZONTAL PIPES/VESEL:

I. GAS AS PROCESS FLUID: The location of pressure taps in the vertical


meridian upwards is preferred mainly for wet gas. For following
draining to occur, taps location angle should be less than 45 0 off the
vertical meridian plane.

II. LIQUID AS PROCESS FLUID: The pressure taps should be located in a


meridian plane with which the horizontal meridian is forming an angle
not greater than 45 O above or below according to the position of the
measuring/sensing device.
If the liquid is clean, it is advisable to avoid the risk of gas in impulse
line by using tap location below the pipe horizontal meridian plane. If
on the other hand the liquid has significant solid content, then a
position above the horizontal centre line is recommended. In neither
case should the taps be more than 45 0 from the horizontal.

In cases where there is considerable volume of gas in liquid line and


needs special considerations a horizontal tap position should be used in
conjunction with gas vent connection and gas collecting chambers in the
impulse lines.

d. LOCATION OF PRESSURE TAPS IN VERTICAL PIPES/VESSELS


In case of vertical pipes/vessel, there are generally no problems as far as
the radial position of pressure taps is concerned.

Nirbhay Gupta 41
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

8.2. CONSIDERATIONS FOR PRESSURE TAP DESIGN


A. CONSIDERATIONS:

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.

II. DYNAMIC RESPONSE CONSIDERATIONS:


From measurement/accuracy considerations specially when the
pipes/vessels contain compressible flowing fluids, the higher size of pressure
taps are preferred for minimizing the possibility of plugging and for
minimizing the error due to friction, inertia and lag in the connections while
measuring dynamic pressures. When dynamics effects are not important
smaller tapping size and impulse tubing may be used.

III. TURBULENCE ERRORS:


It may be noted that for measurement of static pressure in above case if
higher size of opening is used as static pressure tap, the laminar flow past the
tap is affected so that the velocity of tap opening is not effectively zero. Thus
the pressure at tap involves some velocity pressure and is not true static
pressure. Also large tap will produce eddies in the stream and as these
eddies form and break away downstream, the pressure at tap fluctuates even
when the undisturbed pressure is constant.

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.

IV. VELOCITY ERRORS:


In general the measurement errors are proportional to velocity pressure.
Thus when stream velocity is high, it is necessary to take great care in tap
construction with minimum possible tap diameter and special attention to
the sharpness and squareness of the edges of the hole. When the stream

Nirbhay Gupta 42
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

8.3. RECOMMENDATIONS FOR PRESSURE TAP DESIGN


Briefly the design and sizing recommendations for pressure taps for different
applications are given below.

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.

Nirbhay Gupta 43
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

9.0 GUIDELINES FOR ROOT VALVES

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.

Nirbhay Gupta 44
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

10.0 INSTALLATION OF INSTRUMENTATION


TUBING

10.1 Best practices for impulse tubing installation


Separation between redundant instrument sensing lines should be provided
by free air space or barriers or both such that no single failure can cause the
failure of more than one redundant sensing line.
The minimum separation between redundant sensing lines should be at least
450 mm. As an alternate a suitable steel or concrete barrier can be used.
Instrument sensing lines should be run along the walls, columns or ceilings
wherever practicable, avoiding open or exposed area to decrease the
likelihood of persons supporting themselves on the lines or of damage to the
sensing lines by pipe whip, jet forces or falling objects.
Routing of instrument sensing lines should ensure that the lines are not
subjected to vibrations, abnormal heat or stress.
Where redundant instrument sensing lines penetrate a wall or floor the
required separation (Minimum 450 mm) should be maintained. Care should
be taken to ensure that the tubing/piping does not rest on or against any
abrasive surface.
They should be kept as short as possible. This is good for two reasons;

a. The speed of response is reduced for long runs


b. Resonance frequency is increased for longer tube runs. This is
detrimental from vibratory and seismic considerations.

The distance of transmission for instrumentation tubing should be limited to


16 meters only. Beyond this limit electrical or pneumatic transmission should
be used.
They should not cause any obstructions that would prohibit personnel or
traffic access.
They should not interfere with the accessibility for maintenance of other
items of equipment/instrument.
They should avoid hot environments or potential fire risk area.
Sensing lines should be located with sufficient clearance to permit sagging.

Nirbhay Gupta 45
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

The two impulse lines especially in case of ΔP /flow measurements should be


kept close together to avoid a false pressure difference arising from a
difference in temperature.
There should be provision for thermal expansion and contraction preferably
by tube/pipe bends, elbows, offsets or changes in direction of sensing lines.
The number of joints should be kept to a minimum.
Sensing lines should be adequately supported along its entire length.
Supports, brackets, clips, or hangers shall not be fastened to the instrument
sensing lines for the purpose of supporting cable trays or any other
equipment.
Sensing lines should continuously slope downwards towards the sensing
instruments in case of liquid and upwards in case of gases. The slope should
not be less than 1:12. The slope should be increased if the liquid in impulse
lines is more viscous than water.
Bends rather than fittings should be used to change the direction of a run of
piping or tubing. A bending tool should be used when bending the tubing in
cold condition. Fittings are permitted where the use of bends is not practical.
Sharp bends should be avoided.
While installing the sensing lines the bend radius of tubing should not be
less than 3 Do.
Tubes at different temperatures should not be run together for level
measurement. This may affect the density of fluid in reference or
measurement legs.
The instrument sensing tubing or piping runs pertaining to a nuclear safety-
related instrument channel should be identified and coded so as to identify its
channel.
Each instrument-sensing line and associated valves in this channel should
have an identification tag showing the channel and unique line or valve
identification number.
If multiple sensing lines are installed in a single tray, the tray should be
identified with the appropriate sensing line numbers, colors, etc.
Each instrument sensing line, as a minimum, should be tagged at its process
line root-valve connection, at the instrument, and at any point in between
where the sensing line passes through a wall or a floor (on both sides of such
penetration). Each valve also should be tagged.
Where tubing penetrates a radiation, fire, water, or air seal, care should be
taken to ensure that the seal is not degraded by the sensing line's seismic or
thermal movements. In addition, the mechanical properties of the seal shall be

Nirbhay Gupta 46
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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:

1. Demonstrate by documented analysis or calculations that the process


movements are negligible.
Or
2. Demonstrate by documented analysis or calculations that sufficient
flexibility has been provided to accommodate the process movements.

Flexible hose may be used in sensing lines to accommodate the process


thermal, seismic, and vibrational movements if its ratings equal or exceed the
design requirements, including service life. Installation considerations should
include maintaining slope and no low points.
Instrument sensing lines and accessories inside the Containment Building
shall withstand the pressure profile during containment leak-rate testing.

