PREFACE

Swagelok® products have attained leadership in theindustry because of superior design principles in combinationwith close manufacturing tolerances and rigid qualityassurance programs. Since 1947, they have stood the test oftime with unparalleled performance on the job. They havebeen used successfully on some of the most demandingapplications in aerospace, chemical processing, oil refining,nuclear research, commercial fossil and nuclear power, lasertechnology, electronics, pulp and paper, and many otherindustries.

Wherever gases and liquids flow, Swagelok products arepreferred for their reliability and availability. Our system ofRegional Warehouses and Sales and Service Representativesassures off-the-shelf delivery throughout most of the world.

As part of our responsibility to those loyal customers whospecify and use our products every day, we have expandedthe sections on Installation; Trouble-Shooting; and TubingSelection, Specification and Handling. The well-knownSwagelok two-ferrule fitting is the best tube fitting we knowhow to manufacture; however, proper installation and use ofhigh quality tubing will go far to ensure leak-free connections.

The illustrated problems and solutions contained in thismanual have resulted from extensive field research andlaboratory studies conducted by our Research andDevelopment Engineers as well as by our customers. Webelieve that the use of this reference manual will avoid manyof the problems encountered on tubing installation projects.

I would like to thank those who have contributed to thepreparation of this manual, particularly the many pipe fitters,pipe fitter foremen, instrument engineers, and instrument shoppersonnel whose extensive help, suggestions, contributionsand comments made this book possible.

iii

Solon, OhioOctober 1993

F. J. Callahan

TABLE OF CONTENTS

iv

SwagelokNut

Swage10kBody

Swage10kBack Ferrule

Swage10kFront Ferrule

Our mission is to be the best supplier, worldwide, of the highestquality fluid system components readily available to industry andsupported by service that is technically sound, customer driven,and of the highest integrity.

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The Swagelok Tube Fitting

The Swagelok tube fitting is a flareless, mechanical-grip fittingconsisting of a body, nut, front ferrule, and back ferrule. All parts aremade of solid bar stock bought to special restricted requirements.Shaped bodies such as tees, elbows, and crosses are made fromforgings made from bar stock which is also purchased to specialrestricted requirements.

The Swagelok tube fitting is furnished in a variety of configurationsand materials so that a wide range of corrosive fluids and hostileenvironments can be handled with readily available parts.

The Swagelok tube fitting is also available as the integral end of awide variety of hand- or remotely-operated valves ranging from 1/16 in.micro-metering valves up to 2 in. ball valves. Full technical data onSwagelok valves can be obtained from your Swagelok representative.As described above, such valves are available in a wide range ofmaterials, configurations, and combinations of Swagelok connectionswith other connections.

Swagelok tube fittings are also available for conversion to otherfitting types such as male or female pipe, butt weld, socket weld,VCO® or VCR® separable weld couplings, or high pressure conedfittings.

Warning: Only valves from Swagelok may have Swagelok tube fittingconnections integral to the equipment. No one else is licensed tomanufacture Swagelok tube fitting ends on equipment. Therefore, ifyou find any type of equipment with so-called "Swage10k" tube fittingconnections integral to the equipment, you can be sure that it is not a"Swagelok" fitting. This does not apply, of course, to equipment whichhas welded-on or threaded-in Genuine Swagelok fitting ends.

There are many imitations of Swagelok tube fittings availablethroughout the world. Genuine Swagelok tube fittings are made only bySwagelok. Swagelok representatives are listed in the front of thecurrent Swagelok Product Binder. The best way to be sure that thefittings you buy are genuine is to purchase them from your Swagelokrepresentative.

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I

HOW THE SWAGELOK TUBE FITTING WORKS

The Swagelok tube fitting is a sequential phase, controlled actionsealing and gripping device. Superior design, rigid manufacturingtolerances, and strict quality assurance programs produce an all-metalsealing and holding device which performs leak-free when properlyinstalled.

Consisting of a nut, back ferrule, front ferrule, and body, theSwagelok tube fitting functions as follows:

1. Tubing is inserted into the completely assembled fitting until itbottoms against the shoulder of the fitting.

2. The nut is tightened 1 1/4 turns from finger-tight. During thistightening, a number of different movements take place within thefitting in a pre-planned sequence.

a. Through threaded mechanical advantage, the nut moves forward,driving the back ferrule forward.

b. The back ferrule drives the front ferrule forward.

c. The front ferrule is forced inward by the camming mouth of thefitting body.

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d. The front ferrule takes up the tolerance between its inside diameterand the outside diameter of the tube.

e. As the front ferrule moves forward and inward, its trailing edge islifted by the back ferrule to a sealing position with the cammingbody bevel.

f. As greater resistance is encountered because more tubing isdeformed and greater area of body bevel and front ferrule are incontact, the back ferrule is driven inward to form a second hold orgrip on the tubing.

g. At 1 1/4 turns of wrench pull-up, the nut has moved 1/16 in.forward. Within this 1/16 in. movement, the sequence of sealingand holding has been accomplished.

h. One of the unique abilities of this proven design is that of sealingand holding on a wide variety of tubing materials, wall thicknessesand hardnesses. Since the amount of back ferrule grip isdetermined by the tube's resistance to front ferrule action, grip ismuch tighter when heavy wall tubing is encountered. This is animportant design feature because heavy wall tubing is often usedin service conditions such as high pressure or other unusualstresses-vibration, pulsation, or shock. Thus the Swagelok tubefitting, by design, takes a much more secure grip on heavy walltubing than it does on thin wall tubing used for more moderateservice (see Fig. 1).

Compensating ActionFig. 1

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CONFIGURATIONS

A wide variety of configurations is available for fractional or metrictubing as shown in your Swagelok Product Binder - available fromyour Swagelok representative. The following configurations arenormally available for prompt delivery.

Each type of fitting is grouped by its function:

TO CONNECT TUBING TOAFEMALE THREAD USE:

MALE CONNECTOR

BULKHEAD MALE CONNECTOR

MALE ADAPTERTUBE TO PIPE

MALE BRANCH TEE

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TO CONNECT TUBING TOAMALE THREAO USE:

FEMALE CONNECTOR

BULKHEAD FEMALE CONNECTOR

FEMALE ADAPTERTUBE TO PIPE

FEMALE RUN TEE

FEMALE BRANCH TEE

TO CONNECTTWO OR MORETUBES TOGETHER USE:

UNION

BULKHEAD UNION

REDUCING UNION

SWAGELOK TO AN UNION

SWAGELOK TO ANBULKHEAD UNION

TO CONNECT TUBING TO ASWAGElOK PORT USE:

TO CONNECT TUBING TO SAE/MSSTRAIGHT THREAD PORTS USE:

TO CONNECT TUBING TO PIPE ORSTRAIGHT THREAD PORTS USINGAN O·RING SEAL, USE:

SIZE RANGESwagelok tube fittings are readily available in a size range from

1/16 to 2 in. 00 tubing in fractional sizes and 3 to 38 mm 00 tubing inmetric sizes.

Fractional1/16 in.1/8 in.3/16 in.1/4 in.5/16 in.3/8 in.1/2 in.5/8 in.3/4 in.7/8 in.1 in.

1 1/4 in.CD

1 1/2 in.CD

2 in.CD

Standard Fitting Sizes(Tube 00 Size)

Metric3mm6mm8mm

10 mm12 mm14 mm15 mm16mm18 mm20mm22mm25mm28mmCD

30mmCD

32mmCD

38mmCD

MATERIAL DESIGNATORA-B-S-M-

NY-PFA-SS-T-

CD steel and stainless steel only.

Note: Other fitting sizes, both fractional and metric, may be quoted.Consult your Swage10k representative.

MATERIALSSwagelok representatives normally stock fittings in the following

materials:

MATERIALAluminumBrassCarbon SteelAlloy 400/R-405NylonPerfluoroalkoxy316 Stainless SteelTFE

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Fittings in size ranges of 1/4, 3/8, and 1/2 in.; 6, 8,10, and 12 mm arealso normally available in the following materials:

MATERIAL MATERIAL DESIGNATORAlloy 20 C20-Alloy B2 HB-~~C~~ H~

Alloy 600 INC-Titanium TI-

Consult your Swagelok representative for a complete list of fittingmaterials available on special order. Available materials include:

MATERIAL MATERIAL DESIGNATOR304L Stainless Steel 304L-321 Stainless Steel 321-347 Stainless Steel 347-Copper-Nickel 70-30 CN 70-Copper-Nickel 90-10 CN 90-Nickel NI-Tantalum TA-Zirconium Alloy ZR2-

Bored-Thru Swage10k Tube FittingsFor many years, Swagelok tube fittings have been successfully used

for introducing thermocouples or other types of probes into pipingsystems.

There is one physical difference between a bored-thru fitting and astandard fitting. When a fitting body is bored thru, the shoulder of theSwagelok tube fitting is removed and the ferrules will not meet thesame resistance as when the tubing is properly bottomed. The mostobvious effect is that pressure rating is reduced. In general, we havemultiplied the allowable working pressure of the tubing, as found on theTubing Data sheet, by the following factors:

Size (in.) (mm) Factorup to 1/2 in. up to 12 mm 0.75above 1/2 in. to 3/4 in. above 12 mm to 18 mm 0.50above 3/4 in. above 18 mm 0.25

All other requirements for correct installation of Swagelok tubefittings need to be observed for bored-thru fittings: correct tubematerial, hardness and wall thickness, correct pull-up, and temperaturelimitations. Sizes 1/16 and 1/8 in. (4 mm and below) should always bepulled up from the snug position as defined in the catalog located in theSwagelok Product Binder.

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Since many bored-thru fitting applications involve thermocoupleswith different types of filler materials, the user should verify thesuitability of the thermocouple with our fitting.

Please note that over 1 in. and over 25 mm bored-thru fittings aresignificantly derated. Over 1 in. Swagelok tube fittings are designed tobe pulled up in a hydraulic swaging unit (HSU). Since this is notpossible when a bored-thru fitting is used and the tubing is insertedthrough the fitting body, pull-up must be done by wrenches.

Bored-thru Swagelok Male Connector

Bored-thru Reducer withUnion Tee used as aHeat Exchanger Tee

Fig. 2

Checklist for Excellence in Tube Fittings

DesignA tube fitting should ...

• be self-aligning• work on thick or thin wall tubing• have tube support ahead of the seal to resist vibration• have all components made of the same material as the fitting body

for thermal compatibility and corrosion resistance• have a residual spring condition so that temperature cycling will

not cause leakage• seal on machined surfaces• seal between ferrule and body at a point different from where the

heavy work is performed• compensate for the normal variables encountered in tubing

materials• not create torque or leave a residual strain on the tubing• not weaken the tube wall• not significantly reduce flow area.

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PerformanceA tube fitting should ...

• contain any pressure up to the burst point of the tubing withoutleakage

• work on vacuum as well as low or high pressures• seal consistently at cryogenic temperatures• seal consistently at elevated temperatures up to the maximum

tubing temperature rating• seal consistently over a wide range of temperature cycling• seal repeatedly under make-and-break conditions.

Installation

A tube fitting should ...• use geometry rather than torque for uniformity of make-up (1 1/4

turns)• not require disassembly and inspection before or after initial

make-up• not require special tools for installation.

ServiceA tube fitting should ...

• be readily available in a wide variety of sizes, materials, endconnections and configurations from a local representative's stock,with back-up stocks to quickly support representative's inventories

• be designed, manufactured, sold, and serviced by experiencedtube fitting specialists who understand and respect the need forreliable performance.

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WHY CLOSE TOLERANCES ARE IMPORTANTThe Swagelok tube fitting consists of four pieces:

SwagelokBody

SwagelokFront Ferrule

SwagelokBack Ferrule

SwagelokNut

But in actual practice, there is a fifth component-the tubing. Variousorganizations publish tolerance data, notably ASTM in the U.S. Ingeneral, we have found that international specifications follow the sameapproximate guidelines as shown in ASTM standards.

The tolerances published for tubing partially control the tolerancing oftube fittings. For example, a common tubing 00 variable in ASTMA269 for 1/2 in. 00 stainless steel is ±0.005 in. Therefore, the tube 00can vary from 0.495 in. to 0.505 in. Obviously the bore of the nut,ferrules and body must be large enough to accept this tubing. Beyondthis, we must hold the closest bore tolerance achievable. But at thesame time, the ferrule system must allow for the fact that the tube 00could be as small as 0.495 in. Therefore, very stringent quality controlis essential just to overcome the sizeable variation in tube 00.

Besides 00 tolerances, there are tolerances in tube wall thickness,ovality and hardness. All these variables must be overcome in only1 1/4 turns of the nut.

Therefore, we must keep our tolerances within an extremely tightrange. Any variation will degrade fitting performance. We have beentold that our quality is "too good" for some applications. We continue tosay "It's never good enough," and we're constantly looking for ways todo it better.

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Gageability

Because we do control the variables in the fitting so closely,Gageability is available in most Swagelok tube fittings. ConsistentGageability means the ability to use a gap inspection gage to checkeach fitting after it is pulled up. If the gap inspection gage fits betweenthe nut and body hex or shoulder, the fitting is not sufficiently tightened.

A full discussion of Gageability is presented on pp. 3-37 and 38.

Interchangeability of Tube Fitting Components

Over the years, we have become aware of more than 45 brands oftube fittings of various designs, and varying dimensions, which purportto be interchangeable and intermixable with Swagelok tube fittings. Wedo not believe that any manufacturer can reliably, repeatedly, anduniformly replicate the products of another manufacturer. For thisreason, we believe that interchanging and intermixing tube fittingcomponents of different designs, or made by different manufacturers,can result in leaks and tube slippage in a percentage of cases. We alsobelieve this practice can be dangerous in critical applications.

Leak-tight seals that will withstand high pressure, vibration,vacuums, and temperature changes depend upon close tolerances andconsistent, exacting quality control in conjunction with a good designprinciple. Our customers value these features. We believe that when acustomer interchanges and intermixes parts that are different in designprinciple, dimensions, or tolerances, the customer is deprived of thepredictable and consistent engineering that has been paid for. Webelieve that any manufacturer's fittings perform best when only thatmanufacturer's parts are used in its fittings.

Even though parts made by others may look like Swagelok parts,they have not been made from our prints nor have they been inspectedaccording to our exacting quality control requirements. Those qualitycontrol requirements come from know-how developed over 50 years ofspecialization in the field of manufacturing high quality tube fittings.

We do not believe that a tube fitting made up from the interchangingand intermixing of parts of other manufacturers with genuine Swageloktube fitting components will perform to the high standard of an all­Swagelok fitting. This practice may introduce performance and make­up variables that are impossible to predict. For all of these reasons,intermixing and interchanging of parts from other manufacturers withSwagelok components voids the Swagelok warranty and theresponsibility for tube fitting performance.

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Our position on INTERCHANGEABILITY is clear. DON'T DO IT!Note: For further information on testing of interchanged fittings, seeChapter 7.

Service and Availability

The quality reputation earned by Swagelok tube fittings since 1947 isunchallenged. Through all these years, dozens of companies havecopied or tried to copy the many design, engineering, andmanufacturing features of the Swagelok tube fitting. But the bestproduct is useless if it's not available in time to do your job.

There have also been numerous attempts to copy our distributionsystem. Yet no one has succeeded. To present you with all of theadvantages you gain by using our products without including a briefoverview of our distribution system would make this presentationincomplete. Our distribution system is unique because it was originatedand perpetuated with our customers' long-term interests in mind.

The Swagelok distribution system provides you with highly trainedrepresentatives who are available to work with you in person. Therepresentatives provide you with the technical information and trainingyou need to make your fluid systems operate at peak performance;they have been thoroughly trained for this specific purpose. At thefactories where the products are developed and manufactured, thesespecialists routinely enhance their training by acquiring information onthe newest technologies and product applications to serve you better.They know Swagelok products; they are not simply supply house ordertakers.

Your Swage10k representative works for the local stocking distributorin your area, one of over 240 worldwide. This distributor is also aspecialist in our products with years of experience in selling andservicing only Swagelok products. As an independent business owner,your distributor appreciates your need for reliable service, promptdeliveries, and accurate technical information and consistently fulfillsthose needs. A diversified inventory of our products is maintained atthis local site in sufficient quantities to supply you, the end user, withthe products you need, when you need them.

A number of regional distribution centers are strategically locatedthroughout the world. Their function is to carry a widely diversifiedinventory of all our products for immediate shipment to your Swagelokdistributor with extraordinary timeliness and efficiency. This efficiency isa result of the close communication between our regional distributioncenters and your Swagelok distributor.

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Our manufacturing systems are designed to continually replenishstock at the regional distribution centers and to quickly respond to anincrease in demands. While Swagelok factories maintain back-upinventories, they provide technical support and comprehensive traininggroups as well. Product and industry specialists regularly visitSwagelok representatives and their customers to identify new industryand product trends. By investing in advanced technology andemphasizing forward thinking, we are able to continue to develop andsupply innovative products, new options, and product line expansions.This enhances our ability to help you install and maintain safer andmore efficient systems.

With this distribution system in place, our customers are ensured thehighest quality products in the industry that are delivered on time andsupported by technically sound service. These are the tangible resultsof Swagelok's commitment to your future.

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TUbing-Specification and Ordering

General Comments and SuggestionsCareful selecting, specifying, purchasing, and handling of tubing are

essential to the successful use of Swagelok tube fittings. Severalgeneral rules apply:

1. Metal tubing must always be softer than the fitting material.For example, stainless steel tubing should never be used withbrass fittings.

2. When tubing and fitting are made of the same material, thetubing must be fully annealed.Mechanical, structural, or ornamental grade tubing shouldnever be used for fluid systems.

3. Extremely soft or pliable tubing such as Tygon® orunplasticized PVC tubing should always use an insert.Seals on the outside diameter of tubing require a certainamount of tube resistance for tight sealing.

4. Extremes of wall thickness should be checked against oursuggested minimum and maximum wall thickness limitations.A wall too thick cannot be properly deformed by ferrule action.A wall too thin will collapse under ferrule action and may notresist enough to allow the ferrules to coin out surface defects.

5. Tubing surface finish is very important to proper sealing.Tubing which is deeply embossed (such as copper watertube); has a visible weld seam on its outside diameter; or hasflat spots, scratches, or draw marks may not seal properlywhen used with a fitting sealing on the tubing 00.

6. Oval tubing which will not easily fit into fitting nuts, ferrules,and bodies should never be forced into the fitting.Such forced tube entry will scrape the tube 00 surface at themaximum diameter, making sealing difficult.

7. Laminated or multi-wall tubing, such as braided hose, shouldgenerally not be used with Swagelok tube fittings. Since theSwagelok fitting seals on the tube 00, system fluid may leakbetween hose or tube layers, causing "ballooning" andpossible wall rupture.

Tubing for Gas ServiceGases such as air, hydrogen, helium and nitrogen have very small

molecules which can escape through even the most minute leak-path.Some surface defects on the tubing can provide such a leak-path.

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As the tube 00 increases, the likelihood of scratches or other surfacedefects also increases.

The most successful connection for gas service will occur if allinstallation instructions are carefully followed and the heavier wallthicknesses of tubing are selected from the Tables beginning on p. 9-2.

A heavy wall tube resists ferrule action more than a thin wall tube

I and allows the ferrules to coin out minor surface imperfections. A thinwall tube will collapse. Therefore it offers little resistance to ferruleaction during pull-up and reduces the chance of coining out surfacedefects, such as scratches.

For the greatest safety factor against surface defects in any gassystem, use a wall thickness no less than the following:

Fractional Sizes, in inches Metric Sizes, in millimeters

Minimum Minimum Minimum MinimumNominal Nominal Nominal Nominal

Tube Wall Tube Wall Tube Wall Tube Wall00 Thickness 00 Thickness 00 Thickness 00 Thickness

1/8 0.028 3/4 0.065 3 0.8 18 1.5

3/16 0.028 7/8 0.083 6 0.8 20 1.8

8 1.0 22 2.01/4 0.028 1 0.083

10 1.0 25 2.25/16 0.035 1 1/4 0.109

12 1.0 28 2.53/8 0.035 1 1/2 0.134 14 1.2 30 3.01/2 0.049 2 0.180 15 1.5 32 3.0

5/8 0.065 x x 16 1.5 38 3.5

METAL TUBE SELECTION AND SPECIFICATIONWhen using a Swagelok tube fitting, it is important to remember that

the built-in fitting quality will be greatly compromised by the use of poorquality tubing.

Tubing should always be considered as the fifth importantcomponent, since the first four pieces-Swagelok nut, back ferrule,front ferrule, and body-all come to you fully inspected and assembled.It is short-sighted to purchase a high quality fitting and use it with thecheapest tubing available.

Although buying tubing to ASTM or equivalent specifications is astart towards tubing quality, it is only that-a start. Most suchspecifications allow rather wide latitudes in several important factors.For example ASTM A269, a very commonly used stainless steel tube

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specification, refers one to A450 General Requirements which include:

"11. Straightness and Finish

11.1 Finished tubes shall be reasonably straight and have smoothends free of burrs. They shall have a workmanlike finish. Surfaceimperfections (Note 1) may be removed by grinding, provided that asmooth curved surface is maintained, and the wall thickness is notdecreased to less than that permitted by this or the productspecification. The outside diameter at the point of grinding may bereduced by the amount so removed."

Note 1-An imperfection is any discontinuity or irregularity found inthe tube.

What is a "workmanlike" finish? How deep or how flat must thegrinding be?

ASTM A269 also allows OVALITY of the tube to be 2x the 00tolerance of ±0.005 in., or ±0.01 0 in. for thin-walled tube. If this ovalitywere to really be, for example, ±0.010 in. (0.510 in. by 0.490 in. for 1/2in. 00 tubing) the tube would not even fit into most tube fittings.

So the mere use of ASTM specifications does not really mean thatyou have a quality piece of tubing. Tubing quality depends on theintegrity and the quality-consciousness of the tubing supplier.

To be sure of selecting tubing whose quality is good enough toperform properly with the precision-made Swagelok tube fitting, wesuggest that the following variables be considered:

1. Tubing material and method of manufacture2. Tubing wall thickness and outside diameter3. Tubing surface finish4. Tubing hardness5. Tubing concentricity6. Tubing ovality

Fig. 1

Concentricity

Wall Thickness

Outside & InsideDiameter

Ovality

Seamless or Welded

Hardness

Type of Material

Surface Finish

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Often a user can specify certain limits on a tubing purchase order,particularly on large purchases, at no extra cost. These limits may wellbe considerably narrower than those permitted in ASTM specifications.For example:

Restricted OD Tolerances-Typical ASTM tubing specificationsshown on p. 2-12 permit various plus and minus tolerances. Some

Iusers will not accept tUbing with a "minus" tolerance because it is moredifficult to seal undersize tubing. Also for tubing 1/8 in. 00 and smaller,we suggest restriction to ±0.003. in.

Restricted Surface Finish Tolerances-As mentioned above,ASTM specifications are ambiguous and unclear on the subject offinishes. In particular, when stainless steel welded and drawn tubing isspecified, poor quality of weld or weld bead removal can cause sealingproblems when the tube and tube fitting are assembled.

Poor welding usually results in a visible depression, which ferrulescannot seal. Poor weld bead removal results in a raised portion or in aflat spot at the weld. Any of these conditions may result in a leak whenmade up into f1areless tube fittings.

A good rule of thumb, sometimes written into welded tubespecifications, is:

"External weld bead shall not be visible to the naked eye." Youcan always see the weld when you look at the tube inside diameter.Then inspect the 00 at that location. You will not be able to see theweld on the 00 if it is high quality tubing.

Hardness Restrictions-All f1areless tube fittings require that thetubing be softer than the fitting material. Various terms are used todescribe tubing hardness. In general, metal tubing should be fUllyannealed to work properly with Swagelok tube fittings. While moststainless steel tubing is restricted to a maximum Rockwell Hardness of90 HRB, many users specify that this hardness be further restricted to80 HRB. Such tubing lowers installed cost because it is more easilybent and installed. Although Swage10k stainless steel tube fittings maybe used on stainless steel tubing with a hardness of 90 HRBmaximum, we suggest that, whenever possible, you specify amaximum hardness of 80 HRB.

The following are suggested tubing specifications for specifying thebest quality tubing for leak-free tubing systems:

SUGGESTED ORDERING INFORMATION BY MATERIALAluminum Tubing-High quality drawn and seamless aluminum

alloy tUbing, ASTM B210 or equivalent. alloy 5052 or 6061-T6.

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Carbon Steel Tubing-High quality, soft, annealed, seamlesscarbon steel hydraulic tubing, ASTM A179 or equivalent. Hardness72 HRB maximum. Tubing is to be free of scratches and suitable forbending and flaring. Other acceptable specifications: ASTM A161,ASTM A556 grade A2, ASME SA179, AMS 5050, SAE J524b.

Copper Tubing-High quality, soft, annealed, seamless coppertubing to ASTM B68 or B75 or equivalent. If copper water tube toASTM B88 is used, it should be ordered without outside diameterembossing. Such deep embossing interferes with ferrule action. Eventhe areas where there is no embossing are sometimes flattened byblank dies.

Stainless Steel TUbing-High quality, fully annealed, seamless type(316, 304, 321, 347, etc.) austenitic stainless steel hydraulic tubingASTM A213, A269, A632 or equivalent. Hardness 80 HRB or less.Tubing is to be free of scratches and suitable for bending and flaring.OD tolerances for 1/16 and 1/8 in. tubing are not to exceed ±0.003 in.or:

High quality, fully annealed welded and drawn type (304, 316, 321,347, etc.) austenitic stainless steel hydraulic tubing, ASTM A249, A269,A632 or equivalent. Hardness: 80 HRB or less. Tubing is to be free ofscratches, with the weld bead on the outside diameter not visible to thenaked eye. Tubing should be suitable for bending and flaring. ODtolerances for 1/16 and 1/8 in. tubing are not to exceed ±0.003 in.

SPECIAL ALLOY TUBING-Swagelok tube fittings are available inseveral alloys. Suggested ordering instructions are as follows:

Alloy 400 Tubing-Cold-worked, fully annealed, seamless alloy 400tubing, ASTM B165 or equivalent. Hardness 75 HRB or less. Tubing isto be free of scratches and suitable for bending and flaring. ODtolerances for 1/16 and 1/8 in. tubing are not to exceed ±0.003 in.

Alloy 600 Tubing-Cold-worked, annealed, alloy 600 seamlessalloy tubing, ASTM B167 or equivalent. Hardness 92 HRB or less.Tubing is to be free of scratches and suitable for bending and flaring.Order to outside diameter and wall thickness only, not to insidediameter, average wall specification. OD tolerances for 1/16 and 1/8 in.tubing are not to exceed ±0.003 in.

Alloy C-276 Tubing-Fully annealed, seamless, alloy C-276 tubing,ASTM B622 or equivalent. Hardness 100 HRB or less. Tubing is to befree of scratches and suitable for bending and flaring. OD tolerancesare not to exceed ±0.005 in. in 3/16 to 1 in. and are not to exceed±0.003 in. in 1/16 and 1/8 in. OD tubing.

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Alloy B2 Tubing-Fully annealed, seamless alloy B2 tubing, ASTMB622 or equivalent. Hardness 100 HRB or less. Tubing is to be free ofscratches and suitable for bending or flaring. 00 tolerances for 1/16and 1/8 in. tubing are not to exceed ± 0.003 in.

Alloy 20 Tubing-Fully annealed, seamless or welded and drawnalloy 20 tubing, ASTM B468 or equivalent. Hardness 95 HRB or less.

ITubing is to be free of scratches, and the 00 weld bead (whereapplicable) should not be visible to the naked eye. The tubing shouldbe suitable for bending and flaring. 00 tolerances for 1/16 and 1/8 in.tubing are not to exceed ± 0.003 in.

Titanium Tubing-Fully annealed, seamless or welded and drawnGrade 2 titanium alloy tubing, ASTM B338 or equivalent. Tubing is tobe free of scratches, and the 00 weld bead (where applicable) shouldnot be visible to the naked eye. The tubing should be suitable forbending and flaring. 00 tolerances for 1/16 and 1/8 in. tubing are not toexceed ± 0.003 in.

PLASTIC TUBINGMany different types of plastic tubes are available for use in a wide

range of fluid applications. The most common types are listed belowwith certain characteristics and limitations and suggested orderinginstructions.

Nylon Tubing - Nylon tubing is a tough tube material that is readilyavailable for a wide variety of low pressure piping systems. Typicaluses are on low pressure hydraulics or air fluid power systems and inlaboratory piping. Because of its good flexibility and abrasionresistance, it is often used for instrument air, lubrication, beverage andfuel lines. Size ranges generally run from 1/8 00 to 1/2 in. 00. Nylontubing is usually rated by manufacturers by Short-Time Burst Rating,commonly from 1000 to 2500 psig (68 to 172 bar). Working pressure isgenerally 250 to 625 psig (17 to 43 bar) using a 4:1 design factor.Working temperature range is 75 to 165°F (24° to 74°C).

Swagelok metal tube fittings may be used up to the maximumworking pressure of nylon tubing. Swagelok nylon tube fittings may beused at lower tubing pressure ranges. Consult your Swagelokrepresentative for details.

Suggested ordering information: Outside diameter is not to exceed± 0.005 in. from nominal 00 in 3/16 to 1/2 in. tubing, and is not toexceed ± 0.003 in. in 1/8 in. 00.

2-6

Polyethylene Tubing-This inexpensive, flexible tubing is widelyused in laboratories, instrument air lines, and other applications. It ismore flexible than nylon, but not as abrasion-resistant. It is generallyvery corrosion-resistant, so it is very good for air service in corrosiveenvironments.

It is rated by burst pressure from 250 to 500 psig (17 to 34 bar) andworking pressure from 60 to 125 psig (4 to 9 bar) with a 4:1 design Ifactor. It is generally rated to a maximum temperature of 140°F (60°C).

Swage10k metal or nylon tube fittings may be used to the maximumworking pressure of such tubing. No insert is required unless the tubing00 is larger than 1/2 in.

Suggested ordering information: Outside diameter is not to exceed± 0.005 in. from nominal in 3/16 to 1/2 in. tubing; it is not to exceed±0.003 in. in 1/8 in. 00.

Polypropylene Tubing-This is an excellent flexible tubing which ismuch stronger than polyethylene. It is rated by burst pressure from1600 to 2400 psig (110 to 165 bar) and working pressure from 400 to600 psig (28 to 41 bar) with a 4:1 design factor. It has unusually goodtemperature characteristics and is generally rated to a maximumtemperature of 250°F (121°C).

Swagelok metal tube fittings are satisfactory for use onpolypropylene tubing. Swagelok nylon tube fittings may be used forlower tubing pressure ranges. No insert is required unless the tubing00 is larger than 1/2 in.

Suggested ordering information: Outside diameter is not to exceed±0.005 in. in 3/16 t01/2 in. tubing and is not to exceed ± 0.003 in. in 1/8in. 00.

PFA and TFE Tubing-This tough tubing is used in a wide variety offluid handling operations. It has excellent properties which resistcorrosion. It has good temperature capabilities to 400°F (204°C).Standard metal Swagelok tube fittings may be used on TFE or PFAtubing. When TFE fittings are used on TFE tubing, there is very littleholding power because of the very low coefficient of friction when aTFE fitting tries to hold a length of TFE tubing. However, the PFASwagelok tube fitting, when used with Swagelok PFA tubing (andgrooved with the Swagelok groove cutter), will hold to the rated workingpressure of the tubing. Consult your Swagelok representative forpressure rating information on this combination.

Suggested ordering information: Outside diameter is not to exceed± 0.005 in. from nominal 00 in 3/16 to 1/2 in. tubing and is not toexceed ± 0.003 in. in 1/8 in. 00.

2-7

Soft PVC Tubing-This tubing is a very soft, plasticized PVC usedfor flexibility and corrosion resistance in many laboratory, medical,food, and pharmaceutical applications. It is normally rated atapproximately 165°F (74°C). When used with Swagelok metal or plastictube fittings, a serrated insert must be used. The insert supports thetube wall from the inside so that ferrules can grip and seal the tubing.Swage10k hose connectors may also be used with this type of tubing(see Chapter 6). Reinforced soft PVC tubing is also available. An innerbraid is imbedded in the tube wall to increase strength and workingpressure. Swagelok tube fittings should not be used with reinforced softPVC tubing because of possible leakage from the end of the tubearound the braid, within the tube wall. An inside diameter seal, such asa Swagelok hose connector, should be used.

Suggested ordering information: Outside diameter is not to exceed± 0.005 in. from nominal in 3/16 to 1/2 in. tubing and is not to exceed± 0.003 in. in 1/8 in. 00.

TUBING STANDARDSThe following list covers the commonly encountered metal tubing

specifications for tubing to be used with Swagelok tube fittings.

For 00 tolerances, see p. 2-12.

1. Stainless Steel Tubing

ASTM A213 Standard to which seamless austenitic stainlessSeamless ferritic and steel tubing may be purchased for general service.austenitic alloy-steel boiler, Hardness 90 HRB maximum. 00 tolerances aresuperheated and heat determined by ASTM A450. Satisfactory for useexchanger tubes. with Swagelok stainless steel fittings.

ASTM A249Welded austenitic steel boiler,superheater, heat-exchanger,and condenser tubes.

ASTM A269Seamless and weldedaustenitic stainless steeltubing for general service.

2-8

Standard to which welded austenitic stainless steeltubing may be purchased for general and hightemperature service. Hardness 90 HRB maximum.00 tolerances determined by ASTM A450. Adrawpass to blend the weld groove into a smooth tube00 is necessary for satisfactory use with Swagelokstainless steel fittings.

Standard to which both welded and seamlessaustenitic stainless steel tubing may be purchasedfor general, corrosion-resisting, low and hightemperature service. Hardness 90 HRB maximum.Should be purchased cold finished and issatisfactory for use with Swagelok stainless steelfittings in the cold finished condition.

ASTM A450General requirements forcarbon, ferritic alloy, andaustenitic alloy steel tubes.

ASTM A632Seamless and weldedaustenitic stainless tubing(small diameter) for generalservice.

2. Carbon Steel Tubing

ASTM A161Seamless low carbon andcarbon-molybdenum steeltubes for refinery service.

ASTM A179Seamless cold-drawn lowcarbon steel heat exchangerand condenser tubes.

SAE J524bSeamless low carbon steeltubing, annealed for bendingand flaring.

Covers general requirements for steel and stainlesssteel welded or seamless tubing. Many of itsrequirements are mandatory in such specificationsas A179, A213, A249, A269. Except for A269, allthese specifications cover 00 tolerances byreference to A450. Tubing is not purchased to ASTMA450. Rather it is purchased to other specificationswhich usually get their "general" requirements fromA450.

Covers stainless steel tubing which may bepurchased for small diameter work from 0.050 to 1/2in. 00. Wall thicknesses are 0.005 to 0.065 in. Canbe either seamless or welded and drawn. Often usedfor small instrument tube requirements. Has closer00 and 10 tolerances (plus 0.002 in. minus 0.000 in.00, plus 0.000 in. minus 0.002 in. 10).

Standard to which cold drawn, seamless carbon steeltubing may be purchased for elevated pressure­temperature service. Carbon content is 0.10 % to0.20 % . Hardness 70 HRB maximum. 00 tolerancesare determined by ASTM A450. Only the cold drawn,low carbon variety is satisfactory for use withSwagelok steel tube fittings.

Standard to which cold drawn, seamless carbonsteel tubing may be purchased for general service.Carbon content is 0.06 % to 0.18 %. Hardness 72HRB maximum. 00 tolerances are determined byASTM A450. Satisfactory for use with Swageloksteel fittings.

Similar to A179, max carbon 0.18 %. Hardness65 HRB maximum. However, in 3/8 in. 00 andsmaller sizes with awall thickness less than 0.065in., no hardness test is required. Satisfactory for usewith Swage10k steel fittings.

2-9

I

3. Copper TUbing

ASTM 868Seamless copper tube, brightannealed

ASTM 875Seamless copper tube.

ASTM 888Seamless copper water tube.

ASTM 8251General requirements forwrought seamless copper andcopper alloy tube.

Covers annealed seamless copper tubing suitable foruse in refrigerators, oil lines, gasoline lines, etc.,where tube absolutely free of scale and dirt isrequired. Should be specified as "soft annealed,"temper 060 for use with Swagelok brass fittings. Wallthickness and diameter tolerances are determined byASTM B251.

Covers seamless copper tube for general purposes.Should be specified in annealed temper 060 for usewith Swagelok brass fittings. Wall thickness anddiameter tolerances are determined by ASTM B251.

Covers seamless copper water tube suitable forgeneral plumbing. It comes in Type K, Type L, andType M. Sizes 3/8 to 121/8 in. 00 (1/4 to 12 in.nominal). Should always be specified as annealedtemper 0 for use with Swagelok brass fittings. 00and wall thickness tolerances are specified in B88but 00 tolerances generally follow B251 guidelines.Type Kis the heaviest wall, Type L is medium walland Type Mis very thin wall. Type Mis normallyavailable only in hard temper straight-lengths andhas awall too thin to be used with Swagelok brassfittings. Both Type Kand Lare available either in 20foot straight lengths or 60 foot coils and softannealed Type Kor L is usually satisfactory for usewith Swage10k brass fittings but wall thickness maynot be sufficient for gas service. NOTE: Beware oftubing which is marked by embossing into the 00.Such depressed lettering can interfere with properferrule sealing. Water tube is normally sized by"nominal" 00, not actual 00, so actual 00 should bedetermined when using with Swagelok tube fittings.

This is the general specification for copper tubingwhich governs many requirements for ASTM B68and B75 copper tubing. It covers wall thickness and00 tolerances applicable to B68 and B75 tubing.

2-10 ----------------------

4. Aluminum Tubing

ASTM 8210Aluminum-alloy seamlesstubes.

5. Special Alloy Tubing

Alloy 400/R·405ASTM 8165Nickel-copper alloy (UNSN04400) seamless pipe andtube,

Alloy 600ASTM 8167Nickel-chromium-iron alloy(UNS N06600) seamless pipeand tube,

TitaniumASTM 8338Seamless and welded titaniumand titanium alloy tubes forcondensers and heatexchangers.

Alloy C·276ASTM 8622Seamless nickel alloy pipe andtube. (UNS N10276 or UNSN10665)

Alloy 20ASTM 8468Seamless and weldedchromium-nickel-iron­molybdenum-copper­columbium stabilized alloy(UNS N08020) tubes.

Covers drawn seamless aluminum tubes in straightlengths and coils, Alloy 6061 in T4 and T6 tempers issuggested and is indicated in our "Tubing Data" sheet.For Swagelok tube fitting use with other aluminum alloytubing, consult your Swagelok representative,

Covers alloy 400 seamless tubing. Should be specified"annealed" for use with Swagelok alloy 400 fittings,Hardness 75 HRB maximum (annealed), 00 toleranceis plus or minus 0.005 in. up to 5/8 in. aD, Over 5/8 in,00 allows plus or minus .0075 in" so tubing should beordered to a special tolerance of plus or minus 0,005 in.for best results with Swagelok alloy 400/405 fittings.

Covers alloy 600 tubing. Should always be specified"cold drawn annealed" for use with Swagelok alloy 600fittings, Hardness Rb92 maximum, 00 tolerance is plusor minus 0.005 in, up to 5/8 in, 00. Over 5/8 in. 00allows plus or minus ,0075 in" so tubing should beordered to aspecial tolerance of plus or minus 0,005 in.for best results with Swagelok alloy 600 fittings.

Covers titanium tubing which may be used withSwagelok titanium fittings, Swagelok tube fittings aremanufactured from Grade 4 titanium, Tubing should beordered as Grade 2to perform properly with Swageloktitanium fittings, Grade 2titanium is about 98,75 %puretitanium,

Covers several nickel alloys, but in particular it coversalloy 276 tubing such as would be used with Swagelokalloy C-276 tube fittings, 00 tolerance is plus or minus0.005 in, up to 5/8 in, 00. Over 5/8 in, 00 allows plus orminus ,0075 in., so tubing should be ordered to aspecial tolerance of plus or minus 0,005 in. for bestresults with Swagelok alloy C-276 fittings,

Covers alloy 20 tubing such as would be used withSwagelok C20 fittings. Hardness 95 HRB maximum.Covers wall thickness 0.015 to 0.500. in, 00 toleranceis plus or minus 0,005 in. up to 5/8 in. aD, Over 5/8 in,00 allows plus or minus ,0075 in. so tubing should beordered to aspecial tolerance of plus or minus 0,005 in,for best results with Swagelok alloy 20 fittings.

