TRAINING MATERIAL FOR CONTROL TECHNICIAN

INSTALLATION OF INSTRUMENTATION
TUBING
Best practices for impulse tubing installation
Separation between redundant instrument sensing lines should be provided
by free air space or barriers or both such that no single failure can cause the
failure of more than one redundant sensing line.
The minimum separation between redundant sensing lines should be at least
450 mm. As an alternate a suitable steel or concrete barrier can be used.
Instrument sensing lines should be run along the walls, columns or ceilings
wherever practicable, avoiding open or exposed area to decrease the
likelihood of persons supporting themselves on the lines or of damage to the
sensing lines by pipe whip, jet forces or falling objects.
Routing of instrument sensing lines should ensure that the lines are not
subjected to vibrations, abnormal heat or stress.
Where redundant instrument sensing lines penetrate a wall or floor the
required separation (Minimum 450 mm) should be maintained. Care should
be taken to ensure that the tubing/piping does not rest on or against any
abrasive surface.
They should be kept as short as possible. This is good for two reasons;
a. The speed of response is reduced for long runs
b. Resonance frequency is increased for longer tube runs. This is
detrimental from vibratory and seismic considerations.
The distance of transmission for instrumentation tubing should be limited to
16 meters only. Beyond this limit electrical or pneumatic transmission should
be used.
They should not cause any obstructions that would prohibit personnel or
traffic access.
They should not interfere with the accessibility for maintenance of other
items of equipment/instrument.
They should avoid hot environments or potential fire risk area.
Sensing lines should be located with sufficient clearance to permit sagging.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

reviewed to ensure that the seal does not anchor the sensing line when a
guide is required.
All sensing lines including trays, supports, instrumentation, valves, and other
in-line devices should be installed to avoid contact interferences caused by
relative motion between the sensing line and other adjacent equipment or
devices. Sources of relative motion that should be considered are thermal
expansion, seismic motions, vibrations, and design-basis accidents or events.
The Code classification of the sensing line will determine the requirements for
relative motion that shall be considered.
Routing of the nuclear safety-related sensing lines shall ensure that the
function of these lines is not affected by thermal motions due to hot blow
down of the sensing lines. One of the following methods should be used to
ensure that the sensing-line function is not affected:
1. Demonstrate by documented analysis or calculations that the majority
of the sensing line routing is at ambient temperature, and hot blow
down is not a design loading.
Or
2. Design the sensing line routing using the process design temperature
as the temperature value used in the design analysis.
Routing of the nuclear safety-related sensing lines shall ensure that the
function of these lines is not affected by the movement of the main process
(piping, ductwork, equipment, etc.) to which the sensing line is connected.
One of the following methods should be used to ensure that the sensing line
function is not affected:
1. Demonstrate by documented analysis or calculations that the process
movements are negligible.
Or
2. Demonstrate by documented analysis or calculations that sufficient
flexibility has been provided to accommodate the process movements.
Flexible hose may be used in sensing lines to accommodate the process
thermal, seismic, and vibrational movements if its ratings equal or exceed the
design requirements, including service life. Installation considerations should
include maintaining slope and no low points.
Instrument sensing lines and accessories inside the Containment Building
shall withstand the pressure profile during containment leak-rate testing.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Tubing Handling
Imperfection on the tube OD can be potential source of problems in a tubing
system. Handling of the tube shall be done very carefully to avoid scratches
and protect the finish of the tubes.
Dragging the tube across any surface that could scratch the surface can
cause seal corrosion and sealing problems. On offshore facilities
scratches on tube may lead to corrosion of SS tubing from salt water
pitting.
It is a good practice to visually inspect tubing to ensure it is free from
scratches and other damage.
When cutting the tubing hacksaw must not be used, the correct tool is a
tube cutter with a sharp blade.
Correct deburring tool shall be used for deburring both inside and
outside edge of tube ends.
It is good practice to clean the tubing with dry instrument air. If the
surface requires higher degree of cleanliness then a cleaning agent
should be used.

