4.2.16 CETP Instructor PowerPoint Template

1
Installing Copper Tubing in Distribution Systems
Personnel who install copper tubing are required
to know the proper techniques for cutting,
bending, joining and protecting copper tubing, as
well as the appropriate code requirements.

• In this module you will learn to identify
• Characteristics and specifications of copper
  tubing used in propane vapor distribution systems
• Common practices used in working with tubing
• Guidelines for installing copper tubing

4.2.16 Student Book ? 2004 Propane Education Research Council Page 1
2
Characteristics Specifications of Copper
Tubing Approved for Propane
Seamless Copper Water Tubing Copper water tubing
types K and L are designated by ASTM standard
sizes, with the actual outside diameter always
1/8 inch larger than the nominal size. Each type
consists of a series of sizes with different wall
thickness (Figure1). Copper tubing is ordered
by its nominal size.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 1
3
Characteristics Specifications of Copper
Tubing Approved for Propane
Figure 1. Dimensions of Nominal Size Copper
Tubing (ASTM-B88)
4.2.16 Student Book ? 2004 Propane Education Research Council Page 2
4
Characteristics Specifications of Copper
Tubing Approved for Propane
Soft Copper TubingSince soft copper tubing is
flexible and easily bent, proper installation
requires it to be supported by clamps and
suitable brackets. Soft copper tubing is most
often connected using flared and brazed fittings.
Solder used for brazing copper propane lines
must have a minimum melt temperature of 1,000
F. Soft solder should be used only on water lines
and is not permitted for use on gas lines. Air
Conditioning and Refrigeration (ACR ASTM B-280)
Tubing ACR tubing is usually charged with
nitrogen gas to keep it clean and dry until it is
used. When used for propane distribution, it
should have the ends plugged immediately after
cutting a length from a piece of stock tubing.
ACR tubing is sized by the actual outside
diameter (OD) of the tube.
4.2.16 Student Book ? 2004 Propane Education Research Council Pages 2 3
5
Characteristics Specifications of Copper
Tubing Approved for Propane
Figure 2. Common Flare Fittings
4.2.16 Student Book ? 2004 Propane Education Research Council Page 3
6
Common Practices Used in Working with Tubing
Unrolling Short lengths of tubing are
straightened by repeated rolling of the tubing on
a flat surface while pressing down on the tubing
with the palms of your hands. Longer sections of
tubing are straightened by carefully bending the
tubing with your hands. Cutting After the cut is
made, remove any metal chips on the outside of
the tubing with a file. Also, remove the burrs
on the inside of the tubing with a reamer and
make a bevel on the leading edge of the flare.
Figure 4. Tubing Cutter
Bending. Although soft tubing can be bent by
hand, a tube bending tool should be used to
protect the tubing from kinks and flat spots
during bending. Two types of tubing benders are
the spring-type bender and the lever-type bender.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 4
7
Common Practices Used in Working with Tubing
Flaring and Connecting Flared Tubing. In order to
flare the end of a piece of soft copper tubing, a
special flaring tool called a die block is used
to form the flare.
Step 1 Select the appropriate flare nut.
Step 2 Place the flare nut on the tubing before putting the tubing in the die block.
Figure 5. Die Block Flaring Tool
Figure 6. Flared Tubing Connection and Assembly
4.2.16 Student Book ? 2004 Propane Education Research Council Page 5
8
Common Practices Used in Working with Tubing
Step 3 Flare the end of tubing according to the operating instructions for the flaring tool. The following examples illustrate incorrect and correct flaring
4.2.16 Student Book ? 2004 Propane Education Research Council Page 6
9
Common Practices Used in Working with Tubing
Step 4 Clean the flare nut threads on the flared end of the tubing and the threads on the flare fitting before assembling the flared tubing connection.
Step 5 Tighten the flare nut onto the flare fitting by hand first before using a wrench.
Step 6 Once the flare tubing connection is hand tight, use two wrenchesone to hold the flare fitting and one to tighten the flare nut onto the flare fitting.
Do not over-tighten. Over-tightening can produce
a crack in the metal of the flare nut, leading to
a split and loss of the gas-tight seal. Do not
use pipe thread sealing compounds on the seats of
brass flare fittings. Flared copper connections
are metal-to-metal seals that may not seat and
seal properly if thread sealing compounds are
used.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 7
10
Common Practices Used in Working with Tubing
Connecting Copper Tubing by Brazing. Silver
brazing is another method to connect copper
tubing. When silver brazing, follow these steps
Step 1 Measure, mark and cut the tubing to the required length.
Step 2 Use the reaming tool on the tube cutter to remove the burr from the inside of the tube.
Figure 10.
Figure 11.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 7
11
Common Practices Used in Working with Tubing
Step 3 Clean the inside of each fitting by scouring with a fitting brush. Apply a thin layer of flux to the surfaces to be joined, then slide the tubing ends and fittings together.
Step 4 Apply a thin layer of flux to the silver alloy brazing rod. Hold the tip of the torch flame against the fitting until the flux begins to sizzle, then move the flame around to the other side of the fitting to ensure even heat. (When the flux begins to bubble, the connection should be hot enough for brazing.)
Figure 12.
Figure 13.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 8
12
Common Practices Used in Working with Tubing
Step 5 Touch the end of the brazing filler to the pipe just below the fitting. If it melts and is drawn into the joint, the pipe is sufficiently hot.
Step 6 Quickly apply the brazing filler along both seams of the fitting, allowing it to be drawn into the fitting by capillary action. When correctly brazed, the joint will show a thin bead of silver-colored brazing around each seam.
Figure 14.
Figure 15.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 9
13
Common Practices Used in Working with Tubing
Step 7 Allow the joint to cool until the brazing material has a frosty appearance rather than a shiny silver color one. Then, wipe away any excess material with warm water, a wet cloth, and a brush. (Brazing filler will harden in a minute or less if the joint has not been overheated.)
Figure 16.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 9
14
Guidelines for Installing Copper Tubing
Buried Distribution Lines Where copper tubing
is used in an underground tank installation, a
dielectric union should be installed at the
building service entrance to electrically isolate
the copper tubing from steel pipe or tubing used
in the building distribution lines.
Non-conductive insulating material should also be
installed to prevent contact between the copper
tubing and the steel of the underground tank,
dome, and riser. Buried copper tubing should be
one continuous piece. Buried brass fitting
joints should be avoided. Distribution Lines
Inside Homes and Businesses