2-11

ASTM TOLERANCE- TUBE ODStainless Steel Carbon

Tube Swagelok Decimal ASTM ASTM Steel0.0. Tube Equivalents 4213 A269 ASTM

(inches) Size (inches) and A249 A1791/16* 100 0.0625 ± .004 in. ± .005 in. ± .004 in.

1/8* 200 0.125 ± .004 in. ± .005 in. ± .004 in.

3/16 300 0.1875 ± .004 in. ± .005 in. ± .004 in.

1/4 400 0.250 ± .004 in. ± .005 in. ± .004 in.

5/16 500 0.3125 ± .004 in. ± .005 in. ± .004 in.

3/8 600 0.375 ± .004 in. ± .005 in. ± .004 in.

1/2 810 0.500 ± .004 in. ± .005 in. ± .004 in.

5/8 1010 0.625 ± .004 in. ± .005 in. ± .004 in.

3/4 1210 0.750 ± .004 in. ± .005 in. ± .004 in.

7/8 1410 0.875 ± .004 in. ± .005 in. ± .004 in.

1 1610 1.000 ± .006 in. ± .005 in. ± .005 in.

1 1/4 2000 1.250 ± .006 in. ± .005 in. ± .006 in.

1 1/2 2400 1.500 ± .006 in. ± .010 in. ± .006 in.

2 3200 2.000 + .010 in. + .010 in. + .010 in.

Copper AluminumASTM ASTM875 8210

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.003in.

±.002in. ±.004in.±.0025 in. ±.004in.

±.0025 in. ±.004in.

±.0025 in. ±.004in.

Notes: Certain austenitic stainless tubing has an allowable ovalitytolerance double the OD tolerance. Such oval tubing may not fit intoSwagelok precision tube fittings.* ± 0.003 in. maximum recommended for 1/16 and 1/8 in. OD tubingwhen used with Swagelok tube fittings.

2-12 -----------------------

Tubing and Tube FittingHandling and Installation

TUBING VERSUS PIPETubing can be more cost effective than piping for connecting fluid

systems components. The advantages of using tubing for suchconnections are:

1. Ease of Installation-Only standard wrenches are needed to installSwagelok tube fittings. No threading, flaring, soldering, or welding isrequired (see Fig. 1).

Fig. 1

TurnNut

2. Better Strength to Weight Ratio-Full wall thickness of tubing is usedin containing pressure since no threading is necessary. Threadingreduces effective wall thickness in piping (see Fig. 2). The lighterweight of the tubing provides many benefits. Tubing is lessexpensive to transport, is easier to assemble, requires less support,and occupies less space.

LCdT Full wall thickness4 of tubing is used to

contain pressure

Extra pipewall thicknessrequired forthreading

Fig. 2

-.LT2

.-I

I

! '"Wall thicknessof pipe that

must be used 3

Wall thicknessneeded to contain 1

pressure

3-1

3. Lower Pressure Drop-Sharp bends and discontinuities of pipingsystems are not present in the gradual bends and smooth insidediameter of a tubed system (see Fig. 3).

Fig. 3

Piping Tubing

IFig. 4 Fig. 5

Typical application showinguse of tubing. (Photo courtesySouthwest Industries.)

(2) Threaded Joints(2) Separate Fittings

Schematic of similar type ofapplication showing the numberof connections necessary ifpiping were used.

(6) Threaded Joints(7) Separate Fittings

4. Fewer Connections Needed-Bending reduces the number ofnecessary connections and potential leak points. Tubing is veryadaptable and can be bent around many obstructions (see Figs. 4and 5).

Here are some typical installations where stainless steel tubing isused.

3-2

Fig. 6It may be impossible to build the systems shown with pipe.

The ease of bending and assembling stainless steel systemsrequires annealed tubing. (Photo courtesy-Automation,U.S.A.)

Fig. 7It is not always possible to

make piping easily serviceable.Note how difficult it would be toreach those fittings behind thefront fittings.

3-3

I

Fig. 8 Fig. 9

Pipe fittings used to connect Tube fittings required forjacketed pipe. same installation.(13 potential leaks) (4 potential leaks)

5. Leak Tight-At high pressures, pipe connections often leak! Tubingsystems connected with Swagelok tube fittings are leak-tight withoutusing sealing compounds. Compressed air, steam, hydrogen,helium, or hydraulic oil are very expensive services in a plant orrefinery. A cheap fitting that leaks can cost more money than aSwagelok tube fitting that provides positive performance.

6. Easy Maintenance-Every Swagelok tube fitting acts as a union.When disassembly is necessary, it is simple. This, coupled with leaktightness, means easy maintenance. There is no need to disconnecta series of pipe lengths and fittings to remove a particular componentfrom the system.

TUBING HANDLINGOnce tubing has been selected, specified, purchased, and received,

the subject of proper handling must be considered.

The built-in quality of carefully specified tubing can be quicklydegraded by careless handling. Careful handling of tubing from thetime it is received until the time it is installed will help greatly ininstalling leak-free systems.

Good handling practices will reduce scratches, gouges, and nickswhich can interfere with proper sealing (particularly on gas service).

3-4

Tubing should never be dragged off the delivery truck or off storageracks (see Figs. 10 and 11). The weight of the tube as it is draggedover the edge of the truck bed or tube rack may be sufficient to score orscratch tube aD surfaces. Scratches can also occur if an aD burr is lefton tubing under the length you are withdrawing.

Fig. 10

Fig. 11

Tubing should never be dragged across hard surfaces such ascement, dirt, gravel, asphalt or sand.

Soft tubing such as copper or aluminum should be handled withextreme caution to avoid a crushing or an out-of-roundness condition.

Out-of-round tubing which does not easily enter the nut, ferrules, andbody of the fitting should be re-cut. Forcing out-of-round tubing into thefitting may scratch or flatten the major diameter and cause tubingleakage.

3-5

I

PLANNING THE TUBE LAYOUTWhen installing a system, the first step is to draw a layout of the

system to determine the number of tube fittings and the length of tubingrequired. Care in determining the tube run will save time and possiblere-running at a later date. Points to be remembered are listed below.

1. Tubing should be run clear of access doors, bolts, and equipmentthat must have access for maintenance (see Figs. 12 and 13).

Fig. 12Wrong. Fuse panel blocked.

Fig. 13Right. Fuse panel clear.

3-6

2. When tubing is attached to an item that must occasionally beremoved for repair or maintenance, the method of connecting andrunning the tubing should permit easy removal (see Figs. 14 and 15).

Fig. 14Wrong. Neither pump nor motor is accessible for maintenance.

Fig. 15Right. Pump unit connected properly to permit access.

3. Tubing should remain clear of controls and not prohibit the operator'saccess to controls (see Fig. 16).

3-7

==

®®ffir~

Fig. 16Wrong. Operating panel blocked. Right. Operating panel clear.

4. Mechanical damage can often be avoided if a low run of tubing is notused as a bar rail for resting feet (see Fig. 17). A potential dangeralso exists in high runs that can be used like a bus rail (see Fig. 18).

Fig. 17Bar Rail

Fig. 18Bus Rail

3-8

Fig. 19Correct mounting

5. Long runs of tubing should be supported to prevent sagging (see Fig.19). Fluid density and tube size determine the frequency of supports.Generally, supports should allow free axial movement of the tubingand only support the weight of the tubing (see Fig. 20). Allcomponents should be mounted. The tubing should not support theweight of valves, filters, regulators, etc. (see Figs. 20 and 21). Tubingsizes 1/4 through 1/2 in. should be supported about every 3 feet, 5/8in. through 7/8 in. tubing about every 5 feet, and 1 in. and largertubing about every 7 feet.

Fig. 20Tubing supported in long run

Fig. 21Lubricator with angle bracket

support

3-9

I

6. Valves or other devices that require torque to be exerted in theiroperation should be mounted so that a twisting movement is notapplied to the tubing (see Figs. 22 and 23).

Fig. 22tS> Wrong. Strain is placed on tubing because valve is not restrained.

Fig. 23Right. When valve is mounted to prevent rotation of the valve body, no

strain is placed on the tubing.

3-10

7. Tubing should be ganged vertically rather than horizontally to avoidcollection of dirt, corrosives, and contaminants (see Figs. 24 and 25).If it is necessary to gang horizontally, the tubing should be covered.

(S) Fig. 26Wrong. Space wasted

A<:\ Fig. 24 Fig. 25\,;';)I Avoid this Correct method

8. Fittings should be staggered and offset when making multiple runs toprovide easier installation and conserve space (see Figs. 26 and 27).

Fig. 27Right. Installation is neater

and space is conserved

9. Expansion loops should be installed to prevent tension stresses andallow for temperature expansion (see Figs. 28 and 29). In particular,a straight run between two fixed fittings cannot be bottomed in thefittings at both ends.

Fig. 28(S) Wrong. Installations made like this may eventually leak because

of movement of the tubing from temperature changes. Also, the tubeusually cannot be bottomed in the fitting.

3-11

Fig. 29Right. Installations of this type allow for expansion from day to day

temperature changes and allow easy disassembly and properbottoming at both ends of the tube.

......u.-

((,-

::ilL

VII] Jt ...

(]).0::l

1:i(, "5

~:2:

~

...iii ~IIJ Ill' ~ p;;, ~++ ~

II)

R '/ JunctionBox

per:inK-

;.. 1

~~

!)

Swagelok Unions-Swagelok Bulkhead Unions

CopTub

Fig. 30Typical Junction Box Installation

Taking into account the previous points, the next step is to measurethe run. First, determine the type of terminal connections to be usedand, from the dimensions given in the Swagelok tube fitting catalog,determine the end point of the tubing (see Fig. 31).

3-12

End Point

Fig. 31End point of tubing

Then make a layout sketch at the tube run by measuring distanceswith a flexible steel rule. Measure all bends as square as shown inFig. 32. Measure all dimensions to tubing centerlines. For clearances, itis necessary to allow for one-half the tubing diameter to clearobstructions. In the following example, assume that 1/2 in. 00 tubing isto be used.

c

k----6

-Allow 1/2Tube Dia.

I---j---F --->-

E

k----- D----...I

Fig. 32

The length of the tubing required is roughly the sum of dimensions A,B, C, 0, E, F, and G. For example, using numbers A(3 in.) + B(8 in.) +C(6 in.) + 0(7 in.) + E(6 in.) + F(10 in.) + G(3 in.), the total length wouldbe 43 in.

A more accurate tube length can be obtained by actually figuring thelengths with bends. To do this, the diameter of the bends would bedetermined depending upon the tubing to be used and the type ofbending equipment to be employed. Assuming a bend radius of 1 in.,the layout then becomes:

3-13

IFig. 33

Where: A1 = A-1 = 3-1 = 2 in.

B1 =B-2=8-2=6in.

C1 = C-2 = 6-2 = 4 in.

D1 =D-2=7-2=5in.

E1 = E-2 = 6-2 = 4 in.

F1 = F-2 = 10-2 = 8 in.

G1=G-1=3-1=2in.The total straight length would be 31 in.

The length of the tubing required for (6) 90° bends must be added tothe total straight length. The length of tubing in a 90° bend is equal to1.57 times the radius of the bend or:

Length of tubing in 90° bend = 1.57 x bend radius for a bend radiusof 1 in. which we assumed above.

Length of tubing in 90° bend = 1.57 x 1 in. or 1.57 in. For six (6) 90°bends, six times this length is needed, that is: 6 x 1.57 in. = 9.42 in.

BEND RADIUSAngle Factor

30° 0.52Tube Length is

45° 0.78Factor Bend Factor x

60° 1.04 Bend Radius90° 1.57180° 3.14

The total length of tubing needed is the sum of the bend length andstraight length measured above, or: Total length = straight length +bend lengths or: 31 in. + 9.42 in. = 40.42 in.

3-14 -----------------------

As can be seen from this example, runs can be roughly sized bymeasuring straight lengths, assuming square corners, and trimming offexcess tubing after bending.

After cutting the piece of tubing to a length of 43 in., it is nownecessary to bend the tubing to make the installation.

TUBE STRAIGHTENINGStraightness of tubing is important from two standpoints.

1. Where the tube enters the fitting, it is necessary to have a straightrun long enough to allow the tube to bottom in the fitting body. (Seep. 3-24 for necessary straight length.) I

2. Also straight tubing is easier to support properly and makes access Ifor maintenance simpler. Straight tube runs are also more attractiveand reduce support installation time.

Softer tube materials such as copper and aluminum are oftenfurnished in coils, and some straightening must be done to make thetubing ready for use.

HOW TO UNCOIL TUBING

Fig. 34Take the end of the tubing and, with the right hand, hold it down on aflat surface such as a table top, wooden plank, floor, or sidewalk. If theflat surface is rough, put padding down to protect the end of the tubingfrom scratches.

3-15

Fig. 35Begin rolling the coil away from the end of the tubing with the left hand.

Fig. 36Slide the right hand along the tubing, following the coil in such amanner that the tubing lies flat on the flat surface. Unroll the coil ratherthan pulling the tubing end out sideways from the coil. Uncoiling fromthe side of the roll can twist or weaken the tubing and will tend to throwthe tubing out of round.

3-16

Do not uncoil more tubing than is necessary, since repeateduncoiling and recoiling will distort, harden, and stiffen coiled tubing.

Soft coiled copper tubing is sometimes unrolled and then stretchedto straighten it. Stretching can slightly harden the tube. Therefore, wedo not recommend this practice, but if it is performed, tubing should bestretched no more than 1 % (6 in. per 50 ft coil). If tubing is stretchedbeyond this, 00 reduction takes place and will cause sealing problems.

Another common field method to straighten copper tubing is to laythe tubing on a smooth floor or bench and use a wooden board flatwiseto strike the high spots. Do not strike too hard or flat spots will beformed. Soft tubing is easily dented and may collapse at a dent when itis being bent.

TUBE BENDINGOne of the greatest advantages of tubing is that it can be bent.

Though bending to a radius of 2 or 3 times the tube diameter ispossible, proper procedures must be used or difficulties such asflattening, kinking, or wrinkling will occur (see Fig. 37).

Flattened Bend Kinked Bend Wrinkled Bend Good 90° Bend

Fig. 37When such difficulties are encountered, they are usually caused by

bending too short a radius, not using or improperly using a mandrel onthin wall tubing, or slippage in the tube bender. Bending of tubing maybe accomplished by hand, by hand benders, or by production benders.

HAND BENDING

Fig. 38

3-17

I

Hand bending is accomplished by placing the thumbs towards eachother, but far enough apart to allow length for making the bend (seeFig. 38).

Fig. 39Bend the tubing slightly.

Fig. 40

Use your knee as a bending form and bend tubing in smallincrements by shifting knee to various points on the inside of the bend.Coiled springs inside or outside such a bend help prevent deformingthe tube. Hand bending to a small radius is very difficult as flatteningusually results (see Figs. 39 and 40).

3-18

STRENGTH OF TUBING BENDNo allowance needs to be made for the thinning of the tube wall at a

bend. Due to work hardening of the material, a bend in a section oftubing actually has greater strength than the straight run portion.

Fig. 41 shows what happens when a bend is subjected to a hydraulicpressure test. Note that the unbent tubing has burst in one straightsection and yielded to almost the bursting point in the other straightsection while the bend is still in its original form.

Fig. 41Tubing fails on the straight portion showing an increase of tensile

strength of material at the outside of the bend.

3-19

TUBE BENDERSHand benders and production benders are either the compression or

the draw type.

I

Clamp Roll Support

Bender Die

Fig. 42Compression Type Tube Bender

In the compression type tube bender, the form (or bender die) isstationary and the follow-block (or roll support) rotates around to bendthe tube. The portion of tubing to the left remains stationary.

-- ---IRotating Bending Form

Clamp

StationaryPressure Die

Fig. 43Draw Type Tube Bender

In the draw type tube bender, the form moves and the end of thetubing to the left moves with the form. The tubing to the right is drawnpast the stationary pressure point.

3-20

MAKING A BENDStep 1. Measure length A (3 in.) from the end of the tubing (see

Fig. 32), and mark the tubing (see Fig. 44).

43in.----J

Mark theTubing

Fig. 44 IStep 2. Align the scribe mark with the 90° mark on the bender (see I

Fig. 45).

Fig. 45Step 3. Then bend the tubing until the bender indicates a 90° bend

(see Fig. 46).

Fig. 46

---------------------- 3-21

I

The center line dimension from the end of the tubing to the centerlineof the bent tubing is 3 in., since the bender holds 1/2 the diameter ofthe tubing in the bending die (see Fig. 47).

Fig. 47Step 4. Then measure length B (see Fig. 32), (8 in. from the tube

centerline) and again mark the tubing (see Fig. 48).

Fig. 48

3-22 ----------------------

Step 5. As in steps 2 and 3, align the bender and make the secondbend (see Fig. 49).

Fig. 49Repeat this procedure by measuring from centerline, C, 0, E, F, and

G (see Fig. 32), turning the tubing over as necessary to position thetube bender.

When the tubing has reached its final shape, length G will be a littlelong since we started with a 43 in. tube length.

Check the tubing in the proposed installation by placing it alongsidethe two terminal connections. Scribe the tubing at the point it will betrimmed off, trim tubing with a tube cutter, deburr the 00 and 10, andthen install the tubing into the tube fittings (see Fig. 50).

Fig. 50

---------------------- 3-23

I

BENDS NEAR TUBE FITTINGSTube bends which are too close to a fitting installation may be a

source of leaks, and care must be used on such installations. Severalprecautions should be taken:

1. Leave a length of straight tube so that the deformed section at abend does not enter the fitting (See recommended length of straighttube in Fig. 51).

.--------,.-rT

._-----~--L

R Radius of tubing bend asrequired or minimum allowedfor specified wall thickness andtube size as recommended bybender manufacturer.

l Straight tube length requiredfrom end of tube to beginning ofbend.

T Tube outside diameter.

Fig. 51Fractional

T1/16 1/S 3/16 1/4 5/16 3/S 1/2 5/s 3/4 7/S 1 11/4 11/2 2

Tube 00 (in.)

LLength of 1/2 23/32 3/4 13/16 7/S

15/16 13/16 11/4 11/4 15/16 11/2 2 213/32 31/4Straight Tube(in.)

R Radius of tube bend as recommended by bender manufacturer.

3-24 ----------------------

Metric

TTube 00 3 6 8 10 12 14 15 16 18 20 22 25 28 30 32 38

(mm)

LLength of

19 21 22 25 29 31 32 32 32 33 33 40 40 52 51 60Straight Tube(mm)

R Radius of tube bend as recommended by bender manufacturer.

2. Inspect, for proper roundness, the length of tube that will be insertedinto a fitting. Out-of-round tubing could scratch when entering thefitting and result in leaks.

3. Long runs of tubing should be supported as should all othercomponents.

4. When a section of bent tubing is being connected, be certain that thetube is in proper alignment with the fitting before doing anytightening. Springing the tube into position with the fitting can resultin excessive stress on the tubing and the connection.

5. Proper bends in the tubing and proper alignment will ensure a good,trouble-free connection.

BEND RADIUSThe radius of tube bends is defined as the radius to the center of the

tube. The table on p. 3-26 shows commonly used minimum bend radiion currently available tube benders.

Tube material, wall thickness, and type of equipment used willinfluence the smallest bend radius available. The table on the followingpage is only an indication of what minimum bend radius may beexpected.

Follow the directions and recommendations of the bendermanufacturer in attempting to obtain minimum radius bends.

3-25

MINIMUM TUBE BEND RADIUS

Tube 00 Radius

1/8 in. 3/8 in.

1/4 in. 9/16 in.

3/8 in. 15/16 in.

1/2 in. 11/2 in.

5/8 in. 11/2 in.

3/4 in. 13/4 in.

7/8 in. 2 in.

1 in. 4 in.

11/4 in. 5 in.

11/2 in. 6 in.

2 in. Sin.

Fig. 52Here is a close-up of an oil well control panel that shows the intricate

use of quality bending so that all components are serviceable. Note theneatly stacked straight runs. (Photo courtesy: Automation, U.S.A.)

TUBE CUTTINGThere are two common methods of tube cutting:

1. Tube Cutters

2. Hacksaw

Tube cutters generally consist of a frame and handle, screwmechanism to advance the cutting wheel, the cutting wheel itself, androllers to support the tube during the cutting operation.

3-26

Such cutters are commonly used for the cutting of plastic, softcopper, aluminum, or perhaps soft steel tubing. Good quality cutterwheels used on soft tubing provide a long service life before dulling.Most tube cutters do not have a cutter wheel designed for use onharder tubing materials such as stainless steel and are, therefore, notrecommended for use on such tubing.

Fig. 53SWAGELOK TUBE CUTTER

Tube cutters do not remove material, but rather "push" material asideand down. The duller the cutter wheel, the more material is raised atthe tube end, increasing tube 00 at the end. In its worst case, thisraised material can even make it difficult to insert the tube intoprecision tube fitting components. A dull cutter wheel also workhardens the area of the tube near the cut due to excessive pressurefrom back-up rollers.

The Swagelok tube cutter (MS-TC-308) is specifically designed tocut annealed steel and stainless steel tubing as well as softer tubematerials. Its cutting wheel was developed specifically to overcome thedisadvantages of previously available wheels, giving long life andexcellent cuts on steel and stainless steel tubing from 3/16 in. to 1/2 in.00. It can also be used for cutting softer tubes such as copper oraluminum up to 1 in. 00.

HOW TO CUT TUBING WITH A TUBE CUTTERPressure on the cutter wheel is maintained by a constant and

gradual tightening of the handle or knob to advance the cutter wheeldeeper into the tube. Trying to rush this procedure will result in poorcuts and excessive cutter wheel wear. We have found that about a 1/8turn of the knob for each two revolutions of the cutter is optimum forsteel or stainless steel tubing. For soft copper tubing a 1/8 turn of theknob for one cutter revolution is sufficient.

I

3-27

There are two opinions as to whether tube cutting should be aconstant turning or a back and forth motion. On longer lengths oftubing, rock the tube cutter with your hand. First rotate above the tubingthen back around so that your hand goes below the tUbing (see Fig. 55)which will allow you to cut the tubing without taking your hand off thetube cutter. The cutter hand wheel can be adjusted as the rockingproceeds to maintain even tension on the cutting wheel. When cutting ashort piece of tubing, the cutter may be continually rotated around theend of the tubing. The hand wheel can be gradually rotated to maintaineven tension on the cutting wheel.

It is important that the cutting wheel be in top condition, and it isrecommended that spare, sharp cutting wheels be kept available at alltimes. (Part No. MS-TCW-308). When extra resistance is felt due towheel dulling, the cutting wheel should be replaced.

Fig. 54Tightening the handle forces the cutting wheel deeper into the tube

wall.

3-28

Fig. 55The cutter can either be rocked back and forth or turned completely

around the tube.

Deburring should always be performed as described on pp. 3-30 and31.

Fig. 56The raised portions on the handle are placed in 1/8 turn increments.

Use these as your guide when advancing the handle 1/8 turn.

TUBE CUTTING WITH A HACKSAWIf a tube cutter of the proper size is not available, a hacksaw can be

used (see Fig. 57). Tubing should always be cut to length with a squarecut. When using a hacksaw to cut tubing, use guide-blocks to ensure asquare cut and to keep the tubing from flattening out. The Swageloktube saw guide (MS-TSG-16) is an excellent device to hold tubing whilecutting with a hacksaw. Hacksaw blades should have at least 24 teethper in.

I

3-29

IFig. 57

Hacksaw and guide blocks used to cut tubing.

Tube cutters throw a burr into the 10 of the tubing (see Fig. 58), anda hacksaw will burr both the 10 and 00 of the tube (see Fig. 59). Theseburrs should be removed after cutting the tube. Make sure that metalchips are cleaned from the end of the tubing since metal chips cancause a fitting to leak or cause damage to components in the system.

Fig. 58Tube cutter burrs-IO

Fig. 59Hacksaw burrs-IO and 00

TUBE DEBURRINGBoth the 10 and 00 of tubes should be deburred after cutting, no

matter which method (tube cutter or hacksaw) is used for cutting thetube.

1. 10 deburring, while not as important to the function of the tube fitting,is important from the standpoint of system cleanliness. Small burrs,chips and slivers of metal can plug small pilot holes or vents, canscratch valve seats or stem tips, and can damage soft seals such asa-rings. 10 burrs can substantially reduce the tube 10 and affectthrough-flow.

3-30

2. 00 deburring is important for proper fitting function as well as forclean, leak-free systems.

Fig. 60Small 00 burrs may prevent tubing from being fully inserted through

the nut, ferrules, and body bore (see Fig. 60). It is vital, of course, thatthe tube always pass through the nut and ferrules and be bottomedfully against the shoulder of the fitting body.

Even if 00 burrs do not interfere with full insertion, they can lodgebetween sealing surfaces, or break off and interfere with thedownstream system similar to an 10 burr. 00 burrs can also scratchthe fine finish of the ferrule bore, making ferrule to tube sealing moredifficult.

DEBURRING TOOLSOutside deburring can be accomplished with a smooth file. Inside

deburring can easily be accomplished using a Swagelok deburring tool(Part No. MS-44CT-27).

Fig. 6100 deburring with a file.

Fig. 6210 deburring with a Swagelok deburring

tool. Part No. MS-44CT-27

3-31

The Swagelok tube deburring tool (Part No. MS-TDT-24) is used todeburr steel and stainless steel (or other softer tubing) from both insideand outside diameters. It works on tube ID sizes from 3/16 in. to 1 in.

Fig. 63Tube deburring tool

INSTRUCTIONS1. To deburr outside diameter of tube, place the deburring tool, with

blades on the outside, over the end of the tube. Rock the tool backand forth, or rotate in a clockwise direction.

2. To deburr inside diameter, reverse the tool and insert blades insidethe tube. Again, rock the tool back and forth, or rotate in a clockwisedirection.

3. Wipe the tube end clean with a cloth.

Caution: DO NOT PUT FINGER INSIDE TOOL OR NEAR CUTIINGEDGES.

HANDLING OF TUBE FITTINGSGenuine Swagelok tube fittings are designed and manufactured to

rigid quality control requirements. In shipment they are well protectedfrom dirt, moisture, and careless handling. To get the maximum valuefrom your investment in quality, fittings should be kept in the sameboxes they were shipped in. Boxes should be kept closed to keep dirt,dust, sand, water, and other contaminants from getting into the fittings.

Fig. 64

3-32

Thread protectors should be left on any exposed pipe threads untilthey are ready to be used.

Fig. 65Thread Protector

Fittings should have nuts and ferrules kept on them until tubing isinserted and pull-up is completed. If any bodies have beendisassembled or cannibalized for nuts and ferrules, new nuts andferrules should be installed using a length of tubing as a rod to ensureproper replacement and alignment of genuine Swage10k nuts andferrules.

Fig. 66Ferrule Arbor

Before installing pipe thread ends of Swagelok tube fittings, asuitable sealant such as SWAK® anaerobic pipe thread sealant withTFE or Swagelok TFE tape should be wrapped around male threads.On stainless steel fittings, a double wrap will provide added anti-gallingresistance. System parameters of fluid temperature and operatingconditions should be checked for compatibility with pipe sealants.

HOW THE SWAGELOK FITTING IS INSTALLEDSwagelok tube fittings may be installed very simply, using readily

available wrenches. In sizes 1 in. (25 mm) and below, 1 1/4 turns with awrench from finger-tight is the suggested assembly method. However,1/16, 1/8, and 3/16 in. (2, 3, and 4 mm) size fittings require only 3/4turn from finger-tight.

---------------------- 3-33

Sizes 1 1/4, 1 1/2, and 2 in. and 28, 30, 32, and 38 mm Swage10ktube fittings require the use of hydraulic swaging units described onpp. 3-42 and 43. The hydraulic swaging unit is also available in 1/2,5/8, 3/4, and 1 in. fractional sizes, and 12, 14, 15, 16, 18, 20, 22, and25 mm metric sizes.

NORMAL INSTALLATION PROCEDURESwagelok tube fittings come to you completely assembled, finger­

tight, and are ready for immediate use. Disassembly before use canresult in dirt or foreign material getting into the fitting and causing leaks.

ISwagelok tube fittings are installed in three easy steps as shown inFigs. 67, 68, and 69.

Fig. 67

Step 1- Simply insert the tubing into the Swage10k tube fitting.Make sure that the tubing rests firmly on the shoulder of the fitting andthat the nut is finger-tight.

Fig. 68Step 2-Before tightening the Swagelok nut, scribe the nut at the 6o'clock position.

3-34 ----------------------

Fig. 69Step 3-While holding the fitting body steady with a backup wrench,tighten the nut 1 1/4 turns*. Use the scribe mark, make one completerevolution and continue to the 9 o'clock position.

By scribing the nut at the 6 o'clock position as it appears to you,there will be no doubt as to the starting position. When the nut istightened 1 1/4 turns* to the 9 o'clock position, you can easily see thatthe fitting has been properly tightened.

Use the gap inspection gage on initial installation into the fitting bodyto assure you of sufficient pull-up.

*For 1/16, 1/8, 3/16 in., 2, 3, and 4 mm size tube fittings, tighten 3/4turn from finger-tight.

When working in close quarters where the swing room for wrenchesis limited, the Swagelok ratchet wrench is useful (see Fig. 70).Available in hex sizes for 1/8 through 1/2 in. (3 through 12 mm)Swagelok tube fitting sizes, it works with only 1/12 turn of the handleand exerts equal pressure on all six hex points.

Fig. 70

---------------------- 3-35

TORQUEMeasuring torque required to pull up a Swage10k tube fitting is not a

reliable measure of pull up. All the tolerances of precise 00, ovality,wall thickness, and hardness of the tubing will vary the torque requiredfor full pull-up. The 1 1/4 turns of the nut is the measure of sufficientpull-up, and it can be checked with a gap inspection gage.

HIGH PRESSURE APPLICATIONDue to the variation of tubing diameters, a common starting point is

desirable. Therefore, with a wrench, snug up the nut until the tubing willnot turn by hand or move axially in the fitting. At this point, scribe ormark the nut on the fitting. Using the scribe or mark on the nut to keeptrack of the turns, tighten the nut 1 1/4 turns while holding the bodystationary with a backup wrench. Only you can determine what is "highpressure" or "high safety factor" service. Using "1 1/4 turns from snug"merely does away with one variable because the ferrules are in definitecontact with the tube when you start the pull-up.

NO DISASSEMBLY INSPECTIONHaving made the tube connection, there is no need to disassemble a

Swagelok fitting to inspect the connection after assembly. Exhaustivetests and on-the-job performance have proven that disassembly is notneeded as long as the fitting has been pulled up in accordance with theinstallation instructions.

GAGEABILITYProper make-up instructions have already been discussed. The

Swage10k tube fitting has been developed with such stringent controlover all the variables that a reliable checking device is available toassure the fitter or supervisor that sufficient (1 1/4 turn) pull-up hasbeen achieved.

I

ASSEMBLY OF FITTINGS

Finger-tightFig. 71

1 1/4 Turns

3-36

The device itself-a gap inspection gage-is very simple. Itssuccessful use, however, depends on extremely close control of manystacked tolerances in the manufacture of the four components of theSwagelok tube fitting.

HOW THE GAP INSPECTION GAGE IS USEDSwagelok gap inspection gages are designed to assure the installer

or inspector that a fitting has been sufficiently pulled up. They areparticularly applicable to systems where fittings are to be tightened indifficult or inaccessible locations or systems where insufficient pull-upcould cause potentially dangerous or expensive consequences. I

Swagelok gap inspection gages are inserted between the nut andbody of a Swagelok tube fitting after pull-up. If the gap inspection gagewill fit in the gap between the nut and body hex, the fitting nut has notbeen sufficiently tightened.

Fig. 72Gap inspection gage fits

between nut and body hex.Fitting is not sufficiently tightened.

For Multiple Sizes

1/4,3/8, and 1/2 in.;6 and 12 mm

Fig. 73Gap inspection gage does notfit between nut and body hex.Fitting is sufficiently tightened.

6,8,10, and 12 mm

Fig. 74

---------------------- 3-37

Fig. 75

Gap inspection gage does notfit between nut and body hex.Fitting is sufficiently tightened.

I Gap inspection gage fitsbetween nut and body hex.Fitting is not sufficiently tightened.

The thinner end of the (individual size) gap inspection gage is used tocheck for sufficient pUll-up when the high pressure (1 1/4 turns fromsnug) pull-up is used. Snug is determined by tightening the nut until thetubing will not rotate freely (by hand) in the fitting. (If tube rotation is notpossible, tighten the nut approximately 1/8 turn from the finger-tightposition.) At this point, scribe the nut at the 6 o'clock position, andtighten the nut 1 1/4 turns. The fitting will now hold pressures wellabove the rated working pressure of the tubing.

NOTE: Use the gap inspection gage to assure you of sufficientpull-up. Tube 00, material, and hardness affect the torque required topull up 1 1/4 turns (see Fig. 72 and 73).

NOTE: Inspection gages should not be used after retightening,pre-swaging, or hydraulic swaging.

WHICH SWAGELOK TUBE FITTINGS ARE GAGEABLE?Sizes 1 in. (25 mm) and under - The Swagelok end of all male and

female connectors, unions, and reducing unions are gageable. Theshorter end of all bulkhead unions is also gageable.

Plastic fittings are not gageable. Brass and aluminum elbows, tees,and crosses that do not have a reduced diameter neck are notgageable.

Sizes over 1 in. (25 mm) - Because of the wide tolerancesallowable on the 00 of over 1 in. tUbing, all installations should bemade with a hydraulic swaging unit (see pp. 3-42 and 43). Thisrequires snugging the nut to bring the ferrules in contact with the tube00 before swaging. Therefore, use of a gap inspection gage is notfeasible. The hydraulic swaging unit has an indicator arm that tells youwhen swaging is complete (see p. 3-42).

3-38

RETIGHTENING INSTRUCTIONSConnections can be disconnected and retightened many times. The

same reliable, leak-proof seal can be obtained every time theconnection is remade.

Fig. 761. Fitting shown in disconnected position.

Fig. 772. Insert tubing with pre-swaged ferrules into fitting body until front

ferrule seats, then finger-tighten the nut.

Fig. 783. Rotate nut to previously pulled up position with a wrench. At this

point, an increase in resistance will be encountered. Then tightenslightly with the wrench. (Smaller tube sizes will take less tighteningto reach the original position, while larger tube sizes will requiremore tightening. The wall thickness will also have an effecton tightening.)

3-39

PRESWAGING INSTRUCTIONSWhen installing Swage10k tube fittings in cramped quarters or where

ladders must be used, it may be advantageous to use a pre-swagingtool. It allows the pre-swaging of ferrules onto the tube in a more openor safe area. After using the tool, simply follow the re-tighteninginstructions (see Figs. 76, 77, and 78).

Oversized or very soft tubing may occasionally stick in the tool afterpull-up. If this happens, remove the tube by gently rocking it back andforth. Do not turn or twist the tube with pliers or other tools because thismay damage sealing surfaces.

Fig. 79This illustration shows tubing with a union connected high above

ground. If a run of tubing were to be connected, it would be difficult topull up the second end of the union. For a solution, see Figs. 80, 81,82, and 83.

Fig. 80Assemble the Swagelok nut and ferrules to the preswaging tool.

Insert tubing through the ferrules until it bottoms in the preswaging tool,and tighten nut 1 1/4 turns (sizes 1/16, 1/8, and 3/16 in.; 2, 3, and 4mm require 3/4 turn).

3-40 ----------------------

Fig. 81The nut is loosened and the tubing with preswaged ferrules is

removed from the preswaging tool.

Fig. 82The connection can now be made by following the retightening

instructions (see Figs. 76, 77, and 78).

Fig. 83Completed installation.

NOTES ON USE OF PRESWAGING TOOLS1. Preswaging tools have a finite life. After frequent use, ask your

Swagelok representative to have them checked.

2. Dirt, chips, and other metal inclusions can interfere with properswaging action. The tool should be thoroughly cleaned after eachuse.

---------------------- 3-41

SWAGELOK HYDRAULIC SWAGING UNITHydraulic swaging is required for larger size tube fittings (1 1/4 in.,

28 mm, and up). Units are also available in 1/2, 5/8, 3/4, and 1 in.Metric units are available in 12, 15, 16, 18, 20, 22, 25, 28, 30, 32, and38 mm OD sizes. Over 1 in. (25 mm) steel and stainless steelSwagelok tube fittings must be made up using the hydraulic swagingunit. They should never be made up with just wrenches. Torques aretoo high and tube variables make wrench pull-up unreliable.

Fig. 84 Fig. 85

I

The Swage10k hydraulic swaging unit is designed to make a safeand reliable, torque-free, leak-proof seal on large tubing sizes.

The hydraulic swaging unit consists of a swaging tool and anaccessory case. The accessory case contains a hydraulic pump, hoseand service equipment, plus complete installation instructions.

Number ForMS-HSU-810 112 in. Swagelok FittingsMS-HSU-1 01 0 5/S in. Swagelok FittingsMS-HSU-1210 3/4 in. Swagelok FittingsMS-HSU-1410 7/S in. Swagelok FittingsMS-HSU-1610 1 in. Swagelok FittingsMS-HSU-2000 11/4 in. Swagelok FittingsMS-HSU-2400 1112 in. Swagelok FittingsMS-HSU-3200 2 in. Swaqelok FittinqsMS-HSU-12MO 12 mm Swagelok FittingsMS-HSU-15MO 15 mm Swagelok FittingsMS-HSU-16MO 16 mm Swage10k FittingsMS-HSU-18MO 18 mm Swagelok FittingsMS-HSU-20MO 20 mm Swagelok FittingsMS-HSU-22MO 22 mm Swagelok FittingsMS-HSU-25MO 25 mm Swagelok FittingsMS-HSU-28MO 28 mm Swagelok FittingsMS-HSU-30MO 30 mm Swagelok FittingsMS-HSU-32MO 32 mm Swagelok FittingsMS-HSU-38MO 38 mm Swaaelok Fittinas

3-42

Hydraulic Swaging Unit Tubing Recommended Wall Thickness

TUbing 00 Material Min. Wall Max. Wall1/2 in. stainless steel 0.049 in. 0.083 in.1/2 in. carbon steel 0.049 in. 0.083 in.5/8 in. stainless steel 0.065 in. 0.095 in.5/8 in. carbon steel 0.065 in. 0.095 in.3/4 in. stainless steel 0.065 in. 0.109 in.3/4 in. carbon steel 0.065 in. 0.109 in.7/8 in. stainless steel 0.083 in. 0.109 in.7/8 in. carbon steel 0.083 in. 0.109 in.1 in. stainless steel 0.083 in. 0.120 in.1 in. carbon steel 0.083 in. 0.120in.11/4 in. stainless steel 0.083 in. 0.156 in.11/4 in. carbon steel 0.065 in. 0.180 in.11/2 in. stainless steel 0.095 in. 0.188 in.11/2 in. carbon steel 0.083 in. 0.220 in.2 in. stainless steel 0.109 in. 0.188 in.2 in. carbon steel 0.095 in. 0.220 in.12mm stainless steel 1.2 mm 2.0mm12mm carbon steel 1.2 mm 2.2 mm15mm stainless steel 1.5 mm 2.2mm15mm carbon steel 1.5mm 2.2 mm16mm stainless steel 1.5mm 2.2 mm16mm carbon steel 1.5mm 2.5 mm18mm stainless steel 1.5mm 2.5mm18mm carbon steel 1.5mm 2.5mm20mm stainless steel 1.8mm 2.8mm20mm carbon steel 1.8 mm 2.8mm22mm stainless steel 2.0 mm 2.8 mm22mm carbon steel 2.0mm 2.8mm25mm stainless steel 2.0mm 3.0mm25mm carbon steel 2.0 mm 3.0mm28mm stainless steel 2.0mm 3.5mm28mm carbon steel 2.0mm 3.5 mm30mm stainless steel 2.0mm 3.5mm30mm carbon steel 2.0mm 3.5mm32mm stainless steel 2.0mm 4.0mm32mm carbon steel 2.0mm 4.0mm38mm stainless steel 2.2mm 4.5mm38mm carbon steel 2.2mm 4.5mm

For a complete demonstration of the proper use of the hydraulicswaging unit, please contact your Swagelok representative.