Nirbhay Gupta 47
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

10.2 Some Practical Guidelines for Tube Laying and Bending


1. Measure Exactly - Bend Accurately
These are the two most important rules which must be observed when fabricating
a tube line. (See Figure-10-1 below)

Nirbhay Gupta 48
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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)

2. Tube Centerline Basis for Measurement:


The centerline of the tube is the basis for all tube line measurement (See Figure-
10-4 below). Always measure from the centerline except from the first bend which

Nirbhay Gupta 49
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

10.3 Tube Bending Check list


Follow this list to insure good results on each bend.
a. Measure and mark exactly. Insert tube in bender.
b. Always try to bend in the same direction! If you backbend, be sure to
compensate for gain or pickup. Remember, gain always occurs to the right
side of the tube radius block.
c. Clamp tubing securely in bender.
d. Check to make certain length mark is tangent to desired angle on radius
block or in line with the desired degree on the link member.
e. Bend accurately to the desired angle plus spring back allowance.
f. Open bender, remove tube.
g. Double check bend angle with triangle.
h. Check measurement length with tape or ruler.
i. The bending radius selected must be at least three times the outside
diameter of the tube.

Keep Track of Changes of Plane


Benders bend in only one direction. Changes in plane are
accomplished by rotating the tubing in the bender. To
insure that the tubing is correctly placed for the desired
change in plane, a reference mark on the tube is very
helpful.

Bend Direction Mark


One method for keeping track of changes in plane is to
use a longitudinal or lengthwise bend direction mark.

Nirbhay Gupta 50
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.

Marking the Tube


Whenever you make a mark on
tubing, use a sharp pencil. Use a
ferrule as a guide to make
measurement marks all the way
around the tube so that the mark
is always visible. (See Figure 10-7) Don’t use grease
pencils or crayons as these make too wide a line which
can easily affect accuracy.

Measure and Mark


Never use a sharp tool to scratch marks onto tubing.
Scratches create points where corrosion or stress
concentration can ruin or dangerously weaken the tube.

Rules for Positioning Tubing in Bender


A line which is tangent to the desired angle mark on the radius block and which passes
through the measurement mark at the centerline of the tube, is used to control the
distance between bend centerlines. (See Figure below)

Nirbhay Gupta 51
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Tube Positioning Rules

90° angles - tangent flush with length mark (refer to dotted line xy
tangent to radius block @ 90° fig. 10-8 (above).

Angles less than 90° - tangent intersects length mark at centerline.

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)

Horseshoe or u-bends – measure first leg, position for 90°, bend


around to 180°.

Compensate for springback:


a. Test a piece of the material before you start fabricating a line to see how much it
springs back on a 90° bend.
b. Overbend by the amount of
springback. For example, if the material
springs back 3° on a 90° bend, bend to 93°
to secure a finished 90° bend, or to 46-
1/2° to obtain finished 45° bend. This
works especially well with large heavy-
wall tubing.
c. Remember, it is always better to
underbend slightly. You can always bend a
little more if needed, but it’s almost
impossible to remove or straighten a bend,
especially with large, heavy-wall tubing.
REMEMBER - A TUBE BENDER BENDS -
IT CAN NOT UNBEND.

Tube Stretch or Pickup


When bent, tubing seems to stretch or pick up
length. This is because it takes a curved
shortcut across the inside of the angle. A good
“rule of thumb” for most standard tubing
materials and radius blocks is that the tubing
will stretch approximately one tube diameter
for each 90° bend.
Always try to bend in the same direction -
away from the original starting end. If you
reverse the direction of bending (bending
towards instead of away from the original starting end) you will “trap” the stretch. Thus,

Nirbhay Gupta 52
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

Nirbhay Gupta 53
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

accuracy, measure and bend exactly for


each individual bend in the tubing line.
We recommend the practice of Measure
and Bend then again Measure and Bend,
etc.

10.4 Characteristics of a Well-Made Tubing Circuit


In a well made tubing circuit or line, bends are accurate, measurement exact. The run is
plumb, square and level. Tube ends rest firmly in the fittings and entry into the fittings is
straight. Straight tube entry is very important to insure that fittings are not under stress
and can be assembled without leaks. (See Figure 4-13below)

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.

Nirbhay Gupta 54
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Recommended Free Tubing


Lengths
It is important to consider the
length of tubing from the end in the
fitting body to the beginning of the
bend. Table: 10-2 lists the
recommended lengths “L” and “D”
for various sizes of tubes.

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

10.5 Common Causes of Imperfect Bends


Figure A shows an ideal bend. Bends with little or no flattening are produced when
correct equipment and methods are employed; when proper consideration is given to co-
relationship of the radius of the bend, material wall thickness and hardness of the tube.
Figure B shows a flattened bend, caused by trying to bend too short a radius, or bending
smaller diameter tube in larger radius block. Figure C shows a kinked and flattened bend,
caused by the tube slipping in the bender, or by using non-annealed tubing. Tubes must
be firmly clamped by clamp block to prevent slippage during bending process. Figure D
shows a wrinkled bend, sometimes produced when thin wall tube is bent. Breakage will
sometimes occur when mandrel is too far forward in tube, or when too short a radius is
attempts with hard tube.

Nirbhay Gupta 55
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.

STEP 1 First, determine the total


amount of offset required
(dimension “F” in the diagram).
STEP 2 Next, determine the angle of
offset - 30° or 45°. The latter (45°) is
recommended because benders are
calibrated for 45° bending.
STEP 3 Figure the length of the tube required to meet your offset requirements (“L”
dimension) in the diagram. For 30° bends multiply desired offset “F”x 2= 30° offset
dimension “L”. For 45° bends multiply desired offset “F”x 1414=45° offset dimension “L”.
STEP 4 Determine where you want the offset bend of the tube to start; and make a
reference mark (A). Now measure off the “L” dimension (determined in Step 3), starting
from the reference mark and make a second mark (B). You are now ready to make the
bends.
STEP 5 Align mark (A) with reference mark 45° on bender shoe handle (measurement
end to the left) and proceed with first bend. Then align (B) with 45° mark and make
second bend in proper direction (measurement end to the left). Follow previous detailed
instructions for making 45° bends in one plane.

Nirbhay Gupta 56
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

10.6 Routing of Bends


Routing of lines is probably the most difficult yet most significant of these system design
considerations. Proper routing involves getting a connecting line from one point to
another through the most logical path. The most logical path should:

Avoid excessive strain on joints - A strained joint will eventually leak.

Figure-10-17

Nirbhay Gupta 57
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.

Nirbhay Gupta 58
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Get around obstructions without using excessive amount of 90° bends.


Pressure drop due to one 90° bend is greater than that due to two 45° bends.

Keep tube lines away from components that require regular


maintenance.

Have a neat appearance and allow for easy trouble shooting,


maintenance and repair.

Nirbhay Gupta 59
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

10.7 Guidelines for Copper Tube Installation


Following additional guidelines for the installation of copper tubes should be followed.

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.