Some Practical Guidelines for Tube Laying and Bending

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

EXACT MEASUREMENT is required to insure that you obtain the desired distance
between bends. If you do not measure exactly, the tube line will not fit. (See
Figure-10-2 below)

ACCURATE BENDING is necessary to achieve the exact angles required for the
tube line. If you do not bend accurately, the tube line will not fit. (See Figure 10-3
below)

2. Tube Centerline Basis for Measurement:

The centerline of the tube is the basis for all tube line measurement (See Figure10-4 below). Always measure from the centerline except from the first bend which

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

is measured from the end of the tube. On most benders, the edge of the radius
block is at the centerline of the tube.

3. Control Accuracy
Remember only you can control the accuracy of your work. Use good, careful
workmanship at all times.

Tube Bending Check list

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

Keep Track of Changes of Plane

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

Bend Direction Mark

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

(See Figure 10-5 above)Put the mark on the side opposite the direction in which you wish
to bend. When you put the tube in the bender, center the mark face up in the groove of
the radius block. (See Figure 106)This will insure that you bend
in the correct direction. It also
gives you a reference mark in
case you must leave your work
unfinished.

Marking the Tube

Whenever you make a mark on
tubing, use a sharp pencil. Use a
ferrule as a guide to make
measurement marks all the way
around the tube so that the mark
is always visible. (See Figure 10-7) Dont use grease
pencils or crayons as these make too wide a line which
can easily affect accuracy.

Measure and Mark

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

Rules for Positioning Tubing in Bender

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Tube Positioning Rules
90 angles - tangent flush with length mark (refer to dotted line xy
tangent to radius block @ 90 fig. 10-8 (above).
Angles less than 90 - tangent intersects length mark at centerline.
Angles more than 90 - position for a 90 bend and continue on to
desired angle, i.e. 135, 145. (i.e. Length mark @ 90 on link member)
Horseshoe or u-bends measure first leg, position for 90, bend
around to 180.

Compensate for springback:

a.

Test a piece of the material before you start fabricating a line to see how much it
springs back on a 90 bend.
b.
Overbend by the amount of
springback. For example, if the material
springs back 3 on a 90 bend, bend to 93
to secure a finished 90 bend, or to 461/2 to obtain finished 45 bend. This
works especially well with large heavywall tubing.
c.
Remember, it is always better to
underbend slightly. You can always bend a
little more if needed, but its almost
impossible to remove or straighten a bend,
especially with large, heavy-wall tubing.
REMEMBER - A TUBE BENDER BENDS IT CAN NOT UNBEND.

Tube Stretch or Pickup

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

if you unknowingly make a reverse bend of 90, you will trap the gain, in table 10-1
(approximately one tube O.D.) and increase your length between bends by that amount. If
bend direction for either 45 or 90 bend must be reversed, subtract the gain amount
listed in table 10-1.
While our rule of thumb is approximately correct, the amount of stretch is related to the
diameter of the radius block used. This chart (Figure 10-11) gives the accurate increase in
length that occurs with the most commonly used sizes of radius blocks. As long as you
measure and bend with the tube inserted from the left, and measure centerline, pickup
will not affect your actual center-to- center measurement.
NOTE:
1.
Some radius blocks
may differ. Cons ult individual
radius block manufacturers for
details on other radius
diameters.
2.
For metric tubes the
size and radius can be
computed in the similar way.

Table-10-1

Pre-Measuring
You may pre-measure a series
of bends. Measure the first
bend from the end of the tube,
the correct length. Compensate
for each bend after the first by
subtracting the amount of gain
from your chart for each 90 of
bend to allow for stretch
(Figure 4-11). Always custom
measure for the last bend.

