Escolar Documentos
Profissional Documentos
Cultura Documentos
SEPTEMBER 2008
TECHNICAL DOCUMENT ON
INSTRUMENTATION TUBING AND THEIR
CONNECTIONS
ii
PREFACE
Instrumentation design and construction is a very interesting proposition. One is supposed to
know the electronics and electrical aspects as well as the mechanical aspects too.
Instrumentation tubing is one such field where an instrumentation engineer has to don the
robes of a mechanical engineer. In NPCIL, for a long time, it was felt that there is no single
document that can cater to the needs of budding as well as practicing engineers when they
want to search some information on instrumentation tubing and connections.
Instrumentation tubing covers both Impulse tubes (sensing lines) as well as pneumatic tubes.
Connections include tapping points, root valves and tube fittings. Usually one has to refer to
myriad technical documents, codes and standards to s earch for a specific aspect of tubing
design or construction. This technical note is an attempt to put all the information at one
place. The efforts have been put to expose the reader to all the aspects of tubing and make
him aware of all the developments in the world. A comprehensive list of all the reference
documents is given at the end and they have been liberally used while preparation of this note
was underway. Effort has been made to represent all the relevant information here however,
enterprising readers will benefit even more if they peruse the reference documents directly.
Attempt has been made to demonstrate analytically that if the design and installation
practices are followed as per this note then the sensing line will meet the intent of class -I
tubing. Readers may note that the word tube/tubing used here should be inferred as
instrumentation tubing only limited to maximum 1 size.
It may be noted that various tubing practices have not been discussed in this note. The
detailed installation practices for various process measurements will be discussed in respective
process measurement/field installation technical notes. However, salient issues common to all
installations have been discussed in detail.
Author is grateful to a large number of engineers with whom they had an opportunity to work
with during their long career in NPCIL and on the way a lot of design aspects were concluded.
Nirbhay Gupta
23rd September, 2008
Mumbai
iii
iv
TABLE OF CONTENT
Section
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.6.1
2.6.2
2.6.2.1
2.6.2.2
2.6.2.3
2.7
2.8
2.9
2.10
3.0
4.0
4.1
4.2
4.3
4.4
4.5
5.0
6.0
7.0
7.1
TITLE
INTRODUCTION
DIFFERENCE BETWEEN A PIPE AND A TUBE
MAJOR ADVANTAGES OF TUBING OVER PIPING SYSTEMS
TYPES OF TUBES
GUIDELINES FOR SELECTION OF INSTRUMENTATION TUBES
DIFFERENT SIZES OF TUBES
CRITERIA FOR SELECTING THE SIZE OF A TUBE
SELECTION AND DESIGN CRITERIA
DESIGN OF TUBING AND TUBING SYSTEMS
CLASS-I INSTRUMENTATION TUBING DESIGN
REQUIREMENTS OF MATERIAL FOR INSTRUMENT TUBING/PIPING AS PER NB-2000
DESIGN REQUIREMENTS OF INSTRUMENT PIPING/TUBING AS PER SUBSECTION NC (NC
3600)
PRESSURE DESIGN (INTERNAL PRESSURE) OF INSTRUMENT TUBING/ PIPING
ANALYSIS CRITERION OF TUBING/PIPING SYSTEM
ANALYSIS OF SS TUBES USED IN NPCIL
WALL THICKNESS AND PRESSURE RATING OF DIFFERENT SIZES OF INSTRUMENT TUBING
STRESS ANALYSIS OF TUBING SYSTEMS
ANALYSIS FOR SUSTAINED MECHANICAL LOADS
ANALYSIS FOR OCCASIONAL LOADS (LEVEL A&B SERVICE LIMITS)
ANALYSIS FOR STRESS DUE TO THERMAL EXPANSION AND OTHER SUSTAINED LOADS
CONSIDERATION FOR VARIOUS FORCES
TUBE BENDING CONSIDERATIONS
SPECIAL DESIGN ASPECTS TO MEET THE REQUIREMENTS OF CLASS-I TUBING AND
TUBING SYSTEMS
CONCLUSION
TECHNICAL REQUIREMENTS OF SS TUBES
PNEUMATIC TUBING
ADVANTAGES OF USING COPPER TUBES
DIFFERENT TYPES OF COPPER TUBES
RECOMMENDATIONS FOR SELECTION OF A TYPE OF COPPER TUBE
TECHNICAL REQUIREMENTS OF COPPER TUBE
APPLICABLE INTERNATIONAL STANDARDS FOR COPPER TUBES
ASTM TUBING SPECIFICATIONS OUTSIDE DIAMETER/WALL THICKNESS
EMBEDDED PENETRATIONS
METHODS OF CONNECTION OF INSTRUMENTATION TUBES
WELDED JOINTS
Page
No.
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1
2
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5
5
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7.2
7.3
8.0
8.1
8.2
8.3
9.0
10.0
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
11.0
12.0
13.0
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.8.1
13.8.2
13.8.3
13.8.4
13.8.5
13.9
13.10
13.11
14.0
14.1
14.2
14.3
14.4
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14.5
15.0
15.1
15.2
15.3
15.4
15.4.1
15.4.2
15.4.3
15.4.4
15.4.5
15.4.6
15.4.7
15.4.8
15.4.9
15.4.10
15.4.11
16.0
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
1.0Introduction
Impulse sensing linesare the lines containing process fluid which run between the
sensing instruments and process tapping points, and are usually made of
tubing/piping,valvesandtubefittings.
1.1 Differencebetweenapipeandatube
The fundamental difference between pipe and tube is the dimensional standard to
whicheachismanufactured.
Atubeisahollowproductofroundoranyothercrosssection havingacontinuous
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
andMcoppertube (See section6 for details)mayalsobespecifiedbynominalsizeand
type only. Dimensions and permissible variations (tolerances) are specified in the
appropriateASTMorASMEstandardspecifications.
Generally tubing is specified by giving O.D. and wall thickness whereas pipes are
specifiedbygivingnominaldiameter&wallthickness(NBandSchedule).
A pipe is a tube with a round cross section conforming to the dimensional
requirementsfornominalpipesizeastabulatedinANSIB36.10,Table2and4,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.
