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Instrumentation Safety Program

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Front ferrule compresses onto the surface of the tubing while sealing against the body seat ... Back ferrule lightly penetrates tubing, providing for tube ... – PowerPoint PPT presentation

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Title: Instrumentation Safety Program


1
Instrumentation Safety Program
Basic Principles of Tube Line Fabrication
2
Topics
  • Tube Selection
  • Compression Fitting Function Operation
  • Single ferrule vs. double ferrule fittings
  • Tube End Preparation
  • Fitting Make-up
  • Fitting Re-Make
  • Safety Related Topics
  • Troubleshooting

3
Why Use Tubing Over Pipe?
  • 1 - Bending Quality
  • 2 - Greater Strength
  • 3 - Less Turbulence
  • 4 - Economy of Space and Weight
  • 5 - Flexibility
  • 6. Fewer Fittings
  • 7. Tighter Joints
  • 8. Better Appearance
  • 9. Cleaner Fabrication
  • 10. Easier Assembly and Disassembly
  • 11. Less Maintenance

4
Why Use Tubing Over Pipe?
  • 1 - Bending Quality - Tubing has strong but
    relatively thinner walls is easy to bend. Tube
    fabrication is simple.
  • 2 - Greater Strength - Tubing is stronger. No
    weakened sections from reduction of wall
    thickness by threading.
  • 3 - Less Turbulence - Smooth bends result in
    streamlined flow passage and less pressure drop.
  • 4 - Economy of Space and Weight - With its better
    bending qualities and a smaller outside diameter,
    tubing saves space and permits working in close
    quarters. Tube fittings are smaller and also
    weigh less.

5
Why Use Tubing Over Pipe?
  • 5. Flexibility - Tubing is less rigid, has less
    tendency to transmit vibration from one
    connection to another.
  • 6. Fewer Fittings - Tubing bends substitute for
    elbows. Fewer fittings mean fewer joints, fewer
    leak paths.
  • 7. Tighter Joints - Quality tube fittings,
    correctly assembled, give better assurance of
    leak-free systems.
  • 8. Better Appearance - Tubing permits smoother
    contours with fewer fittings for a professional
    look to tubing systems.

6
Why Use Tubing Over Pipe?
  • 9. Cleaner Fabrication - No sealing compounds on
    tube connections. Again no threading minimum
    chance of scale, metal chips, foreign particles
    in system.
  • 10. Easier Assembly and Disassembly - Every tube
  • connection serves as a union. Tube connections
    can be reassembled repeatedly with easy wrench
    action.
  • 11. Less Maintenance - Advantages of tubing and
    tube fittings add up to dependable, trouble-free
    installations.

7
Proper Tube Selection
Four Areas of Consideration and Care
  • Always Match Materials
  • Select Proper Tubing Hardness
  • Select Proper Wall Thickness
  • Protect Tubing Surface Finish

8
Always Match Materials
Examples
  • Stainless Steel Fittings with Stainless Steel
    Tubing
  • Carbon Steel Fittings with Carbon Steel Tubing
  • Brass Fittings with Copper Tubing is the one
    Exception

9
Always Match Materials
Two Main Reasons to Match Materials
  • Dissimilar metals may cause galvanic corrosion
  • Ferrules must to be harder than the tubing

10
Galvanic Corrosion (electromechanical)
  • Please refer to your Instrument Tube Fitting
    Installation Manual (page 19)
  • Dissimilar Metals Create a low energy current.
  • The low energy current will travel between the
    two dissimilar metals.
  • The metal with more anodic potential will begin
    to corrode.
  • Parker does not recommend the use of dissimilar
    metals.
  • The only exception is brass fittings on copper
    tubing.