10.8 Guidelines for Copper tube bending


Because of its exceptional formability,
copper can be formed as desired at the
job site. Copper tube, properly bent, will
not collapse on the outside of the bend
and will not buckle on the inside of the
bend. Tests demonstrate that the
bursting strength of a bent copper tube
can actually be greater than it was
before bending. Because copper is
readily formed, expansion loops and
other bends necessary in an assembly
are quickly and simply made if the
proper method and equipment are used.
Simple hand tools employing mandrels,
dies, forms and fillers, or power-

Nirbhay Gupta 60
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

operated bending machines


can be used. Both annealed tube and hard drawn tube can be bent with the appropriate
hand benders. The proper size of bender for each size tube must be used. For a guide to
typical bend radii, see Table10-3. The procedure for bending copper tube with a lever-
type hand bender is illustrated in Figure below

10.9 Copper tube Joints


Soldered joints, with capillary fittings, are used in plumbing for water lines and for
sanitary drainage. Brazed joints, with capillary fittings, are used where greater joint
strength is required or where service temperatures are as high as 350°F. Brazing is
preferred, and often required, for joints in refrigeration piping.

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.

Nirbhay Gupta 61
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

11.0 Impulse tube/Sensing line support


Following principals should be followed while designing the instrument sensing line
supports.

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

Nirbhay Gupta 62
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)

Nirbhay Gupta 63
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

12.0 Impulse tube installation through EPs


In case where tubing/piping are
penetrating shielding wall, care should
be taken to avoid personnel exposure
to radiation streaming from radioactive
sources to surrounding areas through
instrument sensing lines penetrations
in the shielding wall. To take care of
the above, sensing lines penetrating the
shield wall should be passed through
embedded parts and surrounded by a
pipe sleeve in the shielding wall. The
open space between the pipe

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

Nirbhay Gupta 64
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.0 TUBE FITTINGS


Tube fittings are used to join or connect a tube end to another member, whether that
other member be another tube end such as through T-fittings and elbow fittings, for
example, or a device that needs to be in fluid communication with the tube end, such as
for example, a valve.

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.

13.1 Requirements of a tube fitti ng


Tube fittings that are intended for use with stainless steel tubing, for example, are
particularly challenging to design in order to achieve the desired tube grip and
seal functions. This arises from the nature of stainless steel which, in terms of
typical commercially available tubing material, is a very hard material, usually on
the order of up to 200 Vickers. Stainless steel tubing is also used for high pressure
applications in which the tubing wall thickness is substantial (referred to in this
paper as "heavy walled" tubing). Heavy wall tubing is difficult to grip because it is
not only hard but it is also not particularly ductile. Low ductility makes it more
difficult to deform the tubing plastically so as to achieve a desired tube grip.

A tube fitting has to meet the following requirements:

Offer reliable installation over a range of field conditions, since improper


make-up and tightening remain the leading causes for leakage.

Nirbhay Gupta 65
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Cope with the wide variation in tubing characteristics, including differences


in wall thickness, hardness, ovality, and burst pressures.
Deliver a predictable, consistent “feel” to installers, who sometimes judge
installation quality by effort (torque) rather than the recommended
installation practice. Fittings that require high installation torque or that
vary widely in the “feel” and effort required to achieve complete pull-up
may cause installers to improperly tighten components and severely
degrade tube fitting performance.
Fittings should be of a compatible material with the tubing or pipe material
on which they are used to avoid electrolysis and to provide acceptable weld
joints.
Tube fittings should be used at pressure-temperature ratings not exceeding
the recommendation of the tube fitting manufacturer and to meet the
environmental and process system requirements.
Tube fittings should be installed in accordance with manufacturer's
recommendations.
In the absence of any existing standards, the designer should determine
that the type of fitting selected is qualified for design conditions (including
vibration, pressure, and thermal shock and applicable environmental
conditions) or should demonstrate this by testing the fitting's ability to
perform its intended function. The fittings selected should not degrade the
inherent strength of the tubing specified.
Screwed joints in which pipe threads provide the only seal may be used, as
long as they are in compliance with the appropriate code and system
temperature and pressure requirements.
Thread sealant should be suitable for the required service conditions
considering the process media, radiation environment, and compatibility
with the materials of construction.
It should withstand the temperature and pressure cycling as per
appropriate standard (PB-E-146).
Pull Out Capability: Tube fitting should provide sufficiently robust grip on
the tube such that when a tensile load (e.g. during hydro test or during
operating conditions) is applied on it the tube does not pull out of the grip.
Generally the acceptable pull out tension load is more than four times the
hydrostatic test pressure load.
It is recommended that compression type tube fitting should not be used
for welded tubes. As in such type of tubes the hardness differs at the point
of welding. This difference makes the gripping action of the ferrule

Nirbhay Gupta 66
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)

13.2 Construction of a tube fitting


Tube fittings for stainless steel tubing typically include an assembly of

a tube gripping device, often in the form of a ferrule or ferrules, or a


gripping ring-like structure, and
a pull-up mechanism for causing the tube gripping device to be installed on
a tube end so as to grip the tube end and provide a seal against leakage.

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.

Nirbhay Gupta 67
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.3 Types of tube fittings


Generally following types of fittings are available:

(a) Flareless Compression Type (Single Ferrule)


(b) Flareless Compression Type (Double Ferrule)
(c) Bite Type
(d) Flared Fitting

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.

13.4 Flared Fitting


This is made up of a nut, sleeve and body with a flare or coned end. In some
instances, the sleeve is used as a self-flaring option, usually on thinner wall or
softer tubing materials. Compared to the original compression fitting, the flare
fitting can handle higher pressures and wider system parameters. It is also
available in a larger variety of materials and has a larger seal area, which provides
remake capabilities in maintenance applications. However, special flaring tools are
required to prepare the tubing for installation. Additionally, flaring of the tubing
can cause stress risers at the base of the flare or cause axial cracks on thin or
brittle tubing. Uneven tube cuts will create an uneven sealing surface.

Nirbhay Gupta 68
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.5 Flareless Bite type tube fitting


A Flareless bite type fitting consists of a body, a
special case hardened ferrule (a one-piece precision
machined ferrule) and a nut, put together in a
standard way. On assembly, the ferrule "bites" into
the outer surface of the tube with sufficient strength
to hold the tube against pressure, without
significant distortion of the inside tube diameter.
Hence, the name "bite type fitting". As used herein,
the term "bite" refers to the plastic deformation of
the ferrule into the outer surface of the tube end so
as to plastically deform and indent the tubing with
an almost cutting- like action to create a generally radial shoulder or wall at the
front end of the ferrule. This "bite" thus serves as a strong structural feature to
prevent tube blow out at high pressure, particularly for larger diameter tubing
such as 1/2"and higher.

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.

13.6 FLARELESS COMPRESSION TYPE TUBE FITTI NG


Over the years there have been numerous tube fitting designs that do not rely on
a "bite" type action, but rather merely radially compress the tube gripping device
against the tubing outer surface, some with the effect of indenting into the tu bing
without creating a bite.

The most common commercially available stainless steel tube fittings especially
for high pressure applications have historically been of two radically distinct

Nirbhay Gupta 69
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

designs of the tube gripping device--single ferrule tube fittings and two ferrule
tube fittings.