PipeversusTubes
Standardfluidlinesystems,whetherforsimplehouseholduseorfor
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
leakageproblemsbesidesbeingcumbersome,inefficientandcostlyto
assemble and maintain. Therefore, the use of pipe in these systems
haslargelybeenreplacedbytubingbecauseofthemanyadvantagesit
offers.
Figure11Tubingprovidessimplified,freeflowsystem
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Old Method Each connection is threaded requires numerous fittings system not
flexibleoreasytoinstallandserviceconnectionsnotsmoothinsidepocketsobstructflow.
1.2 MajorAdvantagesofTubingoverPipingSystems
1. Bending Quality Tubing has strong but relatively thinner walls; is easy to bend.
Tubefabricationissimple.
2. GreaterStrengthTubingisstrongerasnothreadsarerequiredforconnection.No
weakenedsectionsfromreductionofwallthicknessbythreading.
Figure12: Withnothreadingnecessary,tubingdoesnotrequireextrawallthickness
3. Less Turbulence Smooth bends result in streamlined flow passage and less
pressuredrop.
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
fittingsaresmallerandalsoweighless.
5. Flexibility Tubing is less rigid, has less tendency to transmit vibration from one
connectiontoanother.
6. Fewer Fittings Tubing bends substitute for elbows. Fewer fittings mean fewer
joints,fewerleakpaths.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
7. TighterJointsQualitytubefittings,correctlyassembled,givebetterassuranceof
leakfreesystems.
8. Better Appearance Tubing permits smoother contours with fewer fittings for a
professionallooktotubingsystems.
1.3
Typesoftubes
Tubescanbecategorizedindifferentways.
1. Categorizationbasedontubedimensionalspecifications:Tubescanbeclassifiedas
a. Metrictubes,wheredimensionsarespecifiedinmmunitse.g.10mm,20mm
etc.
b. Fractionaltubes,wheredimensionsarespecifiedininchunitse.g.,,1
etc.
2. Categorizationbasedonmaterialoftubese.g.carbonsteeltubes,PVCTubes,Copper
tubes,SStubes,Inconeltubes,etc.
3. Categorization based on method of tube drawing i.e. welded and drawn, seamless
etc.
1.4 Guidelinesforselectionofinstrumentationtubes
Proper Tubing Selection
1. AlwaysMatchMaterials
S.S.TubingshouldbeusedonlywithS.S.Fittings.Theonlyexceptiontothisruleis
coppertubingwithbrassfittings.Mixingmaterialscancausegalvaniccorrosion.
GalvanicCorrosion(Electrochemical)
Allmetalshaveaspecificrelativeelectricalpotential.Whendissimilarmetalscome
incontactinthepresenceofmoisture(electrolyte),alowintensityelectriccurrent
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
higherpotential(moreanodic).(SeeGalvanicSeriesChart)
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Figure13:GalvanicSerieschart
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
2. Selectpropertubinghardness
Remember instrumentation tube Fittings are designed to work within specific
hardnessranges.RB90maximumforS.S.,RB80recommended.Forproperswaging
thehardnessofthetubeshouldbelessthanthehardnessofthefitting.
3. Selectpropertubingwallthickness
Properwallthicknessisnecessarytoaccommodateacceptedsafetyfactorsrelative
todesiredworkingpressures.
4. Tubingsurfacefinish
Alwaysselecttubingfreeofvisibledrawmarksorsurfacescratches.Ifpossible,cut
off any undesirable sections. These deep scratches can cause leaks when
attempting to seal lowdensity gases such as argon, nitrogen, or helium. Proper
surfacefinishensuresleakproofcompressionjointwithfitting.
1.5
Differentsizesoftubes
FollowingtubesizeshavebeenusedinNPCILNPPs
SSTubes(metric):6mm,10mm,12mm,20mmand25mm.
SStube(Fractional):,3/8,,and1.
Coppertubes(metric):6mm,10mm,12mm,20mmand25mm.
Coppertubes(Fractional):,3/8,,and1.
1.6
Criteriaforselectingthesizeofatube
Theselectioncriteriaforsizingthetubeareasfollows:
TheO.D.ofthetubes/impulsetubesshouldbethesameandnotsmallerthan
6mmevenwithcleanliquidsandnoncorrosivepiping,owingtothechance
ofblockageafterlongservice.
Ifcondensationislikelytooccurorifgasbubblesarelikelytobeliberated,
theO.D.shouldnotbesmallerthan10mm.
When long runs cannot be avoided, the internal diameter of impulse
tubing/pipingmaybeselectedasperthefollowingtable11:
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
TABLE11
Pressuresignal
InsideDia.inmmofimpulsetubing/pipingfordifferentprocess
transmission
fluids
distance
Water/steam Wetairorgas
Oiloflowto
Verydirty
(meter)
liquidorgas
Dryair/gas
med.viscosity
016
7to9
13
13
25
1645
10
13
19
25
4590
13
13
25
38
1.7
Asverylongrunsofimpulsetubing/pipingarenotexpectedinoursystems
andalsoprocessfluidisexpectedtobeclean,10mmODtubinghavingI.D.
of7.6mmhasbeenfoundtobeadequate,forpressure/Pmeasurement
except for some cases for level measurement in tanks/vessels using P
principle.
Based on hold up, installation and material cost, radiation streaming
considerations, higher size (>10 mm OD) tubing is not recommended for
pressure/Pmeasurementinprimary/nuclearsystemingeneral.
SelectionandDesigncriteria
Following requirements should be met for impulse tubing for sensing the
pressure/differentialpressuresignalforalltypesofprocesssystemsincludingfor
safetyandsafetyrelatedsystems.
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 12 lists common materials and their associated general
application. Table 12 also lists the maximum and minimum operating
temperature for the various tubing materials. Properly designed tubing/piping
basedonserviceconditions,shouldonlybeusedforsensinglines.
The practice of mixing materials should be strongly discouraged. The only
exceptionisbrassfittingswithcoppertubing.Dissimilarmaterialsincontactmay
be susceptible to galvanic corrosion. Further, different materials have different
levelsofhardness,andcanadverselyaffectthefittingsabilitytosealonthetubing.
Theuseofaparticulartypeoftubeforaspecificusagedependsontheapplication
and the process condition. The following table briefly describes the application
guidelinesforaspecifictubematerial.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Table12
1.
2.