TUBE ADAPTERS AND REDUCERSSwagelok Company pioneered the development and use of tube

adapters. Tube adapters consist of a machined tube stub (metric orfractional 00) on one end and a male or female threaded second end.These fittings have two distinct advantages:

I

3-43

1. They greatly reduce inventories. By stocking union tees and unionelbows, plus a few various adapters, a wide variety of male or femaleelbows, male run, male branch, female run or female branch teescan be made up with a minimal inventory investment.

I A. Female Port

B. Male Elbow

C. Male Adapter

Fig. 862. They eliminate difficult alignment problems by simplifying the proper

orientation of elbows, tees, and crosses without regard to pipe threadtightness.

A. In Fig. 86, the required installation is to connect tubing to afemale port (in the direction shown).

B. With pipe connection tight, the male elbow is pointing in thewrong direction for the desired tubing run.

C. To correct this situation, merely tighten the pipe thread of amale adapter into the female port.

O. Connect a union elbow to the adapter by tightening the8wagelok connection with a wrench while holding the elbow inthe desired direction. Then insert the tubing into the other endof the 8wagelok union elbow and connect the tubing.

Reducers are somewhat similar to tube adapters in that they have amachined tube stub on one end and a 8wagelok connection on theother end. Reducers are used to convert from one 8wagelok tube endto a different size 8wagelok tube end. For example, the 1/2 in. tee(88-810-3) shown (see Fig. 87) is required to have 1/4 in. 00 tubingfrom its run port. A 8wagelok reducer (88-400-R-8) accomplishes theconversion in a single step.

Fig. 87

3-44

Note: Swagelok reducers, port connectors, and adapters have amachined groove near the end of the tube stub. This groove isprecisely positioned to receive the Swagelok ferrules during fitting pull­up. The groove is critical to proper ferrule action because it simulatesthe action of the ferrules as they would perform on annealed tubing.

Because of the substantial differences in tolerances, dimensions,and sealing methods, considerable variations in sealing position existbetween Swagelok tube adapter-type fittings and those of othermanufacturers.

Note: See Interchange Information on pp. 1-11, 1-12 and 7-18.

USE OF SWAGELOK ADAPTERS

Fig. 88Align elbows, and tighten the Swagelok nut according to installation

instructions (see Figs. 67, 68 and 69).

Fig. 89

Install the tubing run to the elbows, thus completing the installation.

---------------------- 3-45

The Swagelok bulkhead reducer fitting is found particularlyadvantageous for ease of alignment when connecting tees or elbowsbehind a bulkhead. Examples of this type of application are shown inFig. 90.

I~r-"-_I_'

• - .' , ---,", I '-

I .... :)~

With Union Elbow '...~ With Male Elbow With Union Tee

With Female Elbow With Male Run Tee With Female Run Tee

Fig. 90Applications of bulkhead reducers with standard Swagelok fittings.

USE OF SWAGELOK ADAPTERS FOR VALVE INSTALLATIONSWhen installing a valve, there is usually a preferred location for the

valve handle. For example, if the valve is coming off a piece ofequipment, it is often desired to have the valve handle located directlyabove the valve as shown in Fig. 91.

Equipment

Fig. 91

3-46

If the connection on the equipment is a male or female pipe thread,alignment is extremely difficult, if not impossible. The result is usuallysomething like Fig. 92.

Equipment

I

Fig. 92

To save time, stop leaks, and prevent valve damage duringinstallation, use a male or female adapter (see Figs. 93 and 94).

Fig. 93Male adapter

To orient your valve,equipment (see Fig. 95).

Fig. 94Female adapter

screw the male adapter fitting into the

3-47

rEquipment

I11I II I~

Fig. 95

Using a valve with integral Swage10k tube fittings, slip the tubing stubfrom the adapter into one Swagelok connection. Hold the valve verticalwhile pulling up the nut according to installation instructions, and thevalve is properly oriented (see Fig. 96).

Equipment

Fig. 96

If it is desired to shift the direction of the valve handle, loosen thenuts on the Swagelok connections, move and hold the valve at thedesired location, and retighten the Swagelok nuts.

PORT CONNECTORS

3-48

Fig. 97Port Connector

Fig. 98Reducing Port Connector

Swagelok port connectors are recommended for use where space isat a premium (see Figs. 97 and 98).

Features: Eliminates cutting short lengths of tubing e Allows closecoupling with pre-determined lengths e No pipe threads in system e

Effects a union at every joint to permit complete disassembly forremoval from system e Machined from bar stock for rigidity andstrength.

Note: Although port connectors provide greater structural strength toa tube system, they do not eliminate the need for proper supports.A port connector should be supported like other components.INSTALLATION INSTRUCTIONS1. Remove nut and ferrules from the first of the two Swagelok ports to

be connected.

2. Slip nut only (no ferrules) on port connector over machined ferrule.

3. Insert connector into first port and snug up nut by hand.

4. Tighten with wrench 1/4 turn only (1/16, 1/8, and 3/16 in.; 2, 3, and 4mm, tighten 1/8 turn). Subsequent connections are made bytightening slightly with wrench after snugging the nut by hand.

5. Insert second end of port connector into other port and tighten nut1 1/4 turns from finger-tight, using normal Swagelok nut and ferrules.(3/4 turn for 1/16, 1/8, and 3/16 in., 2, 3, and 4 mm sizes) (seeFigs. 99 through 104)

Fig. 99 Fig. 100 Fig. 101

Fig. 102 Fig. 103 Fig. 104

3-49

BULKHEAD CONNECTIONSSwagelok bulkhead tube fittings are available in a variety of end

connections. They include the following: bulkhead unions • bulkheadreducers • bulkhead male connectors • bulkhead Swagelok to ANunions • bulkhead female connectors • bulkhead reducing unions.

IFig. 105

Swagelok bulkhead tube fittings are available in sizes for 1/16through 1 in. OD tUbing.

BULKHEAD RETAINERS

Fig. 106Bulkhead retainers are used to act as a backup wrench on the body

hex of a bulkhead fitting and are available in tube sizes from 1/8through 1 in. (see Fig. 109).

f /A Jam Nut

\ \Body Hex B

Fig.107Bulkhead Fitting

3-50

To install a bulkhead fitting, it is usually necessary to have oneperson hold the body hex while another tightens the jam nut on theother side of a panel and, again, while the fitting is being pulled-up(see Fig. 108).

Fig. 108Tubing can be connected to end B by one person holding the body

hex and pulling up the fitting according to installation instructions. Topull up the fitting on end A, without a bulkhead retainer, it is necessaryto put a person on side B to hold the body hex while the person on sideA tightens the Swage 10k tube fitting according to installationinstructions.

By using the bulkhead retainer, one person can tighten the jam nuton side A for initial bulkhead installation. Tubing can now be connectedto side A or B by one person with one wrench since the bulkheadretainer acts as a backup wrench (see Fig. 109).

'" 'BBody Hex/,Bull<headRetainer

Fig. 109Bulkhead installation utilizing bulkhead retainer.

I

3-51

I

INSTALLING SWAGELOK TUBE FITTINGS INTO SAE OR MSSTRAIGHT THREAD PORTS

Hydraulic equipment often uses SAE/MS straight thread portsinstead of pipe threads. Such ports require a Swagelok tube fittingusing an O-ring seal. A wide variety of Swagelok tube fittings, adapters,reducers, and plugs are readily available in steel and stainless steelmaterials with SAE/MS straight threads.

Fig. 110Male SAE/MS Connector

Straight fittings have an O-ring which is directly driven into thetapered port to make a seal (see Fig. 110).

Positionable elbows and tees have an elongated male thread, a jamnut, metal washer, and elastomer O-ring (see Fig. 111).

SAEIMS STRAIGHT THREAD POSITIONABLE ELBOWS AND TEES

MetalWasher

WrenchPad

Fig. 111900 SAE/MS Positionable

Male Elbow

1. Lubricate the O-ring with a lubricant that is compatible with thesystem fluid, environment, and O-ring material. (Standard O-ringmaterial is Viton®. Other O-ring materials are available on request.)

2. Turn the fitting into the straight thread boss until the metal back-upwasher contacts the face of the boss and forces the O-ring into thetapered port.

3. Position the fitting by backing it out (not more than 1 turn counterclockwise) until the Swage10k end is oriented in the proper direction.

4. Hold the wrench pad with a back-up wrench and tighten the locknutuntil the washer is against the face of the boss, forcing the O-ringinto the tapered port.

3-52

NOTE: Positionable elbows and tees are compatible with SAE J1926or MS16142 female straight thread a-ring bosses.

While a-ring sealed ports are excellent for tight sealing, rememberthat a-rings do have some inherent disadvantages:

1. Some elastomer compounds are attacked by certain system fluids.

2. Elastomer compounds sometimes harden and crack under certainfield conditions. Both system fluid and environment must beconsidered.

3. Elastomer compounds are easily damaged by sharp surfaces, burrs, Ior chips.

4. Special tools are required to make SAE/MS ports.

For complete data on SAE/MS O-ring ports, see p. 8-8.

PIPE END INSTALLATIONPipe threads are the most common end connections found in

industry. They are well-understood, standardized, and relatively simpleto make up for low pressure service. Pipe threads always need asealant since there are designed-in gaps between male and femalethreads.

There are many different pipe "dopes" or sealants available. Ourtests show that for service up to 450°F (232°C), Swagelok TFE tapegives outstanding leak-free connections.

Swagelok TFE tape is wrapped around male pipe threads. As themale and female thread are wrench-tightened, the TFE tape bunchesup into small plugs of TFE which block leakage.

Another excellent sealant for pipe threads is SWAK® Anaerobic PipeThread Sealant with TFE. It can be used from -65° to 350°F (-53° to176°C). It seals the threads when air is excluded.

SWAK pipe thread sealant with TFE is a semi-liquid, packaged in asqueezable plastic tube with a ribbon applicator.

---------------------- 3-53

SWAGELOK TFE TAPE PIPE THREAD SEALANT

Note: Use 1/4 in. wide tape on1/8, 1/4, and 3/8 in. male taperedpipe threads and 1/2 in. wide tapeon larger male tapered pipethreads.

Tape should be used only onmale tapered pipe threads. Donot use on flared, coned, or tubefitting ends.

1. Clean both maleand female taperedthread ends toensure removal ofdirt or previouslyapplied antiseizecompound or tape.

2. Beginning at the first thread, wrap tape in thedirection of the male tapered thread spiral,and join with a slight overlap. (Two wrapsare suggested for stainless steel taperedpipe threads.)

3. Make sure tapedoes not overhangthe first thread,because the tapecould shred and getinto the fluid system.

4. Cut off excess tape. Draw the free end of thetape around the threads tautly so that itconforms to the threads. Press in firmly atthe overlay point. The connection is nowready for proper make-up.

Fig. 113

3-54

SWAK® ANAEROBIC PIPE THREAD SEALANT WITH TFE

Fig. 114

Application Instructions

1. Remove ribbonapplicator cap fromtube.

2.indentation.Replace cap.

3. Clean all threads ofoil, grease, or othercontaminants. ApplySWAK a full 3600 tothe second and thirdthreads. Any excesscan be easilyremoved with asolvent such asacetone.

SWAK anaerobic pipe thread sealant with TFE provides reliablesealing on metal pipe threads. It also acts as a lubricant duringassembly to prevent galling or seizing of threads

SWAK is applied as a paste. When threaded components areassembled, SWAK hardens or cures to form a reliable seal.

---------------------- 3-55

I

If it is necessary to break the connection, SWAK allows low break­away torque even when fully cured.

Sealing depends on many variables: cleanliness of threads,temperature, component material, quality of threads, proper wrenchmake-up, specific gravity of system media, and system operatingpressures. All gas systems require twenty-four hours for a full cure.

Note: There are some materials not compatible with SWAK sealant.While not intended to be a complete list, they include the following:

• Any plastic pipe or valve system other than TFE• Any halogens • pure oxygen • ozone· hydrazine • nitrogen dioxide• High concentrations of strong acids or bases• Food, cosmetic, drug, or water systems for human consumption• Vacuum systems where small amounts of hydrocarbon outgassing

will affect performanceA list of compatible materials is shown on the SWAK data sheet in

your Swagelok Product Binder.

3-56

Severe ServiceSwagelok tube fittings have been the choice of engineers and

designers when unusually difficult or hazardous service is involved.Types of service vary widely.

For most applications, the installer follows these simple instructions:

1. Insert the tube into the fitting until it is fully bottomed against theshoulder of the body.

2. Tighten the nut 1 1/4 turns. This is sufficient to obtain reliableperformance.

However, for severe service requirements, there are methods toensure that installation is correct.

Fig. 1MS-DMT-600 (3/8 in. tube size)

a. To make sure that the tubing has been inserted through theferrules and has reached the shoulder of the fitting body, the DepthMarking Tool (DMT) can be used (see p. 4-2).

b. Check the gap between the nut and body hex with the GapInspection Gage (see pp. 3-36, 37, and 38) (see Fig. 2).

Fig. 2These two steps have the additional advantage of verification by

post-installation inspection so that the quality of the work done can bechecked after installation without disassembling the tube fitting.

4-1

I

USING THE DEPTH MARKING TOOL* (DMT)

The Swagelok depth marking tool (OMT) is designed to provide safeinstallation of tubing into Swagelok tube fittings. Following aresuggestions on how the OMT will ensure proper bottoming of the tubingon the shoulder inside the Swagelok tube fitting body.

1. Always select proper tubing for each application. Tubing should becut cleanly and fully deburred on both the 00 and the 10 prior tousing the OMT.

2. Insert the tubing into the OMT until it has fully bottomed in the tool(see Fig. 3A).

3. Mark the tube at the top of the OMT with a pen, pencil, or adequatemarking device. (Avoid markers that contain chlorides which maycause stress corrosion in materials such as stainless steel-see Fig.3B.)

4. Remove the tubing from the OMT and insert into the Swagelok fittinguntil it is fully bottomed inside the fitting body (see Fig. 3C). Inspectthe mark on the tubing prior to fitting assembly. If any portion of themark on the tubing can be seen above the fitting nut, the tubing hasnot fully bottomed inside the fitting.

5. After the tubing has been properly bottomed inside the fitting, markthe nut at the 6 o'clock position (see Fig. 3D). While holding the bodywith a back-up wrench, follow recommended Swage10k tube fittinginstallation instructions.

* The depth marking tool should only be used on tubing intended foruse with Swagelok tube fittings. Intermix or interchange of Swageloktube fitting parts with parts made by other manufacturers should not bedone.

4-2

Fig.3A Fig.3B Fig.3C Fig. 3D

SAFETY CONSIDERATIONS FOR SEVERE SERVICE SYSTEMS

1. Do not bleed the system by loosening fitting nut or fitting plug.

2. Do not make up and tighten fittings when the system is pressurized.

3. Use the Swagelok gap inspection gage to ensure sufficient pull up.

4. Never allow problems to go unreported.

5. Always use proper thread lubricants and sealants on tapered pipethreads.

6. Avoid combining or mixing materials or fitting components fromvarious manufacturers - tubing, ferrules, nuts, and fitting bodies.

7. Never turn the fitting body. Instead, hold the fitting body and turnthe nut.

8. Never disassemble new or unused fittings.

9. Use only long reducers in female Swagelok ports.

10. Use metal tubing materials that are softer than the fitting material.For example, stainless steel tubing should not be used withbrass fittings.

11. Use fully annealed tubing when tubing and fittings are made of thesame material.

12. Always use an insert with extremely soft or pliable plastic tUbing.

13. Check extremes of wall thickness against fitting manufacturer'ssuggested minimum and maximum wall thickness limitations.

14. Check the surface finish of the tubing. Surface finish is veryimportant to proper sealing. Tubing with any kind of depression,scratch, raised portion, or other surface defect will be difficult toseal, particularly in gas service.

15. Check tubing for ovality. Tubing that is oval, that will not easily fitthrough fitting nuts, ferrules, and bodies should never be forced intothe fitting.

HIGH PRESSURE GAS SYSTEMS

What is high pressure? For purposes of definition we will consider"high pressure gas" to be gas systems pressurized to 500 psig (34 bar)or higher. Pressurized gas systems contain a large amount of storedenergy. Because light gas can leak through the most minute leak path,the sealing of high pressure, relatively light gases becomes difficult.

4-3

I

Small scratches, gouges, nicks, or weld seams on the tubing aDmay easily create a leak path. These deformities can sometimes causeproblems even when the very best, Swagelok tube fittings, are used.

The general suggestions for this severe service all apply to highpressure gas systems. In particular, tubing wall thickness should becarefully considered and no less than the minimum wall for "GASSERVICE," as shown on p. 2-2, should be used.

Therefore, for best results in sealing absolutely leak-tight on highpressure gas systems, the following items are suggested:

1. Order good quality hydraulic tubing with proper hardness and asurface finish free of scratches or other defects. Be sure thatminimum wall thickness for gas service is used (see p. 2-2).

2. Cut tubing cleanly, deburring both the ID and aD.

3. Insert tubing fully into the Swagelok tube fitting. Make sure that theend of the tube rests firmly on the internal shoulder of the fitting.

4. Follow "1 1/4 turns past snug" pull-up instructions (see p. 3-38).

5. Check each connection with the Swagelok gap inspection gage.

6. Never bend the tube after it has been inserted into the fitting.

7. If special cleaning treatments are used, consider the use of speciallycleaned Swagelok stainless steel or alloy fittings with silver platedferrules.

8. Consider use of VCO® or VCR® fittings if you are unable to getproper surface finish on tubing. Since tube is welded to the fitting,the tube surface finish and hardness do not affect the seal.

COMPRESSED GASES ARE GENERALLY CLASSIFIED IN FIVEDIFFERENT CATEGORIES.

1. Corrosive-Gases which attack and damage materials and actuallyremove some of the material by chemical attack. Such chemicalattack is usually more severe with the presence of water. Care inmaterial selection is vital.

Example: hydrogen chloride-hydrogen sulfide

2. Flammable-Gases which form a flammable mixture in air at 12 % ormore concentration.

Changes in temperature, pressure, and concentration may causewide changes in flammability.

Example: hydrogen, methane

4-4

3. Inert-Gases which generally do not react with ordinary materials atcommonly used temperatures and pressures. Generally non­corrosive, non-toxic. Not hazardous except when used in confinedspaces. Air can be displaced, making life support difficult. Adequateair supply and ventilation should be considered.

Example-Helium, Argon

4. Oxidant-Gases which do not themselves burn, but which supportcombustion.

Example-Oxygen

5. Toxic-Gases which produce deadly or harmful effects on humansby chemical attack.

Example-Arsine, Phosphine

OXYGEN SYSTEMSOxygen has unique and hazardous properties. Handling it, either in

the liquid or gaseous state, is a specialized field. Design and safety arethe responsibility of oxygen system users, who should obtain qualifiedprofessional assistance to establish design specifications and operatingpractices for the safe use of oxygen.

TOXIC, FLAMMABLE, EXPLOSIVE GASES

Many industries such as the chemical, electronic, and analyticalinstruments regularly handle gases which are particularly hazardous.

The exact same care as listed above for high pressure gases shouldbe exercised for such system fluids. See 1 thru 8 above (see p. 4-4).

In particular, these types of system fluids require even closerattention to detail than the high pressure gases above. Tube surfacefinish and careful deburring are essential. In assembly, extra careshould be used in fully bottoming the tube in the fitting body before pull­up.

In some industries, notably electronics, "gas cabinets" are regularlyused. If leakage occurs, such structures contain gas leakage and thenvent such unwanted gases to a safe disposal area.

If gas bottles or cylinders are used, they should always be fullysecured in use, storage, and transit. The tremendous stored energy insuch containers has caused severe damage and injuries in manyrecorded accidents, usually caused by dropping or tipping the containerand breaking off the cylinder valve.

4-5

Fig. 4Epitaxial reactor systems forelectronic wafer production.Note the good bottom mountingsupport of valves and neat,functional stainless tube runs tovalve ports. (Photo Courtesy:Thermco Products Co.)

STEAM PIPING

Steam is one of the most erosive of system fluids. High velocitysteam can erode metals as hard as stainless steel in a very short time.Dry, superheated steam is less erosive than wet steam.

Unless water chemistry is carefully controlled, corrosive inclusionsadd to the erosive properties and make steam a tough fluid to handle.

When installing Swage10k tube fittings for steam service, thefollowing precautions should be taken:

1. Material selection should be based on pressure, temperature, andenvironmental conditions. Both fitting and tubing must havecompatible thermal properties.

2. Steam should be considered a gas for purposes of wall thicknessdetermination (see pp. 2-2 and 9-2).

3. Deep scratches or gouges of tube 00 must be avoided. A very slightsteam leak through such a defect will become a larger leak aserosive steam etches a deeper valley in the tubing.

4. If steam temperatures are above 400°F (204°C), consider the use ofSilver Goop® high temperature thread lubricant on fitting nut threads.

Tracing

Tracing is a method of providing heat or cold input to raise, lower, ormaintain temperature in process piping systems and equipment.Tracing with electrical resistance heating will not be covered here.

Swagelok tube fittings are commonly used to connect steam tracingtubing to prevent freeze-up in cold weather. Some fluids other thansteam, such as Therminol® or Dowtherm®, are also used.

Tracing can also be applied to piping and equipment which containmaterials that could solidify or become extremely viscous, even insummer months.

4-6

This method is not covered in depth, since the amount of tracingrequired will vary with the application. An engineering analysis isrecommended on viscous fluid tracing requirements. The severity ofwinters in a particular locale usually determines the need and methodsof tracing. Of course, individual plant practices and preferences alsoinfluence requirements. The methods suggested in this manual are forguidance only.

Process lines and equipment can be protected from freezing byusing tubing as the tracing lines. Common steam tracing line sizes are1/4 in. 00 x 0.035 in. wall, 3/8 in. 00 x 0.049 in. wall, 1/2 in. 00 x0.049 in. wall copper tubing.

The heavier wall tubing is preferred because the thicker wall givesimproved performance during a cool-down period from full steam Itemperature and increases temperature cycling ability. It is during that Itime that thin wall tubing tries to shrink away from the fitting. Once thisoccurs, any slight scratch becomes a potential leak path. The tubingshould be a fully annealed quality.

Tracer Installation on Process Lines

Locating Horizontal Tracers: A variety of techniques has beendeveloped for positioning the tracing lines in the best manner forsuitable heat transfer. Always supply steam to tracers on the high endof a sloping process line to prevent back-up of condensate. As ageneral guide, small tracers should not exceed 60 feet in length andthe limit for all other sizes should be about 150 feet.

JacketedTracing

Two ChannelPipe Tracing

Single ExternalTube Tracer

Multiple ExternalTube Tracer

(j) Liquid Product @ Insulation

Fig. 5Tracer location on horizontal or sloping lines.

4-7

Tracer Installation on Vertical Lines

Locating Vertical Tracers: A single tracer on a vertical or nearlyvertical process line can be spiral-wrapped. Multiple tracers on verticallines should be equally spaced for the most efficient heat transfer.

Fig. 6Single Tracer; Spiral Multiple Tracers; Equally

Wrapped Spaced

Vertical lines with spiral-wrapped tracers do not require additionalattachment.

Tracer Installation on Horizontal Lines

Unequal1/4 in. OD - 1 1/2 Ft.

1/2 in. OD - 2 Ft.

Fig. 7Wrong

Side ViewRight

Top View

Horizontal lines with 1/4 in. 00 tracers should be fastened every1 1/2 feet, while 1/2 in. 00 tracer lines should be fastened every 2 feet.Fasteners should be equally spaced on each side of flanges. Alwaysuse a large radius bend around the flange on a flat plane so that theloop is not below or above the level of the horizontal tube run.

4-8

The table below gives suggested information on the size and numberof tracers for process lines of various sizes:

I

*Use Individual traps for each tracer Ime. Never manifold tracer lines toone trap.**Or as required by individual needs.

Process Pipe TracerNo. of Max. Max. Tracer

Size Size*'Tracers Tracer Length Between

** Length Traps'

1/4 x 0.035 in. or

11/2 in. and smaller3/8 x 0.049 in.

1 60ft 60 ftwallCopper Tubing

0.065 in. wall,2 in. and 21/2 in. 1/2 in. OD 1 150ft 150 ft

Copper Tubing

0.065 in. wall,3 in. to 4 in. 1/2 in. OD 2 150 ft 150 ft

Copper Tubing

0.065 in. wall,6 in. and 8 in. 1/2 in. OD 3 150 ft 150ft

Copper Tubing

0.065 in. wall,10 in. and 12 in. 1/2 in. OD 4 150ft 150 ft

Copper Tubing..

Tracer Attachment to Process Lines

Single tracer lines may be fastened to the pipe with wire, bands, ortape. Care should be taken to use wires or bands that are galvanicallycompatible with the pipe or tracer tubes. Tapes for stainless steel tubesand pipes should not contain chlorides or halides, since these cancause corrosive failures of the tracer or pipe. There are severalmanufacturers of glass fiber tapes that are free of such corrosives andgood for temperatures up to 500°F (260°C).

Care must be taken with some process fluids in stainless steel pipeto make sure that local spot overheating does not cause very rapid pipecorrosion on the inside of the pipe at the point the tracer contacts theoutside. Such action can be prevented by a layer of insulation betweenthe pipe and the tracer tube. Consult process data for details.

4-9

Multiple Tracers

When attaching multiple tracer lines to a process line, fasten eachtracer individually to the process line. This will prevent the tracer linesfrom sliding to the bottom of the process line.

RightWrongFig. 8

Attachment of Multiple Tracers to a Process Line.

Expansion: Tracer tubing will expand as the temperature increases.The process piping will also expand when heat is transferred. The ratesof expansion of the tracer tubing and the process line will usually differbecause of unlike coefficients of expansion of the two materials and thetemperature differential between the tracer and the process line.Sufficient slack in the tracer lines and expansion bends is required toprevent the tracer tubing from stretching or kinking.

I

Review These ConsiderationsBefore Selecting A Tracing Method

The capability of any given tracing installation must be matchedcarefully with the requirements of the system to be traced. Here aresome important factors to consider:

Extreme care should be used on installations where difficult bendsand complicated valve manifolds are encountered.

The choice of tracing techniques can be narrowed by temperaturerequirements, particularly where high temperatures are needed orwhere temperatures must be held within precise limits.

The length and diameter of the process piping to be traced providean indication of the liquid volume to be maintained at a specifiedtemperature. Therefore, these dimensions should be measuredaccurately to help estimate tracing system heat requirements.

4-10

Heat loss depends, to a large degree, on the location of the piping tobe traced. For example, different tracing methods would be needed fortwo identical installations if one were outdoors in a cold environmentand the other were indoors. Another pertinent factor in estimated heatloss is the type and thickness of the insulation that covers the pipe andtracing.

The choice of tracing techniques is limited if the installation is anexisting process pipe that may not be moved or disconnected. Newinstallations seldom present this problem.

Some tracing methods will be ruled out if hot spots on a pipe wouldbe incompatible with the process to be traced (causing unsafeconditions, for instance). Special installation may be needed.

Heat source for the tracing system must be constant. Steam, forexample, must be available even during shutdown.

Steam Trap Installation

oo1/2 in. Tubing 6 in.

Long Dirt Trap

Swagelok Blow DownValve with Swage10k

Ends (B·18VS8)

Swagelok Union Tee(B-810·3)

_______L-_-'-- Grade

Fig. 9

A typical tracer line steam trap installation is shown in Fig. 9. Theefficiency of tracer systems depends a great deal on the properinstallation of steam traps. It is suggested that the following guide rulesbe used:

1. Insulate the steam tracer line to within 2 lineal feet of the trap inlet.

2. Always install a strainer in front of the trap to protect the steam trapseating surfaces.

3. Install a 6 in. long section of 1/2 in. OD tubing to provide a dirt trap infront of the trap. Large pieces of dirt or contamination accumulate inthe dirt trap, thus increasing the service life of the trap.

4-11

4. Install the trap, control valves, and strainer as close to the ground aspractical.

5. Use 1/2 in. aD tubing for the trap discharge line. This line should beas short as possible and should discharge into a condensate recyclecollection header. Make sure the discharge line is not a safetyhazard.

6. Provide proper support for wiring the horizontal discharge line andaccessories.

7. Suggested arrangement of components is shown in Fig. 9.

System Start-up Instructions

All new tracer lines should be pressurized with air and checked forleaks with SNOOp® or REAL COOL SNOOp® leak detectors. Afterperforming any needed repairs, the system is ready for start-up withsteam.

Fig. 10Snoop Liquid Leak Detectors

Tube Fittings-Swagelok brass tube fittings are suggested for useon copper tracer lines [trace steam temperature up to 400°F (204°C),since they provide easy, reliable, leak-tight connections. In many casesstainless steel tracing systems may be required due to the externalenvironment. For maintenance ease, insulation should not be placedover the Swagelok tube fittings. Each Swagelok tube fitting is a unionjoint. Access to the fittings allows easy replacement of corroded ordamaged tube sections. Wherever possible, locate the Swagelok tubefittings at the process pipe flanges or other uninsulated areas. When aSwagelok tube fitting must be used in an insulated area, provide asmall window in the insulation for accessibility (see Fig. 11).

4-12

3/8 in, 00 x 0.049 in. Copper Tubing

Insulation~

Swagelol< Union600-6

Process Line

,----~-I ", :\ :

/', /I \ ';I I r\ I \, I '----+---

c:::~====,A,

-- -..,..-------- -------,: ~i Window /

----J--~--------L''=:::{}=ltl~~:::tj;;:':::=;t-::-:'~:~WageIOI< Union- 8-600-6-----_...1

Fig. 11

Tracer Installation on Process Equipment

Two methods are available for installing tracers on irregularly shapedequipment such as valves, pumps, and instruments. The two methodsare Spiral Wrapped and Flat Grid.

Spiral Wrapping Method-Approximately 6 in. should be maintainedbetween coils when the spiral wrapping method is used. Use Swagelokunions to permit removal of the equipment without uncoiling the tracerline.

1/2 x 0.065 in.Copper Tubing

Fig. 12Spiral Wrapping of Irregular Shaped Process Equipment.

4-13

When equipment must be frequently removed for servicing, the loopmethod of spiral wrapping is recommended as illustrated below.

1/2 x 0.065 in.Copper Tubing

Fig. 13Spiral Loop Wrapping of Process Equipment for Easy Removal.

Flat Grid Method-For flat or irregular surfaces, 1/4 in. 00 tracertubing should be used. The tubing should be bent to form a grid andshaped to the surface. A 6 in. spacing should be maintained betweencoils as illustrated in Fig. 14.

Swage10k Union t Steam In

+---6=:=:::::3 in. Radius

6 in.

6 in.

6 in.

Swage10k Union

Fig. 14

4-14 ----------------------

HEAT TRANSFER FLUIDS

Commercially available heat transfer fluids are readily available.Some of the best known are the several different forms of Dowthermand Therminol. Both liquid phase and vapor phase fluids cover a widerange of operating temperatures up to about 750°F (399°C).

One of the chief advantages of such fluids is that high pressureequipment, steam traps, and water conditioning equipment are notnecessary. Thus a high temperature system need not operate at highpressures as does a steam trace system.

Heat transfer fluids are generally difficult to seal. Care should beexercised when fittings are used for such systems. In particular, wallthickness of tubing should be selected in line with gas pressuresuggestions (see pp. 2-2 and 9-2).

When selecting materials for Dowtherm or Therminol systems, followthe suggestion of the manufacturer of the fluid.

ULTRA-CLEAN SYSTEMS

Today's high technology demands call for ever-more-stringentcleanliness requirements. Standard production Swagelok tube fittingsare carefully degreased, but for certain electronic, aerospace, andultra-pure gas systems, special cleaning may be required.

Special cleaning can be performed for such applications. A numberof different methods may be used, depending upon systemrequirements and fitting materials. And, specially-cleaned fittings arepackaged individually in sealed, plastic bags. Consult your Swagelokrepresentative for details.

If Swagelok tube fittings are specially cleaned in the field, wesuggest the following:

Cleaning of the nut or back ferrule should be avoided becauseonly the body and front ferrule are wetted parts. Galling andpossible leakage may occur when absolutely dry parts are broughttogether under the high loads necessary to seal. Therefore, usespecially cleaned, silver plated Swagelok front ferrules or apply asystem compatible anti-gall material.

4-15

VACUUM SYSTEMS

Swagelok tube fittings are widely used on industrial vacuumapplications. The importance of keeping all action moving in an axialdirection with absolutely no torque or rotary motion in making a seal isdemonstrated in applying Swagelok tube fittings to vacuum work.

Any scoring of the sealing surfaces could prevent a helium tight seal.The axial motion when making and remaking joints with Swage10k tubefittings results in pressing the sealing surfaces together so that there isno scoring of any surfaces and, therefore, helium tight joints can bemade over and over again. Extreme care should be used in thehandling of tubing for vacuum service to ensure successful use in yoursystem. Scratches on tube surface can cause problems.

In vacuum work, cleanliness is absolutely essential. All tubing usedshould be degreased and then dried thoroughly. If this is not done, oilsand moisture may vaporize as pressure is reduced and the system willappear to leak even though it is tight. Tube fittings for vacuum workshould also be specially cleaned.

When using stainless steel or other special alloys that havetendencies to gall, we suggest that only the body and front ferrule bedegreased as these are the only items that are within the system. Thenut and rear ferrule are outside the sealed system and speciallubricants that have been applied to prevent galling should not beremoved. Swagelok Company can supply Swagelok tube fittingsspecially cleaned. Stainless steel and other special alloys use speciallycleaned, silver plated front ferrules to prevent galling of speciallycleaned parts. Swagelok metal tube fittings with TFE ferrules can alsobe used for quick, easy industrial vacuum connections. Considerationmust be given to the cold-flow and outgassing properties of TFE andthe greatly reduced holding power of TFE ferrules.

Because of partial dependence on tube 00 surface finish, whenusing "00 seal" fittings such as Swagelok tube fittings, we find thatwhen systems are operating in the ranges of Very-High or Ultra-HighVacuum range (below 10-6 torr), all welded systems are the mostreliable. Swage10k tube or weld fittings (see Chapter 6) have been usedin many such systems. Where system requires breakdown for cleaningor maintenance, VCO® or VCR® fittings are suggested (see pp. 6-7 and6-8).

Other Swagelok vacuum products include flexible metal tubing,flexible metal end Pyrex® tubing, and glass/metal transition tubes.Swagelok Ultra-Torr® fittings are ideal for making quick, easily

4-16

removed vacuum seals, such as connecting to helium leak detectors orconnecting metal to glass tubing.

So, both Swagelok tube fittings and other style fittings like SwagelokVCO, VCR, etc., can be used on vacuum systems. Caution should beused if fitting components contain elastomers or plastics, especially ifthe vacuum system will see temperatures in the bakeout range.

In bakeout applications, one should not mix metals when systemtemperatures will be increased unless coefficients of expansion areconsidered. For example, assume a 316 stainless steel fitting(coefficient of expansion 11 x 10-6/in.lin.l°F) were installed on alloy400 tubing (coefficient of expansion 7.8 x 10-6/in.lin.l°F). When thetemperature is raised, the stainless steel would increase in size at agreater rate than the tubing. The fitting would become loose on thetubing because of a property of the material (coefficient of expansion)coupled with the temperature change. On the other hand, if alloy 400 isput on stainless and raised to a high temperature, the joint becomestighter. However, the stainless steel tubing increases in size at agreater rate than the alloy 400 fitting and may yield the fitting, and aleak could result upon returning to lower temperatures. Mixingmaterials is not recommended (i.e., using different materials for fittingsand tubing) unless an engineering analysis is made of temperaturevariation.

For your convenience, coefficients of expansion for materialscommonly employed in tube fitting applications are given below:

MaterialCoefficient of Expansion

in./in.JOF

Stainless Steel (304 and 316) 9.00 to 11 X 10-6

Alloy 400 7.80 x 10-6

Brass 11.40 X 10-6

Aluminum 13.00 x 14 x 10-6

Carbon Steel 8.40 x 10-6

Copper 9.80 x 10-6

4-17

Temperature Rating: Operating temperature ratings are dependenton application and installation methods, cycle life required, and othervariables. Consult your Swagelok representative for additionalinformation.

Use Swagelok TFE tape on pipe threads in a vacuum system tocreate a seal. VAC-GOOP® lubricant is suggested for use in thevacuum system on bolts and surfaces where it is desired to preventgalling.

VIBRATION

Systems such as compressor or pump piping often have stringentrequirements regarding fittings' resistance to vibration. Well-designed

I fittings such as Swagelok tube fittings have built-in vibration protection.

In applications where severe vibration is present, the best protectionis to properly support the tubing near the fitting. Limiting the amplitudeof the vibration increases fitting and tube connection life.

It is particularly important in vibration applications to install fittingsexactly according to suggested installation instructions. In particular,the bottoming of the tube against the shoulder of the fitting body shouldreceive careful attention. If the tube is fully bottomed, the tube ODahead of the ferrules is increased during pull-up.

MAKE/BREAK

One of the key qualities which distinguishes a well designed tubefitting from the ordinary is the ability to take frequent make and breakservice without losing sealing integrity. In instrument systems ortemporary laboratory experiments, where constant cleaning ormaintenance is required, a tube fitting with good make/break abilitiesmay often save its price many times over.

Swagelok tube fittings have earned their reputation since 1947 bytheir ability to seal difficult fluids repeatedly, after many make andbreak cycles. Our test programs are described in Chapter 7.

As in any application, the original installation will often determine justhow many make/breaks a connection can take while remaining leak­free. Our own tests indicate that 25 make/breaks are not unusual withproper care, although our customers routinely report far more than just25 make/breaks.

4-18 ----------------------

The compensating action of the two Swagelok ferrules promoteslongtime service under make/break conditions.

IMPULSE / SHOCK

1. Impulse or pressure cycling is caused by many factors, but primarilyby quick-opening valves in hydraulic systems. It causesconsiderable stress on a tubing system. The Swagelok two ferruledesign absorbs such stress and allows the use of off-the-shelf tubefittings for such service. Proper support of tube runs, as close aspossible to the fitting, will prolong the life of tubing connections.Proper assembly of tubing and fitting is essential. Tube wall (withinthe limits shown in Chapter 9) should be carefully considered and anadditional design factor should be considered where severeimpulses are present.

Our own impulse testing is described in Chapter 7.

2. Shock may take many forms in tubing systems. It normally isconsidered as any type of a sudden, violent stress which may affecta tubing system.

As described above, impulse or pressure cycling may be one type ofshock. One example is a quick-closing valve which causes very rapidpressure changes.

Temperature cycling, particularly very rapid cycling, is another formof shock. An example would be the shock which must be absorbed ifan ambient temperature component is quickly immersed in liquidnitrogen.

Another type of shock is a sudden jolt near a forging hammer orother heavy equipment which causes a sudden, but short-lived, shockcondition.

4-19

ELEVATED TEMPERATURE SERVICE

For purposes of definition, high temperature is considered to beabove 100°F (40°C). A number of different factors must be consideredwhen tubing and fittings are being used at elevated temperatures.

MATERIALS

The first consideration is the material required to resist hightemperatures and temperature excursions over a long period ofservice.

Temperature limits of most fitting and tubing materials are listed inANSI Piping codes, including specific conditions regarding tubing

Imaterials and methods of manufacture.

Table 1 shows the general range of maximum temperatures for thegiven materials.

Aluminum 400°F 204°C

Copper 400°F 204°C

Steel 375°F 191°C

304SS 1000°F 538°C

316SS 1200°F 649°C

Alloy 400 800°F 42rC

Table 1See Appendix, p. B-9 for additional information.

TENSILE STRENGTH

The second consideration is that as temperature increases, thetensile strength of metal decreases. Thus the allowable workingpressure of tubing is lower at elevated temperatures than at roomtemperature.

Table 2 lists the factors used to determine tubing pressure ratings atelevated temperatures. Multiply working pressure rating by the factorsshown for temperature indicated.