• In accordance with NFPA 54, 2002, 6.3.2, flared
  connections are not permitted in concealed
  spaces, while brazed connections are permitted.
• Unprotected copper tubing should not be used in
  wall partitions or other locations that
  potentially subject it to puncture by nails,
  screws or other fasteners. If copper is located
  where it is subject to potential puncture or
  other damage, it must be a single unsecured run
  and protected by a minimum 0.0508 inch thick
  steel pipe casing or suitable metal plate strike
  barrier.

4.2.16 Student Book ? 2004 Propane Education Research Council Page 10
15
Guidelines for Installing Copper Tubing
Distribution Lines Inside Homes and Businesses

• Copper tubing cannot be continually bent back and
  forth without eventual breakage. For this
  reason, it must not be used to connect appliances
  subject to being moved for cleaning or other
  purposes by the customer. The bending action and
  stress on the tubing is especially severe at the
  points where the connections are made.
• Installers must exercise care when flaring copper
  tubing. If a flare is made that contains splits
  or other imperfections, or is too large or too
  small for the flare nut, it must be cut off, and
  a proper flare made. Because flared copper
  tubing joints are metal-to-metal formed seals, do
  not use pipe thread sealing compounds. Also,
  know how to properly tighten brass fittings to
  assure gas-tight joints in copper lines without
  splitting the tubing or flare nut.

4.2.16 Student Book ? 2004 Propane Education Research Council Page 10
16
Guidelines for Installing Copper Tubing
Distribution Lines Inside Homes and Businesses
5.6.5 Workmanship and Defects. Gas pipe, tubing,
and fittings shall be clear and free from cutting
burrs and defects in structure or threading and
shall be thoroughly brushed, and chip and scale
blown. Defects in pipe, tubing, and fittings
shall not be repaired. Defective pipe, tubing,
and fittings shall be replaced.
7.1.1.1 Prior to acceptance and initial
operation, all piping installations shall be
inspected and pressure tested to determine that
the materials, design, fabrication, and
installation practices comply with the
requirements of this code. 7.1.1.3 Where repairs
or additions are made following the pressure
test, the affected piping shall be tested. Minor
repairs and additions are not required to be
pressure tested provided that the work is
inspected and connections are tested with a
non-corrosive leak-detecting fluid or other
leak-detecting methods approved by the authority
having jurisdiction. 7.1.1.4 Where new branches
are installed from the point of delivery to new
appliance(s), only the newly installed branch(es)
shall be required to be pressure tested.
Connections between the new piping and the
existing piping shall be tested with a
non-corrosive leak-detecting fluid or approved
leak-detecting methods.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 11
17
Guidelines for Installing Copper Tubing
8.5.7 Sediment Trap. If there is no sediment
trap, one shall be installed as close to the
inlet of the equipment as practicable at the time
of equipment installation. The sediment trap
shall be either a tee fitting with a capped
nipple in the bottom outlet as illustrated in
Figure 8.5.7, or another device recognized as an
effective sediment trap. Illuminating appliances,
ranges, clothes dryers, decorative appliances for
installation in vented fireplaces, gas
fireplaces, and outdoor grills shall not be
required to be so equipped.
4.2.16 Student Book ? 2004 Propane Education Research Council Page 12
18
Time to See If You Got the Key Points of This
Module

• Complete the Review on pages 13 14.
• See if you are ready for the Certification Exam
  by checking off the performance criteria on
  pages 15 16.

4.2.16 Student Book ? 2004 Propane Education Research Council Pages 13 - 16