Foroperatingtemperaturesabove800F(425C),considerationshouldbegiventomedia.300Series
Stainless Steels are susceptible to carbide precipitation which may lead to intergranular corrosion at
elevatedtemperatures.
AlltemperatureratingsbasedontemperaturesasperASME/ANSIB313ChemicalPlantandPetroleum
RefineryPipingCode,1999Edition.
GasService
Specialcaremustbetakenwhenselectingtubingforgasservice.Inordertoachieveagas
tight seal, ferrules in instrument fittings must seal any surface imperfections. This is
accomplishedbytheferrulespenetratingthesurfaceofthetubing.Penetrationcanonlybe
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
achievedifthetubingprovidesradialresistanceandifthetubingmaterialissofterthanthe
ferrules.
Thick walled tubing helps to provide resistance. Tables13 to 110 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.AcceptabletubinghardnessforgeneralapplicationislistedinTable112.
ThesevaluesarethemaximumallowedbytheASTM.Forgasservice,betterresultscanbe
obtained by using tubing well below this maximum hardness. For example, a desirable
hardnessof80RBissuitableforstainlesssteel.ThemaximumallowedbyASTMis90RB.
SystemPressure
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
requirestrongmaterialssuchassteelorstainlesssteel.Heavywalledsoftertubingsuchas
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
pressurizedbeyondtherecommendedworkingpressure.
The following tables (13 to 110) list by material the maximum suggested working
pressure(inpsi)ofvarioustubingsizes.Acceptabletubingdiametersandwallthicknesses
arethoseforwhicharatingislisted.Combinationswhichdonothaveapressureratingare
notrecommendedforusewithinstrumentfittings.
Table13:Fractional316or304STAINLESSSTEEL(Seamless)
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Table14:Fractional316or304STAINLESSSTEEL(Welded&Drawn)
Table15:SeamlessStainlessSteelmetrictubing
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Table16:FractionalCarbonSteel(Seamless)
Tube
OD
in.
1/8
3/16
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1
1
1/4
1
1/2
2
0.028
0.035
0.049
0.065
0.083
TubeWallThickness,in.
0.09
0.10
0.120
5
9
0.134
0.148
0.165
0.180
0.220
WorkingPressure,psig
Note:Forgasservice,selectatubewallthicknessoutsideoftheshadedarea.
8000 10200
2100 2900
1800 2400
1500 2100
1600
5900
4600
5300
3700
4300
3200
3700
2700
3200
2100
2500
1800
2000
1500
510
0
430
0
370
0
290
0
240
0
170
0
4100
3200
3600
4000
4600
5000
2600
2900
3300
3700
4100
5100
1900
2100
2400
2700
3000
3700
Table17:CarbonSteelMetrictubing
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Table18:ALUMINIUM(SEAMLESS)
Table19:COPPER(SEAMLESS)
Table110:MONEL400(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/ANSIB31.1PowerPiping.
Allcalculationsarebasedonmaximumoutsidediameterandminimumwallthickness.
Allworkingpressuresareatambient(72F)temperature.
Ratingsingrayarenotsuitableforgasservices.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
SystemsTemperature
Operatingtemperatureisanotherfactorindeterminingthepropertubingmaterial.Copper
and aluminum tubing are suitable for low temperature media. Stainless steel and carbon
steeltubingaresuitableforhighertemperaturemedia.SpecialalloyssuchasAlloy600are
recommended for extremely high temperature (see Table 12). Table 111 lists derating
factors which should be applied to the working pressures listed in Table 13 to 110 for
elevated temperature (see Table 12). Simply locate the correct factor in Table 111 and
multiplythisbytheappropriatevalueinTables13to110fortheelevatedtemperature
workingpressure.
Table-1-11
Temperature Derating Factors
Temperature
F (C)
100
200
300
400
500
600
700
800
900
1000
1100
1200
(38)
(93)
(149)
(204)
(260)
(316)
(371)
(427)
(486)
(538)
(593)
(649)
Copper
Aluminum
1.00
.80
.78
.50
1.00
1.00
.81
.40
316
SS
1.00
1.00
1.00
.97
.90
.85
.82
.80
.78
.77
.62
.37
304
SS
1.00
1.00
1.00
.94
.88
.82
.80
.76
.73
.69
.49
.30
Steel
Monel
400
1.00
.96
.90
.86
.82
.77
.73
.59
1.00
.88
.82
.79
.79
.79
.79
.76
EXAMPLE:1/2inchx.049wallseamlessstainlesssteeltubinghasaworkingpressureof3700
psi@roomtemperature.Ifthesystemweretooperate@800F(425C),afactorof80%(or
.80)wouldapply(seeTable111above)andtheattemperaturesystempressurewouldbe
3700psix.80=2960psi
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Table112
Material
Type
ASTMTubingSpec.
Condition
Stainless
Steel
Copper
304,316,
316L
KorL
ASTMA269,A249,A
213,A632
ASTMB75B68,B88*
(KorL)
SAEJ524b,J525b
FullyAnnealed
Carbon
1010
Steel
Aluminum Alloy6061
Monel
400
AlloyC
C276
276
Alloy600
600
Carpenter
20CB3
20
Titanium Commercially
PureGrade2
SoftAnnealedTemper0
Max.
Recommended
Hardness
90RB
FullyAnnealed
60Max.Rockwell
15T
72RB
ASTMA179
ASTMB210
ASTMB165
ASTMB622,B626
T6Temper
FullyAnnealed
FullyAnnealed
56RB
75RB
90RB
ASTMB167
ASTMB468
FullyAnnealed
FullyAnnealed
90RB
90RB
ASTMB338
FullyAnnealed
99RB200Brinell
Typical
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
2.0 DESIGNOFTUBINGANDTUBINGSYSTEMS
2.1
CLASSIINSTRUMENTATIONTUBINGDESIGN
In ASME Section IIIDivisionI subsection NB (Class I components), the design
criterion/design requirements for instrument tubing has not been covered separately.
ThusdesignguidelinesgivenforsmallsizeofpipingisbeingfollowedforClassIinstrument
tubing also. Also as the outside diameter of instrument tubing is being limited to 1 (25
mm);soanydesignconcessionpermittedforlowersizepiping(<1)willalsobeapplicable
toinstrumenttubing.