11
Typical Corrosion Example (electromechanical)
Galvanic corrosion may occur when two different
metals are in contact with each other. An
example of galvanic corrosion of aluminum in
contact with a stainless steel screw after six
months exposure in air at a Florida sea coast
site
12
(page 19)
13
Preventing or Controlling Galvanic Corrosion
  • Galvanic Series Charts as found on page 19, will
    predict which metal will corrode faster or slower

14
Proper Tubing Hardness
  • For the fitting to properly react with the
    tubing, the ferrules Must be harder than tubing.
  • SS tubing should have a maximum hardness of Rb
    90.
  • Rb 80 is recommended.
  • The following slides show how a tube system
    reacts when the ferrules are softer then the
    tubing.

15
Twin Ferrule Fitting Seal Points
A
B
C
D
Conditional Seal based on condition quality
of tubing
16
Typical Twin Ferrule Fitting Design
17
Cross Section of Ferrule Reaction With Tubing
18
Single Ferrule CPI Seal Points
A
B
19
Single Ferrule Fitting Design
20
Cross Section of Ferrule Reaction With Tubing
Front ferrule firmly grips and seals onto the
tubing while sealing against the body seat
21
Selection of Proper Tube Wall Thickness
Four Areas for Consideration
  • Chemical Compatibility
  • System Pressure
  • System Temperatures
  • Gas Service

22
Selection of Proper Tube Wall Thickness
  • Please refer to pages 22 23 of your manual

23
Chemical and Temperature Compatibility
  • Please refer to page 21 of your manual

24
Temperature De-Rating Factors
  • Please refer to page 24 of your manual

25
Gas Service Applications
  • Please refer to pages 22 23 of your manual

26
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27
Protecting the Tubing Surface
Proper Tube Surface Finish is Critical to
Optimizing Fitting Performance
  • Good quality tube surface finish is essential
  • Scratches, abrasions, weld seams or roll
    stampings on the tube surface can create leak
    paths under the ferrule system.
  • Rule of Thumb
  • If you can feel a scratch, or weld seam, with
    your finger nail it may be deep enough to
    create a leak path
  • Work around
  • Cut off bad end
  • Get another piece of tubing

28
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29
Proper Tubing Hardness
  • Please refer to your Instrument Tube Fitting
    Installation Manual (page 25)

30
Brief Exercise on Proper Tube Selection
  • Media Nitrogen
  • Application Main supply header from compressed
    gas bottles delivering nitrogen blanketing on oil
    storage tanks.
  • Location Gulf of Mexico shoreline.
  • System Pressure 2,000 PSIG (will be reduced
    later)
  • Line Size ½
  • Temperature Ambient outdoor conditions

31
Brief Exercise on Proper Tube Selection
Answer
  • Line Size ½
  • Nitrogen is not corrosive but the environment is
    Stainless Steel tubing would be best.
  • System Pressure is 2,000 PSIG, so .035 tubing
    will meet the pressure requirements. This is gas
    service and ½ - .035 wall tubing is listed in
    the gray area (not suitable for gas service) so
    we need to go to .049 wall. (Same specifications
    apply for welded or seamless tubing)
  • There is no need to de-rate the working pressure
    of the tubing to compensate for excessive
    temperatures

32
Practical Example
  • Line Size ½
  • System Pressure 2,000 PSIG
  • Media Nitrogen
  • Please refer to pages 22 23 of your manual

33
Tube Bending Techniques
34
This Program Will Teach
  • What Happens to a Piece of Tubing During Bending
  • Operation of a Manual Hand-Tube Bender
  • Measuring, Bending and Fabricating a Tube Line
  • (Can Also be Applied to Working With Conduit)

35
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36
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37
Minimum Free Length of Straight Tubing
  • Page 12

38
Tube End Preparation
  • Cut Tubing With Tube Cutter or Hacksaw
  • De-burr the Tube End
  • Clean the Tube End
  • Inspect

39
Common Methods of Cutting Tubing
40
Hand Tube Cutters
  • Ensure your cutter wheel is sharp.
  • Use that you are using a stainless steel cutting
    wheel on stainless steel tubing.
  • More turns to cut are better than less turns.
  • Advance the adjusting knob 1/8 to 1/4 turn when
    less resistance is felt.