13.7 SINGLE FERRULE FLARELESS COMPRESSION TYPE TUBE


FITTING
A single ferrule tube fitting, as the name implies, uses a single ferrule to
accomplish both the tube grip and seal functions.
For single ferrule tube fittings, the tube gripping action is usually associated with
the single ferrule being designed to bow in a radially outward direction from the
tube wall in the central region or mid-portion of the single ferrule body between
the front and back ends thereof.

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.

Nirbhay Gupta 70
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.

13.8 TWIN FERRULE FLARELESS COMP RESSION TYPE TUBE


FITTING

It is becoming increasingly recognized that the two primary functions of a tube


fitting viz. tube gripping and sealing are at odds with each other when designing a
tube fitting that can meet a desired tube grip and seal performance criteria. This is
because the design criteria needed to assure that the tube fitting achieves an
adequate tube grip usually works against the ability of the single ferrule to also
provide an effective seal. Consequently, although single ferrule fittings can achieve
adequate tube grip in some cases, this tube grip performance comes at the
expense of having a less effective seal. The shallow camming angle and elongated
camming surface and axial movement needed to achieve an adequate tube grip
with a single ferrule fitting, however, compromises the ability of the single ferrule
to achieve the seal function, especially in extreme environments and for sealing
gas. This is because the front end of the single ferrule attempts to make the seal
against the axially elongated camming surface. The radially outward bowing
action causes a larger portion of the outer surface of the front end of the single

Nirbhay Gupta 71
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.

13. 8.1 Ferrule and its purpose

The ferrule, perhaps the most-critical component in


compression fittings, appears rather simple. Yet it is
highly engineered and, to function properly,
requires considerable design, metallurgy, and
production expertise. Not all products on the
market meet these stringent requirements.
For instance, the ferrule must precisely deform
elastically and plastically during fitting assembly to
properly grip and seal the tubing. Its front edge
must be harder than the tubing to grip and seal through surface scratches and
defects, but if the entire ferrule is too hard, it may not deform properly.
Therefore, only the gripping edge of the ferrule is hardened while the rest has
different, tightly controlled mechanical properties. Also, the hardening process
must not compromise stainless steel's corrosion resistance. And finally,

Nirbhay Gupta 72
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.

Ferrules provide a reliable, leak-proof connection in instrumentation and process


tubing systems. These tube fittings consist of four precision-machined
components: body, front ferrules, back ferrules, and nut. Ferrules make up for the
variation in the tubing material, hardness and thickness of the tube wall in order
to provide leak-proof connections in a large number of applications. They also
reduce the number of potential leak paths in the connection, boosting safety,
reliability and integrity. They also simplify assembly and maintenance.

Ferrules can generally handle pressures up to 15,000 PSI / 1,034bar. They


eliminate the time-consuming 'coning and threading' that usually needs to be
performed when applying traditional high-pressure flared fittings, allowing
fittings to be installed in seconds by simply tightening a nut.

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.

13. 8.2 Swaging

Swaging is a metal-forming technique in which the dimensions of an item


are altered using a die or dies, into which the item is forced. Swaging is a
forging process, usuall y performed cold, howe ver it can b e done hot. T he
most common use of swaging is to attach fittings to pipes or cables ( also
calle d wire rope s); the parts loo sel y fit together, and a mechanical or
hydraulic tool compress es and deforms the fitting, creating a permanent
joint. Pipe flaring machines are another example.

Nirbhay Gupta 73
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Swaging is a process that is used to reduce or increase the diameter of tubes. A


swaged piece is created by placing the tube inside a die that applies compressive
force by hammering radially.

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".

13.8.3 Operation of a twin ferrule tube fitting


Function of Front ferrule

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.

Function of a Back Ferrule


The back ferrule achieves the tube grip function in the two ferrule tube fitting.
The back ferrule is case hardened to be substantially harder than the tube end.
Tube fittings depend on a balance of factors to ensure proper installation and
performance. In a two-ferrule tube fitting design, the back ferrule moves the front
ferrule forward to spring load the fitting assembly, burnish and seal with the
fitting body, and create the primary tubing seal. The front end of the back ferrule
cams against a frusto-conical camming surface formed in the back end of the front
ferrule. The ostensible angle of this camming surface is forty-five degrees, but due
to the sliding movement of the front ferrule, the effective camming angle is
actually a shallow angle of about fifteen to twenty degrees. Although the effective
camming angle for the back ferrule is shallow, the back ferrule is not required to
provide a primary seal (although it can form secondary or backup seals). The
back ferrule also does not exhibit the undesired bowing action but rather grips

Nirbhay Gupta 74
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—

1. Complete surface hardening of the back ferrule:


The use of complete surface hardening on a conventional back ferrule can
have several drawbacks.

First, it typically increases installation torque because a surface-hardened,


conventional back ferrule is unable to flex or “hinge” downward to improve
swaging action on the tube. Instead, it must be wedged into position using
installer torque, and as a result, more torque typically is required.
Second, because it is not engineered to hinge and absorb installer torque on
remakes, a conventional surface-hardened back ferrule can tend to overdrive
the front ferrule when remade. This condition can potentially damage the
tubing and fitting body and compromise the front ferrule action required for
consistent gas-tight remakes.

2. Selectively hardened back ferrule: Use of a selectively hardened back


ferrule, Swagelok reduced installation torque while providing the swaging
and gripping action needed to perform in combination with a wide variation
of commercial grade tubing. In manufacturing back ferrules selectively
hardening the nose of the back ferrule is done, yet the center section and rear
flange are left softer. During make-up, this softer center section acts as a
hinge point when force is applied to the flange. This hinging mechanism
helps limit the amount of torque required by the installer, yet delivers the
right amount of swaging action through the nose of the back ferrule.

The improved engineered hinging action of the back ferrule (Figure 4, next
page) provides several benefits:

Nirbhay Gupta 75
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

It advances and seals the front ferrule predictably and accurately.


It flexes to maintain installation torque at a predictable and
manageable level, even on hard materials.
It smoothly and efficiently delivers more swaging energy earlier in the
pull-up process. As a result, it reduces the potential for improper
installation and leakage in cases where the fitting is less than properly
tightened.
Its proprietary metallurgy and hinging action can absorb excess
torque inputs to help prevent overdriving of the front ferrule, thus
ensuring more predictable gas-tight sealing during remakes.

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.

Fi gure 13-4: 316 SS A dvanc ed S wage lo k Tube Fi t ti ng Pri o r to Make -up

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.

Nirbhay Gupta 76
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Fi gure 13-5: 316 SS A dvanc ed S wage lo k Tube Fi t ti ng A fter Make -up

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.

Nirbhay Gupta 77
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.8.4 Effect of Tube thickness on Swagi ng


The strength of the fitting is such that the tube contained will burst before the
fitting shows any sign of a leak or movement. This is subject to certain constraints
on the wall thickness of the tube. Tube thickness is decided by following factors
a. Pressure rating
b. Corrosion/Threading allowance
c. Swaging considerations

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.