AsperNB3630(Pipingdesignandanalysiscriteria)thepipingof1NBorless,whichhave
been classified as class I in design specification, may be designed and analyzed as per
subsectionNC.
Thusforinstrumenttubing,thematerial&testingrequirementsshallbeaspersubsection
NBwhereasthedesignandanalysiswillbeaspersubsectionNC.
2.2
REQUIREMENTSOFMATERIALFORINSTRUMENTTUBING/PIPING
ASPERNB2000
2.3
DESIGNREQUIREMENTSOFINSTRUMENTPIPING/TUBINGASPER
SUBSECTIONNC(NC3600)
i.
MAXIMUMALLOWABLESTRESS
For design/calculating minimum wall thickness of instrument tubing/piping, the
maximum allowablestressforthe material atdesigntemperatureshallbeusedas
giveninANSI/ASMEB36.19.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
2.4
a)
ii.
PRESSUREANDTEMPERATURERATINGS
ThepressureratingsatthecorrespondingtemperaturegiveninANSI/ASMEB36.19
shallnotbeexceededandpiping/tubingproductshallnotbeusedattemperaturein
excessofthosegiveninANSI/ASMEB36.19forallthematerialsofwhichthetubing
ismade.
iii.
ALLOWANCES
Increased wall thickness of tubing shall be taken for providing allowances for
corrosionorerosion,mechanicalstrength&bendingetc.
iv.
DYNAMICEFFECTS
Impactforcescausedbyeitherexternalorinternalloadsshallbeconsideredinthe
piping/tubingdesign.Alsotheeffectofearthquakeandnonseismicvibrationshall
beconsideredinthetubingdesign.
PRESSUREDESIGN(INTERNALPRESSURE)OFINSTRUMENT
TUBING/PIPNG(Ref.NC3640)
MinimumWallThicknessofstraighttube/pipe:
Theminimumwallthicknessofstraighttube/pipeshallnotbelessthanthatdetermined
byeq.(I)asfollows:
tm=P*
Do
2 S+PY
+A
..(1)
tm=minimumrequiredwallthickness,mm
P=Internaldesignpressure,kPag
DO=Outsidediameteroftube/pipe,mm
S=Maximumallowablestressinthematerialduetointernalpressureandjoint
efficiencyatdesigntemperature,kPa
A=Additionalthickness,toprovideformaterialremovedinthreading,corrosion
anderosionallowancesandallowanceforstructuralstrengthneededduring
erection.
Y=acoefficienthavingavalueof0.4.Forpipe/tubewitha ratiolessthan6,the
valueofYforferriticandausteniticsteelsdesignedfortemperatureof480oC
andbelowshouldbetakenaspereq.(2)below
.(2)
Where
d=Insidediameteroftube/pipe.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
b)
Whereverbendingoftubing/pipingislikelytobeinvolvedininstallations,theminimum
wallthicknessafterbendingshallnotbelessthantheminimumwallthicknesscalculated
aspereq.(1)forstraighttube/pipe.Tomeetthisrequirement,actualwallthicknessof
tubing/pipingistobeincreasedasperfollowingTable21(ThisisbasedonNC3000):
TABLE21
MinimumthicknessrecommendedPriorto
bending
6tube/pipediameterorgreater
1.06tm
5tube/pipediameter
1.08tm
4tube/pipediameter
1.16tm1
3tube/pipediameter
1.25tm
1AsperANSI/ASMEB31.1thisvalueis1.14.HoweverNC3000ismoreconservative.
tm=minimumwallthicknessrequiredaspereq.(1)above.
BendRadius
c)
Also,unlessotherwisejustifiedbythedesigncalculationtheovalityoftubing/pipingafter
bendingshouldnotexceed8%asdeterminedbyfollowingeq.(3).
..(3)
%
100
Where
Do
Dmax
Dmin
2.5
=Nominaloutsidediameteroftube/pipe
=themaximumoutsidediameterafterbendingorforming
=theminimumoutsidediameterafterbendingorforming
ANALYSISCRITERIONOFTUBING/PIPINGSYSTEM
Analysisrequirementsfortubing/pipingsystemsasperNC3650aregivenbelow.
The design of complete piping system shall be analyzed between anchors for the effects of
thermalexpansion,weightandothersustainedandoccasionalloads.
Thedetailrequirements/analysiscriteriaaregiveninfollowingsubsections.
a.
1.5
(4)
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
Ssl
=Stressduetosustainedloads,kPa
P
=Internaldesignpressure,mm
Do
=Outsidediameteroftube/pipe,mm
B1,B2 =Primarystressindicesforthepipe/tube(AsperFigurebelow)NC3673.2(b)1
MA=Resultantmomentloadingoncrosssectionduetoweightandothersustained
loads,kNm.NC3653.3
Z=Sectionalmodulusofpipe/tube,mm3
Sh=Basicmaterialallowablestressatdesigntemperatureconsistentwithloading
underconsideration.
tn=Nominalwallthickness,mm
b.
CONSIDERATIONOFLEVELAANDBSERVICELIMITS(REF.NC3653)
i.
STRESSDUETOSUSTAINEDPLUSOCCASIONALLOADS
Theeffectofpressure,weight,othersustainedloadsandoccasionalloadsincluding
earthquake,forwhichlevelBservicelimitsaredesignated,mustmeattherequirementsof
followingeq.(5).
2
1.8
.(5)
Butnotgreaterthan1.5Sy
ii.
Where
Mb=resultantmomentloadingoncrosssectionduetononreversingdynamicloadse.g.
occasional loads such as thrust from relief and safety valves loads from pressure
andflowtransientsandearthquake.
Sy = material yield strength at temperature consistent with the loading under
consideration,kPa.
Sol=stressduetooccasionalloads,kPa.
Pmax=Peakpressure,kPa
SUSTAINEDPLUSTHERMALEXPANSIONSTRESSES
Theeffectsofpressure,weight,othersustainedloadsandthermalexpansionforwhichlevel
AandBservicelimitsaredesignated,shallmeettherequirementsoffollowingeq.(6).
0.75
(6)
0.75ishallnotbelessthan1.0
Where
=Sustainedplusthermalexpansionstresses.
Ste
=rangeofresultantmomentsduetothermalexpansion
MC
=Allowablestressrangeforexpansionstresses.