4-20 ----------------------

OF Aluminum Copper 5teel 30455 31655 Alloy 400

200 1.00 0.80 0.95 1.00 1.00 0.88

400 0040 0.50 0.86* 0.93 0.96 0.79

600 x x x 0.82 0.85 0.79

800 x x x 0.76 0.79 0.76

1000 x x x 0.69 0.76 x

1200 x x x 0.30 0.37 x

1400 x x x x x x

* Based on 375°F max.Table 2

WALL THICKNESS

Finally, as temperatures increase, some fluids which are normallyliquids can become gases. It is important to use the minimum wallthickness recommended for gas service as listed on pp. 2-2 and 9-2 forthese applications.

CRYOGENIC SERVICE

For purposes of definition, cryogenic temperatures will be consideredas temperatures below -100°F (-73°C). The primary consideration issimilar to the primary consideration for elevated temperatures: materialcharacteristics.

PLASTIC MATERIALS

In general, plastic and elastomer materials are not satisfactory forcryogenic applications. Plastics have much higher thermal coefficientsof expansion than metals. Therefore, plastic components used assealing members at room temperature, will shrink markedly whentemperatures are lowered, causing leakage. Many plastics also havesome porosity which allows water absorption. Water will solidify whentemperatures are lowered and make the tube or fitting material brittle.Plastic manufacturers should be consulted before using plastics incryogenic service.

4-21

ELASTOMER MATERIALS

Most elastomers harden at low temperatures and may crack. Careshould be exercised in selecting elastomer seals when cryogenictemperatures are required. Elastomers also have much higher thermalcoefficients of expansion than metals. Used as sealing members atroom temperature, they will shrink markedly when temperatures arelowered. This shrinkage may result in leakage.

METAL MATERIALS

The most commonly used materials in cryogenic piping systems arealuminum and austenitic stainless steel. Alloy 600, alloy 400 andtitanium are also selected for some applications. It is particularly

I important to use the same alloy for both tube fitting and tubing so thatthermal coefficients are the same.

Tube wall thicknesses should be selected from the "Gas Service"minimum walls as shown in tables on pp. 2-2 and 9-2. It should beremembered that minimum walls for gas service should be consideredeven if cryogenic liquids are the system fluid. If at some time thesystem is brought up to ambient temperatures, the liquid will become agas.

4-22 -----------------------

Trouble ShootingThis information is intended as a guide for installation of trouble-free

fittings. These suggestions are not an exhaustive list of potentialproblems or solutions.

Please be aware that Swagelok maintail)ls a Technical ServiceDepartment for help in solving problems. If the cause of a problem isnot immediately obvious, contact your Swagelok representative forassistance.

Note: Pressure in a system should never be vented by loosening thenut on a Swagelok tube fitting. Such a procedure is dangerous. A bleedor vent valve should be used for this purpose.

5-1

I

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

1. Tubing will Burrs on tubing from Deburr tubing. Use ODnot fit into tube cutting operation. deburring tool.fitting. Flattened tubing from Use caution in cutting soft

bearing too hard with tubing with hacksaw.hacksaw in cutting orusing dull hacksaw.

Tubing out of round Swagelok tube fittings arefrom bending manufactured toimproperly. tolerances to accept the

upper limit of allowedtubing diameters used intubing manufacture. Iftubing is bent too far out ofround, by improper bend,the tubing will not fit intothe tube fitting. Usecaution with bends whennear the end of tubing.

Tubing is the wrong Make sure you use thesize for fitting. This proper size fitting for eachseldom occurs, but diameter tubing. Checkinfrequently a piece OD of tubing. Determine ifof 3/8 in. tubing may it is fractional or millimeterbe used with a 5/16 size tubing.in. fitting by mistake.

Tubing is oversize. Buy good quality tubing.Poor quality tubing For 1/16 or 1/8 in. fittings,may exceed the tubing should beallowed tolerances for ± 0.003 in.tubing.

Tubing end raised Replace with good sharpdue to dull tube cutter wheel or use good qualitywheel. hacksaw for cutting. Use

OD deburring tool.

5-2

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

2. Fitting This could happen Buy fully annealed,cannot be with steel or stainless hydraulic or pressure typepulled up steel tubing that is steel and stainless tubingproper very hard and not of recommendedamount of intended for fluid hardness.turns. system applications.

Interchange of other Use only Swagelok tubemanufacturers fittings. DO NOTcomponents. INTERCHANGE.

Cleaning has been Never remove lubricantsused on components, from nut. If specialremoving proprietary cleaning is required, cleanlubricants. body and front ferrule only.

In stainless steel andspecial alloys, usespecially cleaned, silverplated front ferrules.

Dirt or other Protect all thread and sealcontaminants on surfaces fromthreads. contamination.

Tube wall is too Use tubing withinheavy. suggested wall thickness.

Galled threads on nut Replace complete fitting.or body.

5-3

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

3. Leakage at Fittings not Tighten fittings.Pipe Thread. sufficiently tightened

with mating thread.

Experience indicates Swage10k TFE tape shouldthat pipe threads be used on all pipe threadsmake poor seals, to provide leak-tightespecially on higher sealing. SWAK anaerobicpressure pipe thread sealant withapplications. Pipe TFE is also an excellentthreads require a pipe thread sealant.sealant to make aleak-free connection.

Pipe threads Good pipe thread sealantsdamaged from galling such as Swage10k TFEof materials during tape or SWAK also helpinstallation. prevent galling of pipe

threads. Discard galledcomponents.

Poor quality pipe Use high quality pipethread either on threads, such as onfemale or male end. Swage10k fittings. These

pipe threads are precision-manufactured, but this isnot sufficient to make aleak-tight connection with apipe thread on otherequipment. Use a goodsealant.

4. Leakage at Poor flares. Cracked Use Swagelok tube fittings.Flare Joint. or split flare.

5-4

TROUBLE SHOOTING

Trouble Possible Cause Recommended CorrectiveMeasures

5. Tubing Not using Swagelok Use Swagelok tube fittings.leaks at tube fittings. Fittings not Follow installation instructions.fitting after pulled up properly. Check for hard tubing or galling.initial Use good quality annealedinstallation. tubing. Check for sufficient pull-

up with a Swagelok gapinspection gage.

Tubing not bottomed in Cut-off ferrules and replace.fitting body. Insert tube until it fully bottoms

against shoulder of fitting body.

Tubing has deep Handle tubing with care. Replacelongitudinal scratches or tubing or cut off damaged sectionis nicked or otherwise and reconnect.damaged.

Fitting body was turned, Always connect fittings by turninginstead of nut, galling the nut while holding bodyseat and/or front ferrule. stationary.

Fitting not tightened Pre-swage or use the Hydraulicaccording to installation Swaging Unit, then snug. Seeinstructions because of Pre-swaging and Hydraulicinaccessible location. Swaging Instructions, pp. 3-40

through 3-43.

Fitting was used as vise Replace tubing. Never use theor anchor to bend tubing fitting as a holding device forby hand. bending. This will deform the

tubing inside of the fitting and pullthe tube away from the seal.

Interchange of other Use only Swage10k tube fittings.manufacturer's DO NOT INTERCHANGE.components.

Poor weld bead removal Use high quality annealedon welded and drawn welded and drawn hydraulictubing. Raised bead or stainless steel tubing. If aD weldflat spots interfere with is easily seen with the naked eye,proper sealing. leakage may result.

5-5

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

6. Tubing leaks Damage caused by Replace tubing and fittingat fitting mechanical means and relocate whereafter system outside the system. damage is less likely to beinstallation. a problem. Check tubing

supports.

Corrosion is eating Inspect connection foraway fitting or tubing. corrosion. If present, check

corrosion compatibility offluid, tubing, and fittingmaterials and ambientatmosphere. Considergalvanic action as apossible cause.

Cracking of tubing Swage10k tube fittingsdue to overstressing should be used to replacewhile making flare for such fittings and avoid thisa flare fitting. difficulty.

Interchange of other Use only Swagelok tubemanufacturers' fittings. DO NOTcomponents. INTERCHANGE.

7. Copper Copper tubing Heavier wall copper tubingtubing leaks becomes very weak will help in some cases forat fitting above 400°F temperature cycling, but inafter (204°C). This is an no case should copperoperation inherent tubing be used aboveabove characteristic of the 400°F (204°C). Stainless400°F material and not a tubing and fittings should(204°C). function of fitting be used.

performance. Codeslimit copper tubing to400°F (204°C).

5-6

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

8. Tubing leaks Fitting not properly Follow instructions.at retightened.reconnection

Dirt got into fitting or Observe cleanlinessfollowingmaintenance.

on ferrules while practices wheneverdisconnected. disconnecting and

reconnecting. Clean outforeign material andinspect fitting for damage.If ferrules or seat aredamaged, replace thedamaged parts.

Interchange of other Use only Swagelok tubemanufacturers' fittings. DO NOTcomponents. INTERCHANGE.

9. Flows are Obstruction in When assembling atoo low system. system, be cautious soin system. that gravel, dirt, sand or

other foreign materials donot get in tubing or fitting.

Single ferrule fitting Use only Swagelok tubehas over swaged, fittings.restricting tube 10.

System sized too Check to determine ifsmall. system should be

constructed of a largerdiameter tubing.

10. Fittings Pipe threads have SILVER GOOP® lubricantcannot be welded together. Nut may be used on hightaken apart threads have welded temperature alloys forafter high to threads on tube operation at hightemperature fitting body. temperatures to 1500°Foperation. (816°C). While Silver Goop

may prevent galling, it willnot be a sealant. We knowof no good thread sealantfor use above 450°F(204°C).

5-7

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

11. Tubing is Excessive pressure. Use stronger material ordeformed Tubing of insufficient heavier wall tubing.after tensile strength orsystem wall thickness washas been used.in

Freeze-up of water or Prevention through properoperation.

condensate in steam installation, operation, andtracing. maintenance.

12. Polyethy- Check ferrule Use metal or nylonlene tubing material-TFE Swagelok tube fittings withslips from ferrules not polyethylene tubingfitting. satisfactory or whenever possible.

possible undersizetubing.

13. TFE tubing Slippery Use all metal fittingsslips from characteristic of TFE whenever possible. TFEfitting. material. fittings have very low

pressure ratings.*

14. Glass Metal ferrule used Use Swage10k Ultra-Torrtubing improperly. fittings. With Swagelokbreaks tube fittings, use a plasticwhen front and back ferrule.connectingfitting.

* The Swagelok PFA tube fitting, when used with Swage10k PFA tubing(which has been grooved with the Swagelok groove cutter), will holdto the rated working pressure of the tubing. Consult your Swagelokrepresentative for pressure rating information on this combination.

5-8

TROUBLE SHOOTING

Trouble Possible CauseRecommendedCorrective Measures

15. Seal is not Glass tubing is Use Swagelok Ultra-Torrobtained millimeter size and fittings. Obtain tubing toon glass not fractional size. fractional sizes or usetubing. Swage10k metric tube

fittings, with nylon ferrules.

Glass tUbing is Use Swagelok Ultra-Torrundersize. This may fittings. Obtain tubing thathappen even if some is no smaller than 0.032 in.

sections of the tubing in diameter under thedesignated fractional size.

are the right size. Example: Glass tubingshould be at least 0.218 in.in diameter when usedwith 1/4 in. Ultra-Torrfittings.

16. Tubing Insert not used with Use Swage10k inserts withcreeps plasticized PVC plasticized PVC tubing, orfrom fitting tubing. use Swagelok hosewhen using connectors.plasticizedPVCtubing.

5-9

5-10 ---------------------

Special Purpose FittingsIn previous chapters we have discussed general purpose flareless

Swagelok mechanical grip tube fittings. In addition to these, there areseveral special purpose fittings. Each has certain characteristics whichmake it particularly desirable for specific applications.

WELD FITTINGS

Swagelok produces a complete range of tube and pipe weld fittings.

Swagelok weld fittings provide permanent welded connections forcritical applications involving corrosive fluids, shock from pressuresurges, temperature cycling, system vibration, and ultra pureapplications.

Many different fitting configurations are available for tube socketweld (TSW), pipe socket weld (PSW) , male pipe weld (MPW), maletube weld (MTW), and adapters in standard material of 316 stainlesssteel, as well as automatic socket weld (ASW). Automatic tube weld(ATW) and tube butt weld (TB) are available in 316L stainless steel.

Tube Socket Weld Fittings (TSW)

Tapered socket speedslayout, assembly, aridalignment.

Precise machining ofsocket.

Male Connector

Fig. 1

Accurate socket depth ensures propertube support and consistent assembly.

6-1

Pipe Socket Weld Fittings (PSW)

Male weld end can be buttor socket welded.

I

Union

Adapters

37 1/2° chamferensures proper weldfillet (MPW only).

Smooth internal finishminimizes turbulence.

6-2

Quality machiningof all surfacesensures consistentwelding to pipe.

Heavy wall, plus strength {of material, ensures longlife in severe serviceapplications. 1e_"'¥y....."1

Socket depth equals or exceedsrequirements of ANSI 816.11 andensures proper pipe support.

Fig. 2

Tapered socket speeds layout,assembly, and alignment.

Precise machiningof socket ensuresproper tube fit.

Accurate socket depth ensuresproper tube support andconsistent assembly.

Fig. 3

Pipe Adapter

Pipe to Tube Weld (MPW)

Used to reduce from a pipe butt weld or pipe socket weld to asmaller tube size.

Fig. 4

Tube to Tube Weld (MTW)

Used to reduce from a tube butt weld or tube socket weld to a Ismaller tube size. I

Tube SocketTube

Fig. 5

Swagelok tube butt weld (TB), automatic tube weld (ATW), automaticsocket weld (ASW), and Micro-Fit® weld fittings are designed forsystems welded manually or with automatic welding equipment.Standard material for TB, ATW, and ASW is 316L stainless steel.Standard material for Micro-Fit fittings is 316L VAR (vacuum arcremelt). Some Micro-Fit fitting sizes and configurations are available in316L and alloy C-22.

6-3

Tube Butt Weld Fittings (TB)

Precisely finished diametermatches tube diameter.

\

Union Elbow

Controlled surfacefinish is available forhigh-purity systems.

Tube ends aremachined with squareface and corners to _.LcCCCc.s=.

enhance alignmentand maintain tubewall uniformity.

Fig. 6

Automatic Tube Weld Fittings (ATW)

6-4

Union Tee

Controlled surfacefinish is available forhigh-purity systems. --

Integral filler ringaids in alignment.

Fig. 7

Precisely finished diametermatches tube diameter.

I

Automatic Socket Weld Fittings (ASW)

Union Tee

Tapered socketspeeds layout,assembly, and _alignment.

Precise machiningof socket.

Thin wall reduces weld heat input.

/

Accurate socket depth ensures proper tubesupport and consistent assembly.

Fig. 8

Micro-Fit Fittings

Swagelok Micro-Fit weld fittings aredesigned for tubing systems requiring light­weight, close component spacing, andcleanliness. These miniature fittings equalthe flow rate and service ratings of largerfittings designed for the same size tubing.They are available in standard fractionaland metric sizes.

Fig. 9

Radius junctionallows for a smoothflow transition andis designed toeliminate pocketsand entrapmentzones.

---­Square, sharp, burr free tube weld endsenhance alignment, maintain tube walluniformity, and promote weld repeatability.

Material heat code is rollstamped during firstmanufacturing operation toensure raw material traceability.

Rounded body block prevents injury or damage to othercomponents during system fabrication or maintenance.

Laser etch markingc-;c,?fidentifies manufacturer, ~,;y;;;;;;;;;~ 0'''''\''''''- I

316 LVmaterial, and, when MM !applicable, theappropriate processdesignator according toSwagelok companiesSC-Ol Specification.

Fig. 10

6-5

I

WELDING SYSTEM

The Swagelok welding system is an orbital welding system. It can beused to weld a variety of tubing and valves and fittings with weld endconnections.

The Swagelok welding system uses the gas tungsten arc welding(GTAW) process, which is commonly referred to as TIG (tungsten inertgas) welding. During the welding process, the components to bewelded are held stationary in a fixture while an electric arc ismechanically rotated around the weld joint. Various weld heads areavailable that allow the Swagelok welding system to accommodateoutside diameter sizes ranging from 1/16 to 2 in. and from 3 to 52 mm.

Fig. 11FACE SEAL FITTINGS

VCR Metal Gasket Face Seal Fittings

Swagelok VCR metal gasket face seal fittings offer the high purity ofa metal-to-metal seal, providing leak-free service from critical vacuumto positive pressure.

The seal on a VCR assembly is made when the gasket iscompressed by two highly polished beads during the engagement of amale nut or body hex and a female nut.

Female Nut

Gasket Retainer Assembly

Fig. 12

6-6

"S" Type VCR Face Seal Fittingsfor Ultra-Pure Systems

The Swagelok "s" Type VCR is a boreline face seal fitting with twoopposing glands engaging a retained gasket to create a seal withoutany areas of entrapment. This design utilizes an anti-twist assemblyand is more compact than the VCR fitting.

Fig. 13

VCO O-ring Face Seal Fittings

Swagelok vca a-ring face seal fittings are designed for rapid makeand remake in pipe, tube, and welded systems. Because of theirunique design, zero clearance is accomplished, allowing easyinstallation where space is limited. Sealing is accomplished with acaptive a-ring in the body component. Assemblies can be used fromhigh pressure to critical vacuum, within a wide range of temperatures.

a-ring Body

Fig. 14

6-7

"B" Type VCO Face Seal Fittings

The Swagelok "8" Type VCO fitting uses a unique L-Ring Seal thateliminates concavity at the bore. This feature reduces the potential formedia entrapment.

Nut L-Ring Seal

Fig. 15

VACUUM FITTINGS AND TUBING

Ultra-Torr® Fittings

Swagelok Ultra-Torr fittings are designed to provide a vacuum-tightseal with quick, finger-tight assembly on glass, metal, or plastic tubing.

Although specifically designed for vacuum service, they can also beused in some pressurized systems. However, tubing must bemechanically contained to prevent it from being forced from the fitting.

Fig. 16

6-8

Stainless Steel Flexible Tubing

Swagelok flexible tubing is designed for use in vacuum or low positivepressure applications. Flexible tubing compensates for misalignment,expansion, and contraction in fabricated systems. It is compressible byat least 20 % and extendable by 50 % of its nominal produced flexiblelength.

Fig. 17

HIGH PRESSURE TUBE FITTINGS

Swagelok severe service/high pressure tube fittings are designed andmanufactured for use on heavy wall stainless steel tubing. They areused for high pressure up to 60 000 psig (4134 bar), high safety factor,or unusually difficult applications requiring very high mechanicalstrength.

Instead of the ferrule making the complete seal and hold as withSwagelok tube fittings, the Swagelok severe service/high pressure fittinguses the ferrules as the driving and holding mechanism. The end of thetube, coned to a 57° to 59° angle before fitting make-up, is used for theseal to the body. The coning operation offers two significantadvantages:

1. It reduces seal diameter by about 50 % so that the force of the fluidpressure is reduced by 75 %. Thus the force trying to separate thetube from the fitting is only about 1/4 of that if seals were made onthe tube 00.

2. All seals are made on machined surfaces. Tube surface imperfectionssuch as scratches and nicks do not affect the sealing integrity.

6-9

I

Typical sizes and tube wall thicknesses are:

Outside Diameter Wall Thickness

1/4 in. 0.083 and 0.095 in.

3/8 in. 0.125 in.

9/16 in. 0.125 and 0.187 in.

Both tempered 60 000 psig (4130 bar) and annealed 30 000 psig(2060 bar) tubing are commonly used. Tempered tubing should alwaysbe pulled up in a Swage10k Pre-Setting Tool. Annealed tubing may bemade up in a Pre-Setting Tool, but can also be made up directly in thefitting body. Swagelok Inspection Gages can be used to check forproper pull-up of the fitting.

Fig. 18

FITTINGS FOR VERY SOFT PLASTIC TUBING(such as unplasticized PVC)

Many types of soft plastic tubing are used in laboratory or lowpressure air systems. Unplasticized PVC tubing, such as Tygon, isoften used because of its purity, transparency, excellent flexibility, andsmooth interior surface.

Swagelok metal or plastic tube fittings have been used for manyyears on this tubing with excellent results. The only additionalrequirement beyond the needs for use on metal tubing is an insert,made to support the tubing so that it will not collapse when the ferrulesdeform the tube.

Fig. 19Insert

6-10 ...,.----------------------

Fig. 20Insert used in Tygon tubing with Swagelok male connector

Another excellent connection for such service is the Swagelok hoseconnector (HC). This hose-type fitting has a specially designedserrated shank which properly stretches the tube for optimum sealing.An optional sleeve may be used when working pressure is more than50 % of the maximum worl<ing pressure of the tube.

Fig. 21Male hose connector for soft PVC tubing with sleeve

FITTINGS FOR HARDER PLASTIC TUBING

Fittings for polyethylene, polypropylene, TFE, and PFA tubing areavailable in a wide range of Swagelok tube fitting sizes and materials.Both metal and nylon fittings can be used on these tubes. TFE fittingson TFE tubing have reduced pressure ratings due to the slippery finishon both components. However the PFA Swagelok tube fitting, whenused with Swagelok PFA tubing (and grooved with the Swagelokgroove cutter), will hold to the rated working pressure of the tubing.Consult your Swagelok representative for pressure rating informationon this combination.

---------------------- 6-11

I QUICK-CONNECTS

Fig. 22Control panel using Swagelok brass fittings with nylon tubing.

(Insert not required.)

Swagelok quick-connects are mechanical devices which rapidly joinand separate fluid system components without the use of tools. Quick­connects offer these benefits:

o easy to useo minimum equipment downtimeo no tools required to make or break a connectiono no possibility of cross threading, galling, under-tightening, or over­

tighteningo single-end shutoff (SESO) - These quick-connects offer a shutoff

valve in the body with no shutoff in the stem. The body valveautomatically shuts off when the stem is removed.

o double-end shutoff (DESO) - These quick-connects are the sameas the SESO, but they have a small poppet valve in the stem aswell. Thus, when the stem is removed from the body, pressure isshut off automatically at both ends. This feature minimizes:

SPILLAGE-The amount of system fluid that escapes when a quick­connect is uncoupled.

AIR INCLUSION-The amount of air trapped between the body andstem valves that enters the system when a quick-connect is coupled.

6-12 ----------------------

A typical quick-connect assembly consists of a male stem and afemale body. The male stem is inserted into or against the femalebody. A locking mechanism then locks the component halves together.

Typically, an O-ring or elastomer is employed to create a seal toatmosphere.

Quick-Connects for Instrument Applications (QC)

These quick-connects are designed for use in positive pressure andvacuum services. They can be used in a wide range of applicationsincluding gauge calibration, system sampling, portable test equipment,and laboratory equipment. They are available in single-end shutoff ordouble-end shutoff designs. They are standard in brass or stainlesssteel with pressures to 3000 psig (206 bar) and temperatures to 400°F(204°C).

Fig. 23QC Single-End Shutoff (SESO) Quick-Connect

Fig. 24QC Double-End Shutoff (DESO) Quick-Connect

---------------------- 6-13

Keyed Quick-Connects (QC)

These quick-connects are similar to Figs. 23 and 24, but have animportant additional safety and convenience feature. Color-coded,positive mechanical lockout devices or keys prevent intermixing ofkeyed stems into an unlike color-coded keyed body. No connection canbe made between unlike stems and bodies. Thus unwanted fluid mixingcannot occur. As an example, a gauge calibration stand might havefour different pressure ranges. The use of keyed quick-connects wouldprevent damage to a gauge which could occur if, for example, an 0-100psig (7 bar) gauge were to be accidentally plugged into a 0-500 psig(35 bar) test supply. They are also used extensively in keying variousgas or liquid connections where cross-mixing could be dangerous orexpensive.

Fig. 25

Keyed QC Series - 8 different keys available

Full-Flow Quick-Connects (QF)

These qUick-connects have no valve and offer high capacity,straight-through flow with no restrictions. They are commonly used ontransfer lines or drain and vent systems. They can be used with flexibleor rigid tube, pipe, or hose. Pressures are to 6000 psig (413 bar) andtemperatures are to 400°F (204°C).

Fig. 26

QF Series Full-Flow Quick-Connect

6-14 ----------------------

Quick-Connects for Industrial Applications (QH)

These quick-connects are designed for applications where lowspillage, minimal air inclusion, and higher pressure ratings are required.Typical applications include steam, air, water, and hydraulics withpressure ranges to 6000 psig (413 bar) and temperatures to 400°F(204°C). These rugged quick-connects are available in carbon steel forhigh performance in a less costly design. Viton seals provide largesealing areas with excellent fluid compatibility. The flush valve designin both the body and the stem minimizes air and dirt inclusion whencoupling and spillage when uncoupling. The unique safety releasebutton protects the operator and prevents accidental uncoupling at allpressures. Flow in the QH series is available in double-end shutoff,single-end shutoff, and full-flow designs.

Fig. 27QH Series Quick-Connect

Miniature Quick-Connects (QM)

These quick-connects are for use in systems utilizing small sizes ofpipe or tubing. QM series are available in brass or stainless steel. Theyallow for finger-tip operation and provide a lightweight, reliableconnection in vacuum or pressure service. They are available in single­end shutoff, double-end shutoff, and full-flow models. They will provideservice to 4000 psig (275 bar) and 400°F (204°C) with minimal airinclusion and spillage.

Fig. 28QM Series Quick-Connect

---------------------- 6-15

Quick-Connects Without Elastomer O-rings (QTM)

Most quick-connects use elastomer O-rings as their seals. All quick­connects shown above are included in this category. The QTM quick­connect series has several unique features which make it ideal for useon many fluids which would degrade elastomeric O-ring materials.They are ideal also for use in contaminated atmospheres whereexterior factors could affect elastomer seals. This family of quick­connects is made entirely of 316 stainless steel with TFE seals. Single­end shutoff and double-end shutoff models are available with the keyedoption. Pressures are to 4500 psig (310 bar) and temperatures are to120°F (48°C).

Because this particular type of quick-connect is used on manycorrosives or otherwise hazardous fluids, it has several added safetydevices:

1. An engineered safety release button must be depressed and slidforward to uncouple (see Fig. 29). Accidental uncoupling is virtuallyimpossible.

I 2. Stainless steel metal parts protect all working parts so accidentaldamage to seal areas will not occur if the quick-connect is droppedor otherwise roughly handled.

3. "Locking dog" locking mechanism holds the stem securely in thebody when coupled.

4. Keyed QTM quick-connects are available (see Fig. 30).

Fig. 29

Fig. 30

Keyed QTM Series

6-16 ----------------------

HOSE PRODUCTS

Fig. 31Flexible Metal Hose

Flexible metal hose is a length of tubing made flexible by means ofconvolutions. It may be readily bent and yet remain gas and liquid tight.Swagelok flexible metal hose can be used for many applications suchas reduction of piping stresses, compensation for misalignment,thermal expansion and contraction, vibration absorption, noise control,and flexible connection for reciprocating motions. Swage10k flexiblemetal hose is made of 316L heavy wall stainless steel tube with 321stainless steel braid. Many Swagelok components can be welded to theend of the hose. End connections include Swagelok tube fitting, tubeadapter, VCO, VCR, and NPT. Temperatures range from cryogenic to1000°F (537°C) and pressure ratings are to 3100 psig (213 bar).

6-17

TFE Lined Hose

This metal braided hose, lined with TFE, is used where an extremelysmooth, corrosion resistant interior is required. Swagelok TFE linedhose consists of a TFE core tube, 304 stainless steel braid, and 316stainless steel end connections. TFE is inert to almost all commercialchemicals, acids, alcohols, solvents, and many other system fluids. Itworks well in temperatures from cryogenics up to 450°F (230°C). It isnot affected by continuous flexing, vibration, or impulse, and itwithstands temperature cycling. It does not absorb either hot or coldmoisture and, therefore, can be used in steam applications to 250 psig(17.2 bar). TFE hose has maintained a 0.040 maximum wall thicknessto help resist permeation, kinking, and abrasion. The smooth core tubeis also available in carbon filled TFE if the possibility of static electricdischarge exists. End connections include Swagelok tube fitting, tubeadapter, NPT, VCO, male AN, sanitary flange, and JIC 37° AN Swivel.

Push-On Hose

Swagelok Push-On Hose is designed to take advantage of a fast,

Ilow cost method of assembling low pressure lines on the job site. Hoselines can be installed in seconds. Push-on hose eliminates the need forclamps, bands, or tools when assembling. Due to its Suna-N cover andcore tube, the hose can be used in a wide variety of applicationsincluding air, water, oil, grease, and many solvents. When assemblingthe hose and the end connection, it is only necessary to push thebarbed end into the hose until completely bottomed. The endconnection may be reused by simply cutting and removing the hose.Tube adapter and male NPT and SSP/ISO tapered end connectionsare available in brass and 316 stainless steel. Pressures are to 350psig (24 bar) and temperatures are to 200°F (93°C).

Thermoplastic Hose

Swagelok offers several different varieties of thermoplastic hoses tomeet a wide range of services and applications. Hoses are availablewith Swagelok tube fitting, tube adapter, NPT, JIC 37° AN Swivel, andSSP/ISO parallel and tapered thread end connections.

6-18 ----------------------

Thermoplastic Hose for Industrial Fluid Applications (7R/8R)

Swagelok thermoplastic hose is designed to handle a wide range ofindustrial fluids. The use of thermoplastic materials for the tube,reinforcement, and cover ensures performance capabilities beyondconventional wire-reinforced rubber hose. The Nylon 11 core tube isfree of manufacturing soapstone or grit and is compatible with mostchemicals, solvents, hydraulic oils, and synthetic fluids. The synthetiGfiber reinforcement, unlike wire reinforcement, resists fatigue caused byflexing and rugged handling. Swagelok thermoplastic hose is also 60 %lighter in weight than conventional rubber hoses with wirereinforcement. The rugged polyurethane cover provides for abrasionresistance and longer service life over comparable rubber hose. Unlikerubber hose which cures on the shelf, thermoplastic hose has anunlimited shelf life and is resistant to UV light and ozone. The 7R hoseis available in pressures to 2750 psig (190 bar), and the 8R hose isavailable in pressures to 5000 psig (345 bar). Both hoses can be usedin continuous service to temperatures of 200°F (93°C).

Thermoplastic Hose for High Purity Service (7P)

Swagelok poly-pure hose is designed with a polyethylene corematerial that is in compliance with FDA regulations and NSF standardsfor contact with water, food, and beverage. Applications includedrinking water, potable water, deionized water, washdown lines in foodservice, water filtration, and food filling lines. The light blue, non­perforated polyurethane outer cover protects against abrasion, cuts,cracks, and exposure to UV light and ozone. Swagelok poly-pure hoseshould not be used in gas service due to its non-perforated cover. Thishose can be used in temperatures to 150°F (65°C) and pressures to2750 psig (190 bar).

Thermoplastic Hose for Electrical Isolation (7N)

Swagelok non-conductive thermoplastic hose has been designedwith a non-perforated cover to prevent moisture from entering the hoseand affecting its overall conductivity. Applications for this hose includeareas where there is a need for electrical isolation of instrumentation,equipment, or an operator. The hydraulic tool and mobile equipmentare two of the major uses for the 7N hose. An orange polyurethanecover protects the hose from abrasion and identifies the hose as non­conductive. This hose is pressure rated to 2750 psig (190 bar).Swagelok 7N hose should be used for liquid service only.

6-19

Thermoplastic Hose (with Conductive Core Tube) for Natural GasService (CCNG)

Swagelok conductive compressed natural gas hose is designed tomaintain electrical continuity during use. Applications include placeswhere the conductive core tube needs to transmit all electrical chargealong the hose to a ground instead of to equipment or operators. Also,in applications such as fill stations for natural gas vehicles (NGV),where an electrically charged build-up could result in a spark, theSwagelok CCNG hose will eliminate the static electric build-up. Hose ispressure rated to 5000 psig (345 bar).

SWAGING TOOL

An advantage of using Swagelok thermoplastic hose is the ability tomake assemblies on site. Swagelok has made available two efficient,simple-to-operate tools for swaging end connections to thermoplastichose.

Power Swager

The power swager is anelectric tool whichhydraulically swages endconnections to hose. Thisefficient, high speed toolwith its unique designallows the dies to openand close automatically. Ittakes only seconds toassemble an endconnection. It is ready touse and an operator canbe trained quickly. Onemachine can swage allsizes of end connectionsand hose.

Fig. 32

6-20 ----------------------

Fig. 33

Hand Swager

This rugged, die-cast aluminum tool can makequality hose assemblies where electrical power isnot available. Its light weight (8 Ib/3.6 kg) makes itportable for field assembly. It can be benchmounted or, with its own carrying case, the swagercan be carried right to the job site.

6-21

I

6-22 ---------------------

Testing and Evaluation ofTube Fitting Performance

This chapter discusses a number of different tube fitting tests whichrequire specialized equipment. Also, some of the tests are destructivein nature. Before undertaking such a test program, be sure that allsafety precautions are followed.

AVOIDING PITFALLS

1. What is the test trying to prove?

2. Will test results be the basis for recommended changes, etc.?

3. Will an independent test laboratory be used?

4. Will valid statistical sampling be employed?

5. Will extrapolation be used to minimize test costs?

6. Will field use conditions be simulated?

PLANNING THE TEST PROGRAM

1. Obtaining fittings

2. Obtaining tubing

3. Selecting sizes

4. Selecting materials

5. Selecting fitting configurations

IMPLEMENTING THE TEST PROGRAM

1. Gas leak tests

A. Call a leak a leak

2. Vacuum tests

3. Make-break tests

A. Use of a variety of configurations

B. Random interchange of components

C. Importance of make-break testing

a. Tube expansion

b. Different ferrules into one body

c. Different bodies with same ferrules

d. Thread integrity

e. Degrading of seal surfaces

4. Vibration tests

7-1

5. Tensile pull tests

6. Rotation tests

7. Hydraulic impulse and burst tests

A. The value of hydraulic burst tests

8. Thermal cycling tests

A. Factors affecting seals

a. Relative wall thickness

b. Different thermal coefficients

c. Length of tube support in fitting

d. Rate of temperature change

B. Effects of steam

9. Interchangeability/intermixability tests

OVERVIEW

Increasing complexity of tubing systems places growing importanceon testing and evaluation of tube fitting performance. The goal: toeliminate the high costs and safety hazards of leakage in fluid systems.

However, not all tests are reliable. Some may not be objective. Somemay be based on predetermined results. And some may lack statisticalvalidity or use extrapolation to short cut costs.

This chapter includes suggestions on how to avoid the above pitfallsas well as a discussion on types of tests and procedures to ensurecredible results.

Most of the observations, data, and recommendations herein are theresults of experience gained by Swagelok Company through in-housetesting, customer tests, competitor tests as published, and outside orindependent tests.

AVOIDING PITFALLS

The following questions should be considered before starting a testprogram. (They also can be asked in the past tense when evaluatingcompleted tests.)

1. What is the test trying to prove?

Often the purpose of a test is to prove a predetermined conclusion.Perhaps a department has been told to cut the tube fitting costs bytesting to "prove" that a cheaper fitting will do as good a job as a moreexpensive one. If the result is predetermined, the "test" is a waste oftime.

7-2

2. Will test results be the basis for recommended changes even ifgood or bad long-time experience contradicts those results?

Often we have seen poor test results on a few fittings undercontrolled lab conditions far outweigh the success of hundreds or eventhousands of leak-free connections in the field. Conversely, excellentlab test results often are accepted even though in-plant operatingresults for the product are disastrous.

3. Will an "independent" test laboratory be used?

There are many reputable test laboratories where tests areperformed in a thorough and objective manner.

Since someone, however, must pay for independent testing, there isalways the possibility that the payor tells the payee what to test andhow to test it. Usually there is no way of knowing whether additionaltests were performed and the results not published.

There are documented cases of a tube fitting manufacturer makingup tube assemblies with two different manufacturers' fittings anddifferent tubing, and then submitting them to an "independent" lab.Naturally, the payor's fittings performed admirably, while those of hiscompetitor did not do as well. Yet the results of this rigged test arebelieved by those who do not take time to carefully evaluate thepublished report.

Tests of this nature seldom can be considered truly "independent"because the scope of tests, sizes tested, materials tested, and thetypes of tests and reporting methods are all determined by the payor.

4. Will valid statistical sampling be employed?

Often, as indicated previously, a major company using more than100 000 tube connections a year will test only five or ten connections inone or two sizes. Test results are likely to ignore supremely satisfactoryor grossly unsatisfactory performance in the field. Such invalidstatistical methods often lead to erroneous conclusions.

5. Will extrapolation be used to minimize test costs?

Many times brass fittings are tested on copper tubing in, for example,1/4 and 3/8 in. sizes. Then the assumption is made that the fittings willwork equally well on other materials such as steel, stainless steel,aluminum, alloy 400, etc. Further assumptions may be made that largerfitting sizes will work as well as the smaller ones. Such assumptionsare dangerous.

If the fittings are to be used in 1/4 through 1 in. sizes, the 1 in. sizealso should be tested.

7-3

6. Will field use conditions be simulated?

Field conditions involving varying pressures, temperatures,impulsing, vibration, and make-break can affect a fitting's performance.Also, variations in tube material, wall thickness, concentricity, andhardness can affect fitting success.

Merely following manufacturers' recommendations is not enough,because a considerable percentage of fittings are not installedcorrectly. Undertightening and, particularly, overtightening are therules, not the exceptions.

Also, be wary of applying laboratory test results to field use. Labtests may lack validity because laboratory technicians, by their natureand training, try to make things work. They are unusually careful. Onthe other hand, field fitters seldom take the same care as laboratorytechnicians do for test work.

Careful consideration of the foregoing six questions will avoid pitfallsin new test programs or will reveal them in tests which have beencompleted and published.

The best test of any component, such as a tube fitting, is repeateduse in large numbers under various installation and operating

Iconditions in the field.

PLANNING THE TEST PROGRAM

Good planning includes careful selection of fittings, tubing, sizes,materials, and configurations to be tested. Again, the sameconsiderations can apply to evaluation of completed tests.

1. Obtaining fittings

Never use free samples. There is always the shadow of suspicionthat they are specially made, hand-inspected, or treated differently fromoff-the-shelf products.

Ideally, test fittings should be purchased through normal suppliersdisguising in every possible way the fact that they are for evaluationtesting. Obviously, defective fittings should be considered and recordedas failures.

Some users buy fittings through a different department or from aplant in another area or several different areas.

7-4

2. Obtaining tubing

Tests should employ tubing normally used in the plant. No specialselection or treatment should be involved.

If plant tubing is not available, tubing can be bought to specsrecommended by fitting manufacturers, or to ASTM or other applicablestandards.

If stainless steel tubing is required, both welded and drawn andseamless should be tested, unless only one or the other is usedexclusively in actual plant service.

Certain manufacturers recommend only seamless tubing. It is unfairto test their fittings on welded and drawn tubing. Also, it is unfair to testonly seamless tubing if welded and drawn tubing is a plant requirementbecause of wall thickness, concentricity considerations, or itssubstantially lower cost.

Fig. 1Thick and thin wall stainless steel tubing

Test more than one wall thickness. If, for example, fittings are to beused on 0.035, 0.049, 0.065, and 0.083 in. wall thickness, at least0.035 and 0.083 in. should be tested (minimum and maximum wall).

All tubing should be cut in exactly the same way. The two sides ofeach tube cut should be put into competitive fittings if competitive testsare being conducted. This offers the best chance of cutting thevariables and assuring a valid test.

7-5

3. Selecting sizes

Leakage at a fitting seal is approximately proportional to sealdiameter. A 1 in. fitting is about eight times as likely to leak as a 1/8 in.fitting. Bigger circles are tougher to seal than smaller circles; so itfollows that if you test the largest fitting you expect to use, it is betterthan testing the smallest. If the larger fitting works, it is even more likelythat it works in smaller sizes. The reverse is not true.

4. Selecting materials

Test fittings in all materials you expect to use. A brass fitting maywork well, but the same fitting in steel or stainless steel may failmiserably. The fact that it works in stainless does not necessarilyindicate that it will work in other alloys-alloy 400, alloy C-276, etc.

5. Selecting fitting configurations

Test several configurations. Elbows, tees, and crosses are madefrom forgings, which normally are softer than the bar stock used instraight fittings. Therefore, different factors may affect sealing andholding ability, as well as thread life.