41
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42
Tru-Kut vise Model 710439. Blades with 32 teeth
per inch minimum
43
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44
Abrasive Cut-off Wheels (Chop Saws)
  • Least desirable and recommended method to cut
    instrument tubing.
  • Excessive burrs.
  • Considerable contamination blown into tubing

45
De-Burring the Tube End
  • Burrs formed by cutting must be properly removed
  • O.D. burrs can prevent tubing from seating
    properly in a fitting body.
  • I.D. burrs can restrict flow, as well as possibly
    break loose and damage fine filtration elements.
  • Note Do not over deburr the O.D. of tubing.

46
Take Care Not to Excessively De-Burr the O.D.
Sizing Angle
47
Cleaning the Tubing
  • After De-Burring
  • Flush With Solvent or Compressed Air
  • Swab With a Lint Free Cloth
  • Inspect for Ovality Burrs
  • Do NOT polish, wire wheel or Emory Cloth the tube
    end!

48
Proper Tube Fitting Make-up and Re-Make
49
Proper Component Orientation and Sequence
50
Proper Component Orientation
  • Single Ferrule Fitting
  • One Ferrule One Direction
  • Incorrect Assembly
  • Ferrule Missing
  • Ferrule Backwards
  • Both are very obvious

51
Component Orientation Two Ferrule Fittings
  • Two Ferrule Fitting
  • No need to disassemble new fittings for
    inspection.
  • Back ferrule is the most common cause for error
  • Backwards
  • Missing
  • Insert tubing into the fitting before
    disassembling and inspecting components.

52
NPT Port Preparation with Teflon Tape
  • The port (pipe) end should be inspected and
    prepared before the fitting is installed and the
    compression end is set
  • Ensure thread is clean and free of dirt, burrs,
    Etc.
  • Starting with the first thread, apply 1-1/2 to 2
    Wraps of Tape if tape is thicker, 2 to 3 wraps is
    tape is of a thinner variety - Do Not Overhang
    Tape
  • Wrap tape in the direction of male pipe spiral

53
Insert fitting into pipe port and turn it in
finger tight. Tighten with wrench.
54
Insert fitting into pipe port and turn it in
finger tight. Tighten with wrench.
55
Thread Sealants
  • NOTE If thread sealants are being used - follow
    manufacturers recommended instructions for
    application.
  • Also ensure the sealant is compatible with the
    process media

56
SAE Straight Thread O-ringFitting - Non
adjustable
  • Make sure both threads and sealing surfaces are
    free of burrs, nicks scratches, or any foreign
    material.
  • Lubricate O-ring with system compatible
    lubricant.
  • Tighten to torque level listed in the torque
    chart on page 32.

57
SAE Straight Thread O-ringFitting - Adjustable
  • Inspect and correct both mating parts for burrs,
    nicks, scratches or any foreign particles.
  • Lubricate O-ring with system compatible
    lubricant.

58
SAE Straight Thread O-ringFitting - Adjustable
  • Back off lock nut as far as possible toward
    fitting body make sure back-up washer and O-ring
    are pushed up as far as possible toward upper
    thread.
  • Screw fitting by hand into the port until back-up
    washer contacts face of the port and continue
    turning until snug. (Very slight wrenching maybe
    needed). Back-up washer is now in correct
    position for assembly.

59
Proper Fitting Make-up
60
1/16 - 3/16
1/4 - 1
Because of considerable variations in tubing wall
thickness and surface hardness, Instrument Tube
Fittings are NOT made up by torque. Rather they
are assembled by the following simple
instructions
61
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62
1-1/4 Turns
63
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64
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65
A-LOK - Fully Installed 1 and ¼ Turns
66
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67
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68
CPI - Fully Installed 1 and ¼ Turns
69
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70
Review of Installation Steps
  • Select Inspect Appropriate Tubing
  • Fully Insert Tubing
  • Mark Reference Point on Nut / Tube
  • Securely Hold Body Rotate Nut Clockwise (1-1/4
    turns)

71
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74
Basic Troubleshooting
75
Presented by the RG Group
  • Thank You!!!
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