SA
i=Stressintensificationfactor(referNC3673.2)
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
=ratioofbendingmomentproducingfatigueinagivennumberofcyclesina
straight pipe/tube with girth butt weld to that producing failure in the
samenumberofcyclesinthefittingorjointunderconsideration.
Othertermsaresameasofeq.(4)
Allowablestressrangeforexpansionstresses(SA)canbecalculatedusingfollowingequation
S A
=f(1.25SC+0.25Sh) .(7)
=Basicmaterialallowablestressatminimum(cold)temperature.
SC
=Basicmaterialallowablestressatmaximum(hot)temperature.
Sh
f
=stressrangereductionfactorforcyclicconditionsfortotalnumberNoffull
temperature cycles over total number of years during which system is
expectedtobeinservicefromtable21AbelowNC3611.2(e)1
TABLE:21A
Numberofequivalentfull
temperaturecycles(N)
7000andless
7000to14000
14000to22000
22000to45000
45000to100000
100000andover
Stressrange
reductionfactor(f)
1.0
0.9
0.8
0.7
0.6
0.5
Stressintensificationfactoricanbecalculatedusingfollowingequation(8)
(8)
Where
C2andK2arestressindicesforclass1pipingproductsorjointsfromNB3681(a)1.For
straightpipe/tubethevalueofC2andk2are1.
Forcurvedpipe/tubeorweldedelbowsIcanbecomputedasperequation(9)below(refer
NB3681)
.
(9)
(10)
where
tn
R
r
=nominalwallthicknessoftube/pipe
=bendradius
=meanradiusoftube/pipe
iii.
CONSIDERATIONOFLEVELCSERVICELIMITS
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
In section II in calculating the resultant moment MB, moment due to SEE conditions is
proposedtobeusedwhichismoreconservative,thusseparateanalysisforlevelCservice
limitsisnotrequired.
iv.
TESTINGREQUIREMENTSASPERSUBSECTIONNB
2.6 ANALYSISOFSSTUBESUSEDINNPCIL
2.6.1
WALLTHICKNESSANDPRESSURERATINGOFDIFFERENTSIZESOFINSTRUMENTTUBING
The maximum design pressure and temperature are taken as 195 kg/cm2 and 310oC
respectively.Thoughtheabovepressureandtemperaturemaynotexistsimultaneouslyin
any system, still to be on conservative side, all the sizes of tubing will be designed for
aboveratings.
Usingeq.(1)intheanalysiscriteriaabove,theminimumwallthicknessofstraighttubing
canbecalculated.
Thusfollowingequationcanbeused
tm=P*
Do
2 S+PY
+A
Wecanmakefollowingassumptions
Therewillbenothreadingonthetubes
Corrosion,erosionisnegligible(henceallowanceforcorrosionanderosionmay
beneglected)
Bendradiusisnotlessthan3Do.Theactualwallthicknessistobeincreasedas
perTable21above.
Followingdatamaybeused
P=designpressure(=195kg/cm2)
S=maximumallowablestressofS.S.304Lmaterialat310oCtemp.(=986kg/cm2)
Y=0.4
By putting the above variables, the minimum wall thickness for different sizes (Do) of
straighttubingistabulatedinfollowingTable22.
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
TABLE22
TubeO.D.
(Do)mm
Minimum recommended
wall thickness (mm)
prior to bending (1.25
tm)
Specifiedwall
thicknessasper(PB
M17)inmm
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(Seenotebelow)
20
1.83
2.29
2.5
25
2.29
2.86
3.0
Note:ItcanbeseenfromTables22&23thatspecifiedwallthicknessofallsizesoftubingasperPBM
17 is more than required wall thickness as per ASME Section III except for 16 mm size. As
maximumpressureandtemperaturemaynotbesimultaneousso1.8mmwallthicknessinsteadfor
1.83mmof16mmsizewillbeadequatefrompressureratingconsiderations.
Forexample,themaximumpressure&temperatureinPHTsystemwillbe125kg/cm2 and310oC
respectively. For this application, the required minimum wall thickness for 16mm OD tube,
includingthebendingallowance,shouldbe1.3mm,whichislessthanspecifiedwallthicknessof
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
whichislessthanspecifiedwallthicknessof1.8mm.
2.6.2
STRESSANALYSISOFTUBINGSYSTEMS(TUBINGCONFORMINGTOPBM17)
2.6.2.1
ANALYSISFORSUSTAINEDMECHANICALLOADS
When the tubing is installed in the field, the effects of pressure, weights and other
sustainedmechanicalloadsmustmeettherequirementsofeq.(4)i.e.
<1.5Sh
StressduetoSustainedload=Ssl
Theaboveequationmaybeverifiedfordifferentsizesoftubinghavingwallthicknessas
giveninTable22andotherconstantstobecalculated/takenasbelow:
B1=0.5(asperNB3680)
.
2
/ and
Where
tn=nominalwallthicknessoftube
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
R=Bendradius
r=(Dot)/2=meanradiusoftubing
32
ThusfordifferentsizesoftubingsystemsSslvalueistabulatedinTable24
2.6.2.2
ANALYSISFOROCCASIONALLOADS(LEVELA&BSERVICELIMITS)
As per requirement of ASME Section III installed tubing system should satisfy the
equation(5)ofSection4.2.1asgivenbelow:
1.8
Basedontheseismicanalysiscarriedoutfordifferenttubinglayouts,therecommended
conservative value of Mb is 200 kg mm for all sizes of tubing systems for SSE level of
earthquake.ThusfordifferentsizesoftubingsystemsSolvalueistabulatedinTable24.
ThiscanbeseenthatSolislessthan1.8Shforallthesizesoftubingthussatisfyingthe
aboveequation.
2.6.2.3
ANALYSISFORSTRESSDUETOTHERMALEXPANSIONANDOTHERSUSTAINED
LOADS
As per requirement of ASME Section III installed tubing system should satisfy the
followingequation
4
0.75
The maximum value of stress (iMc/Z) due to thermal loading (temperature variation
from25oCto310oC)fordifferenttubingsystemscomesouttobe1600kg/cm2provided
thattubingsystemissupportedasperrecommendedpractices.Basedontheabovedata
and other parameters/constants, Ste has been calculated & tabulated in TABLE23 for
differentsizesoftubing.