Nirbhay Gupta 78
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Advanced Swagelok Fitting


The adv a nced S w a gelok tw o -f errul e tu be f itti ng of f ers predict abl e, l eak f ree perf orm ance up to t he b urs t
pres s ure of ANS I 316 and 304 s tai nles s s teel tu bin g. A s um m ary of its benef its includ e:

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 .

Nirbhay Gupta 79
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13. 8.5 Safety precautions for tube fitting installation

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.

 Additional tubing considerations:


Always use an insert with extremely soft or pliable plastic tubing.
Wall thickness should always be checked against the fitting
manufacturer’s suggested minimum and maximum wall thickness
limitations.

Nirbhay Gupta 80
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Surface finish is very important to proper sealing. Tubing with any


kind of depression, scratch, raised portion, or other surface defect will
be difficult to seal, particularly in gas service.
Tubing that is oval and will not easily fit through fitting nuts, ferrules,
and bodies should never be forced into the fitting.
When installing fittings near tube bends, there must be a sufficient
straight length of tubing to allow the tube to be Bottomed in the fitting
(see figure-13-7). The following table indicates the minimum straight
length required.

Figure 13-7: Tube fitting at a bend

Special precautions for Gas Service


Gases (air, hydrogen, helium, nitrogen, etc.) have very small molecules that can
escape through even the most minute leak path. Some surface defects on the tubing
can provide such a leak path. As tube outside diameter (OD) increases, so does th e
likelihood of a scratch or other surface defect interfering with proper sealing.
The most successful connection for gas service will occur if all installation
instructions are carefully followed and the heavier wall thicknesses of tubing on
the tables-1-3 to 1-10 are selected.

Nirbhay Gupta 81
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.9 Repeated assembly and Disassembly of tube fitting

Figure-13-8: Tube fitting in assembled condition

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.

Nirbhay Gupta 82
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.10 SPECIFICATIONS FOR SS TUBE FITTI NGS


1 Type : Flareless compression, twin ferrule
2 Material / type : SS-316 as per ASTMA-A-314 - forged
3 Fluid : water / steam/lube oil
4 Max. Pressure : 200 kg/cm2 (g)
5 Maximum : 320 °C
Temperature
6 Overall : As per ANSI-B-1.20.1
Dimensions
7 Hardness : > Rockwell B-90

8.0 Tests
8.1 Type Test

8.1.1 Chemical : Incoming material as per ASTM-A-314


Composition test
8.1.2 Ferrule Hardness : On each size of ferrule as per ASTM-A-3145
Test
8.1.3 Test on Raw : Raw material for body, nut and ferrules should be tested
Material for physical properties (i.e. tensile strength, %
elongation, hardness)
8.1.4 Seismic Test : Required. Vibration should be in the frequency range
from 1-33 Hz, Peak acceleration at frequencies 1, 1.26,
1.59, 2 and 2.5 Hz should preferably be between 1g and
3.5g or capability of shake table. For and beyond 3.75 Hz
Peak acceleration should be 3.5 g. Test duration should
be 30 seconds at each frequency. Frequency should be
increased in step of 1/3 octave in the specified
frequency range 1-33 Hz. Before and after the test the
fitting assembly should be tested and should qualify all
the other tests.

8.2 Routine Tests

8.2.1 Overall Dimension : Required to be done on 1% items of each type


Thread
8.2.2 Check for End :
Connections
8.2.3 Hydrostatic test : At pressure of 300 kg/cm2 (g); duration = 10 min.
Required to be done on 10% items of each type
8.2.4 Pneumatic leak : At a pressure of 4 kg/cm2 (g); duration = 10 min.

Nirbhay Gupta 83
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

test (required to be done on 10% items of each type.)


8.2.5 Reassembly Test : Required to be done 25 times on 1% items (min. 2 nos.),
from each lot.

9.0 Applicable codes & standards:

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

Nirbhay Gupta 84
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

13.11 SPECIFICATIONS FOR BRASS TUBE FITTINGS


1 Type : Flareless compression, twin ferrule
2 Material / type : Brass as Per ASTM-B-124 / Forged
3 Fluid : Air
4 Max. Pressure : 40 kg/cm2 (g) @ ambient temperature
5 Maximum : 320 °C
Temperature
6 Overall : As per ANSI-B-1.20.1
Dimensions
7 Hardness : > Rockwell B-90

8.0 Tests
8.1 Type Test

8.1.1 Chemical : Incoming Material as per ASTM-E-54/478


Composition test
8.1.2 Ferrule Hardness : On each size of Ferrule as per ASTM-B-124
Test
8.1.3 Test on Raw : Raw material for body, nut and ferrules should be tested
Material for physical properties (i.e. tensile strength, %
elongation, hardness)
8.1.4 Seismic Test : Required. Vibration should be in the frequency range
from 1-33 Hz, Peak acceleration at frequencies 1, 1.26,
1.59, 2 and 2.5 Hz should preferably be between 1g and
3.5g or capability of shake table. For and beyond 3.75 Hz
Peak acceleration should be 3.5 g. Test duration should
be 30 seconds at each frequency. Frequency should be
increased in step of 1/3 octave in the specified
frequency range 1-33 Hz. Before and after the test the
fitting assembly should be tested and should qualify all
the other tests.

8.2 Routine Tests

8.2.1 Overall Dimension : Required to be done on 1% items of each type


Thread
8.2.2 Check for End : Required to be done on 1% items of each type
Connections
8.2.3 Hydrostatic test : At a pressure of 60 kg/cm2 (g); duration = 10 min.,
required to be done on 10% items of each type
8.2.4 Pneumatic leak : At a pressure of 4 kg/cm2 (g); duration = 10 min.

Nirbhay Gupta 85
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

test (required to be done on 10% items of each type.)


8.2.5 Reassembly Test : Required to be done on 1% items (min. 2 nos., from each
lot, six times after sixth, pneumatic test)

9.0 Applicable codes & standards:

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.

IS 4218 Indian standard for Metric Straight Pipe Threads

Notes:

1. Pipe threads should be NPT threads as per ANSI-B-1.20.1


2. Needs the above seismic test is required on 1% of each type of fitting. This test
should be performed on limited samples taken from the lot.

Nirbhay Gupta 86
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

14.0 THREADS USED FOR TUBE FITTINGS

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.

14.1. Evolution of threads


In the nineteenth century, many different types of screw threads were required for
hydraulic and pneumatic circuits as well as fastening components. As a result,
manufacturers started to devise their own fastening systems. This resulted in
compatibility problems. The English mechanical engineer and inventor, Sir Joseph
Whitworth devised a uniform threading system in 1841 to address the incompatibility
problem. The Whitworth thread form is based on a 55 degree thread angle with
rounded roots and crests.
In America, William Sellers set the standard for nuts, bolts, and screws which became
the National Pipe Tapered (NPT) Thread in 1864. His 60 degree thread angle, in
common use by early American clockmakers, enabled the American Industrial
Revolution. These thread forms later became the American National Standard.
The Whitworth thread form was selected as a connecting thread for pipes, which was
made self sealing by cutting at least one of the threads on a taper. This became known
as the British Standard Pipe thread (BSP Taper or BSP Parallel thread). The
Whitworth thread is now used internationally as a standard thread for jointing low
carbon steel pipes.
The best known and most widely used connection where the pipe thread provides both
the mechanical joint and the hydraulic seal is the American National Pipe Tapered
Thread, or NPT Thread. NPT has a tapered male and female thread which seals with
Teflon tape or jointing compound.