Testing several configurations negates the possibility of all testfittings being made on the same machine on the same day with the

Isame tools. Testing for quality control of four different configurations,for example, is a much tougher and more valid test than testing fourfittings of one configuration. Nuts and ferrules are more likely to comefrom different manufacturing lots.

The following in each size, material, and wall thickness would giveyou a representative test for quality and consistency.

--Cap

Union Elbow

Male Connector

Fig. 2Typical test set-up

7-6

Such an assortment will make six connections-four bar stock fittingconnections and two forged body fitting connections. This ensures amore valid test of consistency because the fittings would be made onvarious machines at various times.

Testing different configurations also provides an excellent qualitycontrol check on a manufacturer in terms of holding critical tolerancesthroughout the product line. Such tolerances are discussed under"Make-break testing."

A good test of quality control and consistency is to take apart all thefitting components and measure the following:

BodyFront Back

NutFerrule Ferrule

Inside Bore Diameter x x x xSkirt Diameter xOutside Diameter x xLength x x x

Measure the total spread of measurements of each manufacturer tocheck consistency and quality control.

Never "average" the variations in any critical dimension. Maximumdeviation from highest to lowest measurement of such dimensions willreveal a great deal about a manufacturer's quality control.

Thorough planning in the above areas is time well spent in ensuringa comprehensive, objective, and valid test program, and informationgained may determine that further tests are not needed.

The best test of any component, such as a tube fitting, is repeateduse in large numbers under various installation and operatingconditions in the field.

IMPLEMENTING THE TEST PROGRAM

The following discussion covers nine common types of tube fittingtests. Some can be performed by the user without major expense,while others are more practically performed by manufacturers becauseof the time and expense involved.

1. Gas leak tests

These are tests of seal integrity. Inert gas such as nitrogen or heliumshould be used. Air is acceptable.

7-7

Test pressures should be at least equal to the working pressuresrecommended by tubing manufacturers.

Various test methods can be used depending on cost, equipmentavailability, and sensitivity desired. These include bubble checking(under water), using a leak detector fluid (see Fig. 3) at all connections,or more sensitive methods such as ultrasonic, halogen torch, or massspectrometer helium leak detectors (see Fig. 4).

Fig. 3SNOOP leak test

A. Call a leak a leak.

Fig. 4"SNIFFER" test of helium

pressurized system

Another very important facet of gas leak testing is to determine inadvance what will be considered a "leak." The test pressure and arealistic "leak rate" should be decided upon based on the maximumplant requirements and the limitations of the fittings and tubing. Thetest pressure may be determined by multiplying the plant pressuretimes an appropriate safety factor - i.e.: 1000 psig (68 bar) x 2 (2:1) =2000 psig (138 bar).

Probably the most common error is to decide that "a leak is not aleak" if it can be stopped by further tightening. If a fitting is installed andreinstalled according to instructions, it should not leak. Or, at least aleak should be considered a leak.

The reason for this is to simulate field conditions where leaks arecostly. For example, a system with 100 connections is tested as asystem. Leaks are located, isolated, and repairs or replacements aremade. All these steps are costs-and the cost of failures is high, even ifleaks can be stopped by further tightening.

2. Vacuum tests

These are excellent tests of seal integrity. Any fitting which must relyon internal system pressure to help affect a seal usually will fail vacuumtests.

7-8

Vacuum tests are advisable where vacuum is in regular use,particularly ultra-high vacuum in sophisticated instruments. Theequipment is expensive, but so is the cost of failures.

Usually helium leak detectors of the mass spectrometer type areused (see Fig. 5). A fitting-tube assembly is attached to the test port,vacuum is pulled internally, and a helium gun is used to squirt helium atall seal points.

Fig. 5Mass spectrometer helium leak test

Our standard laboratory evaluation for gas leakage is a leak rate of1 x 10-9 atm. cm3/sec. helium, with internal vacuum in the leak detectorin the 10-2 torr range.

Other methods employ a component sealed in a plastic bag or glassbell jar. Leakage is checked from the component into the envelope orfrom a helium filled envelope into the component.

3. Make-break tests

A tube fitting's ability to stand many make-break cycles is perhapsthe best measure of comparison among competitive products.

These tests can be extremely important in instrumentation fittingapplications where periodic maintenance requires making, breaking,and remaking tube connections. Make-break tests, therefore, should beperformed very carefully.

When equated to field usage, make-break test results can greatlyreduce in-service tube fitting costs. But such tests will not relate to fieldusage unless they incorporate these two vital procedures:

7-9

I

A. Use a variety of configurations (elbows, tees, crosses, unions,bulkhead unions, male and female connectors) for the reasonsdiscussed previously under "Selecting fitting configurations."

B. Randomly interchange components to simulate field conditions (seeFigs. 6 and 7).

Fig. 6Typical make-break test

Fig. 7Additional make-break test with tubes reversed

Let's examine procedure "B" in more detail, and consider what reallyhappens in the field.

For example, analytical instruments such as chromatographs havecolumn changes, where the nut-ferrule-tubing assemblies are removedwith columns. The fitting stays attached to the instrument. Anothercolumn with nut-ferrule-tubing assembly is connected to the samebody.

7-10 ----------------------

In another example, process or measuring instruments, such ascontrollers or transmitters, are dropped from a system with fittingbodies attached, while the nut-ferrule-tubing assemblies stay on thesame tubing. Other instruments with different fitting bodies are installedas replacements. Here the bodies are changed, but the nut and ferrulesystems stay.

You can see that in these realistic make-break situations, the samenut-ferrule-tubing combination seldom sees the same body twice.Therefore, make-break testing with the same nut-ferrule-tubingassembly repeatedly into the same body does not simulate field make­break conditions.

C. Importance of make-break testing.

There are several reasons why make-break testing is one of the bestways to check the quality control of any fitting manufacturer.

a. Tube expansion ahead of the sealing ferrule usually takes place inflareless fittings. This mayor may not be important to the fittingworking at all, but it becomes critical if make-break is tested indifferent bodies.

The tube swell to a diameter of 0.512 in. in fitting "A," for example,will not allow that tube even to enter the bore of fitting "8" which mightbe 0.506. in. In other words, a tube with 0.512 in. outside diameter will Inot fit in a 0.506 in. hole.

This is why testing several configurations provides an excellentcheck on a manufacturer's quality control (not all from the samemachine).

b. If, due to sealing ferrule design, galling takes place at the body sealarea (particularly in stainless and other corrosion resistant alloys),another ferrule trying to seat in the damaged body seal area oftencauses a leak; yet, this is merely a simulation of what happens in thefield.

c. If, in the sealing mechanism, several different nut-ferrule-tubecombinations must seal at different points on the body seal area(because it is necessary to coin or groove the body seal at a slightlydifferent spot each time), leakage often results.

d. Thread integrity during repeated make-break cycles is an importantindication of good quality control, as well as good design.

7-11

e. Smooth sealing surfaces indicate good surface quality control.Obviously, in any metal-to-metal sealing device, good surface finishis a necessity. But a smooth beginning surface finish is only abeginning. If that surface is greatly degraded during original orsubsequent make-breaks, especially with several different bodies,there is a good chance of field failure.

Tests and calculated data show that leakage varies by a cubefunction as seal smoothness degrades. A 50 % improvement in thesealing surface provides an 800 % improvement in seal integrity(see p. 10-2).

4. Vibration tests

Usually the specialized equipment costs of such tests make themimpractical for the user to design. Our own tests use a 1750 rpm motorwith a deflection block which adjusts the center line deviation of thetube assembly under test.

VIBRATION TEST STAND

o

E

PressureSwitch

\

Rigid BaseRigid f/L----~~~----------'

Clamps

IFig. 8

Vibration test stand

A-Connected to pressure source

B-Fitting under test-held rigid

C-Tube under test-block at motor end

D-Adjustable block

E-Deflection checked at 12 in. from fitting

7-12 -----------------------

Fig. 9Adjustable tube deflection for vibration tests

An internal tube pressure is selected (1.6 x maximum workingpressure of the tubing). Motor rotation causes the motor end of thecapped tube to move in a circle whose radius is the tube deflectionfrom center line measured 12 in. from the test fitting. This testcontinues until 10 000 000 cycles without leakage are completed at agiven deflection. The rotation of the assembly is such that it attempts toback off the fitting nut of the assembly under test.

We have seen other tests where a 90° bend in the tubing is placedbetween the eccentric causing the deviation and the fitting under test.Obviously, this is not nearly as stringent a test as the straight line test,which causes more severe strains via a back-and-forth bend simulatingfield conditions.

5. Tensile pull tests

These tests usually are performed only by fitting manufacturersbecause of costs and equipment requirements.

Tensile pull tests (see Fig. 10) are used to check the holding abilityof fitting connections rather than sealing ability. Results allowcalculation of the internal pressure needed to cause separation, wherethe tube actually could blowout of the fitting. Most quality tube fittingswill hold tubing to hydraulic pressures approaching yield or burst of thetubing. Hydraulic burst testing is discussed on p. 7-14.

7-13

Fig. 10Tensile pull test

6. Rotation tests

IThese tests sometimes are performed to determine what torque

would be required to twist a piece of tubing so severely as to break theferrule-tubing seal and cause leakage. Although we can test fittings thisway, the test rarely would be equated to a field type of malfunction.Such a malfunction typically would be so severe that it would becatastrophic, and fitting connections' success or failure would be purelyacademic.

7. Hydraulic impulse and burst tests

Hydraulic impulse tests commonly are run by fitting manufacturers todetermine the ability of the tube and fitting assembly to resist severeand sudden pressure impulses without failure.

Our impulse method is to shock the assembly under test with animpulse of 1.5 x tubing maximum working pressure. A quick-openingvalve is used to achieve the shock at a frequency of 35 to 40 cycles perminute for 100 000 pressure cycles. This provides valuable bits of testinformation but, again, is not as valuable as actual field use.

7-14 ---------------------

Fig. 11Hydraulic impulse test

A. The value of hydraulic burst tests.

Hydraulic burst tests probably are the most used and leastunderstood (and perhaps the least valuable) of all fitting tests. They arean excellent test of short-term holding ability, but a poor test of sealingability.

Fig. 12Hydraulic burst test

Unfortunately, many fitting manufacturers use the burst test to"prove" fitting quality in sales demonstrations, literature, and exhibits.The truth is that many cheap hardware store fittings made for homewater service will hold tubing to burst.

7-15

Burst tests can be significant, however, when designed properly. Ourown general program tests, for example, are performed after at least 25make-break cycles. After each five assembly cycles, the system ispressurized to 2 x maximum tube working pressure and checked forleakage. After the 25th make-break, the tube is pressurized to theminimum calculated burst pressure, and this pressure is held for fiveminutes while checking for leakage (see Fig. 12). A dial indicator at thecapped end of the tube shows whether any tube slippage is occurring.Any leakage at this point is considered a failure. Only after all of thispretesting is the burst test itself performed (see Figs. 13 and 14).

I

Fig. 13 Fig. 14Tubing yield before burst Tube burst

On the other hand, most "sales pitch" types of burst tests are of suchshort duration that they do not allow enough time for small leakage tobe observed. Water or hydraulic oil is used and is, of course, hundredsof times less likely to leak than nitrogen, air, or helium. Also, theyinvolve careful installation techniques which may not simulate fieldconditions.

The best test of any component, such as a tube fitting, is repeateduse in large numbers under various installation and operatingconditions in the field.

7-16 -----------------------

8. Thermal cycling tests

Temperature cycling is one of the toughest services a tube fittingmust see. Examples: • steam • cryogenics • arctic or tropicalenvironments • heat transfer fluids such as liquid metals, Dowtherm®and Therminol® • space simulation • analytical instrument ovens,chambers, columns.

Again, the cost of setting up a test facility is usually prohibitive,except in a major fitting manufacturer or a government funded researchprogram.

As mentioned previously, most large users of tube fittings have theirown "test labs" in the form of their existing in-plant applications. In thecase of thermal cycling, most process plants have some or all of theservices listed above.

Fig. 151000 psig (68 bar) gas test at 1OOO°F (538°C)

While we maintain in-house test capabilities for thermal cycling, mostof our valuable "test" data comes from actual field use in widely varyingtemperature-pressure-fluid combinations.

A. Factors affecting seals.

In general, seal integrity between fitting components is severelyaffected by temperature excursions. Factors directly affecting sealsinclude:

a. Relative wall thicknesses (thin tube wall versus relatively heavy fittingwall thickness).

b. Differential thermal coefficients of expansion (copper tube versusbrass fitting).

c. Length of tube support within the fitting (affecting heat transfer astube cools faster than fitting).

7-17

d. Rate of temperature change. (Thermal shock or very rapidtemperature change is a much more severe test than temperatureexcursion made slowly.)

B. Effects of steam.

Among all temperature cycling applications, steam is perhaps themost common fluid and, in many ways, the most difficult. Its erosiveproperties are well known, and these properties often preclude theluxury of retightening if a leak does occur.

A high-velocity, erosive steam leak passing through a very smallorifice usually increases the original leak rate greatly and, therefore, thecost of leaks. Extra tightening seldom stops that first steam leak(particularly on copper steam-trace tubing) because the high velocitysteam etches a deeper and deeper path in the soft tubing under thesealing ferrule.

9. Interchangeability/lntermixability tests

Many manufacturers claim that their fitting components areinterchangeable and/or intermixable with those of other manufacturers.Usually they back up such claims with reams of test data. But since thetest data is developed for the purpose of "proving" interchangeability, itsuffers from the pitfalls mentioned at the beginning of this chapter (lack

Iof objectivity, governed by predetermined results, lack of statisticalvalidity, extrapolation).

It should be noted that many tube fitting users have developed theirown tests of tube fitting component interchangeability, and they haveagreed, almost universally, that component interchange is not arecommended or accepted practice.

Interchangeability and/or intermixability testing, as with all the othertests discussed previously, should simulate field conditions as closelyas possible. A realistic test is to take several shapes of completefittings of Brand "A" and make them up with all Brand "A" components.On the same lot of tUbing, make up several different shapes ofcomplete Brand "B" fittings. Then randomly reinstall Brand "A" nut­ferrule-tube assemblies into the Brand "B" bodies. This closelyapproximates the conditions of field interchange. Any difficulties inassembly should be noted, and any gas leakage should be considereda failure. All possible combinations should also be assembled; in otherwords, back ferrule "A" with front ferrule "B," with nut "C." Wheninterchange is accepted, you may be sure that every combination willbe used. Some manufacturers try to confuse the customer by wordgames, such as, it's OK to "interchange" but don't "intermix."

7-18 ----------------------

Time, costs, and number of fittings required make it difficult for thetypical tube fitting user to thoroughly test all sizes, materials, andconfigurations through all the foregoing types of tests. But specific testprograms can be selected to provide performance evaluations asrelated to specific plant requirements. Manufacturers' and independenttest results also can be useful if they are objective and statisticallyvalid.

SUMMARY

Plan test programs with fittings, tubing, materials, and configurationswhich will ensure objectivity and statistical yalidity, while avoidingpredetermined results and extrapolation. No one performs enough teststo establish statistical certainty.

Pay close attention to the same considerations when evaluating testresults from any outside source.

Recognize the fact that existing plants represent the most reliable"test labs" possible. Those who ignore field operating results and relyon limited lab test programs are overlooking their most valuable input.

7-19

I

7-20 ---------------------

ThreadsThreads of many different kinds are used for different purposes in

small piping components. The most common are:

PIPE THREADS

Tapered pipe threads work by "interference" fit. The tolerances forangles, lengths, heights, etc., cannot be held closely enough to make aseal. Male pipe threads cannot be manufactured to tolerances whichwill seal on a taper with female pipe threads without a sealant.

A good thread sealant is essential. The sealant, such as SwagelokTFE tape, will fill the voids between the threads and will act as ananti-galling lubricant between the threaded surfaces.

The following are the more common types of pipe threads used inthe small pipe industry:

1. NPT Tapered Pipe Threads

.. 600 thread angle

.. Pitch measured in inches

.. Truncation of root and crest are flat

.. Taper angle 10 47'

Fig. 1American Standard Pipe Thread (NPT)

NPT (National Pipe Tapered) is made to specifications outlined inANSI B1.20.1. This is the pipe thread used on the pipe end of allSwagelok tube fittings when the abbreviation "NPT" is used in theSwagelok Product Binder.

Swage10k manufactures NPT pipe ends which exceed the standardsof ANSI B1.20.1 (Pipe Threads, except Dryseal). Some type of pipethread sealant is always required. Swage10k TFE tape is made

8-1

specifically for pipe thread sealing. Swagelok SWAK® is an anaerobicpipe thread sealant with TFE. For further information, consult yourSwage10k representative.

2. NPTF (National Pipe Tapered Dryseal) made to specificationsoutlined in ANSI 81.20.3. This pipe end is used on some hydraulicequipment and is sometimes specified on military hardware.

In "Dryseal" threads, the roots of the threads are more truncated thanthe crests so that an interference fit causes the roots to crush thecrests of the mating threads, leading to galling. Supposedly, whenmade up, the crests, roots, and flanks are always in full contact, but thiscan lead to galling, particularly without lubrication or a sealingcompound on stainless steel or nickel alloys.

Swagelok tube fittings are not manufactured with Dryseal PipeThreads.

3. ISO 7/1 Tapered Pipe Threads

.. 55° thread angle

.. Pitch measured in inches

.. Truncation of root and crest are round

.. Taper angle 1° 47'

Fig. 2International Organization For Standards (ISO 7/1) Tapered.

ISO tapered threads are equivalent to DIN 2999, BSPT, JIS B0203.

In application ISO threads are used similarly to NPT threads.However, care should be used that ISO and NPT threads are notmixed. ISO threads have a 55° angle versus 60° for NPT. Thread pitchis usually measured in millimeters but may be expressed in inches. Inmany sizes the threads-per-inch are different, and the root and crestconfigurations are different from NPT.

8-2

4. ISO 228/1 Parallel Pipe Threads

" 55° thread angle

" Pitch measured in inches

" Truncation of root and crest are round

" Diameter measured in inches

Fig. 3International Organization For Standards (ISO 228/1) Parallel

ISO Parallel threads are equivalent to DIN ISO 228/1, BSPP, JIS B0202.

These pipe threads are similar in configuration to 7/1 threads exceptthere is no taper. Therefore they do not work by thread interference likethe tapered pipe threads of ISO 7/1 or NPT. A gasket or a-ring isnormally used to seal into the parallel female threaded component. Insome cases, the body is tightened until a face on the hex is imbeddedinto the female threaded component. Surface flatness perpendicular tothe axis of the threads is essential.

Parallel threads are never sealing threads. Even the use of goodquality thread sealants will not provide reliable seals for these threads.

Four methods of sealing ISO 228/1 male threads to female ports arelisted below.

1. A metal-to-metal seal between the face of the body hex and theface of the female threaded component (Swagelok "RP" thread)(see Fig. 4).

Fig. 4

8-3

I

8-4

2. A metal gasket (usually copper) performs the seal betweenthe face of the body and the face of the female threadedcomponent (Swagelok "RP" thread) (see Fig. 5).

Fig. 5

3. A self-centering taper is used at the hex which centers acomposite washer (usually metal and elastomer) to seal to thesurface surrounding the female thread (Swage10k "RS" thread)(see Fig. 6).

Fig. 6

4. A gasket is dropped into the flat bottom of the female thread.The face of the male thread exerts a load on the gasket toseal (Swagelok "RG" thread) (see Fig. 7).

'\

i!"!J/If\. If\. If\ "1\./Y y

'W}

I I

Fig. 7

COMPARISON CHART

Pipe Threads

Nominal Threads Pipe IncludedPitch

Size Per Inch 0.0. Thread Angle

1/16 in.NPT/NPTF 27 0.312 in. 60° 0.037 in.ISO 28 0.312 in. 55° 0.036 in.

1/8 in. NPT/NPTF 27 0.405 in. 60° 0.037 in.ISO 28 0.398 in. 55° 0.036 in.

1/4 in.NPT/NPTF 18 0.540 in. 60° 0.057 in.ISO 19 0.535 in. 55° 0.053 in.

3/8 in. NPT/NPTF 18 0.675 in. 60° 0.057 in.ISO 19 0.672 in. 55° 0.053 in.

1/2 in. NPT/NPTF 14 0.840 in. 60° 0.071 in.ISO 14 0.843 in. 55° 0.071 in.

3/4 in. NPT/NPTF 14 1.050 in. 60° 0.071 in.ISO 14 1.060 in. 55° 0.071 in.

1 in.NPT/NPTF 11-1/2 1.315in. 60° 0.087 in.ISO 11 1.331 in. 55° 0.091 in.

11/4 in.NPT/NPTF 11-1/2 1.660 in. 60° 0.087 in.ISO 11 1.669 in. 55° 0.091 in.

11/2 in.NPT/NPTF 11-1/2 1.900 in. 60° 0.087 in.ISO 11 1.900 in. 55° 0.091 in.

2 in.NPT/NPTF 11-1/2 2.375 in. 60° 0.087 in.ISO 11 2.374 in. 55° 0.091 in.

UNIFIED SCREW THREADS

" 60° thread angle

" Pitch measured in inches

" Truncation of root and crest are flat

" Diameter measured in inches

Fig. 8American Standard Unified Screw Thread

8-5

Class of Fit/orGage Tolerance

UNF-2A

L'A" Denotes ExternalThread

("B" for Internal)No. of Threads Per Inchor Pitch

Screw threads are the workhorse of the threaded product industry.Almost all tube fittings and valves use these for nut and fitting endthreads, valve stems, lock nuts, jam nuts, etc. They are straight (nottapered) threads, and they are called out by thread OD and threads perinch. An example might be a nominal 3/8 in. SAE port using a 9/16-18UNF-2A thread.

Typical Designation:

9/16-18

Thread Diametet tOD I

Unified Fine Pitch

There is always a 60° included angle in this thread.

Fig. 9The "F" in "UNF" can be misleading. The "F" stands for fine pitch.

Whether a thread is UN (Constant) UNC (Coarse) or UNF (Fine) is therelationship of threads per inch to thread diameter.

For example:

5/16 - 20 is a UN thread

5/16 -18 is a UNC thread

5/16 - 24 is a UNF thread

8-6

Also confusing is the fact that, for example:

1/4 - 20 is a UNC (coarse) thread

5/16 - 20 is a UN (constant) thread

7/16 - 20 is a UNF (fine) thread

So the determination of Coarse, Constant, or Fine is not merelythreads per inch, but the relationship of threads per inch to threaddiameter.

All Swagelok fittings use American National screw threads when anut and threaded body work together to advance the nut and swage theferrules onto the tube.

Unified screw threads are commonly used in the hydraulics industryand in military hardware. Swage10k SAE/MS Straight Thread Fittingsare used to seal to SAE/MS ports by means of elastomer O-rings.

Thread sizes and other dimensions of SAE ports per SAE J 1926Standard are shown below:

SAE/MS INTERNAL STRAIGHT THREAD BOSS

":t

B MinimumBoss Height

r-D Diameter- This Dimension AppliesOnly When Tap Drill CannotPass Thru Entire Boss.

Fig. 10

8-7

I

SAE PORT DIMENSIONS (SEE FIG. 10)

BStraight Thread J KU*

Nom 0 Full +0.015 0 P§ SotOia Z

Tube Thread Pitch Dia Minor Dia Dia Thread -0.00 Oia +0.005 yt±1

00 Depth -0.000 Dia OegSizeMin Max Min Max Min Min Min Min Max Max

1/8 5/16-24 0.2854 0.2902 0.267 0.277 0.062 0.390 0.074 0.438 0.468 0.062 0.358 0.672 123/16 3/8-24 0.3479 0.3528 0.330 0.340 0.125 0.390 0.074 0.500 0.468 0.062 0.421 0.750 121/4 7/16-20 0.4050 0.4104 0.383 0.395 0.172 0.454 0.093 0.563 0.547 0.062 0.487 0.828 125/16 1/2-20 0.4675 0.4731 0.446 0.457 0.234 0.454 0.093 0.625 0.547 0.062 0.550 0.906 12

3/8 9/16-18 0.5264 0.5323 0.502 0.515 0.297 0.500 0.097 0.688 0.609 0.062 0.616 0.969 121/2 3/4-16 0.7094 0.7159 0.682 0.696 0.391 0.562 0.100 0.875 0.688 0.094 0.811 1.188 155/8 7/8-14 0.8286 0.8356 0.798 0.814 0.484 0.656 0.100 1.000 0.781 0.094 0.942 1.344 153/4 11/16-12 1.0084 1.0158 0.972 0.990 0.609 0.750 0.130 1.250 0.906 0.094 1.148 1.625 157/8 13/16-12 1.1334 1.1409 1.097 1.115 0.719 0.750 0.130 1.375 0.906 0.094 1.273 1.765 15

1 15/16-12 1.2584 1.2659 1.222 1.240 0.844 0.750 0.130 1.500 0.906 0.125 1.398 1.910 1511/4 15/8-12 1.5709 1.5785 1.535 1.553 1.078 0.750 0.132 1.875 0.906 0.125 1.713 2.270 1511/2 17/8-12 1.8209 1.8287 1.785 1.803 1.312 0.750 0.132 2.125 0.906 0.125 1.962 2.560 15

2 21/2-12 2.4459 2.4540 2.410 2.428 1.781 0.750 0.132 2.750 0.906 0.125 2.587 3.480 15

All dimenSions In Inches.

* Diameter U shall be concentric with thread pitch diameterwithin 0.005 full indicator reading (FIR), and shall be freefrom longitudinal and spiral tool marks. Annular tool marksup to 100 J.L in. max. shall be permissible.

• Maximum recommended spotface depth to permit sufficientwrench grip for proper tightening of the fitting or locknut.

t If face of boss is on a machined surface, dimensions Y and Sneed not apply.

§ Tap drill depths given require use of bottoming taps toproduce the specified full thread lengths. Where standardtaps are used, the tap drill depths must be increasedaccordingly.

NOTE: MS16142 ports are almost identical to SAE ports except forspotface dimensions.

8-8

METRIC SCREW THREADS (ISO 261)

" 600 thread angle

" Pitch measured in millimeters

" Truncation of root and crest are flat and ofdifferent width

" Diameter measured in millimeters

Fig. 11International Organization For Standards (ISO Metric)

Metric screw threads are straight (not tapered) and are often used toconnect to metric threaded equipment. The system is similar to theUNIFIED SCREW THREAD SYSTEM above, but they are specified asfollows. A 10 mm 00 x 1.5 mm pitch thread would be designated as:

Typical Designation:

M

Metric rThread Designation

10 X

LaD in MM

1.5

l Pitch in MM I

900

-------'---Axis -------

Fig. 12Either a gasket or O-ring is used to seal male metric screw threaded

components to female threaded components.

8-9

8-10 ---------------------

Pressure Ratings

TUBING CALCULATIONS AND PRESSURE RATINGS

Tubing aD and ID are related by the following formulas:Tube aD = 2t + Tube IDTube ID = Tube aD - 2tWhere t = Tube wall thickness

Proper wall thickness of tubing to contain internal pressure may befound by using one of the "Allowable Pressure Tables" on the followingpages. Tables 1 through 5 are for aluminum, copper, carbon steel,stainless steel, and alloy 400 tubing respectively. All tubing pressureratings are based on ANSI Code for Pressure Piping, 831.3-1993.

All pressure ratings are based on "minimum" wall and "maximum"aD within the applicable ASTM tubing specifications. A conservativerating is thus established based on "worst case" conditions. Sincevarious ASTM specifications have different outside diameter and wallthickness tolerances, use of tubing purchased to ASTM specificationsother than those shown in Tables 1 through 5 may cause somechanges from the pressure ratings shown in the tables.

As an example, we will use 3/8 in. aD x 0.049 in. wall seamlessstainless steel tubing purchased to ASTM A269 specification.

Nominal aD 0.375Actual aD 0.370 to 0.380 in. (± 0.005 in.)Nominal Wall 0.049 in.Actual Wall 0.042 to 0.056 in. (±15 %)

Pressure rating-nominal wall aD =5820 psi (401 bar)Pressure rating-minimum actual wall (0.042 in.) and maximum

actual aD (0.380 in.) = 4860 psi (335 bar). (Rounded off in table tolower 100 psi = 4800 psi [331 bar]).

No allowance is taken for corrosion or erosion in the following tables.

As used in this chapter, the term "maximum allowable pressure" isdefined as the maximum pressure a system will encounter. Theallowable system pressure should be based on the maximum pressurewhich one can reasonably expect the system will see. Then the systemdesigner, with knowledge of other system variables, can assign anadequate design factor based on his familiarity with the system.

Table 6 gives derating factors for elevated temperatures for thesame five tubing materials listed in Tables 1 through 5.

9-1

Table 7 shows a "Chart of Factors" for calculating working pressuresof tubing where allowable stress ("S") values are known. Such "s"values are referenced in the ANSI Code for Pressure Piping 831.3. 8ymultiplying the factors shown by the "s" value for a given material,approximate allowable working pressures may be easily calculated.These values are approximate, since the "Chart of Factors" is based onthe minimum wall thicknesses and maximum OD from ASTM A269specification. Actual tubing dimensions are likely to differ slightly fromthese values.

Metric Sizes, in millimeters

Minimum Minimum Minimum MinimumNominal Nominal Nominal Nominal

Tube Wall Tube Wall Tube Wall Tube WallOD Thickness OD Thickness OD Thickness OD Thickness

1/8 0.028 3/4 0.065 3 0.8 18 1.5

3/16 0.028 7/8 0.083 6 0.8 20 1.8

1/4 0.028 1 0.083 8 1.0 22 2.0

10 1.0 25 2.25/16 0.035 1 1/4 0.109

12 1.0 28 2.53/8 0.035 11/2 0.134 14 1.2 30 3.01/2 0.049 2 0.180 15 1.5 32 3.0

5/8 0.065 x x 16 1.5 38 3.5

GAS SERVICE

Gases (air, hydrogen, helium, nitrogen, etc.) have very smallmolecules which can escape through even the most minute leak-path.Some surface defects on the tubing can provide such a leak-path. Astube OD increases, so does the likelihood of a scratch or other surfacedefects interfering with proper sealing.

The most successful connection for gas service will occur if allinstallation instructions are carefully followed and the heavier wallthicknesses of tubing on Tables 1 through 5 are selected.

A heavy wall tube resists ferrule action more than a thin wall tube,and, therefore, allows the ferrules to coin out minor surfaceimperfections. A thin wall tube will collapse, thus offering littleresistance to ferrule action during pull-up. This reduces the chance ofcoining out surface defects, such as scratches.

For the greatest safety factor against surface defects in any gassystem, use a wall thickness no less than the following:

ITUBING FOR GAS SERVICE

Fractional Sizes, in inches

9-2

ALLOWABLE PRESSURE TABLES

ALUMINUM TUBING

Based on ultimate tensile strength 42 000 psi (2894 bar). For metaltemperatures -20° to 100°F (-29° to 37°C). Allowable working pressureloads calculated from S values of 14 000 psi (965 bar) as specified byANSI B31.3. code.

Tube Tube Wall Thickness (in.)00

(in.) 0.035 0.049 0.065 0.083 0.095

1/8 8600

3/16 5600 8000 Working Pressure (psig) Note:For gas service, use tubing where

1/4 4000 5900 working pressure is listed outsideof the shaded area (see "Tubing

5/16 3100 4600 for Gas Service" on p. 9-2).

3/8 2600 3700

SwagelokTube Filling

Series

200

300

400

500

600

3100

2300 2700

810

1010

1210

1410

1610

Table 1Note: 1. No allowance is made for corrosion or erosion.

2. Calculations based on minimum wall and maximum 00allowable under ASTM B210 specification.

Suggested Ordering Information:

High quality aluminum-alloy drawn seamless tubing ASTM B210 orequivalent. (Values shown are for alloy 6061-T6.)

9-3

COPPER TUBING

Based on ultimate tensile strength 30 000 psi (2067 bar). For metaltemperatures -20° to 100°F (-29° to 37°G). Allowable working pressureloads calculated from S values of 6000 psi (413 bar) as specified byANSI B31.3 code.

900 1100 1300 1500 1610

400

200

300

500

600

810

1410

1010

1210

2100

1100 1300 1500

1300 1500 1800

1600 1900

Swagelok1-----------------------1 Tube Fitting

Series

Tube Tube Wall Thickness (in.)00

(in.) 0.028 0.035 0.049 0.065 0.083 0.095 0.109 0.120

1/8 2700 3600Working Pressure (psig)

3/16 1800 2300 3400 Note: For gas service, usetUbing where working

1/4 1300 1600 2500 3500 pressure is listed outside ofthe shaded area (see''Tubing for Gas Service" onp.9-2).

Table 2Note: 1. No allowance is made for corrosion or erosion.

2. Calculations based on minimum wall and maximum ODallowable under ASTM B75 specification.

Suggested ordering information:

High quality soft annealed seamless copper tubing ASTM B75 orequivalent. Also soft annealed (Temper 0) copper water tube type K ortype L to ASTM B88.

9-4

CARBON STEEL TUBING

Soft annealed carbon steel hydraulic tubing ASTM A179 or equivalent. Based on ultimate tensile strength 47 000 psi(3238 bar). For metal temperatures -20° to 100°F (-29° to 37°C). Allowable working pressure loads calculated fromS values of 15700 psi (1082 bar) as specified by ANSI B31.3 code.

Tube 00 Tube Wall Tbickness (in.)

(in.) 0.028 0.035 0.049 0.065 0.083 0.095 0.109 0.120 0.134 0.148 0.165 0.180 0.220Swage10k TubeFitting Series

2000

1210

1610

1410

2400

3200

5100

3700

4100

50004600

3700

4000

3300

3600

2900

3/16 5100 6600 9600 3001/4 3700 4800 7000 9600 Working Pressure (psig) Note: 400

3700 5500 7500 For gas service, use tubing where 500_~AA .___ working pressure is listed outside

6200 of the shaded area (see "Tubing 6004500 5900 for Gas Service" on p. 9-2). 810

---- .--- ---- 1010

1/8 I 8000 10200 I 200

Table 3Note: 1. No allowance is made for corrosion or erosion.

2. Calculations based on minimum wall and maximum OD allowable under ASTM A179 specification.

Suggested ordering information:

High quality soft annealed seamless carbon steel hydraulic tubing ASTM A179 or equivalent. Hardness 72 HRBco or less. Tubing is to be free of scratches and suitable for bending and flaring.Q,

2000

2400

3200

1610

1410

1210

4900

3600

-100

.;",.===-==-----For Seamless Tubing* 200

______________Working Pressure (psig) Note: 300

5100 7500 10200 gas service, use tubing where 400 I.--- ---- ---- working pressure is listed outside 500

of the shaded area (see "Tubing 600==----------'u, Gas Service" on p. 9-2). 810

1010

Tube 00 Tube Wall Thickness (in.) Swagelok Tube

(in.) 0.010 0.012 0.014 0.016 0.020 0.028 0.035 0.049 0.065 0.083 0.095 0.109 0.120 0.134 0.156 0.188 Filling Series

STAINLESS STEEL TUBING

Annealed 304 or 316 stainless steel tubing ASTM A269 or equivalent. Based on ultimate tensile strength 75 000 psi(5167 bar). For metal temperature from -20° to 100°F (-29° to 3rC). Allowable working pressure loads calculated fromS values of 20 000 psi (1378 bar) as specified by ANSI B31.3 code.

<0en

Table 4Note: 1. No allowance is made for corrosion or erosion.

2. Calculations based on minimum wall and maximum 00 allowable under ASTM A269 specification.3. For welded and drawn tubing, a derating factor must be applied for weld integrity:

a. for double welded tubing multiply pressure rating by 0.85.b. for single welded tubing multiply pressure rating by 0.80.

Suggested ordering information:

Fully annealed high quality (Type 304, 316, etc.) (seamless or welded and drawn) stainless steel hydraulic tubingASTM A269 or A213, or equivalent. Hardness 80 HRB or less. Tubing is to be free of scratches and suitable forbending and flaring.

co~

ALLOY 400 TUBING

Annealed alloy 400 seamless tubing ASTM B165 or equivalent. Based on ultimate tensile strength 70 000 psi (4832bar). For metal temperatures from -20° to 100°F (-29° to 37°G). Allowable working pressure loads calculated fromS values of 18 700 psi (1288 bar) as specified in ANSI B31.3 code.

Tube Wall Thickness (in.) SwagelokTube Fitting

0.035 0.049 0.065 0.083 0.095 0.109 0.120 Series

10100 200Working Pressure (psig) Note:

4800 7000 9500 For gas service, use tubing where 400working pressure is listed outside

4400 6100 of the shaded area (see "Tubing 600for Gas Service" on p. 9-2).

4400 810

4000 4600 1210

2900 3400 3900 4300 1610

Table 5Note: 1. No allowance is made for corrosion or erosion.

2. Calculations based on minimum wall and maximum OD allowable under ASTM B165 specification when tubingis ordered specifying the nominal wall thickness.

Suggested ordering information:

Fully annealed quality seamless alloy 400 hydraulic tubing ASTM B165 or equivalent, hardness 75 HRB maximum.Tubing is to be free of scratches and suitable for bending and flaring.

FACTORS USED TO DETERMINE TUBING PRESSURE RATINGSAT ELEVATED TEMPERATURES

Factors

of °C Aluminum Copper 8teel 30488 31688 316L Alloy 400

200 93 1.00 0.80 0.95 1.00 1.00 1.00 0.88

400 204 0.40 0.50 0.86* 0.93 0.96 0.92 0.79

600 316 - - - 0.82 0.85 0.80 0.79

800 427 - - - 0.76 0.79 0.74 0.76

1000 538 - - - 0.69 0.76 0.67 -

1200 649 - - - 0.30 0.37 0.38 -

*Based on 375°F max

Table 6To determine allowable pressure at elevated temperatures, multiply

allowable working pressure from Tables 1, 2, 3, 4, and 5 by the factorshown in Table 6.

Example:Type 316 Stainless Steel 1/2 in. 00 x 0.049 in. wall at 1000°F

(538°C) 3700 psig x 0.76 = 2812 psig (255 bar x 0.76 = 193 bar).

Allowable working pressure for 1/2 in. 00 x 0.049 in. wall type 316stainless steel tubing is therefore 2812 psig (193 bar) at 1000°F(538°C).

9-8

CHART OF FACTORS

Tube 00 Tube Wall Thickness (in.) Swagelok Tube(in.) 0.010 0.012 0.014 0.0160.020 0.028 0.0350.049 0.065 0.083 0.095 0.109 0.120 0.134 0.148 0.156 0.180 0.188 Filling Series

1/16 0.280 0.343 0.409 0.474 0.604 100

1/8 0.426 0.545 200

3/16 0.274 0.352 0.513 300

1/4 0.201 0.257 0.375 0.513 400

5/16 0.202 0.293 0.403 500

3/8 0.167 0.240 0.329 600

1/2 0.123 0.176 0.239 0.314 810

5/8 0.104 0.148 0.200 0.261 0.304 1010

3/4 0.122 0.165 0.241 0.249 0.290 1210

7/8 0.104 0.140 0.182 0.210 0.244 1410

1 0.0909 0.122 0.158 0.182 0.211 0.235 1610

11/4 0.0968 0.124 0.144 0.166 0.184 0.208 0.231 0.245 0.287 2000

11/2 0.103 0.118 0.137 0.151 0.170 0.189 0.200 0.234 0.246 2400

2 0.0880 0.101 0.112 0.126 0.139 0.147 0.172 0.180 3200

For use in calculating Allowable Working Pressures of Tubing. Allowable working pressure = Factor x AllowableStress Value in psi. Based on ANSI B31.3-1993

Table 7Note: All pressure ratings are based on minimum wall thicknesses of ASTM A269. Various tubing specifications withinthe code have varying wall thickness tolerances.

All charts and tables are for reference only and are based on information contained in the 1993 edition of the code.No implication is made that these figures can be used for design work. Applicable codes and practices in industryshould be considered. Swagelok Company is not responsible for the accuracy of information presented in these tables.

e:p ANSI Codes are the successor to and replacement of ASA Piping Codes.<0

I

PIPE END PRESSURE RATINGS

Many Swagelok tube fittings have a male or female pipe end. Asdescribed below, these ends often have a lower pressure rating thanthe maximum pressure rating of the tube fitting end.