ThismaybeseenfromthetablethatStevaluefordifferentsizesoftubingislessthanthe
valueofSh+SA(viz.2615kg/cm2).
TubeSize
NominalWall
TABLE23
Calculated
valuetobe
STE
Sh +SA
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TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
(OD)mm
Thickness(tn)(mm)
(Seenote2)
usedforanalysis
(kg/cm2)
0.42
0.67
0.65
0.71
0.65
0.67
6
1.2
1.33
2164.94
10
1.2
1.33
2169.92
12
1.5
1.33
2205.82
2615
16
1.8
1.33
2112.3
20
2.5
1.33
2043.24
25
3
1.33
2045.4
Note:
1. ThevaluesofMA,Z,P,ShusedforcalculationofSTEaresameasgiveninTable24.
2. Thevalueof usedisbasedonrequirementsuchthat0.75 shouldnotbelessthan1.0
3. SA=f(1.25Sc+0.25Sh)wheref=1&Sc=1106(kg/cm2)
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1.8
257.06
0.775
0.512
224.87
383.4
1479
2.5
0.93
1.0
536.89
1.293
0.64
321.62
310.5
Yes
347.75
Yes
0.94
1.0
1022.21
1.971
0.8
446.37
310.27
Yes
329.83
Yes
Yes
Yes
Yes
754.78
Yes
1558.76
WhetherSol<1.8Sh
1
1.8Sh
Mb(Kgmm)
WhetherSsl<1.5Sh
1774.8
556.17
Yes
463.54
Yes
1.5Sh(kg/cm2)
Ssl(kg/cm2)
200
Yes
32
B1PDo
2tn
Ma(kg/mm)
Yes
WF(wt.offitting)(kg)
475.34
67.5
B2Ma
WL(wt.of1moftubefilledwithD2O)kg/m
Z(mm3)
449.07
119.37
0.192
B2valuetobeusedforanalysis(asB2cannotbelessthan1)
383.7
154.25
0.32
0.156
5
0.384
0.315
18.46
1.0
0.466
65.42
1.0
WallThickness(t)(mm)
CalculatedB2
TubesizeOD(Do)mm
115.97
1.0
0.61
1.2
1.03
0.97
1.2
10
1
0.94
1.5
12
1.03
16
20
23
TECHNICALDOCUMENTONINSTRUMENTATIONTUBINGANDTHEIRCONNECTIONS 2008
TABLE24
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2.7
2008
2.8
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)
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
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For seismic classification the instrument sensing lines should be of SSE Category
for safety and safety-related instrumentation systems.
A single instrument sensing line should not be used to perform both a safetyrelated 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.
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2008
Tolerances on O.D.
[mm]
-00 + 0.10
10
-00 + 0.10
12
-00 +0. 10
16
-00 +0. 12
20
-00+ 0. 12
25
-00 + 0.12
Length of tube
Pieces
6 meters
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b. EXPANSION TEST : On one sample piece of each size and each batch as per
relevant ASTM standard
c. TENSILE TEST : On one sample piece of each size and each batch as per
relevant ASTM standard
d. FLATTENING AND DOUBLING OVER TEST
: On one sample piece of
each size and each batch as per relevant ASTM standard
e. CHEMICAL ANALYSIS : One sample of each batch as per relevant ASTM
standard
12. ROUTINE TESTS
a. DIMENSIONAL TEST : Required to be done on 10 % of the lot
2
Code/Standard
Description
1.
ASTM-A-213
2.
ASTM-A-450
3.
ASTM A 262
4.
ASTM A 370
5.
6.
PB-M-17
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4.0
2008
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 pass, they still provide a very reliable alternative to
electronic instruments.
4.1
Strong, corrosion resistant, copper tube is the leading choice for pneumatic piping. There
are seven primary reasons for this:
1.
2.
3.
4.
5.
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7.
4.2
2008
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 fittinga procedure that can be efficient
and economical in many installations.
Tube in both the hard and soft tempers can also be joined by a variety of
mechanical joints that can be assembled without the use of the heat source
required for soldering and brazing.
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2008
Tabl e-4- 1
There are many other copper and copper alloy tubes and pipes available for specialized applications.
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.
1.
2.
4.3
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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.
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.
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2008
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2008
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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.
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4.4
2008
Tolerance On OD In mm
+0.1
-0
1.2 + 0.16
-0
10
+0.1
-0
1.2 + 0.16
-0
12
+0.1
-0
1.2 + 0.16
-0
20
+0.12
-0
1.5 + 0.20
-0
25
+012
-0
1.5 + 0.20
-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.
8.5 kg/cm2(g)
Rockwell F50
8. Ovality Variation
9. Surface Finish
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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 & ASTMB-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
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5.0
2008
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.
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2008
Table-C: Permissible Variations in Wall Thickness for ASTM B68 and ASTM
B75 cold drawn copper tubes
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2008
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)
(c)
In floor penetration EPs bore through connector is installed only on the top
opening of the EP. Bottom opening is left as it is. This allows thermal
expansion of the tube through the EP and no additional stress is caused on
the EP.
(d)
In the top plate of a floor EP a hole is made and a suitable plug is installed in
it. This hole is used to fill the Steel/lead shielding balls in the EP.
(e)
In the bottom plate of a floor EP a hole is made and a suitable plug is installed
in it. This hole is used to take off the Steel/lead shielding balls from the EP.
Note: For further details on the EP installation refer section 12. 0 of this
technical note.
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2008
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-B16.11. 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.
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2008
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8.0
2008
Following guidelines pertaining to the take off connections (pressure taps) should be
followed.
8.1.
II.
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41
8.2.
2008
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.
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
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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.
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9.0
2008
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.
b.
c.
d.
e.
f.
g.
h.
Root valves should not affect the pressure signal during normal operation.
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.
Isolating/root valves should be located immediately following the tapping
point.
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.
Root valve bore/should not be less than the inside diameter of impulse
tubing/piping.
It is recommended that the root valves be inch unless special requirements
necessitate a different size.
The root valves may or may not perform the function of the accessible
isolation valve, dependent on its location.
Root valves should be of the same material as that of the pipe they are
connected to.