14.2. Type of Threads


Pipe threads used in hydraulic circuits can be divided into two types:

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.

Nirbhay Gupta 87
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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:

NPT American Standard Pipe Taper Thread


NPSC American Standard Straight Coupling Pipe Thread
NPTR American Standard Taper Railing Pipe Thread
NPSM American Standard Straight Mechanical Pipe Thread
NPSL American Standard Straight Locknut Pipe Thread
NPTF American Standard Pipe Thread Tapered (Dryseal)
BSPP British Standard Pipe Thread Parallel
BSPT British Standard Pipe Thread Tapered

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

Nirbhay Gupta 88
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

internal variations in product wall thickness, a standard torque specificatio n cannot be


generically applied.

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.

Table-XVI-American Standard Taper Pipe External Thread


Nominal Actual Threads Length of engagement Length of
size OD per inch (tightened by hand) effective thread
1/8 0.407 27 0.124 ≈ 3.3 turns 0.260
1⁄4 0.546 18 0.172 ≈ 3.1 turns 0.401
3/8 0.681 18 0.184 ≈ 3.3 turns 0.408
1/2 0.850 14 0.248 ≈ 3.4 turns 0.534
3/4 1.060 14 0.267 ≈ 3.7 turns 0.546
1 1.327 11.5 0.313 ≈ 3.6 turns 0.682

14.4. Taper/Parallel Threaded Joints


Despite the standards created to maintain uniform fittings, tapered pipe threads are
inexact and during the course of use and repair the threads can become damaged and
susceptible to leakage. The area where the crest and the root of the thread meet can
form a spiral leak path no amount
of tightening will eliminate.

A pressure tight joint is achieved


by the compression in the threads
resulting from tightening. This
compression and sealing occurs in
the first few turns of the internal
thread. As wrenching takes place,
material from both the male and
female threads deform into each
other. This ensures full thread
contact which minimizes spiral
leakages. Variations between
injection molded plastic and
machined metal thread forms can
occur due to different
manufacturing processes.

Nirbhay Gupta 89
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

Using both tapered male and female


BSPT threads would offer a better
chance of sealing since you are now
matching the taper of the male and
female thread. See figure-14-2. This
offers more threads a chance of sealing
against spiral leakage. Crest and root
control is still missing, but with thread
sealant, a pressure tight joint would be
easier to accomplish.

A number of variations of the NPT


thread have been introduced to
overcome the problem of spiral leakage
and are known as Dryseal threads (See
SAE standard J476). The best known is
the NPTF (F for Fuel). With this
thread design, there are controls on the crests and roots of both the male
and the female threads to ensure the crest crushes or displaces material into the
root of the mating thread. The interference fit between the crest
of one thread and the root of the other along with the thread flanks matching, seals
against spiral leakage. Figure 14-3 shows an NPTF male tightened into an NPTF female
hand tight. You can see the crest of both the male and female thread flanks meet.

Nirbhay Gupta 90
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Figure 14-4 shows the NPTF male and


female threads tightened approximately 1
turn past hand tight, and you can see the
flanks meet and the crests are displaced
into the roots.
Although these threads are considered
Dryseal, a Teflon tape or liquid is still
recommended to aid in the assembly
process.
The Teflon works as a lubricant to avoid
galling of the material when tightening
the two threads together and also fills
any voids that may cause leakage.
However, in Nuclear power plants Teflon is
not used since its properties deteriorate
very fast under radiation conditions.
A variation of the Dryseal thread is the NPSF (National Pipe Straight Fuel). It is used for
internal threads and a NPTF external thread can be screwed into it to provide a
satisfactory mechanical connection and a hydraulic seal. The combination of a parallel and
tapered is not regarded as ideal but is widely used. High quality plastic quick disconnect
couplings typically use NPT threads.
Another tapered thread is the British Standard Pipe
taper, or BSP, covered by British Standard 21. BSP
thread is commonly used for low pressure plumbing,
but is not recommended for medium and high
pressure hydraulic systems. This form uses the
Whitworth thread with an angle of 55°and a 1 in 16
taper. It is not interchangeable with the American NPT
thread, though at the 1/2" and 3/4" size, they both
have 14 threads per inch.

Problems arise when threading a NPT male thread


form into a BSP female straight thread form. The
1/16”, 1/8”, 1/4”, and 3/8” sizes have a dissimilar
pitch, which causes a misalignment of the threads. The flank angles of the threads are also
different between NPT and BSP. NPT has a 60° thread where the BSP has a 55° thread.

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.

Nirbhay Gupta 91
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

an appropriate thread sealant is incorporated.


Many issues arise when plastic quick disconnect couplings, with their corresponding
injection plumbed into metal piped hydraulic systems. Leaks and plastic thread form
failures may occur if care is not taken. When investigating a metal to plastic pipe joint
failure, two factors viz. chemical attack and over tightening, need to be considered.
Chemical attack can occur when improper thread sealants are used. Thread sealing is an
attempt to block the spiral leak path which occurs when the crests and roots of the thread
forms do not match. Anaerobic thread sealants should be avoided when sealing plastic
thread forms. These sealants contain chemicals which may attack plastics. Use of a Teflon-
based pipe thread sealant is a better choice for plastic threads.

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.

Nirbhay Gupta 92
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

14.5. Dry Seal NPTF Threads


Dryseal pipe threads are based on the USA (American) pipe thread; however, they
differ from the USA (American) pipe thread in that they are designed to seal
pressure tight joints without the necessity of using sealing compounds. To
accomplish this some modification of thread form and greater accuracy in
manufacture is required.

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.

Nirbhay Gupta 93
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

Nirbhay Gupta 94
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Figure14-8-: Basic dimensions of NPTF threads

Nirbhay Gupta 95
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.0 Welding Methods


15.1 300 Series Stainless Steels
May be welded by the TIG, MIG, or stick arc-weld process. TIG welding is
recommended as being best for welding Weld fitting systems because it allows
better operator control of heat penetration and filler material deposition. Stick arc
welding is not recommended in many cases because of the likelihood of excessive
burn-through and improper root penetration. In all cases where stick welding is
used, it is recommended that backing gas be used. MIG welding gives the same
characteristics as stick electrode welding with faster deposition of the filler
material.

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.

15.2 C1018 Steel Fittings


May be welded by the TIG, MIG, stick and oxyacetylene methods. As scale formation
remains a problem, the use of a backing gas is still recommended.

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.