There is no completely accurate way to rate pipe threads because ofthe way they are designed, manufactured, and used. Threadengagement varies considerably within even the tight tolerancesmaintained on Swagelok products. Different codes allow varying stressvalues.

The ratings shown below are based on the 1993 edition of ANSI831.3. Female pipe ends generally have ratings lower than male pipein a given size because the inner and outer diameters of femalethreads are larger than those of male pipe ends.

To have the same pressure ratings for male and for female pipethreads of the same nominal size, a female threaded fitting would needa heavier wall and would thus be too bulky and heavy to be practical. Inorder to keep material and manufacturing costs down, most of the tubefitting industry has adopted wall thicknesses on female pipe threadswhich result in lower pressure ratings on the female ends than on themale ends.

Pressure Ratings (PSI)

SizeNPT/ISO 316 Stainless

Brass Carbon SteelDesig-

Pipe SteelSize

nator(in.) Male Female Male Female Male Female

1 1/16 11 000 6700 5500 3300 11 000 67002 1/8 10000 6500 5000 3200 10000 65004 1/4 8000 6600 4000 3300 8000 66006 3/8 7800 5300 3900 2600 7800 53008 1/2 7700 4900 3800 2400 7700 4900

12 3/4 7300 4600 3600 2300 7300 460016 1 5300 4400 2600 2200 5300 440020 1 1/4 6000 5000 3000 2500 6000 500024 1 1/2 5000 4600 2500 2300 5000 460032 2 3900 3900 1900 1900 3900 3900

9-10

Calculations based on:

MaterialsAllowable Design Ultimate

Stress Value Factor Tensile Strength

316 SS 20000 psi 3.75:1 75000 psi

Brass 10000 psi 4:1 40000 psi

Steel 20000 psi 3:1 60000 psi

Conversion of pressure ratings:

To convert pressure ratings from psi or bar to other pressure ratingsystems use the following conversions:

1 bar=14.51 psi=100kPa

1 psi = 0.0689 bar = 6.89 kPa

1 kPa = 0.01 bar = 0.1451 psi

1 kg/cm2 = 0.980 bar = 14.22 psi

For additional conversion data see Appendix.

NOTE: SEALING PIPE ENDS OF FITTINGS-A good qualitysealant is always required when sealing NPT or ISO tapered pipethreads. A good sealant will also act as a lubricant, reducing the gallingtendency of many materials when subjected to the high loads of theinterference fit between a male and female pipe thread. Swagelok TFEtape is an excellent thread sealant for temperatures up to 450°F(232°C.) SWAK anaerobic pipe thread sealant with TFE is also anexcellent thread sealant for use to 350° F (180° C.) (see Chapter 3).

---------------------- 9-11

I

9-12 ---------------------

10-1

The Hidden Costs of leakage

WHAT IS LEAKAGE?

It is unwanted flow out of or into a fluid system.

HOW IS IT EXPRESSED?

Leakage is expressed as a flow-a volume per unit of time,cm3/minute, gallons/day etc.

The system fluid is the leakage vehicle. Therefore, costs of a givenamount of leakage will vary greatly depending on what is leaking.

In vacuum systems, leakage is into the system, rather than out of thesystem. Leakage into a vacuum system is usually expressed in cm3/secHelium at a 1 atmosphere pressure (atmospheric pressure outside thesystem, no pressure in the system). Thus a leak rate might beexpressed as less than 4 x 10-9 atmosphere cm3/sec He. This meansthat no leakage was detectable when the Helium Leak Detector wasset to a sensitivity able to detect a leak of 4/1 000 000 000 of a cubiccentimeter per second of helium at a one atmosphere pressuredifferential.

WHAT CAUSES LEAKAGE?

The making of metal-to-metal highly reliable seals is a difficult task.Perhaps the clearest study of what causes leakage was developed bythe Engineering Standards Committee on Control Valves of the FluidControls Institute. This was published in the August 1966 edition ofInstruments and Control Systems Magazine.* They found that "zeroleakage" was an inaccurate and misleading term, and they set out tomore accurately study leakage and how it occurs.

Using the data developed for control valve seating and applying it to Ithe two seals of the Swagelok tube fitting (front ferrule to tube and front Iferrule to body), we find that leakage depends on the following fivefactors (Fig. 1):

1. "LiP" or differential pressure. A 1000 psi (68 bar) system will normallyshow about 10 times the leakage of a 100 psi (6.8 bar) system.

2. "H" or height of gap between two surfaces. In the formula shown, "H"is cubed. Therefore if leakage is directly proportional to the cube ofthe gap height, then an improvement in the surface finish of 50 % willresult in an 800 % improvement in seal integrity.

*"Should a Control Valve Leak," Hans Baumann, Instrumentsand Control Systems, August, 1966.

3. "W" or width of leakage area. The diameter of the seal will affectleakage-smaller sizes are easier to seal than larger sizes. A 1 in.OD tube is four times more likely to leak than a 1/4 in. OD tube.

4. "fL" or absolute viscosity. Fluid viscosity affects leakage rate. Themore viscous the fluid, the less leakage will occur.

5. "L" or length of seal. The longer the intimate contact between sealingmembers, the less leakage will occur.

LEAKAGE FORMULA

Q= 6.P H3 W96 fL L

Where: Expressed in:

Q= Flow (leak) rate ft3/sec

Stem6.P = Pressure Drop psi

I H= Height of gap betweensealing surfaces in.

W= Width of leakage area(for this example, 'IT D-circumference of theseal) in.

fL = Absolute viscosity #sec/ft2

L = Length of leakage path in.

Fig. 1

Swagelok tube fittings take advantage of good design principles andsuperb manufacturing quality control to make a product that has a longsmooth seal and that will perform properly in a very wide range ofcustomer applications. The Gap (H) and Length (L) are the only factorsin the formula we can control. Gap can be a problem if tubing surfacefinish is poor. Since we cannot control operating pressure, sealdiameter, or fluid viscosity, we must work within the parameters of gapand length of seal to make good, reliable, repeatable seals.

Swagelok tube fittings are often chosen for applications where thecosts or consequences of leakage are expensive, inconvenient, ordangerous.

10-2 -----------------------

Very often, however, we hear comments such as "A little leakagedoesn't bother us." "Air is cheap." "Oil is cheap; a few drops aren'tworth saving."

Leakage costs industry hundreds of millions of dollars each year.These losses are in many forms:

1. Lost Fluid-It is estimated that 100 million gallons of hydraulic oil arelost each year from oil circulating and hydraulic systems just throughleakage!

2. Equipment Damage-Loss of lubrication due to leakage accounts forfurther millions in damage.

3. Lost Production-Loss of lubrication or hydraulic line leakage shutsdown machines and stops production.

4. Energy Conservation-Power is used to pressurize hydraulicsystems and to compress air.

5. Unsafe Work Places-Oil drippage causes accidents. Leaking gasescause fires, explosions, sickness, and death.

6. Degraded Environment-Fugitive emissions (leakage) can beexpensive, illegal, and dangerous, and they can lead to a lowering ofthe quality of life for workers and the surrounding population.

7. Product Contamination-Food, beverage, pharmaceutical, or otherplants making products for human consumption cannot havehydraulic or other leakage which could contaminate their products.

ACTUAL COSTS

HydraUlic Oil

Many large companies monitor oil leakage using a system which canaccurately assess direct leakage costs. The Hydraulic Fluid Index(H.F.I.) system compares hydraulic fluid use per year with the hydraulicfluid capacity of all hydraulic systems. For example, a plant with 5000gallons of hydraulic fluid in all its systems would have an H.F.1. of 5 if it Iused 25 000 gallons per year. Such figures are not out of the realm of Ipossibility; H.F.I.'s of 11 have been reported in some plants wheresubstantial leakage is tolerated.

An example of the costs of hydraulic leakage is the table listed onthe next page, quoted from Design News magazine, May 25,1981. Wehave extended this table by arbitrarily assigning a rather low $2.00 agallon figure as a value per gallon. With this extension you can see thatthe direct cost of oil leakage alone is over $800.00 per year for oneleak of one drop per second!! By multiplying this figure by the numberof leaks in a plant, using your own current cost per gallon for hydraulicoil, you can quickly assess whether leakage is worth being concernedabout.

----------------------10-3

LOSS FROM A SINGLE OIL LEAK

Loss Loss Loss Direct Oil TotalPer Day Per Month Per Year Cost Per Year Cost Per YearGallons Gallons Gallons Per Leak Per Leak

One Drop/10 Sec 0.112 3.4 40.8 $81.00 $648.00

One Drop/5 Sec 0.225 6.7 81.6 $163.00 $1304.00

One Drop/Sec 1.125 33.7 404.4 $809.00 $6472.00

Three Drops/Sec 3.38 101.4 1219 $2434.00 $19472.00

Stream breaks24.00 720.0 8640 $17280.00 $138240.00

into drops

Note: Drops approx. 11/64 in. diameter Hydraulic oil @ $2.00 a gallon.

In the same article Glenn R. Jordan, Engineering Manager of MobilOil Commercial Marketing Department, points out that their studiesshow that for every $1.00 of oil purchased, $7.00 is spent on labor,downtime, clean-up, product contamination, safety, and fire hazards.Thus the actual, but hidden, costs of oil leakage of one drop persecond at one machine can be over $6000 per year! Multiply this timesthe number of leakage-prone components, and you have a major cost!

LEAKS COST MONEY-BIG MONEY!

Air and Gas Leakage

Compressed air costs money! The raw material is free, but theequipment, the energy used to compress it, and the piping system totransport it make up the cost of using (or wasting) air.

The table below shows the approximate volumes of air leaking froma small orifice at given pressures. Various cost studies on compressedair normally use this "equivalent leak size" to show how costs mount upwhen a number of small air leaks total the leak from a given orifice size(1/32,1/16, and 1/8 in.).

Monthly AirMonthly Cost

Leak Size Leakage at Compressed Air Instrument Airin. 100 psig at $0.20/MCF at $0.40/MCF

1/32 70000 SCF $14.00 $28.00

1/16 280000 SCF $56.00 $112.00

1/8 1 100000 SCF $220.00 $440.00

10-4

It doesn't take long for air leaks in a small system to total up to theequivalent of a 1/32 or 1/16 in. orifice.

We have previously evaluated leak rates. In our opinion, the averageleak rate is approximately 600 cm3/min. This information is taken from aprevious study (1981) we made. We are in the process of revalidatingthe study.

When process gases, analyzer gases, nitrogen, helium, andhydrogen are considered, the cost of leakage alone can make thedifference between profit and loss. Add to this the fire or explosiondanger and the damage to the quality of life. Add to this the cost ofimproperly calibrated or operating instruments which can result in off-spec product. .

LEAKS COST MONEY, BIG MONEY!

Steam Leakage

Steam is used in virtually all process plants. It is a difficult fluid tohold because it is always at elevated temperatures and pressures canexceed 4000 psig (275.6 bar). Steam leaks are particularly difficultbecause the well-known erosive properties of steam usually makeleaks grow larger with time.

One larger user of process steam has developed a "Rule of Thumb"Steam Leak Chart. They have an active energy team which constantlyseeks out waste. They characterize steam leaks as:

• A wisp

• Moderate• Severe

At an estimated steam cost of $4.00 per million BTUs, calculatedcosts are:

• A wisp-$11 00 a year

• Moderate-$8000 a year

• Severe-$26 000 a year

Remember, this is from one leak. In one survey, their audit teamdiscovered steam leaks costing $350 000 a year.

LEAKS COST MONEY-BIG MONEY!

Use Swagelok tube fittings to reduce your leakage costs. YourSwagelok representative can show you how to conduct an EnergyEmission Survey to see if you have more leakage than you thought.

10-5

I

10-6 ---------------------

ValvesVALVE FUNCTIONS

This Tube Fitter's Manual would not be complete without adiscussion of valves. Valves are one of the oldest and most basicmechanical components in fluid handling systems. Although there aremany variations in the types and designs of valves, most perform oneof four basic functions:

Isolation. The valve is either open or closed; its function is to turn theflow on or off by connecting it or isolating it from the rest of the system.

Regulation. The valve regulates the rate of flow through the system.It usually is neither fully open nor fully closed.

Direction. The valve selects the direction of fluid flow through two ormore branches of a system or allows flow to pass in only one direction.

Protection. The valve protects the system from excessive pressure.

Isolation

Needle valves are used for isolation. Screw actuation allows thevalve to be opened gradually-the threaded stem requires three or fourturns of the handle to open and close the valve (see Fig. 1).

Fig. 1Swage10k Integral Bonnet Needle Valve

11-1

For exceptionally high pressures-generally above 10000 psig (690bar)-a special variation of needle valves has been designed. Althoughsimilar to other needle valves, these valves contain unique designfeatures and materials specially selected for high-pressure operation(see Fig. 2).

Fig. 2Swagelok High-Pressure Valve

Ball and plug valves are used widely for isolation. A quarter turn ofthe handle quickly opens or closes the valve. These compact valvesare quick and easy to operate, and they provide a highly reliable seal.However, they do not allow a system to be turned on slowly and manyshould not be used in a partially open position for throttling (see Fig. 3).

11-2

Swagelok Ball ValveFig. 3

Swage10k Plug Valve

Regulation

Regulating and metering valves are designed to adjust the rate offlow. They usually have a long, finely tapered stem tip and a fine-pitchstem thread, and open in five to ten turns. Valves of this type are notsuggested for isolation service and are generally designed so theycannot be shut off (see Fig. 4).

Swagelok Metering Valve

Fig. 4

Swagelok Regulating Needle Valve

Direction

Selection valves have three or more connections, allowing flow to bedirected towards two or more parts of the system (see Fig. 5).

Fig. 5Swage10k 6-Way Crossover Valve

11-3

Check valves are held closed by a spring, opening automaticallywhen the inlet pressure exceeds the outlet pressure by enough toovercome the spring force. When the flow stops, the check valve closesto prevent flow in the reverse direction (see Fig. 6).

Fig. 6Swagelok Check Valve

Protection

Relief valves protect a fluid system from excessive pressure. Thevalve is held closed by a spring as the system operates at its normalpressure. When the pressure increases to the set point of the valve, itopens automatically and remains open until the system pressuredecreases to the reseal point (see Fig. 7).

Fig. 7Swagelok Relief Valve

END CONNECTIONS

Valves are made with many different end connections to suit thevalve function and for convenience in building the system. The mostcommon connections are:

Swagelok tube fittingsVCR® and VCO® face seal fittingsTapered pipe threadsWeld connectionsFlanges

11-4 -----------------------

Swagelok Tube Fitting

Swage10k tube fitting end connections are used on the ends ofvalves in tubing systems to eliminate adapters and extra connections atthe valve. This will reduce cost and minimize the number of potentialleak points, along with making tubing systems smaller, easier tofabricate, and more reliable (see Fig. 8).

Fig. 8Swage10k needle valve with Swagelok tube fitting end connections

VCR and VCO Face Seal Fitting

VCR and VCO face seal fitting end connections allow valves to beinstalled and removed without axial clearance in the system. They oftenare used in high-vacuum and ultra-high purity gas systems (see Fig. 9).

Fig. 9Swagelok bellows valve with VCR end connections

11-5

I

Tapered Pipe Threads

Tapered pipe threads are the most common end connection whenvalves must be connected directly to other equipment. Valves with amale pipe-thread inlet and a female pipe-thread outlet connection areoften used as the isolation valve between the equipment and thesystem. When used with a pipe-thread inlet and a Swagelok tube fittingoutlet connection, the isolation valve replaces the male connector fittingat the equipment and simplifies the system (see Fig. 10).

Pipe threads always need a sealant, such as Swage10k TFE tape orSWAK anaerobic pipe thread sealant, to fill the gaps between male andfemale threads for a leak-tight joint (see pp. 3-54, 55, and 56).

Fig. 10Swagelok Valves with pipe thread andSwagelok tube fitting end connections

Weld End Connections

Weld end connections are used when permanent, leak-tightconnections are required. Small valves often have butt or socket weldconnections for tubing. Larger valves generally have socket weldconnections for tubing or pipe (see Fig. 11).

Swagelok Ball Valve withpipe socket weld end connections

IFig. 11

Swagelok Bellows Valve withbutt weld end connections

11-6 ----------------------

Flanges

Flanges commonly are used on process valves to connect tostandard pipe flanges (see Fig.12).

Fig. 12Swagelok Process Ball Valve with ANSI Pipe Flange connections

Special flanges frequently are used for connecting manifold valvesdirectly to pressure measurement instruments (see Fig. 13).

Fig. 13Swagelok Three-Valve Manifold with Flange connection for direct

mounting to a differential pressure cell

11-7

Other special flanges are used for sanitary piping systems in thefood and biotech industries (see Fig. 14).

Fig. 14Swagelok Pinch Valve with Sanitary Flange end connections

PRESSURE-TEMPERATURE RATINGS

Valve pressure and temperature ratings specify the maximum andminimum temperatures and pressures at which the valve can beoperated safely. These ratings are based on the properties of materialsused in pressure-containing parts and those of other materials thatcontact the system fluid, on design requirements, and on performancetests. Swagelok Technical Bulletin No.4 describes the design basis forour process and instrument valves, explains how pressure-temperatureratings are determined, and lists national codes and standards relatingto valve ratings. Technical Bulletin No.4 also provides pressure­temperature ratings tables for Swagelok valves.

MATERIALS

The material of the valve body must be selected to suit the needs ofthe application. The three most common materials are stainless steel,brass, and carbon steel. Also used are alloys of nickel, copper,chromium, and others. Valves made of plastic are available for certain

Iapplications (see Fig. 15). The choice of material is determined bycompatibility with the system fluid, which encompasses such factors ascorrosion resistance, pressure, temperature, and cleanliness. Materialsare purchased in accordance with specifications published by theAmerican Society for Testing and Materials (ASTM).

11-8

Fig. 15Swagelok PFA Needle Valve

SIZE

The size of a valve often is described by the nominal size of the endconnections. A more important measure of size is the rate of flow thatthe valve can provide. Flow through valves or other fluid systemcomponents depends primarily on component design, inlet and outletpressures, and fluid density. Flow coefficients (Cv) for each valve arepublished in catalogs. Cv values, determined by testing, andsubsequent calculations are conducted in accordance with methodsand formulas specified by the International Society for Measurementand Control (ISA).

Swagelok Technical Bulletin No.8 provides three simple graphs forestimating the flow of water or air through valves and othercomponents, based on the Cv value given in the catalog. TechnicalBulletin No. 8 also explains how to use the Cv value to calculate theflow and pressure drop for other fluids (see Fig. 16).

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I

§§ § §cicici ci

Flow rate, mo/h~ M"<t <D 00000"" ~ M"<t <D 0ci cici ci d ci cici ci ...;

200

100

60

403020

tii10 .0

ci:6 e4 "0

3 ~

2::lVlVl

1.0~"-

0.60.40.30.2

0.1

Flow rate, gal/min

I1/

/- I ;;1 ,., 1/ 1/ 1/ II

== 7 !:~rt-v':' It -C)" '& ~

~C)- v':' 1/ C)" C)v':' v~ ~"

C)" 9 ~,,' r) II C)) ~C) 1/ 1/0':' v~ ~"6! <:?

'"0':' j~ ;;" ,,' ~~~~v':' ~ ;;

~~~~# ~(j vt-

"'''~JW/ /

r7 r7 1/ / 11/ '1111/1

80

" ~ §~ ~ ~0000

30002000

1000

600400300

"~ 200

g: 100

-0 60e 40~ 30Vlet 20

10

Fig. 16Water Flow Graph

STEM SEALS

Stem seals, which prevent leakage of system fluids to atmosphere,are available in several designs to suit different valves andapplications. The system designers and users may select from thesechoices to prevent leaks, minimize system fluid loss, and reducemaintenance, repair, and downtime expenses. Selecting the optimumseal can increase system efficiency and lower total costs of ownership.

Conventional Packing

A TFE packing cylinder fits closely around the valve stem (see Fig.17). Tightening the packing nut forces the soft plastic material outwardagainst the body and inward against the stem, forming a seal.

We prevent leakage and minimize need for frequent packingadjustments by:

• fine surface finishes on the stem shank to reduce wear of the packingas the stem slides during operation.

• maintaining close tolerances-especially concentricity-of thepacking, stem, and bonnet.

• fully supporting the packing with metal or reinforced plastic glands toprevent extrusion under pressure.

11-10 ---------------------

Fig. 17Swage10k Needle Valve with TFE packing

Live-Loaded Packing

Live loading maintains a constant pressure on the packing to ensurethat it remains leak-tight. This is especially valuable in applications withfrequent temperature or pressure changes, or high operatingtemperatures. It eliminates the need for frequent packing adjustmentand extends packing service life. The two most common methods oflive loading are an elastomeric a-ring seal or a spring-loaded plasticpacking.

The simplest live-loaded seal is an elastomeric a-ring. Elastomersare synthetic or natural rubber-like materials which return to theiroriginal shape after being deformed. The resilience of the elastomerprovides the live load which maintains enough pressure on the seal tocompensate for temperature or pressure changes and for wear.

Spring-loaded stem seals employ a plastic packing, but becauseplastics are not as resilient as elastomers, live loading is provided by aseries of disc springs above a metal gland. The packing nutcompresses the springs to maintain a constant load on the packing,compensating for packing wear and for changes in pressure ortemperature. For additional seal integrity, the packing is a two-piecesplit chevron design supported by an antiextrusion ring and a metalgland. The two packing rings move uniformly against the stem andbonnet, and form a larger seal area that also increases packing life(see Fig. 18).

Of course, the same smooth surface finishes, close tolerances, andconcentricity that characterize conventional packing systems areequally important in effective live-loaded packing systems.

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Swage10k Ball Valve with live-loaded packing

Fig. 18Swage10k Needle Valve with spring-loaded stem seal

Packless Valves

Packless valves employ a bellows or diaphragm as an all-metal staticseal that the stem does not penetrate. This design ensures no leakage toatmosphere.

11-12 -----------------------

In bellows valves, a flexible metal bellows is welded to a stem at oneend and to a ring at the other end. The ring is welded or gasketed tothe valve body. The seal to atmosphere is maintained by the flexiblebellows as the valve is cycled (see Fig. 19).

In diaphragm valves, a formed metal disc is placed between thebody and the bonnet and sealed to the valve body at its outercircumference. As the stem is actuated, the diaphragm flexes to openor close the valve.

Fig. 19Swagelok Bellows Valves

Packless Valves with Secondary Stem Packing

These valves have a primary and secondary stem seal. The primarystatic seal is a bellows; a secondary packing is provided outside thebellows (see Fig. 20). The secondary seal can be either a conventionalor live-loaded packing. A sniffer tube connection normally is provided tomonitor the space between the two seals and to detect a leak in theprimary seal.

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Fig. 20Swagelok Bellows Valve

ACTUATION

Valves are actuated manually or mechanically. Manual actuation, byfar the most common, is accomplished by rotary action with a screwthread stem, quarter-turn rotary, or toggle lever. They are illustrated inFigs. 1, 3, and 10, respectively.

Valves that are operated frequently, located inconveniently, usedwith a hazardous system fluid, or integrated into an automated systemusually require mechanical actuation. Mechanical actuators are

Ioperated by either pneumatic or electric power.

Most common are pneumatic actuators, which are available in threetypes-normally closed, normally open, and double acting. In the firsttwo, a spring holds the valve either closed or open, and pneumaticpressure moves the valve to the opposite position. Double-actingactuators have no springs and require pneumatic pressure to bothopen and close the valve. Pneumatic actuators may also include direct­mounted solenoid valves for control by an electrical signal from acontrol system (see Fig. 21).

11-14 --------...,..--------------

Fig. 21Swagelok Ball Valve with Pneumatic Actuator and Direct-Mounted

Solenoid Valve

Electric actuators are especially suitable for automated systemsrequiring direct electrical control, position indication, limit switches,slower cycle times and steady actuation. They also are used for remoteactuation where compressed air is not readily available (see Fig. 22).

Fig. 22Swage10k Ball Valve with Electric Actuator

INSTALLATION

Proper installation is an essential part of valve selection and use.

---------------------- 11-15

Mounting

Valves should be mounted so that the weight of the valve is notsupported by the tubing or piping system, but by the valve mountingitself. The valve support should be adequate to handle external loads,such as piping system expansion or seismic loads. The valve mountingalso should absorb the torque used to actuate the valve, so that nostress is transferred to the valve end connections, piping, or tubing.Valves are designed with panel mounting, bottom mounting, or specialbrackets to provide adequate support. Most actuator brackets (see Fig.21) include provisions to mount and support the valve-actuatorassembly (see Fig. 23).

Swagelok Ball Valve panelmounted with a directional label

Swagelok Ball Valve withMounting Bracket

Swagelok Bellows Valve withBottom Mounting Screw Holes

Swage10k Mounting Bracket forManifold Valves and Differential

Pressure Cells

Fig. 23

11-16 ----------------------

Position

Valves should be installed so they can be readily seen, easilyreached for actuation, and protected from accidental damage oroperation. The valve should not be positioned so it becomes aconvenient step ladder or hanger. Ball valves with lever handles shouldnot be located so that the handle can be turned accidentally, or an ovalhandle should be used.

Lockout Protection

Current safety regulations require that valves be locked out duringsystem maintenance. Some valve handles are available with a latchand locking mechanism. A convenient lockout box is available to fitover many standard valve handles (see Fig. 24).

Fig. 24Swagelok Lokout Accessoryfits over standard handles

Swagelok Ball Valvewith Latch-Lock Handle

----------------------11-17

I

SAMPLE CYLINDERSSwagelok Sample Cylinders are manufactured in accordance with

U.S. Department of Transportation specifications and can be used tosample and transport gases and liquids. A variety of valves are suitablefor use with sample cylinders, including valves with a built-in rupturediscs for overpressure protection (see Fig. 25).

Fig. 25Swage10k Sample Cylinder with a Needle Valve and Rupture Disc for

Overpressure Protection

SAFE VALVE SELECTION

When selecting a component, the total system design must beconsidered to ensure safe, trouble-free performance. Componentfunction, material compatibility, adequate ratings, proper installation,operation, and maintenance are the responsibility of the systemdesigner and user.

11-18 ----------------------

-------------------- 11-19

Flow/Pressure Charts and Conversions

• Flow & Pressure Charts

• Heads and Equivalent Pressure Conversions

• Pressure Conversions

• Flow Rate Conversions

DETERMINING INSIDE DIAMETER OF TUBING

The 10 of tubing is set by flow requirements, permissible pressuredrop, and maximum allowable velocity. To aid in selecting the proper 10of tubing for liquid flow, Charts 1 through 10 are provided on thefollowing pages. Charts 11 through 20 are provided for sizing tubing forgas flow.

These charts give pressure drop for 100 feet of tubing for both waterand air flow. By using the formula provided, it is also possible to obtainthe pressure drop of fluids other than water and gas.

To allow for pressure drops in bends and fittings, the equivalentlengths in Table A can be used when obtaining equivalent length oftubing for pressure drop calculations. To obtain equivalent length oftubing, total all straight lengths and then add lengths for each bend,elbow, or tee from Table A.

EQUIVALENT FEET OF STRAIGHT TUBE

Tubing 90° 90° 180° 45° TeeOD Elbow Bend Bend Bend Branch(in.) (tt) (tt) (tt) (tt) (tt)

1/4 1 1/2 1 1/2 1

3/8 11/2 1/2 1 1/2 11/2

1/2 2 1/2 1 1/2 2

5/8 21/2 1 2 1/2 21/2

3/4 3 1 2 1/2 3

1 41/2 1 2 1/2 41/2

11/4 5 2 4 1 5

11/2 6 2 4 1 6

2 9 2 4 1 9

Table A

A-1

CALCULATIONS FOR LIQUID FLOW

EXAMPLE 1. Water is to flow through 50 feet of tubing at 4 gallons perminute (GPM). Water velocity is not to exceed 5 feet per second. Themaximum allowable pressure drop is 5 psig. What diameter of tubingcan be used?

Step 1. Pressure drop for 100 feet would be two times theallowable pressure drop for 50 feet, i.e. 10 psi.

Step 2. By looking at Charts 1 through 9, it can be determinedthat only 3/4 in. or 1 in. 00 tubing can be used becausethe pressure drop would be over 10 psi for a 4 GPM flowin smaller tubing. From Chart 5, for 4 GPM flow rate, thepressure drop per 100 feet of any of the 3/4 in. 00 tubeswould be satisfactory.

Step 3. The smallest 10 on Chart 5 is 0.560 in. An 10 of 0.560 in.on Chart 10 shows velocity of 5 feet per second for 4GPM. Therefore, any of the 3/4 in. tubing can be used,and wall thickness selection would be determined bypressure requirements.

EXAMPLE 2. Suppose the maximum pressure drop of Example 1 was1 psig. Find the proper size tubing.

Step 1. For 100 feet, maximum pressure drop would be 2 psi.

Step 2. The 3/4 in. tubing is now too small as determined byChart 5. Looking at Chart 6, it can be seen that 1 in. 00tubing of wall thickness less than 0.100 in. can be usedbecause it will have less than a 2 psi pressure drop.

For liquids with specific gravity near water, the equivalent water flowrate can be calculated and then used to find pressure drop. Anexample follows:

Equivalent Flow Rate of water = Flow Rate of other liquid

times --J S.G. Liquid

Ow = O2

.y'-s-p-ec-:if~iC-gr-a-v-itY-Of-o-t-he-r-l-iq-U-id-

EXAMPLE 3. Acetone at 1/10 GPM is to flow through 100 feet of tubing

Iwith a pressure drop not to exceed 5 psi.

Step 1. Ow = O2 --J S.G.L.,..-----------=(1/10) .yO.792 (Specific Gravity Acetone =0.792)

=0.089 GPM water

A-2

Step 2. Chart 2 shows that 1/4 in. 00 tubing of wall thickness0.049 or less will be of sufficient 10 to produce less than a5 psi drop with a water flow of 0.089 GPM.

CALCULATIONS FOR GAS SYSTEMS (CHARTS 11 THROUGH 20)

Pressure drop is directly proportional to length, inversely proportionalto absolute pressure, and directly proportional to absolute temperature.Using this information, the pressure drop formula for use with Charts 11through 20 is:

~PL = ~~ 1~0 (1~.~4:p) e~~; t)

where ~PL - refers to pressure drop (in psi) of air per L feet oftubing at conditions of pressure (P in psig) andtemperature (t in OF).

~P - refers to pressure drop at 100 psig, 70°F for 100 feet100 of tubing.

In order to use Charts 11 through 20, it is necessary to obtainequivalent conditions at 100 psig. This is most easily explained byexample problems given below.

EXAMPLE 1. What is the pressure drop for 6 CFM of 100 psig air at70°F for 100 feet of 3/4 in. 0.095 wall tubing?

SOLUTION: From Chart 15 read 7.5 psi pressure drop.

EXAMPLE 2. Same problem as 1 but for 200 feet of tubing.

SOLUTION: Pressure drop is directly proportional to length. Therefore,if 7.5 psi is the pressure drop for 100 feet, 2 x 7.5 = 15 psi is drop for200 feet.

EXAMPLE 3. Same problem as 1 but for 50 feet of tubing.

SOLUTION: Pressure drop is directly proportional to length. Therefore,if 7.5 psi is the pressure drop for 100 feet, 1/2 x 7.5 = 3.75 psi is thedrop for 50 feet of tubing.

EXAMPLE 4. 10 CFM free air is to pass through 75 feet of tubing at 80psig inlet pressure and 75°F. The diameter of the proper tubing is to befound knowing the maximum allowable pressure drop is 6 psi.

SOLUTION:

Step 1.I

Find the pressure drop for 100 feet of tubing at 70°F and100 psig so that the charts may be used.

A-3

~P = 6 = ~P

100(.Ii.) ( 114.7 ) (460+75)\100 \14.7+80 \ 530

~P = 6.55 psi drop per 100 feet at 100 psig at 70°F.100

Step 2. Change flow rate at 80 psig and 75°F to the flow rate at100 psig and 70°F.

Qair at 100 psig, 70°F = Qair at 80,75 {14.7 + 80 ) ( 530 )\ 114.7 \ 460+75

=8.18CFM

Step 3. On Chart 16, note that all 1 in. tubing will give a pressuredrop of less than 6.55 psi at 8.18 CFM flow at 100 psig.

EXAMPLE 5. Helium is to pass through 100 feet of tubing at 25 psiginlet pressure and 70°F. The flow rate of free helium is 8 CFM. What isthe pressure drop in 3/8 in. 0.035 in. wall tubing?

SOLUTION:

Step 1. Find the equivalent air flow so that air flow charts may beused.

flow rate of air = flow rate of helium ~specific gravity of helium

Q a = QHe ~ (S.G.) He

Qa = 8 ~0.138 = 3 CFM free air

Step 2. Change flow rate at 25 psig to the flow rate of air at 100psig.

Qair at 100 = Qair at 25 (14.7 + 25) =1.0 CFM\ 114.7

Step 3. See Chart 13 and find that the pressure drop of 100 psigair at 1.0 CFM is 6 psi for 100 feet of tUbing.

Step 4. Solve for pressure drop in the problem by using thepressure drop formula.

~P= 1~0 (1~0)(11.~4:p)(4~~;t)

6 (~~~) ~;.;;725) (;~~)= 6 (2.9) = 17.3 psi pressure drop.

A-4

EXAMPLE 6. 8 CFM of 15 psig, 70°F air is to pass through 10 feet of1/2 in. 00, 0.049 wall tubing. What is the pressure drop?

SOLUTION:

Step 1. Change flow rate at 15 psig to flow rate at 100 psig.

Qair @ 100 = Qair @ 15 (14.7+15) = 8 (29.7) = 2.07100+14.7 114.7

Step 2. From Chart 14, pressure drop at 100 psig is found to be 6psi for 100 feet of tubing.

Step 3. Change this pressure drop to the condition of theproblem.

~P= ~~ (1~O)( 11.~4:p)(4~~;t)

= 6 (11g0) (1;.~~715 ) ( ;;~)= 6 x 1/10 x 3.86 = 2.3 psi drop.

OR:

Step 1. Change flow rate to that of free air.

Qair @ 14.7 psia = Qair @ 15 psig (14.7 + 15)14.7

= 8 x 2.02 =

= 16.16 CFM

Step 2. From Chart 14, pressure drop at 14.7 psia for 100 feet of1/2 in. 0.049 wall tubing and 16.16 CFM free air flow is 6psi.

Step 3. Same as Step 3 above.

A-5

I

Chart 1: 1/8 in. 00 Tubing

0.2

0.1

0.3

20.0

I

I,

~A

,

I

I s ......: 1--""1I

'/ I ~ I I

""" I

,

II I

I I I

I I , I I I, I I

I WATER FLOW CURVES I I

Pressure Drop per 100 feet ofl/S inch OD tubing

WALL INSIDE ,CURVE THICKNESS DIAMETER

A 0.035 in. 0.055 in.S 0.028 in. 0.069 in.

,,

i-- f--t-I I II

, ' I I

I I

10.0

8.0

100.0

80.0

60.050.0

40.0

30.0

C}zi1i:;)I­lJ..otuUJ 6.0lJ..o 5.0

~ 4.0UJ0.. 3.0

Ci5e:. 200..oa:oUJa: 1.055 0.8(f)

~ 0.60.. 0.5

0.4

0.004 0.008 0.012 0.016 0.02

WATER FLOW (GPM @ 70°F)

A-6

Chart 2: 1/4 in. 00 Tubing

, I I I

A ~l

I-l-+-+-+-+--+-+-+-I-l-+-III-l-+-+-i'-+-+-+--l--+-+-+-HTURBULENT FLOW Re > 4000 ;;;<~100

60 1-­

50

40

:

I I iI i

i

WATER FLOW CURVESPressure Drop per 100 feet of1/4 inch OD tubing

D

C

B

v

I

CRITICAL ZaNE i- -f,r' -t--+-+-"J'k"c-J, C :;:c:

LAMINAR

FLOW Re < 2000

, 1/\

I

r-H-+-+--+-+-+--1-+.. -I-

I I i lX'"\ ! ... '...

HI-l-+--"'t--+-+-\l--+...-+,c.+-i- -+--+-+-I-l,-+-+-+-i.•,.;-J......~'-+-+-"Ii""'--iA

2

65

4

0.2

==...:...

=--WALL INSIDE =--

CURVE THICKNESS DIAMETER =A 0.065 in. 0.120 in. __B 0.049 in. 0.152 in. =C 0.035 in. 0.180 in. _

f D 0.028 in. 0.194 in.

0.1 f-I--I-+-+-+--t--t-+-t-I-l-+---t-'j I I I IT

0.60.5

0.4

0.3

U5@:. 30...oa:ollJa::::J(j)

[3 1 f

a:llJ0...

Cl 30zi!i 20:::Jf-LLof-

~ 8~

0.05 0.1 0.15 0.2 0.25

WATER FLOW (GPM @ 70°F)

A-7

,

,1./

'" 1/ I ./ ,..-IL /' I '" l.-"

;f V I.--

A;;

B

C

CRITICAL ZONE TURBULENT FLOW Re > 4000 F1=

/.'

A\ I1\ B ,/

,WATER FLOW CURVES ==

C Pressure Drop per 100 feet of -=3/8 inch 00 tUbing ;::::

WALL INSIDE =CURVE THICKNESS DIAMETER ~ ==::::A 0.065 in. 0.245 in. =B 0.049 in. 0.277 in. t=

C 0.035 in. 0.305 in. l=l=

~ rt1 LAMINAR FLOW Re < 2000I

" I III I I

I i I

A-8

100.0

80.0

60.0

50.0

40.0

30.0CJZas 20.0::::>f-u..0

tiJ 10.0w

8.0u..0

S2 6.0a: 5.0w0-

4.0ii5e:. 3.00-0a: 2.00wa:::::>(fJ(fJ 1.0wa: 0.80-

0.60.5

0.4

0.3

0.2

0.1o

Chart 3: 3/8 in. OD Tubing

0.2 0.4 0.6 0.8

WATER FLOW (GPM @ 70°F)1.0

40.0

30.0<!J?:; 200co .:::>l-LL0I- 10.0ww 8.0LL0

6.0;2II 5.0w0. 4.0

Ci53.0e:-

o.0 2.0II0WII:::>CfJ 1.0CfJw

0.8II0.

0.6

0.5

0.4

0.3

0.2

0.1

Chart 4: 1/2 in. OD Tubing

TURBULENT FLOW Re > 4000 "../

1/ 1/ ...../ ,r / /'

A

B

CID

N '\ II 1 1=1===i=l A WATER FLOW CURVES ==1=== =i=Pressure Drop per 100 feet of ==1=112 inch 00 tUbing

===f=SE B

WALL INSIDE ':':" ==ECURVE THICKNESS DIAMETER == =1=

~ CRITICAL A 0.083 in. 0.334 in. ~ :-::: 1===1== eft == f=

ZONE B 0.065 in. 0.370 in. ===t=0 C 0.049 in. 0.402 in. =--+._..

0 0.035 in. 0.430 in. - I--1--

-i-I I I I I I I I I III LAMINAR FLOW Re < 2000 I

I I I I I I I I I I I 1

0.5 1.0 1.5

WATER FLOW (GPM @ 70°F)

2.0

A-9

I

II II

~1 I

I

1 A f:;;$/ ,.1/

""I....

VI B V !/1 V I ./ ""

,C

1m1

I 1 II I I

I III I I

II I I 1

I I I I I I I I

WATER FLOW CURVES =--t==t=Pressure Drop per 100 feet of =~3/4 inch OD tubing =~

t=~WALL INSIDE 2=~

CURVE THICKNESS DIAMETER i=:=t====A 0.095 in. 0.560 in. !:=!:=FFB 0.065 in. 0.620 in. l=f=C 0.035 in. 0.680 in. !=E=II

1 -+ III + I

I 1

100.0

80.0

60.0

50.0

40.0

30.0

20.0C)ziii:::>I- 10.0lJ..0 8.0I-W 6.0wlJ..

5.000

4.0~

a:w

3.0a..Ci5e:- 2.0a..0a:0w 1.0a::::> 0.8(f)(f)w 0.6a:

0.5a..

0.4

0.3

0.2

0.1

I o

Chart 5: 3/4 in. 00 Tubing

246

WATER FLOW (GPM @ 70°F)

8 10

A-10 --------------------

",-j- ,

A

B

./ C .-'V ./ ./ l.-

V ./ ........V V /,

DVI

,

I II / J-i, I I I I I

WATER FLOW CURVESPressure Drop per 100 feet of .::;=1 inch OD tubing :E

WALL INSIDE ==-

CURVE THICKNESS DIAMETER ~A 0,120 in, 0,760 in, =:==B 0,095 in, 0,810 in. ~C 0,065 in, 0,870 in, L.

D 0,035 in, 0,970 in. FII

-

"'1-4 I

I

100,0

80,0

60,0

50,0

40,0

30,0(9

~ 20,0CO:::>I-I.l..0I- 10,01IJ1IJ 8,0I.l..0

6,0;2a: 5,01IJ0.. 4,0

U:i 3,0e::-o..0 2,0a:Cl1IJa::::>(f) 1,0(f)1IJ

0,8a:0..

0,6

0,5

0.4

0,3

0,2

0,1o

Chart 6: 1 in, 00 Tubing

4 8 12

WATER FLOW (GPM @ 70°F)

16

A-11

Chart 7: 1 1/4 in. OD Tubing

40302010

,

II

E A,,

I7 ~-':B

I

C,1--

'" /" ./ ..A'..; .." At" D"

I 1/ /' ,

~

1----.

f-----' " § I

--"'-,,--

, .', ,II /II I

WATER FLOW CURVES,~-

Pressure Drop per 100 feet of1'/4 inch 00 tubing

WALL INSIDE. -

CURVE THICKNESS DIAMETERA 0.156 in. 0.938 in. IB 0.120 in. 1.010 in.

.-~

-t------- C 0.095 in. 1.060 in.

I D 0.065 in. 1.120 in.I

1----

II

, I0.1o

20.0

100.090.080.070.060.050.0

40.0

30.0

CJzCi'i 10.0::::lI- 9.0Ll. 8.00 7.0I-W 6.0w 5.0Ll.0 4.0S?a: 3.0wIl..

U5 2.0e:.-ll..0a:0w 1.0a: 0.9::::l(J) 0.8(J) 0.7w 0.6a:Il.. 0.5

0.4

0.3

0.2

WATER FLOW (GPM @ 70 0 E)

A-12 ----------------------

Chart 8: 1 1/2 in. OD Tubing

-

~Af--- -- I---- -:-1== ~--:;;

--' B

- /" ~C .... .......

~..;'

f--- ---

----

-----t"'"'- -

-_.- -- I1'--- -- .-.- .- --1---

--

--

WATER FLOW CURVESPressure Drop per 100 feet of

• 11/2 inch OD tubing,>---- ~-'"'-

WALL INSIDE_... =0___.= --CURVE THICKNESS DIAMETER

~- A 0.188 in. 1.124 in. .=====B 0.134 in. 1.232 in.C 0.109 in. 1.282 in. ---I--D 0.083 in. 1.334 in. --I--~""

--f---- -~.,,-

1

20.0

100.090.080.070.060.050.0

40.0

30.0

02

o.

C)Z0510.0~ 9.0LL 8.0o 7.0tu 6.0w 5.0LL.

~ 40

a: 3.0w0..~

Ci5 2.0e:-o..oa:o 1.0~ 0.9:;:) 0.8i2 0.7w 0.6g: 0.5

0.4

0.3

WATER FLOW (GPM @ 70 0 E)

o 10 20 30 40 50 60

I

A-13

Chart 9: 2 in. 00 Tubing

100.090.080.070.060.050.0

40.0

30.0

20.0

GZiii 10.0:;) 9.0I- 8.0~ 7.0I- 6.0w 5.0wu.. 4.0o~ 3.0CCwa.fg 2.0

e::-o.o~ 1.0w 0.9CC 0.8~ 0.7(f) 0.6~ 0.5

a. 0.4

0.3

0.2

,,I

------ --~r

8,

'-~ !/Ce--' .~ /-j;..

-- . AI" ./ /1 D

"" ./ "./ !./'" "/

~/./ i-'-

~

-

-/-

===t='---J-..

!-._--'I

8 17I r,

JvATER FLOW CURVES71 fI

"I. Pressure Drop per 100 feet of2 inch 00 tubing

1- 1-8--. --i-- WALL INSIDE1-- 'I- I----- -- CURVE THICKNESS DIAMETER f-·-1----

------ A 0.188 in. 1.124 in.S 0.134 in. 1.232 in.

-- C 0.109 in. 1.282 in.- .

1-·-- -- D 0.083 in. 1.334 in. f---- f--·---"-""

1---- i---

- ..-

1-· -- .

,

0.1o 30 60 90 120 150 180

WATER FLOW (GPM @ lOOE)

A-14 -----------------------

....1\ '\ '" '" <0 i+-~\ '\ '" --,.;.: GPI/1-

\ \ ~ '\I--

~ 1''''':'1

'0O,o"'-Bf=S-Gp.

(J

-2 GPI/10,o1?

I--I--$ '\ "'-'0,0I'.. ......I' .....

I--~'\ <?J~1tt

...... ......-~ I\. I'0-: 0,0

'0' ~GAl, ~0

'?<?O ~.

~OJ~gU'Q .~1=;:::: '0 _I=~'"O

:'>;=f=--' ~~~

'\ ...........

1\ i'o.. ......

0.2

10.0

8.0

6.0u.:o 5.012 4.0(§J0' 30w~ 2.0I-~

~o9 10w 0.8>Z 0.6<l:w 0.5:2

0.4

0.3

Chart 10:Mean Velocity versus Tube Inside Diameter for Various Water Flows

20.0

0.1o 0.2 0.4 0.6 0.8 1.0

INSIDE DIAMETER (INCHES)

A-15

Chart 11: 1/8 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

,.A , -'r I

i I ,;' ,I \ ,

II is ./ I\ V I

--j-'

,,

TURBULENT FLOW Re > 4000I

0.078

,,

i I, I II I i

, +,

0.156 0.23 0.31

i CRITICAL ZONEI--I+-I,-+,-.!y ' I ',--1--;--1-+--+-+-+-+-++-1

-iJ/+-+!I-IA+-'++Jijt+-+-i-+-+--+-+-+-+++-i -+-+-+1--+-+-11.0

0.8 ==1=t1LAMINAR FLOW Re < 2000 +-I--!

,--

I

rr--~,

II ! I

I !--r- ~

.--,--,-:,

r--i-

.01 0.02 0.03 0.04

AIR FLOW (CFM AT 100 PSIG @ 70°F)

A-16 ----------------------

Chart 12: 1/4 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 700 F)

.78 1.56 2.31 3.1 3.9

A./, .....

".... l.--'i/

B ""V V....

C f7' D

, ,

I

II 11/I

~-

,

AIR FLOW CURVES.=t=!====

Pressure Drop per 100 feet of 1/4 inch -===OD tubing. 100 psig Line Pressure ===, ---

WALL INSIDE - - -CURVE THICKNESS DIAMETER =~ -

- -A 0.065 in. 0.120 in. - f-- -

I B 0.049 in. 0.152 in. :=:1=:=C 0.035 in. 0.180 in. =f=D 0.028 in. 0.194 in. =1==- i=-_. =f= f--

f- ..

-t--+-t-

400

30.0

UJ 20.0a:::::)if)if)UJa:: 10.00..UJ 8.0z:::::i 6.0(9

5.0(j)0.. 4.0e;2

3.0\;;:(9

2.0ziii:::)I-U.0 1.0I-UJ 0.8UJu.e 06;2 0.5a::UJ 040..

(j) 0.3e:-o.. 0.20a::0UJa:::::) 0.10if)if)

0.08UJa::0.. 0.06

0.05

0.04

0.030.1 0.2 0.3 04

AIR FLOW (CFM AT 100 PSIG @ 700 F.)0.5

A-17

I

Chart 13: 3/8 in. OD TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

31 6.2 9.4 12.5 15.640.0

30.0

UJ 20.0a:::J(f)(f)UJa:a... 10.0UJ

8.0z::J<D 6.01i5 5.0a...0 4.0S2~ 3.0

<Dz

2.0iii::Jl-LL0I- 1.0UJUJ 0.8LL0

0.6S2a: 0.5UJa... 0.41i5e:.. 0.3a...0 0.2a:0UJa:::J(f)

0.1(f)UJ

0.08a:a...

0.060.05

0.04

I0.03

A

B ",

I ./ ./I V ./ C ....V

R./ v

I II

II

I

I I I!

I IJ II I II ! I

I

AIR FLOW CURVES =f=f=Pressure Drop per 100 feet of 3/S inch = f=f==t=t=OD tubing. 100 psig Une Pressure - 1=r-

I - r-WALL INSIDE - - f-

CURVE THICKNESS DIAMETER =- r-

/ I 0.065 in.- f-

A 0.245 in. _ - r-B 0.049 in. 0.277 in. = =F=C 0.035 in. 0.305 in. =::

==~I

I

0.4 0.8 1.2 1.6 2.0

AIR FLOW (CFM) AT 100 PSIG @ 70°F.

A-18

Chart 14: 1/2 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 700 F)

3.0

2.0

0.20

0.035

3931.223.41567.8

234

AIR FLOW (CFM AT100 PSIG @ YO°F.)

~... --+--1 A,

B

!C . L.

i ;'

/( D/, i /i ;'

I i/ V /

.

~ 'r -F -t,,, ,

"" .--I

I / / 1// i/ i

~

.- ~.h ~..

,-...,....., ....

::::'• 1-_._ I··~- ~.~ . ----; . .. - t--..- T""""T" . ..j......

F1= .-+-

AIR FLOW CURVES =:::f==Pressure Drop per 100 feet of 1/2 inch =:::f=

.'

00 tubing. 100 psig Une Pressure :::=§;::::WALL INSIDE -c- -

..CURVE THICKNESS DIAMETER ~ '-- -

A 0.083 in. 0.334 in. =.... -c- -

B 0.065 in. 0.370 in.=: r=:=.

C 0.049 in. 0.402 in. :::0 0.0235 in. 0.430 in. =:t=:::m .,. I' r--=1=:::

1-;..=r--=_....

6.05.0

4.0

0.060.05

0.04

0.10

0.08

10.0

8.0

0.60a: 0.50

g: 0.40

ii5 0.30e:.-o.oa:owa:::::>(/)(/)wa:a.

40.0

30.0

~ 20.0::::>(/)(/)wa:a.wz::Joii5a.o;2

~oziii::::>l-LLoI- 1.0ttl 0.80LLoo

A-19

Chart 15: 3/4 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

40.0

30.0

23 47 70 94 117

0.20

10.0

8.0

6.05.0

4.0

0.10

0.08

15.03.0 6.0 9.0 12.0

AIR FLOW (CFM) AT 100 PSIG @ 70°F.

A~

B 1-:"_ J--..-..- C -I i I 1/ L....

, ,

~

III I,

il I I

,'t-+-

I ,

~

AIR FLOW CURVES t=~

.f-

Pressure Drop per 100 feet of 3/4 inch t=, OD tubing. 100 pslg Une Pressure f-I--

I i WALL INSIDE l-I--

i CURVE THICKNESS DIAMETER l-I--

A 0.095 in. 0.560 in. t;=:~1·::- B 0.065 In. 0.620 In. I:::1=

t=~, C 0.035 In. 0.680 In. I--; r= t="1""'-

~

~..

~.. '..+..+.f-. ·f ..1--

+..;.....

UJII 20.0::J(j)(j)UJII0...UJz::JCDUS0...o~

0.060.05

0.04

0.03

!;;: 3.0CDzai 20::Jl-ll.oti:i 1.0

tJ: 0.80oo 0.60

ffi 0.50

0... 0.40

USe.:.. 0.300...oIIoUJII::J(j)(j)UJII0...

I

A-20

Chart 16: 1 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

2.0

4.0

3.0

0.20

I25.0

1951561177839

5.0 10.0 15.0 20.0

AIR FLOW (CFM AT 100 PSIG @ lOOE)