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44
10.0
10.1
2008
INSTALLATION OF INSTRUMENTATION
TUBING
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2008
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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.
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Tubing Handling
Imperfection on the tube OD can be potential source of problems in a tubing
system. Handling of the tube shall be done very carefully to avoid scratches
and protect the finish of the tubes.
Dragging the tube across any surface that could scratch the surface can
cause seal corrosion and sealing problems. On offshore facilities
scratches on tube may lead to corrosion of SS tubing from salt water
pitting.
It is a good practice to visually inspect tubing to ensure it is free from
scratches and other damage.
When cutting the tubing hacksaw must not be used, the correct tool is a
tube cutter with a sharp blade.
Correct deburring tool shall be used for deburring both inside and
outside edge of tube ends.
It is good practice to clean the tubing with dry instrument air. If the
surface requires higher degree of cleanliness then a cleaning agent
should be used.
10.2
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EXACT MEASUREMENT is required to insure that you obtain the desired distance
between bends. If you do not measure exactly, the tube line will not fit. (See
Figure-10-2 below)
ACCURATE BENDING is necessary to achieve the exact angles required for the
tube line. If you do not bend accurately, the tube line will not fit. (See Figure 10-3
below)
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is measured from the end of the tube. On most benders, the edge of the radius
block is at the centerline of the tube.
3. Control Accuracy
Remember only you can control the accuracy of your work. Use good, careful
workmanship at all times.
10.3
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(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 106)This will insure that you bend
in the correct direction. It also
gives you a reference mark in
case you must leave your work
unfinished.
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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 461/2 to obtain finished 45 bend. This
works especially well with large heavywall tubing.
c.
Remember, it is always better to
underbend slightly. You can always bend a
little more if needed, but its almost
impossible to remove or straighten a bend,
especially with large, heavy-wall tubing.
REMEMBER - A TUBE BENDER BENDS IT CAN NOT UNBEND.
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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
Pre-Measuring
You may pre-measure a series
of bends. Measure the first
bend from the end of the tube,
the correct length. Compensate
for each bend after the first by
subtracting the amount of gain
from your chart for each 90 of
bend to allow for stretch
(Figure 4-11). Always custom
measure for the last bend.
Nirbhay Gupta
Radius of
Tube size
(in
inches)
1/8
3/16
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1
1-1/4
1-1/2
2
Size
2
3
4
5
6
8
10
12
14
16
20
24
32
Bender
Gain
Gain
(in inches)
90
45
3/8
7/16
9/16
11/16
15/16
1-1/2
1-7/8
2-1/4
2-5/8
3
3-3/4
4-1/2
8
.16
.19
.24
.30
.40
.64
.80
.97
1.13
1.29
1.61
1.93
3.43
.02
.02
.02
.03
.04
.06
.08
.10
.11
.13
.16
.19
.34
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10.4
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.
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10.5
2
3.25
2.65
1-1/2
2.41
1.96
1-1/4
1.94
1.61
1
1.50
1.22
7/8
1.31
1.05
3/4
1.25
.98
5/8
1.25
.98
1/2
1.19
.94
3/8
.94
.69
5/16
.88
.66
1/4
.80
.61
3/16
.75
.56
1/8
.70
.52
1/16
.38
D Tube
Insertion
Depth
(inches)
L
Free
Length
of Strai ght
Tubing
(inches)
.50
TUBE O.D.
inches
Table: 10-2
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 corelationship 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.
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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. Heres 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 Fx 2= 30 offset
dimension L. For 45 bends multiply desired offset Fx 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.
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10.6
2008
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
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Figure-10-18
Allow for expansion and contraction - Use a U bend in long lines to allow for expansion
and contraction.
Allow for motion under load - Even some apparently rigid systems do move under load.
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10.7
2008
10.8
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10.9
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11.0
2008
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 youve taken the time to make good bends and installed them, its not enough to just
let them lay suspended in mid-air. When tubing is left unsupported, shock and vibration
will cause the tubing to shake, and in turn, cause the fitting to loosen and leak or even
allow tube to fall through fatigue.
Tube support and clamping is a necessary
requirement in the fluid power industry.
Tubing can be clamped individually, in sets,
and can also be stacked. The most
important part of any clamping system is
having enough
clamps to attain the final result. That being,
a well supported, vibration and noise free
system.
Also, most manufacturers specify SAE and
JIC approved components on their
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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.
Table-11-1
TUBE
O.D.
EQUIVALENT
TUBE
(mm)
FOOT
SPACING
BETWEEN
SUPPORTS
1/4 - 1/2
3/8 - 7/8
1
1-1/4 & up
6 - 13 mm
14 - 22 mm
23 - 30 mm
31 & up mm
3 ft.
4 ft.
5 ft.
7 ft.
SPACING
IN
METE RS
(Approx.)
.9 m
1.2 m
1.5 m
2.1
Alongside Table-11-1 is
showing
maximum
permissible
spacing
between clamps. It is
recommended to clamp
as close to each bend of
the tube as possible; and
one must clamp each
side. This eliminates
thrust in all directions.
The tube should be
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12.0
2008
Figure-12-2
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unreliable. (This may be noted that NAPS onwards welded tubes have
replaced by Seamless annealed tubing in all NPCIL plants/projects)
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A flareless tube fitting generally refers to a type of tube fitting in which the tube
end remains substantially tubular, in contrast to a flared tube fitting in which the
tube end is outwardly flared over a fitting component. Flared tube ends are
commonly encountered in use with plastic tubing and plastic tube fittings.
The present note is not directed to plastic tubing or tube fittings because such
fittings have significantly different challenges and material properties that affect
the ability of the fitting to both grip the tube and provide an adequate seal.
Operating pressures and temperatures are also typically substantially lower in the
plastics tubing systems. In other words, with respect to tube grip and seal,
whatever works in a plastic tube fitting provides little or no guidance for a non plastic tube fitting.
Among the above, the recommended fitting is flareless compression type twin
ferrule tube fitting. Because of its ease of installation and higher reliability this
type of fitting is most commonly used.
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designs of the tube gripping device--single ferrule tube fittings and two ferrule
tube fittings.