Nirbhay Gupta 96
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.3 TIG WELDING


The "TIG" in TIG welding stands for Tungsten Inert Gas. But before it was called TIG"
it was given the name "Heliarc" because helium was the gas that was used when the
process was invented. But then someone discovered that argon worked better and
so it was called TIG because inert gas could refer to either helium or argon. But wait,
then someone else discovered that small additions of hydrogen worked well for
some metals. The word "Inert" no longer held true so it was decided that a new
name was required. So nowadays, the technical term for what used to be called ‘TIG’
and ‘Heliarc’ is Gas Tungsten Arc Welding or "GTAW". People still call it TIG and
even Heliarc. In fact more people call it TIG welding than Gas Tungsten Arc Welding.

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.

What Metals can be welded using the TIG process?

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.

Nirbhay Gupta 97
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.4 ORBITAL TUBE WELDING


Orbital welding was first used in the 1960's when the aerospace industry
recognized the need for a superior joining technique for aerospace hydraulic lines. A
mechanism was developed in which the arc from a tungsten electrode was rotated
around the tubing weld joint. The arc welding current was regulated with a control
system thus automating the entire process. The result was a more precision and
reliable method than the manual welding method it replaced.

Orbital welding became practical for many


industries in the early 1980's when combination
power supply/control systems were developed that
operated from 240 VAC and were physically small
enough to be carried from place to place on a
construction site for multiple in-place welds.

Modern day orbital welding systems offer computer


control where welding parameters for a variety of
applications can be stored in memory and called up
when needed for a specific application. The skills of
a certified welder are thus built into the welding
system, producing enormous numbers of identical welds and leaving significantly
less room for error or defects.

Nirbhay Gupta 98
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.4.1 Orbital Welding Equipment

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.

15.4.2 Reasons for Using Orbital Welding Equipment

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:

Productivity. An orbital welding system will drastically outperform manual


welders, many times paying for the cost of the orbital equipment in a single
job.

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.

Consistency. Once a weld program has been established an orbital welding


system can repeatedly perform the same weld hundreds of times, eliminating
the normal variability, inconsistencies, errors and defects of manual welding.

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.

Nirbhay Gupta 99
TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Orbital welding may be used in applications where a tube or pipe to be


welded cannot be rotated or where rotation of the part is not practical.

Orbital welding may be used in applications where access space restrictions


limit the physical size of the welding device. Weld heads may be used in rows
of boiler tubing where it would be difficult for a manual welder to use a
welding torch or view the weld joint.

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.

15.4.3 Industrial Applications for Orbital Welding

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.

Nuclear Piping/Tubing: The nuclear industry with its severe operating


environment and associated specifications for high quality welds has long been an
advocate of orbital welding.

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

Nirbhay Gupta 100


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

joints welded with orbital equipment offer superior corrosion resistance and
mechanical properties.

Pharmaceutical Industry: Pharmaceutical process lines and piping systems deliver


high quality water to their processes. This requires high quality welds to ensur e a
source of water from the tubes that is uncontaminated by bacteria, rust or other
contaminant. Orbital welding ensures full penetration welds with no overheating
occurring that could undermine the corrosion resistance of the final weld zone.

Semiconductor Industry: The semiconductor industry requires piping/tubing


systems with extremely smooth internal surface finish in order to prevent
contaminant buildup on the tubing walls or weld joints. Once large enough, a build
up of particulate, moisture or contaminant could release and ruin the batch process.

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.

15.4.4 General Guidelines for Orbital Tube Welding

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.

Each orbital welding equipment supplier differs slightly in recommended welding


practices and procedures. Where possible, follow the recommendations of your
orbital equipment supplier for equipment set-up and use, especially in areas that
pertain to warranty issues.

This section is intended as a guideline for those applications where no specification


exists and the engineer responsible for the welding must create the welding set-up,
and derive the welding parameters in order to arrive at the optimum welding
solution.

Nirbhay Gupta 101


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.4.5 The Physics of the GTAW Process

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.

15.4.6 Material Weldability

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.

Accommodation must be made for the potential differences of different material


heats. The chemical composition of each heat batch number will have minor
differences in the concentration of alloying and trace elements. These trace
elements can vary the conductivity and melting characteristics slightly for each heat.
When a change in heat number is made a test coupon should be made for the new
heat. Minor changes in amperage may be required to return the weld to its original
profile.

Nirbhay Gupta 102


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

It is important that certain elements of the material be held to close tolerances.


Minor deviations in elements such as sulfur can vary the fluid flow in the weld pool
thus completely changing the weld profile and also causing arc wander.

15.4.7 Weld Joint Fit-Up

Weld joint fit-up is dependent on the weld specification requirements on tube


straightness, weld concavity, reinforcement and drop through. If no specification
exists the laws of physics will require that the molten material flow and compensate
for tube mismatch and any gap in the weld joint.

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.

Nirbhay Gupta 103


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

Alignment mismatch (high-low) should be avoided by using engineering


stands and clamps to align the two tubes to be welded. This system also
removes the mechanical requirement of aligning the tubes from the orbital
weldhead.

15.4.8 Shield Gas (es)

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.

Nirbhay Gupta 104


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

15.4.9 Tungsten Electrode

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.

Alternative, non-radioactive tungsten materials are now available, such as 2%


ceriated electrodes, which often offer superior arc welding. While these materials
are commercially available they have been largely ignored until recently.

Recommended Electrode Materials: Cerium, as a base material, has a lower work


function than thorium, thus it offers superior emission characteristics. Thus, not
only do ceriated electrodes offer an advance in electrode safety, they also improve
the arc starting ability of the orbital equipment. However, as mentioned earlier, it is
always best to follow the advice of your orbital equipment manufacturer. 2%
ceriated and 2% thoriated electrodes are the most commonly recommended
materials for orbital welding equipment.

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

Nirbhay Gupta 105


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

weld quality is up to par. Consistency and repeatability are key to welding


applications. The shape and quality of the tungsten electrode tip is finally being
recognized as a vital process variable. Once a weld procedure has been established,
it is important that consistent electrode material, tip geometry and surface
condition be used.

15.4.10 Welding Basics and Set-Up

Figure-15-5: We ld Electrode tip di ameter

To produce high consistent welds the Tungsten electrode must provide the
following:

1. High quality electrode material

2. The electrode tip dimensions shown must be held to close tolerances

3. The surface finish (ground or polished) of the electrode grind must b e


consistent.

Welders should follow an equipment supplier's suggested procedures and


dimensions first, because they have usually performed a significant amount of
qualifying and troubleshooting work to optimize electrode preparation for their
equipment. However, where these specifications do not exist or the welder or
engineer would like to change those settings to possibly improve and optimize their
welding, the following guidelines apply:

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:

Nirbhay Gupta 106


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Sharper Electrodes Blunter Electrodes

Easy arc starting Usually harder to start the arc

Handle less amperage Handle more amperage

Wider arc shape Narrower arc shape

Good arc stability Potential for more arc wander

Less weld penetration Better weld penetration

Shorter electrode life Longer electrode life

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.