Rule of Thumb Method

Compensate
each
measurement after the first by
subtracting the gain listed in
table 10-1. Best Way to
Measure
For
maximum

Radius of
Tube size
(in
inches)
1/8
3/16
1/4
5/16
3/8
1/2
5/8
3/4
7/8
1
1-1/4
1-1/2
2

Size

2
3
4
5
6
8
10
12
14
16
20
24
32

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Bender

Gain

Gain

(in inches)

90

45

3/8
7/16
9/16
11/16
15/16
1-1/2
1-7/8
2-1/4
2-5/8
3
3-3/4
4-1/2
8

.16
.19
.24
.30
.40
.64
.80
.97
1.13
1.29
1.61
1.93
3.43

.02
.02
.02
.03
.04
.06
.08
.10
.11
.13
.16
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TRAINING MATERIAL FOR CONTROL TECHNICIAN

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

Characteristics of a Well-Made Tubing Circuit

In a well made tubing circuit or line, bends are accurate, measurement exact. The run is
plumb, square and level. Tube ends rest firmly in the fittings and entry into the fittings is
straight. Straight tube entry is very important to insure that fittings are not under stress
and can be assembled without leaks. (See Figure 10-13below)
Remember too, that length magnifies bend angles errors. If the leg following the bend is
fairly long, an error of 1 may result in the tube line missing the desired point completely.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

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

2
3.25
2.65

1-1/2
2.41
1.96

1-1/4
1.94
1.61

1
1.50
1.22

7/8
1.31
1.05

3/4
1.25
.98

5/8
1.25
.98

1/2
1.19
.94

3/8
.94
.69

5/16
.88
.66

1/4
.80
.61

3/16
.75
.56

1/8
.70
.52

1/16
.38

D Tube
Insertion
Depth
(inches)

L
Free
Length
of Strai ght
Tubing
(inches)
.50

TUBE O.D.
inches

Table: 10-2

Common Causes of Imperfect Bends

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Offset Bends
To form a tube offset, it is obviously necessary to make two bends. With the tube benders,
it is easy to make double 45 bends. To make an offset bend simply follow the Offset
Bend Allowance steps below to determine the proper distance between the two 45
bends. Heres the procedure.
STEP 1 First, determine the total
amount
of
offset
required
(dimension F in the diagram).
STEP 2 Next, determine the angle of
offset - 30 or 45. The latter (45) is
recommended because benders are
calibrated for 45 bending.
STEP 3 Figure the length of the tube required to meet your offset requirements (L
dimension) in the diagram. For 30 bends multiply desired offset Fx 2= 30 offset
dimension L. For 45 bends multiply desired offset Fx 1414=45 offset dimension L.
STEP 4 Determine where you want the offset bend of the tube to start; and make a
reference mark (A). Now measure off the L dimension (determined in Step 3), starting
from the reference mark and make a second mark (B). You are now ready to make the
bends.
STEP 5 Align mark (A) with reference mark 45 on bender shoe handle (measurement
end to the left) and proceed with first bend. Then align (B) with 45 mark and make
second bend in proper direction (measurement end to the left). Follow previous detailed
instructions for making 45 bends in one plane.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Routing of Bends
Routing of lines is probably the most difficult yet most significant of these system design
considerations. Proper routing involves getting a connecting line from one point to
another through the most logical path. The most logical path should:
Avoid excessive strain on joints - A strained joint will eventually leak.

Figure-10-17

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Figure-10-18

Allow for expansion and contraction - Use a U bend in long lines to allow for expansion
and contraction.

Allow for motion under load - Even some apparently rigid systems do move under load.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Get around obstructions without using excessive amount of 90 bends.

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

Keep tube lines away from components that require regular

maintenance.

Have a neat appearance and allow for easy trouble shooting,

maintenance and repair.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Guidelines for Copper Tube Installation
Following additional guidelines for the installation of copper tubes should be followed.
Generally long runs of copper tubes are not used because of slow response.
Therefore, extension of tube length is not required. However, if it is needed union
is used (instead of brazing and welding).
Separation is being maintained between the pneumatic tubing used for redundant
valves/instruments.
Because of response time considerations 6 mm tubes are for short distances
whereas 10 mm tubes are used for air supply connections.
Pneumatic tubing for redundant instruments should be taken from different
supply headers.
Considering the strength and hardness of copper tubing, brass tube fitting
becomes the preferred choice. The tube fitting that is used is Brass compression
type single ferrule tube fitting.
The installation procedure of brass tube fitting is more or less similar to that of SS
tube fitting. However galling problem of straight threads is not there to that extent
as that of SS tube fittings.
Moisture free instrument air is recommended from the consideration of corrosion
of tubing.
Tubing should not be laid at a place where human or machine movements are
expected. As these tubes are soft they may get damaged.