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In order to achieve an adequate tube grip on stainless steel tubing, single ferrule
stainless steel tube fittings have historically used a rather shallow camming angle
of between 10o and 20o. This range of angles is referred to herein as "shallow" only
as a term of convenience in that the angle is rather small. The shallow camming
angle has been used in single ferrule fittings to obtain a mechanical advantage
because the shallow angle provides an axially elongated camming surface against
which to slide and radially compress the single ferrule front end to bite into the
tube end outer surface. Hard stainless steel tubing material necessitated this
elongated sliding camming action in order to be able to get the single ferrule to
create an adequate bite for tube grip. Over the years, the single ferrule has been
through hardened or case hardened so as to be significantly harder than the
stainless steel tubing, however, the shallow camming angle is still used today in
such single ferrule fittings to obtain a mechanical advantage from the ferrule
sliding along the camming surface to produce the "bite" so as to assure an
adequate tube grip. An example of a commercially available single ferrule tube
fitting that uses a case hardened ferrule and a shallow camming angle of about
twenty degrees is the CPI fitting line available from Parker-Hannifin Corporation.
Another example is the EO fitting line available from Ermeto GmbH that uses a
through hardened single ferrule and a twelve degree camming angle.
In some single ferrule designs, a non-conical camming surface has been tried
whereby an attempt is made to simply press the ferrule against the outer surface
of the tube end, thereby not creating a bite. The result in such cases however is a
low grip or low-pressure-only fitting that are not well suited to stainless steel
fittings.
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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,
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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.
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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
ferrules leading edge must be sufficiently harder than the tube. Two methods of
producing this differential hardness may be employed
1.
2.
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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
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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
manufacturers suggested minimum and maximum wall thickness
limitations.
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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.
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Type
Material / type
3
4
5
Fluid
Max. Pressure
Maximum
Temperature
Overall
Dimensions
Hardness
8.0
Tests
8.1
Type Test
8.1.1
Chemical
Composition test
Ferrule Hardness
Test
Test on Raw
Material
8.1.2
8.1.3
8.1.4
Seismic Test
8.2
Routine Tests
8.2.1
8.2.3
Overall Dimension
Thread
Check for End
Connections
Hydrostatic test
8.2.4
Pneumatic leak
8.2.2
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: As per ANSI-B-1.20.1
: > Rockwell B-90
83
8.2.5
test
Reassembly Test
9.0
2008
ASTM-A-269
ISOR-206
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Type
Material / type
3
4
5
: Air
: 40 kg/cm2 (g) @ ambient temperature
: 320 C
Fluid
Max. Pressure
Maximum
Temperature
Overall
Dimensions
Hardness
8.0
Tests
8.1
Type Test
8.1.1
Chemical
Composition test
Ferrule Hardness
Test
Test on Raw
Material
8.1.2
8.1.3
8.1.4
Seismic Test
8.2
Routine Tests
8.2.1
8.2.3
Overall Dimension
Thread
Check for End
Connections
Hydrostatic test
8.2.4
Pneumatic leak
8.2.2
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: As per ANSI-B-1.20.1
: > Rockwell B-90
85
8.2.5
test
Reassembly Test
9.0
2008
ASTM-B-16
Free cutting brass rod, bar and shapes for use in screw
machine.
IS 4218
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.
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Different types of screw threads have evolved for fastening, and hydraulic systems. Of
special concern are plastic-to-metal, taper/parallel threaded joints in hydraulic circuits. A
discussion and recommendations are provided to create an awareness of diff erent types of
threads and how they are used.
Jointing threads are pipe threads for joints made pressure tight by sealing on the
threads and are taper external and parallel or taper internal threads. The sealing
effect is improved by using a jointing compound.
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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
NPSC
NPTR
NPSM
NPSL
NPTF
BSPP
BSPT
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 116 inch in an inch, which is the same as
3/4 inch in a foot.
Because of the taper, a pipe thread can only screw into a fitting a certain distance
before it jams. The standard specifies this distance as the length of hand tight
engagement, the distance the pipe thread can be screwed in by hand. It also specifies
another distance the effective thread, this is the length of the thread which makes the
seal on a conventional machined pipe thread. For workers, instead of these distances, it
is more convenient to know how many turns to make by hand and how many with a
wrench. A simple rule of thumb for installing tapered pipe threads, both metal and
plastic, is finger tight plus one to two turns with a wrench. Torque installation values
can be determined as per application, but due to the variations involved in pipe joints
such as dissimilar materials of male and female threads, type of sealants used, and
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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 -141. 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.
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Figure 14-6 shows an NPT tightened into a BSPT. The NPT thread to engage further, but
pitch difference eventually causes a binding of the threads. Pitch and thread angle
differences will allow spiral leakage.
The 1/2 and 3/4 sizes in the NPT and BSP are all 14 threads per inch, and the NPT will
engage the BSP fairly well.
Although these threads are the same pitch and engage well there are still issues with the
tread form. The thread angles and the crest and root tolerances being different will allow
spiral leakage as shown in figure 14-6. These threads might be used effectively together if
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The minimum material condition as shown at the left is established by having the mating
crests and roots of equal truncation so as to assure metal to metal contact at these points
coincident with flank contact. The condition is established at the sharpest root and the
flattest crest and gives no clearance. Tolerances at the crests and the roots are established
in the direction of interference only, therefore the maximum material condition shown at
the right is established by having the extreme combination of sharpest crests and flattest
roots, which provide the maximum interference.
When threaded joints are made wrench tight, it is intended that the flanks and crests and
roots shall be in contact.
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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 solutiontreated condition, capable of passing ASTM-A-262 Tests for Detecting Susceptibility
to Intergranular Corrosion.
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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.
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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.
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15.4.10
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Blunter Electrodes
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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.
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Improved arc starting, increased arc stability and more consistent weld
penetration.
2.
3.
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.
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15.4.11
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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.
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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
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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.
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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
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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.
2.
3.
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The above data gives starting parameters. On completion of the first test weld, the
parameters will be modified to obtain the final result desired.
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An installers pocket guide for Swagelok tube fittings: Swagelok instruction manual.
2.
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.
6.
7.
8.
ISA-S 67.02.02(1996): Nuclear safety related instrument sensing line piping and tubing.
9.
10.
11.
12.
13.
14.
15.
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-ISubsection NB: Class 1 Components
18.
19.
20.
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21.
22.
23.
24.
25.
26.
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