~~~,

, ,

1--I-l-+- - -+- 1

I I ,..- ....1 1

t.-,..- 1/....

B,

-c

,

, ,,

j

~~ /I I 1/

I~~

~-l--1--1-- ~~~~

--,~

=IC~~~ ..t _~~ .-L-.......-l

AIR FLOW CURVES'-f~~-f--: =t: Pressure Drop per 100 feet of 1 inch

1--- - , ,OD tUbing. 100 psig Une Pressure

,WALL INSIDE

I CURVE THICKNESS DIAMETERJ A 0.120 in. 0.760 in. I

I,

I B 0.083 in. 0.834 in.

c- C 0.035 in. 0.930 in.~~~ ,

-+-,

~

~~~

I--'l-~ ~- '~~-I-i-~

6.05.0

0.060.05

0.04

0.03

0.10

0.08

10.0

8.0

(i) 0.30f!:-a..oa:owa:;:)(J)(J)wa:a..

40.0

30.0

~ 20.0;:)(J)(J)wa:a..wZ:JC)(i)a..oS2~C)zin;:)I-u..oI- 1.0

ill 0.80;; 0.60oa: 0.50

1l: OAO

---------------------- A-21

Chart 17: 1 1/4 in. OD TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

,

r::-_

-~1

.",....... I

A"...",. :7..

/'

~B'

C

III.-£0 lA'"

'---f-. _ ... . .-

.f-_.

..- -," "- , ,

"--

" "._.!--_. .~- '-._~-_..-

/ / ./'f--~'

_ .

J 1/ /.

=- AIR FLOW CURVES =Pressure Drop pi,r 100 feelot'i '/4 'inch ==I OD tubing. 100 psig Une Pressure i~

WALL INSIDE ~

-+_. "-f- CURVE THICKNESS DIAMETER ====A 0.165 in. 0.938 in. =--'-r--- B 0.120 in. 1.010 in. =C 0.095 in. 1.060 in. -

--D 0.065 in. 1.120 in. -

--

I '1 I 1 1 1 1--

!I I I I II I

100.090.080.070.060.050.0

UJgs 40.0(J)

[3 30.0

a:Cl.UJ 20.0z::J<!J(jjCl. 10.0g 9.0~ 8.0~ 7.0<!J 6.0~ 5.0co:J 4.0I-

~ 3.0

I­UJtl: 2.0o;2a:~ 1055 0.9Cl. 0.8CC 0.7o 0.615 0.5

UJ 0.4a:115 0.3(J)UJg: 0.2

0.1o

78

10

156

20

234

30

312

40

AIR FLOW (CFM AT 100 PSIG@70°F.)

A-22 ----------------------

Chart 18: 1 1/2 in. 00 TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 700 F)

"-

'­---

468

+.

351234

I-f---·

117100.090.080.070.060.050.0

UJ 40.0

--

----_.- --

Ii 20.0 +::=t=:t==t=t-=::t-=-::t'=-=':::jl='-==1-=-:::j-'~=-j:::f-=--'-~ct;;;;:;~""-=1UJ f----- -. 1-- - ._-A--t:.."""T--1Z t---t--·--t--t--·~--·--1----j'-·1 --t--..·-I---·t---t-"..-::;;p""F--t--·----j::i _-- ~···--I-·-j---+---+--+--+-_·-j--+V-..."'F---j--~o -+---f---+·-f---f----+--f---t--+..........,-"F-+- 8+,""""'9--=>1Ci5 10.0 ,-Q.. 9.0 1---.1--

:5 8.0~ 7.0!;( 6.0~ 5.0

~ ::~~-~-~~~~!~!~~~-r~~~~-.-~~~__ ~,_g~'''~''~---~=~~ If-f-,'-/-#t/"'y---+---i .....-I-..+--+- --1-....-+ ---·1

o /J

ffi 1.0 I J,i'c#:'/::$====1~~;:;6~Mf(~~~-$==lQ.. 0.9 __!-.. --If--I'~ F 1--. AIR FLOW CURVES LCi5 0.8t~~~§~~§~~1 Pressure Drop per 100 feet of 1'/2 inch ==e:- 0.71-' 00 tubing. 100psig Une Pressure ==Q.. 0.6 __o 0.5 • WALL INSIDE ===is 0.4~ - -- - - CURVE THICKNESS DIAMETER ~UJ:::='.=. --__.. A 0.188 in. 1.124 in. ===§ .f--- . 8 0.134in. 1,232 in. -(f) t-- ..- C 0.109 in. 1.282 in. ===ffj I-- D 0.083 in. 1.334 in. ==a:: _ .==Q.. -- ,---

30 45 60

AIR FLOW (CFM AT 100 PSIG@70°F.)

A-23

Chart 19: 2 in. OD TubingCFM Air Standard Temperature and Pressure (14.7 PSIA @ 70° F)

,

,--

II

I, -jA ./~

, t= .~I

'--

I ;"

,;I ,

" I7 '7

il1//VAIR FLOW CURVES L--

Pressure Drop per 100 feet of 2 inch '=I--

OD tubing. 100 psig Une Pressure ===WALL INSIDE =

- CURVE THICKNESS DIAMETER ~A 0.188 in. 1.624 in._B 0.156 in. 1.688 in. -==,-C 0.120 in. 1.760 in. ---:::D 0.095 in. 1.810 in. --

" .. ~--

I

-I

AIR FLOW (CFM AT 100 PSIG@70°F.)

100.090.080.070.060.050.0

li:! 400::)

i2 30.0w0:a. 20.0wz:::J('}

~ 10.0o 9.0~ 8.0ti: 7.0

6.0~ 50

iii 4.0::)

~ 3.0oI-ill 2.0li­oo~

0:g: 1.0~ 0.9u.i 0.8e:. 0.7a. 0.6~ 0.5o 04w .0:::) 0.3(f)(f)

li:! 0.2a.

0.1o

156

20

312

40

468

60

624

80

780

100

936

120

1092

140

A-24 ---------------------

Chart 20:Air Velocity versus Tubing ID for 100 PSIG Air and 14.7 PSIA Air

2000

1000

u.: 800oR 600~ 500

~ 400::J(J) 300(J)UJ

g: 200UJZ::Jo(ij 100

~ 80;2~ 606' 50UJ 40(J)

~ 30

>-I- 20(5

9UJ>:2: 10

lfi 8a:ti 6~ 5

~ 4UJ:2: 3

2

I

\ -\1\ CURVE FLOW -\ \ \ 100 psig 14.7 psia -

A 20CFM 156CFM ::::B 15CFM 117CFM :=C 10CFM 78CFM ==D 5CFM 39CFM =E 3CFM 23.4CFM -

I F 1 CFM 7.8CFM ==:::::::G 0.5CFM 3.9CFM ==H 0.3CFM 2.34CFM ~,I 0.1 CFM 0.78CFM =-

- -f'\ " '"\ \ i'\. I" '"\ '\ i ....... "-c- 1+-

~A=r==

B

~ C

D,

~. '"" "'\ 1"\ ::'\ I\.. ....1-

H FI

...G

- -' '"H

I+- ........'I. ......-~i "0.2 0.4 0.6 0.8

ID OF TUBING (inches)

A-25

HEADS AND EQUIVALENT PRESSURE CONVERSIONS

To Convert Into Multiply Byatmospheres pounds per sq in. 14.696atmospheres pounds per sq ft 2116.22atmospheres in. of water at 60°F 407.17atmospheres ft of water at 60°F 33.931atmospheres in. of mercury at 32°F 29.921atmospheres mm of mercury at 32°F 760ft of water at 60°F pounds per sq in. 0.4335ft of water at 60°F pounds per sq ft 62.43ft of water at 60°F in. of water at 60°F 12ft of water at 60°F in. of mercury at 32°F 0.8826ft of water at 60°F mm of mercury at 32°F 22.418ft of water at 60°F atmospheres 0.029481in. of water at 60°F pounds per sq in. 0.03613in. of water at 60°F pounds per sq ft 5.204in. of water at 60°F ft of water at 60°F 0.08333in. of water at 60°F in. of mercury at 32°F 0.073483in. of water at 60°F mm of mercury at 32°F 1.8665in. of water at 60°F atmospheres 2.458 x 10.3

in. of mercury at 32°F pounds per sq in. 0.49116in. of mercury at 32°F pounds per sq ft 70.7266in. of mercury at 32°F in. of water at 60°F 13.608in. of mercury at 32°F ft of water at 60°F 1.1340in. of mercury at 32°F mm of mercury at 32°F 25.40005in. of mercury at 32°F atmospheres 0.033421mm of mercury at 32°F pounds per sq in. 0.019337mm of mercury at 32°F pounds per sq ft 2.78450mm of mercury at 32°F in. of water at 60°F 0.53576mm of mercury at 32°F ft of water at 60°F 0.04461mm of mercury at 32°F in. of mercury at 32°F 0.03937mm of mercury at 32°F atmospheres 1.3158 x 10.3

pounds per sq ft pounds per sq in. 6.9445 x 10.3

pounds per sq ft in. of Water at 60°F 0.19224pounds per sq ft ft of Water at 60°F 0.01603pounds per sq ft in. of mercury at 32°F 0.01414pounds per sq ft mm of mercury at 32°F 0.35916pounds per sq ft. atmospheres 4.725 x 10.4

pounds per sq in. pounds per sq ft 144.0pounds per sq in. in. of water at 60°F 27.684pounds per sq in. ft of water at 60°F 2.307pounds per sq in. in. of mercury at 32°F 2.03601pounds per sq in. mm of mercury at 32°F 51.7148pounds per sq in. atmospheres 0.06804

A-26 ----------------------

PRESSURECONVER~ONS

To mmHg in.Hg in.H2O ItH20 aim Ib/in.2 Kg/cm2 kPa barFrom

mmHg 1 0.03937 0.5353 0.04461 0.00132 0.01934 0.00136 0.1333 0.0013

in.Hg 25.40 1 13.60 1.133 0.03342 0.4912 0.03453 30.387 0.0339

in.H2O 1.868 0.07355 1 0.08333 0.00246 0.03612 0.00254 0.2490 0.0025

ItH20 22.42 0.8826 12 1 0.02950 0.4334 0.03048 2.988 0.0299

aim 760 29.92 406.8 33.90 1 14.70 1.033 101.3 1.013

Ib/in.2 51.71 2.036 27.69 2.307 0.06805 1 0.07031 6.894 0.0689

kg/cm2 735.6 28.96 393.7 32.81 0.9678 14.22 1 98.05 0.981

kPa 7.500 0.2953 4.016 0.3347 0.00987 0.1451 0.0102 1 0.01

bar 750 29.53 401.6 33.47 0.987 14.51 1.02 100 1

FLOW RATE CONVERSIONS

ToLit/sec gal/min It3/sec It3/min bbl/hr bbl/dayFrom

Lit/sec 1 15.85 0.03532 2.119 22.66 543.8

gal/min 0.06309 1 0.00223 0.1337 1.429 34.30

It3/sec 28.32 448.8 1 60 641.1 1.54x104

1t3/min 0.4719 7.481 0.01667 1 10.69 256.5

bbl/hr 0.04415 0.6997 0.00156 0.09359 1 24

bbl/day 0.00184 0.02917 6.50x105 0.00390 0.04167 1

A-27

A-28 ---------------------

General Information

• Birmingham Wire Gauge Table

• O-ring Dimensional Table

• Properties of Saturated Steam

• Specific Gravity of Water

• Specific Gravity of liquids

• Specific Gravity of Gases

• Table of Elements

• Temperature Ratings of Materials

• Volume Conversions

• Area Conversions

• Decimal Equivalents and in. to mm Equivalents

• °C to OF Conversion Table

• Pipe and Tube Wall Thickness, Area

B-1

I

BIRMINGHAM WIRE GAUGE TABLE

B-2

BWG

30

29

28

27

26

25

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

Wall Thickness DecimalEquivalent in in.

0.012

0.013

0.014

0.016

0.018

0.020

0.022

0.025

0.028

0.032

0.035

0.042

0.049

0.058

0.065

0.072

0.083

0.095

0.109

0.120

0.134

0.148

0.165

0.180

0.203

0.220

0.238

0.259

0.284

0.300

O-RING DIMENSIONAL TABLE

Actual Dimensions

Uniform CrossSize ID Section OD

Number (in.) (in.) (in.)

006 0.114 0.070 0.254007 0.145 0.070 0.285008 0.176 0.070 0.316009 0.208 0.070 0.348010 0.239 0.070 0.379011 0.301 0.070 0.441012 0.364 0.070 0.504013 0.426 0.070 0.566014 0.489 0.070 0.629111 0.424 0.103 0.630112 0.487 0.103 0.693113 0.549 0.103 0.755114 0.612 0.103 0.818115 0.674 0.103 0.880116 0.737 0.103 0.943117 0.799 0.103 1.005118 0.862 0.103 1.068119 0.924 0.103 1.130120 0.987 0.103 1.193121 1.049 0.103 1.255122 1.112 0.103 1.318123 1.174 0.103 1.380125 1.299 0.103 1.505126 1.362 0.103 1.568128 1.487 0.103 1.693130 1.612 0.103 1.818132 1.737 0.103 1.943133 1.799 0.103 2.005134 1.862 0.103 2.068136 1.987 0.103 2.193212 0.859 0.139 1.137215 1.046 0.139 1.324219 1.296 0.139 1.574223 1.609 0.139 1.887902 0.239 0.064 0.3679021/2 0.070 0.040 0.150904 0.351 0.072 0.495905 0.414 0.072 0.558906 0.468 0.078 0.624908 0.644 0.087 0.818910 0.755 0.097 0.949912 0.924 0.116 1.156916 1.171 0.116 1.403920 1.475 0.118 1.711924 1.720 0.118 1.956932 2.337 0.118 2.573

B-3

PROPERTIES OF SATURATED STEAMAbs Abs Abs Abs Abs

press. Temp. press. Temp. press. Temp. press. Temp. press. Temp.psia of psia of psia OF psia OF psia OF

1.0 101.74 38 264.16 84 315.42 160 363.53 520 471.071.2 107.92 39 265.72 85 316.25 162 364.53 540 475.011.4 113.26 40 267.25 86 317.07 164 365.51 560 478.851.6 117.99 41 268.74 87 317.88 166 366.48 580 482.581.8 122.23 42 270.21 88 318.68 168 367.45 600 486.212.0 126.08 43 271.64 89 319.48 170 368.41 620 489.752.2 129.62 44 273.05 90 320.27 172 369.35 640 493.212.4 132.89 45 274.44 91 321.06 174 370.29 660 496.582.6 135.94 46 275.80 92 321.83 176 371.22 680 499.882.8 138.79 47 277.13 93 322.60 178 372.14 700 503.103.0 141.48 48 278.45 94 323.36 180 373.06 720 506.254.0 152.97 49 279.74 95 324.12 182 373.96 740 509.345.0 162.24 50 281.01 96 324.87 184 374.86 760 512.366.0 170.06 51 282.26 97 325.61 186 375.75 780 515.337.0 176.85 52 283.49 98 326.25 188 376.64 800 518.238.0 182.86 53 284.70 99 327.08 190 377.51 820 521.089.0 188.28 54 285.90 100 327.81 192 378.38 840 523.88

10 193.21 55 287.07 102 329.25 194 379.24 860 526.6311 197.75 56 288.23 104 330.66 196 380.10 880 529.3312 201.96 57 289.37 106 332.05 198 380.95 900 531.9813 205.88 58 290.50 108 333.42 200 381.79 920 534.5914 209.56 59 291.61 110 334.77 205 383.86 940 537.1614.696 212.00 60 292.71 112 336.11 210 385.90 960 539.6815 213.03 61 293.79 114 337.42 215 387.89 980 542.1716 216.32 62 294.85 116 338.72 220 389.86 1.000 544.6117 219.44 63 295.90 118 339.99 225 391.79 1.050 550.5718 222.41 64 296.94 120 341.25 230 393.68 1,100 556.3119 225.24 65 297.97 122 342.50 235 395.54 1,150 561.8620 227.96 66 298.99 124 343.72 240 397.37 1,200 567.2221 230.57 67 299.99 126 344.94 245 399.18 1,250 572.4222 233.07 68 300.98 128 346.13 250 400.95 1,300 577.4623 235.49 69 301.96 130 347.32 260 404.42 1,350 582.3524 237.82 70 302.92 132 348.48 270 407.78 1,400 587.1025 240.07 71 303.88 134 349.64 280 411.05 1,450 591.7126 242.25 72 304.83 136 350.78 290 414.23 1,500 596.2327 244.36 73 305.76 138 351.91 300 417.33 1,600 604.9028 246.41 74 306.68 140 353.02 320 423.29 1,700 613.1529 248.40 75 307.60 142 354.12 340 428.97 1,800 621.0330 250.33 76 308.50 144 355.21 360 434.40 1,900 628.5831 252.22 77 309.40 146 356.29 380 439.60 2,000 635.8232 254.05 78 310.29 148 357.36 400 444.59 2,200 649.4633 255.84 79 311.16 150 358.42 420 449.39 2,400 662.1234 257.08 80 312.03 152 359.46 440 454.02 2,600 673.9435 259.29 81 312.89 154 360.49 460 458.50 2,800 684.9936 260.95 82 313.74 156 361.52 480 462.82 3,000 695.3637 262.57 83 314.59 158 362.03 500 467.01 3,200 705.11

Note: To convert PSIA into PSIG subtract 14.7 (approx.)

B-4

SPECIFIC GRAVITY OF WATER VS. TEMPERATURE

WaterTemperature

of

32405060708090

100110120130140150160170180190200210212220240260280300350400450500550600

SpecificGravity

1.00131.00131.00061.00000.99890.99760.99630.99450.99200.99020.98720.98480.98170.97870.97510.97160.96810.96450.96050.95940.95650.94800.93860.92940.91930.89170.86060.82690.78630.73580.6797

8-5

I

SPECIFIC GRAVITY OF LIQUIDS

Liquid

AcetoneAlcohol, Ethyl (100 %)Alcohol, Methyl (100 %)Acid, Muriatic (40 %)Acid, Nitric (91 %)Acid, Sulfuric (87 %)Bunkers C Fuel Max.DistillateFuel 3 Max.Fuel 5 Min.Fuel 5 Max.Fuel 6 Min.GasolineGasoline, NaturalHydrochloric AcidKeroseneM. C. ResiduumMercuryOlive OilPentaneSAE 10 Lube*SAE 30 Lube*SAE 70 Lube*Salt Creek CrudeSea Water32.6° API Crude35.6° API Crude40° API Crude48° API CrudeWater

*100 Viscosity Index.

B-6

Specific GravityRelative to

Water at GO°F

0.7920.7890.7961.201.501.801.0140.8500.8980.9660.9930.9930.7510.6801.2560.8150.935

13.5700.9190.6240.8760.8980.9160.8431.0250.8620.8470.8250.7881.000

SUGGESTED MAXIMUM TEMPERATURESFOR FITTINGS-TUBING-SEAL MATERIALSMetals of

Alloy 20 1200Aluminum 400Brass 400Copper 400Copper-Nickel (70/30) 700Copper-Nickel (90/10) 600Alloy B2 800Alloy C-276 1000Alloy 600 1200Alloy 400 800Nickel 600Stainless Steel 304L 800Stainless Steel 316-321-347 1200Steel 375Tantalum* 2000Titanium 600

* Protective coating may be required above 900°F.

Plastics

Delrin®t 195Kel-F® 200Nylon 165PFA (Perfluoroalkoxy) 400Polyethylene 140Polypropylene 250TFE 450Vespel® 500

t Ratings may be reduced for water or air service.

Elastomers

°C

649204204204371316427537649427316427649190

1093316

919374

20460

121232260

Buna 255 124Ethylene-Propylene 300 149Kalrez® 500 260Neoprene 280 138Silicone 450 232V~n ~O ~4

Note: The data presented above is believed to be reliable, but thistype of table cannot cover all conditions of fluid types, concentrations,aerations, etc. I

It is suggested that this table be used only to select possible Imaterials for use, and then a more extensive investigation be made ofpublished material standards and applicable piping standards.

Swagelok Company is not responsible for the accuracy of theinformation in the above tables.

B-9

VOLUME CONVERSIONS

To Convert Into Multiply By

I

Cubic feetCubic feetCubic feetCubic feetCubic feetCubic feetCubic feetCubic feetGallonsGallonsGallonsGallonsGallonsGallonsGallonsGallonsGallonsLitersLitersLitersLitersLitersLitersLitersLitersLitersCubic centimetersCubic centimetersCubic centimetersCubic centimetersCubic centimetersCubic centimetersCubic centimetersCubic centimetersCubic in.

Cubic centimetersCubic metersCubic yardsCubic in.Gallons (Br.)LitersBBL(oil)BBL (liq.)Cubic centimetersCubic millimetersCubic feetCubic in.Gallons (Br.)LitersPounds of waterBBL (oil)BBL (Iiq.)Cubic centimetersCubic millimetersCubic yardsCubic feetCubic in.Gallons (Br.)GallonsBBL (oil)BBL (Iiq.)Cubic metersCubic feetCubic in.Gallons (Br.)GallonsLitersBBL (oil)BBL (Iiq.)Cubic centimeters

2.83 X 104

0.028320.03704

17286.229

28.320.17810.2375

37850.003790.1337

2310.83273.7858.350.023810.03175

10000.0010.001310.0353

61.020.22000.26420.006290.008391 x 10-6

3.531 X 10-5

0.061022.20 x 10-4

2.642 X 10-4

0.0016.29 x 10-6

8.39 X 10-6

16.387

B-10 ----------------------

SPECIFIC GRAVITY OF GASES RELATIVE TO AIR @ 70°F

Chemical Specific GravityName of Gas Formula Relative To Air

Acetylene C2H2 0.9107Air 1.000Ammonia NH3 0.5961Anthracite Producer Gas 0.85Argon Ar 1.377Benzene CsHs 2.6920Bituminous Producer Gas 0.86Blast-Furnace Gas 1.000Blue Water Gas 0.53Butane C4H10 2.06654Butylene C4Hs 1.9936Carbon Dioxide CO2 1.5282Carbon Monoxide CO 0.9672Carbureted Water Gas 0.65Chlorine CI2 2.486Coke Oven Gas 0.42Ethane C2Hs 1.04882Ethyl Chloride C2HsCI 2.365Ethylene C2H4 0.974Freon (F-12) CCI2F2 4.520Helium He 0.138Hydrogen H2 0.06959Hydrogen Chloride HCI 1.268Hydrogen Sulphide H2S 1.190Methane CH4 0.5543Methyl Chloride CH3CI 1.738Natural Gas' 0.667Neon Ne 0.696Nitrogen N2 0.9718Nitric Oxide NO 1.034Nitrous Oxide N20 1.518Oxygen O2 1.1053Pentane CSH12 2.4872

IPropane C3Hs 1.5617Propylene C3Ha 1.4504Sulphur Dioxide S02 2.264Toluene C7Hs 3.1760Xylene CSHlO 3.6618

• Representative value

B-7

TABLE OF THE ELEMENTSname sym. at. no. at. wt. name sym. at. no. at. wI.

Actinium Ac 89 227 Mercury Hg 80 200.59Aluminum AI 13 26.9815 Molybdenum Mo 42 95.94Americium Am 95 243 Neodymium Nd 60 144.24Antimony Sb 51 121.75 Neon Ne 10 20.183Argon Ar 18 39.948 Neptunium Np 93 237Arsenic As 33 74.9216 Nickel Ni 28 58.71Astatine At 85 210 Niobium Nb 41 92.906Barium Ba 56 137.34 Nitrogen N 7 14.0067Berkelium Bk 97 247 Nobelium No 102 254Beryllium Be 4 9.0122 Osmium Os 76 190.2Bismuth Bi 83 208.980 Oxygen 0 8 15.9994Boron B 5 10.811 Palladium Pd 46 106.4Bromine Br 35 79.909 Phosphorous P 15 30.9738Cadmium Cd 48 112.40 Platinum Pt 78 195.09Calcium Ca 20 40.08 Plutonium Pu 94 242Californium Cf 98 249 Polonium Po 84 210Carbon C 6 12.01115 Potassium K 19 39.120Cerium Ce 58 140.12 Praseodymium Pr 59 140.907Cesium Cs 55 132.905 Promethium Pm 61 147Chlorine CI 17 35.453 Proactinium Pa 91 231Chromium Cr 24 51.996 Radium Ra 88 226Cobalt Co 27 58.9332 Radon Rn 86 222Copper Cu 29 63.54 Rhenium Re 75 186.2Curium Cm 96 247 Rhodium Rh 45 102.905Dysprosium Dy 66 162.50 Rubidium Rb 37 85.47Einsteinium Es 99 254 Ruthenium Ru 44 101.07Erbium Er 68 167.26 Samarium Sm 62 150.35Europium Eu 63 151.96 Scandium Sc 21 44.956Fermium Fm 100 253 Selenium Se 34 78.96Fluorine F 9 18.9984 Sililcon Si 14 28.086Francium Fr 87 223 Silver Ag 47 107.870Gadolinium Gd 64 157.25 Sodium Na 11 22.9898Gallium Ga 31 69.72 Strontium Sr 38 87.62Germanium Ge 32 72.59 Sulfur S 16 32.064Gold Au 79 196.967 Tantalum Ta 73 180.948Hafnium Hf 72 178.49 Technetium Tc 43 99Helium He 2 4.0026 Tellurium Te 52 127.60Holmium Ho 67 164.930 Terbium Tb 65 158.924Hydrogen H 1 1.00797 Thallium TI 81 204.37Indium In 49 114.82 Thorium Th 90 232.038Iodine I 53 126.9044 Thulium Tm 69 168.934Iridium Ir 77 192.2 Tin Sn 50 118.69Iron Fe 26 55.847 Titanium Ti 22 47.90Krypton Kr 36 83.80 Tungsten W 74 183.85Lanthanum La 57 138.91 Uranium U 92 238.03Lawrencium Lw 103 257 Vanadium V 23 50.942Lead Pb 82 207.19 Xenon Xe 54 131.30Lithium Li 3 6.939 Ytterbium Yb 70 173.04Lutetium Lu 71 174.97 Yttrium Y 38 88.905Magnesium Mg 12 24.312 Zinc Zn 30 65.37Manganese Mn 25 54.9380 Zirconium Zr 40 91.22Mendelevium Md 101 256

B-8

AREA CONVERSIONS

To cm2 m2 km2 in.2 IF mile2From

cm2 1 0.0001 1 x 1010 0.1550 0,00108 3.86 x 1011

m2 1 x 104 1 1 X 106 1550 10.76 3.86 x 107

km2 1 x 1010 1 X 106 1 1.55 X 109 1.08 X 107 0.3861

in. 2 6.452 6.45 x 104 6.45 X 1010 1 0.00694 2.49 x 1010

fl2 929.0 0.09290 9.29 x 108 144 1 3.59 x 108

mile2 2.59 x 1010 2.59 X 106 2.590 4.01 x 109 2.79 X 107 1

DECIMAL EQUIVALENTS

8ths

1/8 = 0.1251/4 = 0.2503/8 = 0.3751/2 = 0.5005/8 0.6253/4 = 0.7507/8 = 0.875

16ths

1/16 = 0.06253/16 = 0.18755/16 = 0.31257/16 = 0.43759/16 0.5625

11/16 0.687513/16 0.812515/16 = 0.9375

32nds

1/32 = 0.031253/32 = 0.093755/32 = 0.156257/32 = 0.218759/32 = 0.28125

11/32 = 0.3437513/32 0.4062515/32 = 0.46875

17/32 = 0.5312519/32 = 0.5937521/32 = 0.6562523/32 0.7187525/32 = 0.7812527/32 = 0.8437529/32 = 0.9062531/32 = 0.96875

64ths

1/64 = 0.015625 33/64 = 0.5156253/64 = 0.046875 35/64 = 0.5468755/64 = 0.078125 37/64 0.5781257/64 = 0.109375 39/64 0.6093759/64 0.140625 41/64 = 0.640625

11/64 = 0.171875 43/64 = 0.67187513/64 = 0.203125 45/64 0.70312515/64 = 0.234375 47/64 = 0.734375

17/64 = 0.265625 49/64 = 0.76562519/64 = 0.296875 51/64 = 0.79687521/64 = 0.328125 53/64 = 0.82812523/64 = 0.359375 55/64 = 0.85937525/64 = 0.390625 57/64 = 0.89062527/64 = 0.421875 59/64 = 0.92187529/64 = 0.453125 61/64 = 0.95312531/64 = 0.484375 63/64 = 0.984375

INCHES TO MM MM TO INCH EQUIVALENT

1/16 in. = 1.59 mm1/8 in. = 3.17 mm3/16 in. = 4.76 mm1/4 in. = 6.35 mm5/16 in.= 7.94mm3/8 in. = 9.52 mm7/16 in. = 11.11 mm1/2 in. = 12.70 mm9/16 in. = 14.29 mm5/8 in. 15.87 mm11/16 in. = 17.46 mm3/4 in. = 19.05 mm13/16 in. = 20.64 mm7/8 in. = 22.22 mm15/16 in. = 23.81 mm1 in. = 25.40 mm1 1/4 in. = 31.75 mm11/2 in. 38.10mm2 in. = 50.80 mm

1 mm = 0.039 in.2 mm = 0.079 in.3 mm=0.118 in.4 mm = 0.157 in.5 mm 0.197 in.6 mm = 0.236 in.7 mm = 0.276 in.8 mm = 0.315 in.9 mm = 0.354 in.

10 mm 0.394 in.11 mm 0.433 in.12 mm = 0.472 in.13 mm = 0.512 in.14 mm = 0.551 in.

15 mm = 0.590 in.16 mm = 0.630 in.17 mm 0.669 in.18mm 0.709 in.19 mm = 0.748 in.20 mm = 0.787 in.21 mm = 0.827 in.22 mm = 0.866 in.23 mm = 0.905 in.24 mm = 0.944 in.25 mm = 0.984 in.25.4 mm = 1 in.

8-11

I

TEMPERATURE CONVERSION FORMULAS

DegreesFahrenheit

(OF)

of = 1.8 (0C) + 32

OF = oR - 459.69

Degrees Celsius(Centigrade)

(ec)

°C = OF - 321.8

°c = oK - 273.16

AbsoluteDegrees Rankine (OR)Degrees Kelvin (OK)

OOR = OOKoR = OF + 459.69oK = °C + 273.16

I

CELSIUS eC) FAHRENHEIT eF) CONVERSION TABLETEMPERATURE CONVERSION TABLE

°C OF °C of °C of °C of

-200 -328 65 149 410 770 790 1454-180 -292 70 158 420 788 800 1472-160 -256 75 167 430 806 810 1490-140 -220 80 176 440 824 820 1508-120 -184 85 185 450 842 830 1526-100 -148 90 194 460 860 850 1562-95 -139 95 203 470 878 900 1652-90 -130 100 212 480 896 950 1742-85 -121 110 230 490 914 1000 1832-80 -112 120 248 500 932 1050 1922-75 -103 130 266 510 950 1100 2012-70 -94 140 284 520 968 1150 2102-65 -85 150 302 530 986 1200 2192-60 -76 160 320 540 1004 1250 2282-55 -67 170 338 550 1022 1300 2372-50 -58 180 356 560 1040 1350 2462-45 -49 190 374 570 1058 1400 2552-40 -40 200 392 580 1076 1450 2642-35 -31 210 410 590 1094 1500 2732-30 -22 220 428 600 1112 1550 2822-25 -13 230 446 610 1130 1600 2912-20 -4 240 464 620 1148 1650 3002-15 5 250 482 630 1166 1700 3092-10 14 260 500 640 1184 1750 3182-5 23 270 518 650 1202 1800 32720 32 280 536 660 1220 1850 33625 41 290 554 670 1238 1900 3452

10 50 300 572 680 1256 1950 354215 59 310 590 690 1274 2000 363220 68 320 608 700 1292 2050 372225 77 330 626 710 1310 2100 381230 86 340 644 720 1328 2150 390235 95 350 662 730 1346 2200 399240 104 360 680 740 1364 2250 408245 113 370 698 750 1382 2300 417250 122 380 716 760 1400 2350 426255 131 390 734 770 1418 2400 435260 140 400 752 780 1436 2450 4442

B-12 ----------------------

PIPE WALL THICKNESS

Nominal Wall Thickness Inside Diameter00Size Sch 10 Sch 40 Sch 80 Sch 10 Sch 40 Sch 80

1/8 0.405 0.049 0.068 0.095 0.307 0.269 0.2151/4 0.540 0.065 0.088 0.119 0.410 0.364 0.3023/8 0.675 0.065 0.091 0.126 0.545 0.493 0.3811/2 0.840 0.083 0.109 0.147 0.674 0.622 0.5463/4 1.050 0.083 0.113 0.154 0.884 0.824 0.7421 1.315 0.109 0.133 0.179 1.097 1.049 0.957

1 1/4 1.660 0.109 0.140 0.191 1.442 1.380 1.2781 1/2 1.900 0.109 0.145 0.200 1.682 1.610 1.500

2 2.375 0.109 0.154 0.218 2.157 2.067 1.939

All dimenSions In In.

-------------------- B-13

FRACTIONAL TUBING 00, WALL, 10 CROSS SECTIONAL AREATube 00 Wall Thickness Tube ID ID Cross Sectional Area(in.) (in.) (in.) (in.) (in.2)

0:015 I0.042 0.0014

1/16 0.062 0.032 0.00080.020 0.022 0.0004

1/8 0.1250.028 0.069 0.00370.035 0.055 0.0024

0.028 0.131 0.01353/16 0.187 0.035 0.117 0.0108

0.049 0.089 0.0062

0.028 0.194 0.030

1/4 0.2500.035 0.180 0.0250.049 0.152 0.0180.065 0.120 0.011

0.035 0.242 0.0465/16 0.312 0.049 0.214 0.036

0.065 0.182 0.026

0.035 0.305 0.0733/8 0.375 0.049 0.277 0.060

0.065 0.245 0.047

0.035 0.430 0.145

1/2 0.5000.049 0.402 0.1270.065 0.370 0.1080.083 0.334 0.088

0.049 0.527 0.218

5/8 0.6250.065 0.495 0.1920.083 0.459 0.1660.095 0.435 0.149

0.049 0.652 0.3340.065 0.620 0.302

3/4 0.750 0.083 0.584 0.2680.095 0.560 0.2460.109 0.532 0.222

0.049 0.777 0.4740.065 0.745 0.436

7/8 0.875 0.083 0.709 0.3950.095 0.685 0.3690.109 0.657 0.339

0.065 0.870 0.5950.083 0.834 0.546

1 1.000 0.095 0.810 0.5150.109 0.782 0.4800.120 0.760 0.454

0.083 1.084 0.9230.095 1.060 0.883

11/4 1.250 0.109 1.032 0.8370.120 1.010 0.8010.134 0.982 0.7570.156 0.938 0.691

0.095 1.310 1.3480.109 1.282 1.291

11/2 1.5000.120 1.260 1.2470.134 1.232 1.1920.156 1.188 1.1090.188 1.124 0.992

0.109 1.782 2.4940.120 1.760 2.433

2 2.000 0.134 1.732 2.3560.156 1.688 2.2380.188 1.624 2.071

8-14

METRIC TUBING OD, WALL, ID CROSS SECTIONAL AREA

Tube 00 Wall Thickness Tube 10 10 Cross Sectional(mm) (mm) (mm) Area (mm2)