Figure-15-6: Arc Shapes and resultant weld profiles

B. Electrode Tip Diameter - Grinding an electrode to a point is sometimes desirable


for certain applications, especially where arc starting is difficult or short duration
welds on small parts are performed. However in most cases it is best for a welder to
leave a flat spot or tip diameter at the end of electrode. This reduces erosion at the
thin part of a point and reduces the concern that the tip may fall into the weld.
Larger and smaller tip diameters offer the following trade-offs:

Nirbhay Gupta 107


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Smaller Tip Larger Tip

Easier arc starting Usually harder to start the arc

Potential for more arc wander Good arc stability

Less weld penetration More weld penetration

Shorter electrode life More electrode life

Tungsten Electrode Grinders and Pre-Ground Electrodes: Using electrodes pre-ground


to requirements or a dedicated commercial electrode grinder to provide electrode
tip quality and consistency offers the following benefits to the user in their welding
process:

1. Improved arc starting, increased arc stability and more consistent weld
penetration.

2. Longer electrode life before electrode wear or contamination.

3. Reduction of tungsten shedding. This minimizes the possibility of Tungsten


inclusions in the weld.

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.

Nirbhay Gupta 108


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Consult electrode charts or a pre-ground electrode


supplier to obtain the electrode diameter and tip
geometry that is most suitable for your welding
application.

Fi gur e- 15- 7: Us i ng p re -g rou nd el ec tro des


ens u re t ha t th e el ect rod e ma te ri al qual i ty , ti p
geom et ry an d gro un d el ect rod e s urf ace i np ut
to th e w el di ng p ro c ess i s c o nstant

15.4.11 Welding Parameter Development

Many welding equipment suppliers offer a series of pre-calculated weld programs


for a variety of tube diameters, wall thicknesses and materials. Welders should
always follow an equipment supplier's suggested procedures first, because they
have usually performed a significant amount of qualifying and troubleshooting
work to optimize electrode preparation for their equipment.

However, it is impossible for the equipment suppliers to have welding procedures


for every welding application and there will always exist a trade off in maximum
weld speed possible versus weld quality and repeatability. Where weld parameter
specifications do not exist or the welder or engineer would like to change those
settings to possibly improve or optimize their welding, the guidelines noted below
give information on how to modify the welding parameters for a desired result.

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.

Nirbhay Gupta 109


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

The welding current is dependent on the material to be welded, wall thickness,


weld speed, and the shield gas chosen. The objective is to achieve full penetration,
defect free welds.

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.

Weld Current Levels

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.

Nirbhay Gupta 110


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

Nirbhay Gupta 111


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

Figure 15-9: Weld program data sheet of a typical weld in RAPP-6

Nirbhay Gupta 112


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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

Nirbhay Gupta 113


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

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.

It is important to understand how to choose convenient weld development


starting parameters and the effect on the weld by changing each parameter.

The primary objective is to use the benefits of weld pulsation to improve weld
quality and output.

Peak/Background Current Ratios: The peak to background current ratios basically


provides a means for the welding current to pulse from one level to another.
Industry usage generally varies from 2:1 ratios to 5:1 ratios. A good starting point
is to use 3:1 ratios, make the required weld and test other parameters to see if any
benefit can be gained.

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%.

Welding Parameter Development Example for 1" Tube/.030" Tube Wall


Thickness:

1. Arc Length/Gap = .010" + (0.5 x penetration required)


Starting Parameters: .010" + (0.5 x .030") = .025"

2. Weld Speed = 5 ipm surface speed


RPM = ipm/(3.1415 x dia.)
Starting Parameters: 5/(3.1415 x 1") = 1.59 RPM

3. Welding Current Levels


Level 1 = 1 amp per .001" of wall thickness for level 1 current
Level 4 = 80% of Level 1 current
Levels 2 and 3 gradually decrease the current from Level 1 to Level 4
Starting Parameters:

Nirbhay Gupta 114


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

Level 1 Peak Current = .030" wall thickness = 30 amps


Level 4 Peak Current = 30 amps x 80% = 24 amps
Level 2 Peak Current = 28 amps
Level 3 Peak Current = 26 amps

Background Current will be 1/3rd of peak current. Pulse width/duty cycle is 35%

4. Tungsten Electrode Diameter & Tip Geometry - Use your equipment


manufacturer's specifications or consult your pre-ground electrode supplier

The above data gives starting parameters. On completion of the first test weld, the
parameters will be modified to obtain the final result desired.

Nirbhay Gupta 115


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

16.0 REFERENCES AND SUGGESTED READING


1. An installer’s pocket guide for Swagelok tube fittings: Swagelok instruction manual.

2. ANSI/ASME B31.1-1980: Power piping


3. ISO-2186-1973 (2001): Fluid flow in closed conduits- connections for pressure signal
transmissions between primary and secondary elements.
4. SA 655: Specification for special requirements for pipe and tubing for nuclear and other
special applications.
5. TAPP-3&4/60610/93/B/4670 dated 9th June, 1993: Design note on Class-I Instrument
tubing.
6. TAPP-3&4/60610/93/B/4671 dated 9th June, 1993: recommendation note on impulse
connections and their installations

7. Eric Lundin, “Is your bend good enough”, The Fabricator.

8. ISA-S 67.02.02(1996): Nuclear safety related instrument sensing line piping and tubing.

9. ASME PTC code 19.5: Flow measurement.

10. ASME PTC code 19.2: Pressure measurement.

11. PB-E-344: Specifications for SS tubes

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

14. PB-E-44: Specifications for Brass compression type (flareless)tube fittings


15. ANSI/ASME B1.20.1-1983, Pipe Threads, General purpose (inch)
16. IS-1239 (part-II)-1982, Specification for mild steel tubes, Tubular and other Wrought
steel fittings
17. ASME Section-III- Rules for construction of Nuclear Power Plant Components; Division-I-
Subsection NB: Class 1 Components

18. BS-4368-Part-I-1972; Carbon and Stainless Steel Compression Couplings for Tubes

19. “Fundamentals of orbital tube welding”, Pro-Fusion technologies, Inc.

20. ANSI/ASME B1.20.4-1976, Dryseal Pipe Threads

Nirbhay Gupta 116


TECHNICAL DOCUMENT ON INSTRUMENTATION TUBING AND THEIR CONNECTIONS 2008

21. “Tools and Manufacturing Engineer’s Handbook: A Reference Book for Engineers,
Managers and Technicians”, Tom Drozda, Charles Wick.

22. “Perry’s chemical Engineers’ Handbook”, Robert H. Perry, D.W. Green.

23. Brochure of Tubes and Tube fittings, Parker Hannifin, USA.

24. “TIG Welding Basics-for TIG Welders, by a TIG Welder”, Jody Collier.

25. Swagelok SWS Orbital tube welding machine training notes.

26. Swagelok Manual on Orbital tube welding machine SWS D-100.

Nirbhay Gupta 117

You might also like