Guidelines for Copper tube bending

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

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

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

Copper tube Joints

Soldered joints, with capillary fittings, are used in plumbing for water lines and for
sanitary drainage. Brazed joints, with capillary fittings, are used where greater joint
strength is required or where service temperatures are as high as 350F. Brazing is
preferred, and often required, for joints in refrigeration piping.
Mechanical joints are used frequently for underground tubing, for joints where the
use of heat is impractical and for joints that may have to be disconnected from time
to time.
Copper tube may also be joined by butt-welding without the use of fittings. Care
must be taken to use proper welding procedures.

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

Impulse tube/Sensing line support

Following principals should be followed while designing the instrument sensing line
supports.
Hanger, support and clamps design should include provision for seismic, pipe
whip and thermal expansion of process taps and instrument sensing lines to which
the hangers, supports or clamps may be subjected during normal operation,
seismic or other credible events.
Material for hanger, clamps, pads and spacers in contact with sensing lines should
be compatible to avoid corrosion.
From the consideration of seismic qualification the following supporting criterion
should be followed:
b) Supports should be placed at a distance of about 150 mm from each end of
tube fittings as well as bends in the tubing layout.
c) Instrument isolating valves or other instrumentation valves coming in the
sensing lines should be supported with suitable clamps.
d) In the intermediate tubing runs supports should be located in such a way
that the maximum unsupported span is not more than 1m.
From the consideration of thermal loading, tube fittings and bends coming in the
sensing lines should not be supported. This criterion will be applicable for sensing
lines/tubing where temperature cycling is expected.

Tube Clamping
Once youve taken the time to make good bends and installed them, its not enough to just
let them lay suspended in mid-air. When tubing is left unsupported, shock and vibration
will cause the tubing to shake, and in turn, cause the fitting to loosen and leak or even
allow tube to fall through fatigue.
Tube support and clamping is a necessary
requirement in the fluid power industry.
Tubing can be clamped individually, in sets,
and can also be stacked. The most
important part of any clamping system is
having enough
clamps to attain the final result. That being,
a well supported, vibration and noise free
system.
Also, most manufacturers specify SAE and
JIC approved components on their

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TRAINING MATERIAL FOR CONTROL TECHNICIAN

equipment. The best way to meet these specs concerning clamps is to utilize a clamp that
employs both an upper and lower unit made of metal and a rubber split bushing which
surrounds the tube or pipe and fits on the inside of the clamping units.
Parker Hannifin offers a tube clamp support system by the name of ParKlamp. ParKlamp can clamp and
support tube fro m 1/4 to 2 and pipe or hose fro m 1/4 to 1-1/2. It comes standard in steel and uses a rubber
grommet around the tube for vibration dampening.

Table-11-1

TUBE
O.D.

EQUIVALENT
TUBE
(mm)

FOOT
SPACING
BETWEEN
SUPPORTS

1/4 - 1/2
3/8 - 7/8
1
1-1/4 & up

6 - 13 mm
14 - 22 mm
23 - 30 mm
31 & up mm

3 ft.
4 ft.
5 ft.
7 ft.

SPACING
IN
METE RS
(Approx.)
.9 m
1.2 m
1.5 m
2.1

clamped at 1 m distance preferably.

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Alongside Table-11-1 is
showing
maximum
permissible
spacing
between clamps. It is
recommended to clamp
as close to each bend of
the tube as possible; and
one must clamp each
side. This eliminates
thrust in all directions.
The tube should be