0.2 0.6 0.28271 0.3 0.4 0.1257

0.4 0.2 0.0031

0.5 2.0 3.143 0.6 1.8 2.54

0.8 1.4 1.54

0.6 4.8 18.100.8 4.4 15.21

61.0 4.0 12.571.25 3.5 9.621.5 3.0 7.071.6 2.8 6.160.8 6.4 32.171.0 6.0 28.27

8 1.25 5.5 23.761.5 5.0 19.641.6 4.8 18.100.8 8.4 55.421.0 8.0 50.27

10 1.25 7.5 44.181.5 7.0 38.481.6 6.8 36.32

1.0 10.0 78.541.25 9.5 70.88

12 1.5 9.0 63.621.6 8.8 60.822.0 8.0 50.271.0 12.0 113.101.2 11.6 105.68

141.5 11.0 95.031.8 10.4 84.952.0 10.0 78.542.2 9.6 72.38

1.2 12.6 124.691.5 12.0 113.10

15 1.6 11.8 109.362.0 11.0 95.032.3 10.4 84.95

1.2 13.6 145.271.5 13.0 132.73

16 1.6 12.8 128.682.0 12.0 113.102.3 11.4 102.07

1.2 15.6 191.131.5 15.0 176.721.6 14.8 172.03

18 2.0 14.0 153.942.3 13.4 141.032.5 13.0 132.732.6 12.8 128.681.5 17.0 226.981.6 16.8 221.67

202.0 16.0 201.062.3 15.4 186.272.5 15.0 176.712.6 14.8 172.03

Table Continued

8-15

METRIC TUBING 00, WALL, 10 CROSS SECTIONAL AREA(continued)

Tube OD Wall Thickness TubelD ID Cross Sectional(mm) (mm) (mm) Area (mm2)

1.5 19.0 283.531.6 18.8 277.59

222.0 18.0 254.472.3 17.4 237.792.5 17.0 226.982.6 16.8 221.67

1.5 22.0 380.131.6 21.8 373.252.0 21.0 346.36

25 2.3 20.4 326.852.5 20.0 314.162.6 19.8 307.913.0 19.0 283.53

2.0 24.0 452.382.2 23.6 437.43

282.5 23.0 415.472.8 22.4 394.083.0 22.0 380.133.5 21.0 346.36

2.0 26.0 530.922.2 25.6 514.71

302.5 25.0 490.872.8 24.4 467.593.0 24.0 452.383.5 23.0 415.47

2.0 28.0 615.752.2 27.6 598.282.5 27.0 572.55

32 2.8 26.4 547.393.0 26.0 530.923.5 25.0 490.874.0 24.0 452.382.2 33.6 886.682.5 33.0 855.292.8 32.4 824.47

38 3.0 32.0 804.243.5 31.0 754.764.0 30.0 706.854.5 29.0 660.51

B-16 ----------------------

Corrosion ChartsThe data presented is believed reliable but a chart of this sort cannotcover all conditions of concentration, temperature, impurities, andaeration. It is suggested that this chart be used only to select possiblematerials for use and then a more extensive investigation be made ofpublished corrosion results under the specific conditions expected.Where such information cannot be found, corrosion testing should beconducted under actual usage conditions to determine which materialscan be utilized.

C-1

I

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

~ Q)

::t a3 <DE 0 « -:::: Q) 0 I"-::J 0 LL ~ cooNEC '<t U) .c Z ~ C <D N () .~.- (/J - >. U) e:: c 1i5 ell c 0..§gJ350<DW.Q..2:'cooE~~~[ij_ lI-+-,=,-LL >'0 ::J:t::::: Q) Q)===:'!:::«COU)«0?f--Zo...CO>ZO«««f--

2

2

2

2 1

2 2

2 1

1

2

2 3

22 1

1

1

2 22 1

1 12 1 1

1 1

4

2

1

1 4

1 21 21 1

2

1

1

1 2

42 1

1 2

1

1

1

1

1 1

1 22 22

1 1

4 43 21 1

2 11 1

1 1

1 1

1 1

1 1

1 1

43422

34342 3

3 4 3 4 1

443 1

1 1 1 1

4 3 4 4

1 1 1 1 1

2 1 214

444

4 3 3

1 1 1

1 1 1

313

1 1 1

1 1 1

1 1 1

2

2 22 22

2 22

2 2 2

212

2

2

3

1

1

11

3

4 3

2

2 3

2 23 21 1

2 2

21

1 1

3 22 22 2

2

113211

24431 1

144124

212111

121111

211111

222111

44424 1

144231

22222 1

34423 1

222111

241111

242421

23222 1

44322 1

242411

244221

241311

1 1 1 1 1

44322 1

4443212

121111

241211

23421

44422 1

121111

4 1 222 1

22222 1

442211

24232 1

2 2 221

Acetaldehyde

Acetic Acid

Acetic Anhydride

Acetone

Acetylene

Acrylonitrile

Alcohols

Aluminum Chloride

Aluminum Fluoride

Aluminum Hydroxide

Aluminum Sulfate

Amines

Ammonia-Anhydrous

Amm. Bicarbonate

Amm. Carbonate

Ammonium Chloride

Ammonium Hydroxide

Amm. Monophosphate

Ammonium Nitrate

Ammonium Phosphate

Ammonium Sulfate

Ammonium Sulfite

Amyl Acetate

Aniline

Apple Juice

Arsenic Acid

AsphaltBarium Carbonate

Barium Chloride

Barium Hydroxide

Barium Nitrate

Barium Sulfate

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-2

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

44 3 3 231 4

43442

2 2

1 1

3 2

1

1

1

1 4

4 1

2 1

2 1

1 1 14 4 4

4 4 4 4

3 1 1

411

1 2 2 11 1 2 1 1

1 2 1 1

1 4 2 1

141

4 2 11 1

1

1

1

1

1

1

1

1 1

2 4

1 1

1

1 1

1 12 4

2 41 2

1 1

3 3

1 1 11 1 1

1 1 1

212

1 1 1

424

414

312

1 1 1 1

424 1

424 1

1 1 1 11 1 2 1

434 1

2 1

1

1

4

1

21

1

4

4

112

2 2

2 22 3

1 1

2

2

4 24

441411

1231112

1321112

222 1 2 1

332111

4 2 1 1 1

2242212

3 1 2 1

24434 1

44424 1

1 2 2 1 1

1 4 4 1 1

24422 1

44441 1

321211

222 1 2 1

34222 1

44333 1

2222112

2332112

132221

111111

114111

424111

134121

1 2 2 1 1

1 1 2 1 1

111111

44433 1

444 1 3 1

442 1 2 1

44423 1

Barium Sulfide

Beer

Beet Sugar Liquor

Benzene

Borax

Blk. Sulfate Liquor

Boric Acid

Brine

Bromine-Dry

Bromine-Wet

Bunker Oil

Buttermilk

Butyric Acid

Cal Bisulphite

Cal Carbonate

Calcium Chloride

Cal. Hydroxide

Cal. Hypochlorite

Calcium Sulphate

Carbolic Acid

Carbon Bisulfide

Carbon Dioxide

Carbonic Acid

Carbon Tet-Wet

Carbon Tet-Dry

Carbonated Water

Castor Oil

Chlorinated Solv.

Chloric Acid

Chlorinated Water

Chlorine Gas-Dry

Chlorine Gas-Wet

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-3

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

Chloroform-Dry

Chlorosulphonic-Dry

Chlorosulphonic-Wet

Chrome Alum

Chromic Acid

Citric Acid

Coconut Oil

Coke Oven Gas

Copper Acetate

Copper Chloride

Copper Nitrate

Copper Sulfate

Corn Oil

Cottonseed Oil

Creosote

Crude Oil, Sweet

Diesel Fuel

Diethylamine

Dowtherm

Drying Oil

Epsom Salt

Ethane

Ethers

Ethyl Acetate

Ethyl Alcohol

Ethyl Chloride, Dry

Ethyl Chloride, Wet

Ethylene Glycol

I Ethylene Oxide

Fatty Acid

Ferric ChlorideFerric Nitrate

8 QJ

~ ~ wE 0 « -::: QJ 0 I"-:::J 0 LL ~ CooNEC -<:t(J) .cz ~cWNO:::J.- (f) - >- (J) e:: C Q) <b c 0.. .-§~gsOWW.Q.2:'cooE666~_ 1o....+-<=.,-LL >'0 ::::J::t:: Q) (l)===:"!::::«CO(J)«C')I-Zo..CO>ZO«««1-

11111124241 21

141321444314

444441 4 4 3 1

33211 2244244 1 4 2 4 3 4 422

24423 1 441 1 1 1 1

133211 11211

13211 2231

443121 1 2

4442414

44442142 421

424221 2 12

444411421 12

223 21 1 21

222 1 2 1 4 4 442

12211 12

1111113

241211 23

11211 441

333 21 1 21

12321 111

11111 121

121 11 3333

12111 444111

211121 11111 1

221211 43311 2

224211 3311 2

1211112212131 1

44222 1 1 3 4 4 4 221

13221122121 1

4444414211142

444421 2111 42

NOTE: USE THIS CORROSION CHART WITH CAUTIONl See p. C-1

C-4

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

1 1

1 1

1 11 1

1 1

1 1

1 11 1

1

4

2 12 3

2 21 11 1

1 1

1

2

2

2 4

2 4

42 2 4

2 1

2 11 1 4

2 2 4

2 3

444

4 14 4

3

1 1 1 1 1

1 1 1 1 4

11112

1 1 2 1

1

1

1

3 1

222

221 2

4 1 4 3

4 1 4 4

333 2

1 1 2 1

44131 2

43141 1

1 1 1 1 1

1 111

1 1 1 1

1 1 1 1 1

111111

1 1 1 1 1

111311

1 1 3 1 1

1 1 2 1 1

1 1 2 1 1

1 1 3 1 1

1 1 2 1 1

3 3

2 32

3

2

2

4 3

4

4 2

2 4

2 2

1 4 2

1 4

1 4 2

1

1

1

44442

44444

34422

222 1

2 3 1 1 2

44414

4 1 1 1

414111

111111

22422 1

124321

4 2 4 4 2 1

223 1 3 1

111111

22222 1

11111 1

22221

11111

1 1 2 2 1

1 1 4 1 1

1 1 2 1 1

1 2 1 2 1

11111

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

111111

44444 1

44424 1

141211

44424 1

Ferric Sulfate

Ferrous Chloride

Ferrous Sulfate

Fish Oils

Fluorine-Dry

Fluorine-Wet

Fluoroboric Acid

Fluorosilicic Acid

Formaldehyde Cold

Formaldehyde Hot

Formic Acid Cold

Formic Acid Hot

Freon

Fuel Oil

Furfural

Gasoline

Gas, Manufactured

Gas, Natural

Gas Odorizers

Gelatin

Glucose

Glue

Glycerine

Glycols

Grease

Heptane

Hexane

Hydraulic Oil

Hydrobromic Acid

Hydrochloric Acid

Hydrocyanic Acid

Hydrofluoric Acid

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-5

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

L() (lJo c

E :::t .$!1 (lJ 0 ~:::l 0 « >, cooNEc ~(J)u...cZ ~c<DN():::l.- (f) - >, (J) e:: c (j) ell c 0.. .­§gJg;O<DW..Q~cooE6'6'6'iii

_ 1- ...... =.,.-LL >'0 ::J.~ Q) (J.)===:!::=«CO(J)«C0f-ZQ..CO>ZO«««f-

Kerosene

Ketchup

Ketones

Lactic Acid

Lard Oil

Magnesium Bisulfate

Magnesium Chloride

Mag Hydroxide-Cold

Mag Hydroxide-Hot

Magnesium Sulfate

I Maleic Acid

Malic Acid

Mayonnaise

Melamine Resin

Hydrogen Gas-Cold 1

Hydrogen CI-Dry 4

Hydrogen CI-Wet 4

Hydrogen Perox-Dil 1

Hydrogen Perox-Con 1

Hydrogen Sulfide-Dry 2

Hydrogen Sulfide-Wet 2

Hydrofluosilicic 4

Illuminating Gas 1

Ink 3

Iodine 4

Iodoform 1

Isooctane 1

Isopropyl Alcohol 2

Isopropyl Ether 1

JP-4 Fuel 1

JP-5 Fuel 1

JP-6 Fuel 1

1

1

1

1

1

2

2

4

4

1

224

2

111 1

32121

4 4 341

4 4 221

4 4 4 1 1

2 2 2 1 1

43111

44131

1 1 111

3 4 1 1

4 4 221

1 1 2 1 1

1 1 1 1 1

2 1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

1 1 1 1

4 4 221

1 3 2 1

2 3 2 1

221 2

2 2 1 1

4 2 1 1

1 1 1 1

3 2 2 2242 1

4 4 1

2

2 1

2 1

4

4 2 1 1 1 2

441

4234442

4 2 3 4 4 4 2

2 1 1

1 2

1 1

3 2 2 4

21 3

3 33 3

1 3 1

1 3 1

1 3 1

2 1 3 1

1 1 1 1

444 1

233 4

1 121

2 1

2 1

22 1 1

1 2

1 1

1

1

1

2

2

2 4

2 1

1

1

1

1

1

1

1

1

1

2 1

1 1

1

2

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-6

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

Mercuric Cyanide

Mercury

Methane

Methyl Acetate

Methyl Acetone

Methyl Alcohol

Methyl Chloride

Methylamine

Methyl Ethyl Ketone

Methylene Chloride

Milk

Mineral Oil

Molasses

Mustard

Naphtha

Naphthalene

Nickel Chloride

Nickel Nitrate

Nickel Sulphate

Nitric Acid-1 a %

Nitric Acid-30 %

Nitric Acid-80 %

Nitric Acid-1 00 %

Nitric Acid-Anhyd.

Nitrobenzene

Nitrogen

NitrousAcid-10 %

Nitrous Oxide

Oils Animal

Oleic Acid

Oleum

4 4 2 2 1

44221 1

111111

222111

211111

222 1 2 1

411211

242321

111111

122221

144211

11111 1

111111

2 1 2 1 1

111111

221211

44422 1

34222 1

434 1 2 1

44441 1

444411

44441 1

44441 1

441411

111111

111111

44442 1

32242 1

111111

223 1 2 1

22221

12111 1

1 1 2 1

444 1

4 4 4

1 4 1 1 1

2 3 312

2 3 3 1 1

44412

3 4 341

311111

1 1 1 121

22111 1

1 1 1 1

3 1 4 1 1

3 1 412

2 1 1 1 1 4

11'112

2 1 1 1 1 2

3 1 2 4 4

3 1 343

4 2 4 4 1

42441

4 14 3 4 1

1 1 1 1

3 1 1

224

1 2

1 1 3 1 1

33342

2 1

1 4

1 11 1

1

1

2 22 12 1

221

1

4 24 2

2 4

2

1

2I

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-7

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

L() <llo c=! ~ <D

E ° « >- <ll 0 "-:::l 9(/)LL..cZ a3 oOOC\JEc .... Q."'" .... c<DC\J:::l.- (f) - >- (/) c <ll <1l c Cl. .-5gJ25o<D UJ .2.ccoo:E:666@_ 1......--=.-LL >'0:J:t::: (l) CD===."!:::::«D:l(/)«0?I-ZQ.D:l>ZO«««1-

Olive Oil

Oxalic Acid

OxygenOzone-Dry

Ozone-Wet

Palmitic Acid

Paraffin

Paraformaldehyde

Pentane

Parez 607

Phenol

Phosphoric-10 %-Cold

Phosphoric-10 %-Hot

Phosphoric-50 %-Cold

Phosphoric-50 %-Hot

Phosphoric-85 %-Cold

Phosphoric-85 %-Hot

Phthalic Acid

Phthalic Anhydride

Picric Acid

Pine Oil

Pineapple Juice

Potassium Bisulfite

Potassium Bromide

Potassium Carbonate

Potassium Chlorate

Potassium Chloride

Potassium Cyanide

Pot. Dichromate

Pot. Diphosphate

Pot. Ferricyanide

Pot. Ferrocyanide

1 2 23 2 4

1 1 21 4 11 4 3

2 2 2

112

213

1 2 24

2 1

1 2 4

1 2 4424

424

422

423

223

1 2 13 4 4

1 2 21 3 3

2 2 4

424

4 3 2

423

4 3 3442

1 2 22 2 12 2 3

1 2 1

1 1221

1 1 1

1 1 1

1 12 1 1

1 1

1 1 1

221

4 1221

121

1 4 1121

1 4 1

111

1 1 1

2 1 1111

421

1 11 1

421

221

221

3 1 1

2 1 1

1 2 12 1 1

1 1

221

221

2 22 22 22 2

2 22 2

1 2 13 1 3 2

1 111

1

1

2 2 1 1121

2 2 2 1

121 2

42442

2 1 1 4 1

2 1 144

2 1 241

2 1 244

3 2 4 1

3 2 4 4

331 2

3 3 1 1

3 1

1 3

1 11 1 4

1 1 2

1 1 2

1 1 3

1 1 2

1 1 2

1 1 21 11 1 2

1 1 2

2 41 1

1

2

1

1

1

4

44 4

4

42 1

1

2

3

2

12

2

2

2

2

2

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-8

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

I

21 11 1

1 12 1

1 1

1 1

2 1

1 1

2 1

2 2

2

1 1

2 11 11 1

1 1

2 22

1 1

2

2

1

2

2 4

2 1

2

1

2

1

1

2

2

1

4

2

2

22 1

3 1

1 1 2

1 1112

1 1 1

1 1 1

2 1 1 1 1 2

111111

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1 1

1 1 1 1

2 3 2

3 1 1

3 1 1

3 1 1

22

2 22 2

2 2

2 1

1

2

23131 2

2221211

11112

1 1 1 1 1

11112

11112

2

2 22 1

2

221

221

1

1

1

1

1

1

1

1 3 2

1

1

11

1

1

11

1

1

1

1

11

1

1

11

1

1

11

1

1

1

1

1

11

1

1

4 4 3 1 1

44342

1 2 2 2 2

1 3 2 1 1

44442

1 1 1 1 1

11111

22322

44421

22412

1 2 3 1 3

2 2 3 1 1

44424

44424

4 4 4 4 1

1 1 1 1 2

4 2 1 1 1

2 2 2 1 1

23422

4 4 2 2 1

4 3 2 2 2

4 4 1 1 1

22212

1 2 3 1 3

1 1 1 1 1

4 4 1 4 1

2 4 4 1 2

4 4 2 1 1

1 3 1 1 1

4 4 2 2 1

44122

Pot. Hydroxide

Pot. Hypochlorite

Pot. Permanganate

Potassium Sulfate

Potassium Sulfide

Propane

Propyl Alcohol

Pyrogallic Acid

Salad Oil

Salicylic Acid

Salt

Seawater

Silver Bromide

Silver Chloride

Silver Nitrate

Sodium Acetate

Sodium Aluminate

Sodium Bicarbonate

Sodium Bisulfate

Sodium Bisulfite

Sodium Borate

Sodium Bromide

Sodium Carbonate

Sodium Chlorate

Sodium Chloride

Sodium Chromate

Sodium Cyanide

Sodium Fluoride

Sodium Hydroxide

Sodium Nitrate

Sodium Perborate

Sodium Peroxide

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-9

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

Sodium Phosphate

Sodium Silicate

Sodium Sulfate

Sodium Sulfide

Sodium Sulfite

Sodium Thiosulfate

Soybean Oil

Stannic Chloride

Starch

Steam-212°F

Stearic Acid

Styrene

Sulphate, Blk. Liq.

Sulphate, Grn. Liq.

Sulphate, Whi. Liq.

Sulphur

Sulphur Chloride

Sulphur Dioxide-Dry

Sulphur Dioxide-Wet

Sulphur-Molten

Sulphur Trioxide

Sulphuric Acid 0-7 %

Sulphuric Acid 20 %

Sulphuric Acid 50 %

Sulphuric Acid 100 %

Sulphurous Acid

Tannic Acid

Tartaric Acid

Tetraethyl Lead

Toluene

Tomato Juice

Transformer Oil

4 1 4 1 2 1

111111

222211

133221

144211

244111

2 2 3 1 1

44434 1

1 2 3 2 1

211111

433111

11111 1

142221

44222 1

2 3 3 2 1

142111

44433 1

132211

44441 1

142111

22222 1

134121

434 1 4 1

43444 1

432411

24442 1

11111 1

144111

22321

1 1 1 1 1

1 3 3 1 1

1 2 1 1 1

2 2

2 1 1

2 2 1 1

2 2 1 12 2

1 1 1

1 1 2

1 1 1

1 1 1

4 3 4

1 1 3

4 43 3 1

3 3 1

3 3 1

4

433

44 4 3 4

2 13 23 3

4 2 4

313

2 1 1 24 3 1 1

4 4 2 4

1 1 1

1 1 2

1

1

2

22

1 21

1 4

14 1

1 2

2

2

4

1

2

2

2321

141

4 4 2

442

3 4

1 1

1 1

1

11

1

1 1

2 1

2 222

2

2 2

12 21 1

1

2

21

41

2

234

4

2 1

2 1

1 2

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

C-10 ----------------------

1. Excellent.2. Good, Most Conditions.3. Fair, Limited life and

restricted conditions.4. Unsatisfactory.

22 1 1 1

2 1 111

424 1

4221112

11112

2 1 1 1 1 2

3

1

2 4

1

1 2

4 4

Tributyl Phosphate

Trichloroethylene

Turpentine

Urea

Varnish

Vegetable Oil

Vinegar

Water, Boiler Feed

Water, Fresh

Water, Salt

Whiskey

Wine

Xylene-Dry

Zinc Chloride

Zinc Hydrosulfite

Zinc Sulfate

111111

131121

211111

22322 1

1 1 3 1 1

142211

344111

332111

1 1 3 1 1

334 1 2 1

334311

324211

1 121 2 1

44424 1

1 2 1 1

34422 1

1 43 3

4 2 4 1 1

3 1 4 1 1

1 2

1

1

2

21

1 1

2

NOTE: USE THIS CORROSION CHART WITH CAUTION! See p. C-1

CREDITS

FERRULE PAK, GOOP, SNOOP, SWAGELOK,SWAK, ULTRA-TORR, VAC GOOP, VCO, VCR -TM Swage10k Marketing Co.DOWTHERM-TM Dow ChemicalDELRIN, FREON, KALREZ, VESPEL, VITON-TM DuPontKEL-F-TM 3M CompanyPYREX-TM Corning GlassTHERMINOL-TM Monsanto CompanyTYGON-TM Norton Company

Various products throughout this manual are subjects of patent or patent pending applications.

---------------------- C-11

I

C-12 ---------------------

PAGEAllowable pressure charts. See Pressure ratingsAnaerobic sealant 3-55, 3-56ANSI Code 831.3 9-1-10Appendix

Birmingham wire gauge table B-2conversions

area B-11decimals to fractions B-11flow rate A-27fractions to decimals B-11inches to millimeters B-11length B-11millimeters to inches B-11pressure A-26, A-27temperature of to °C B-12volume B-10

corrosion charts C-1-11credits C-11decimal equivalents B-11elastomers B-3elements, table of B-8equivalent straight lengths tubing A-1flow calculations

air A-16-25liquid A-2-15

flow chartsair A-16-25water A-6-15

material temperature ratings B-9mean velocity vs. tube ID A-15O-ring dimensional table B-3pipe wall thickness B-13specific gravity

of gases B-7of liquids B-6of water vs. temperature B-5

1-1

Appendix (cont.)steam, properties of B-4temperature

conversion formulas B-12conversion tables °C to OF B-12ratings of materials B-9

tubing, wall cross sectional area B-14-16ASTM

specifications, tubing 9-1-7A161 steel 2-5, 2-9A179 steel 2-5, 2-9A213 stainless steel. 2-5, 2-8A249 stainless steel 2-5, 2-8A269 stainless steel 2-3, 2-5, 2-8A450 general requirements 2-9A632 stainless steel 2-5, 2-9B68 copper. 2-5, 2-10B75 copper. 2-5, 2-10B88 copper. 2-5, 2-10B165 alloy 400/R-405 2-5, 2-11B167 alloy 600 2-5, 2-11B210 aluminum 2-4, 2-11B251 copper. 2-10B338 titanium 2-6, 2-11B468 alloy 20 2-6, 2-11B622 alloy C-276 2-5, 2-11

standards, tolerances 1-1 0, 2-8-11Bending 3-17-25

factors 3-14near tube fitting 3-24, 3-25radius 3-26

Birmingham wire gauge table B-2Checklist for excellence in tube fittings 1-8, 1-9

design 1-8, 1-9installation 1-9performance 1-9service 1-9

1-2

Compressed gas systemscorrosive 4-4flammable 4-4inert 4-5oxidant 4-5oxygen 4-5toxic 4-5

Conversionsarea B-11decimals to fractions B-11flow rate A-27fractions to decimals B-11inches to millimeters B-11length B-11millimeters to inches B-11pressure A-26, A-27temperature of to °C B-12volume B-10

Corrosion charts C-1-11Credits C-11Cryogenic service .4-21Decimal equivalents B-11Depth marking tool .4-1 , 4-2Distributors 1-12,1-13Elastomers 6-7,6-8,

11-11, B-3Elements, table of B-8Fittings, types of

automatic tube weld 6-4bored-thru 1-8bulkhead 3-50

retainers 3-50, 3-51configurations 1-4, 1-5face seal

"B" Type VCO 6-8VCO 1-1,6-7,6-8VCR 1-1,6-6,6-7

ferrules 1-2, 1-3flareless 1-1, 1-2

1-3

Fittings, types of (cont.)hose connectors 6-11

hose c1amps 6-11inserts 2-8, 6-10, 6-11serrated shank 6-11sleeves 6-11tapered 6-11

materials 1-6, 1-7mechanical grip 1-1pipe 1-1port connectors 3-48, 3-49positionable

elbows 3-52, 3-53tees 3-52, 3-53

reducers 3-44-46size range 1-1, 1-6tube adapters 3-44-48vacuum

butt weld 6-4Ultra-Torr 6-8VCO 6-7VCR 6-6, 6-7

weldadapter 6-2, 6-3alignment 6-1permanent 6-1-6to threaded pipe 6-1zero clearance 6-6-8

Flow calculationsair A-16-25liquid A-2-15

Flow chartsair A16-25water A-16-15

Gageability, Swagelok tube fitting 1-11, 3-35-38Gap inspection gage 1-11, 3-35-38,

4-1,4-2

I Gasket fittings 6-6, 6-7, retainer 6-6

1-4

Heat transfer fluids .4-15High pressure gas systems .4-3, 4-4Hose

flexible metal hose 6-17push-on hose 6-18swaging machines 6-20,6-21TFE lined hose 6-18thermoplastic hose 6-18-20

Hydraulic Fluid Index (HFI) 10-3Hydraulic swaging unit (HSU) 3-42, 3-43Imitation of Swagelok fittings 1-11, 1-12Impulse service .4-19Installation

1 1/4 turns 1-1, 1-3,3-34,3-35

bottoming of tubing 1-2, 3-34depth marking tool 4-1, 4-2gap inspection gage 1-11, 3-35-38,

4-1,4-2how it works 1-2, 1-3hydraulic swaging unit 3-42, 3-43instructions, Swagelok tube fitting 3-33-53make/break service .4-18, 7-9-11preswaging 3-40-43retightening 3-39SAE/MS port 3-52,3-53sealing 1-2torque 3-36troubleshooting 5-1-9

Interchangeability, intermixabilityof tube fittings 1-11, 1-12,

7-18leakage

causes 10-1compressed air 10-4, 10-5cost of 10-2-6definition 10-1formula for determining 10-2

1-5

Leakage (cont.)how expressed 10-1-4hydraulic systems 10-3, 10-4loss from one single oil leak 10-4pressurized systems 10-1, 10-2steam 10-5, 10-6vacuum systems 10-1

Materials. See Fittings, types ofSee Tubing

O-rings 6-7,11-11dimensional table 8-3

Oxygen 4-5Pipe

diameters 8-5end connection ratings (male and female) 9-10metric screw threads

pitch 8-9thread angle 8-9typical designators 8-9

thread sealing components 3-53-56threads

dryseal 8-2gaskets 8-3, 8-4180 8-2, 8-3, 8-5NPT 8-1,8-5parallel 8-3protectors 3-33pitch 8-1-3, 8-5, 8-98AE 3-52, 3-53sealants 8-1tables of sizes 8-5tapered 8-1,8-2thread angles 8-1, 8-2, 8-5threads per inch 8-5truncation 8-1-3, 8-5, 8-9

wall thickness 8-13Plastic

fittings 1-6tubing 2-6-11valves 11-9

1-6

Pressure ratingsallowable pressure charts 9-3-7chart of factors 9-9design factors 9-11pipe end ratings 9-10S (stress) values 9-3-7temperature 9-8tensile strength 9-3-7

Quick-Connects 6-13-16keyed OC series 6-14OC series 6-13OF series 6-14OH series 6-15OM series 6-15OrM series 6-16

Safetyconsiderations .4-3factors 9-11high pressure gas .4-3, 4-4severe service .4-3

Service and availabilitydistributors 1-12, 1-13regional warehouses 1-13

Severe service fittingsexplanation 6-10pressure ratings 6-10principle 6-10sizes 6-10tube walls 6-10with annealed tube 6-10with tempered tube 6-10

Sizes (tUbe fittings)fractional. 1-6, 1-7metric 1-6,1-7

SNOOP, liquid leak detector .4-12Specific gravity

of gases B-7of liquids B-6water vs. temperature B-5

1-7

I

Specifications. See ASTMSee Tubing

Steampiping 4-6-14properties of B-4systems testing .4-12tracing 4-6-14

Swagelok tube fitting11/4turns 1-1, 1-3,

3-34,3-35bends near tube fitting 3-24, 3-25gageability 1-1, 3-35-38gap inspection gage 1-1, 3-35-38,

4-1,4-2handling 3-32installation instructions 3-33-35materials 1-6, 1-7ultra-clean systems .4-15, 6-6, 6-7vibration .4-18

Temperatureconversion formulas B-12conversion tables °C to OF B-12high temperature service .4-19-21material ratings B-9

Testing and evaluationof tube fitting performance 7-1-19burst 7-14-16configuration selection 7-6evaluation 7-1-19extrapolation of test results 7-3field testing 7-4gas leak 7-7, 7-8impulse 7-14independent labs 7-3interchange 7-18, 7-19make/break 7-9, 7-10

1-8

Testing (cont.)material selection 7-6measurements 7-7obtaining test samples 7-4obtaining tubing 7-5quality assurance testing 7-7rotation 7-14sampling 7-3size selection 7-6steam 7-17,7-18tensile 7-13, 7-14testing pitfalls 7-2test planning 7-4test purpose 7-2thermal cycling 7-17, 7-18tube cutting 7-5tube wall thickness 7-5vacuum 7-8, 7-9vibration 7-12,7-13

TFE tape 3-53, 3-54Threads

metric screw 8-9pipe. See Pipe

Tubingallowable stress 9-3-7ASTM specifications. See ASTM specificationscomments and suggestions 2-1copper water 2-1corrosion allowance 9-3-7cutting 3-27-30deburring 3-30-32derating factors 9-8embossed copper 2-1equivalent straight lengths A-1erosion allowance 9-3-7for gas service 2-1 , 2-2, 9-2ganging 3-11handling 3-4, 3-5hardness tolerances 1-10, 2-8-11

1-9

Tubing (cont.)heavy wall 2-2laminated 2-1layout planning 3-6materials 2-3, 2-4mean velocity vs. tubing ID A-15measuring 3-13, 3-14minimum wall 9-2multi-wall 2-1OD tolerances 1-10, 2-8-12ovality 2-1-3ovality tolerances 1-10, 2-3,

2-8-11restricted hardness 2-4restricted surtace finish 2-4restricted tolerances 2-4Rockwell hardness 9-5-7SAE specifications 2-9scratches 2-1 , 2-2seamless 2-3selection 2-2, 2-3soft plastic 2-1specification and ordering 2-1-12stacking 3-11standards 2-8-11straightening 3-15-17support 3-8, 3-9surtace defects 2-1, 2-2surtace finish 2-1-3thin wall 2-2tolerances 1-1 0, 2-4-12wall thickness 2-2welded 2-4

TUbing calculations 9-1,9-2TUbing tolerances 1-1 0, 2-8-12Tubing versus piping 3-1-4Tubing wall/lDI cross sectional area B-14-16

1-10 ----------------------

Vacuumfittings. See Fittings, types ofultra-high 6-6

Valvesactuation 11-14, 11-15end connections, types 11-4-8

face seal 11-5VCO 11-5VCR 11-5

flanges 11-7, 11-8pipe threads 11-6Swagelok tube fitting 11-5weld 11-6

flow capacity 11-10flow coefficient 11-9, 11-1 0functions, explanation 11-1

directional. 11-3, 11-4isolation 11-1, 11-2overpressure protection 11-4, 11-18regulation 11-3

installation 11-15-18lockout protection 11-17mounting 11-16positioning 11-17sample cylinders 11-18

materials 11-8pressure ratings 11-8safe valve selection 11-18size 11-9stem seals, packing types 11-10-13

conventional. 11-10live-loaded 11-11packless 11-12, 11-13

temperature ratings 11-8Welding

full penetration 6-1orbital head 6-6weldable material 6-1

1-11