Copper Tubing & Fittings Installation Checklist and Commissioning

This article is about Copper Tubing & Fittings Installation Checklist and Commissioning & Requirements of Instrumentation and Control Systems as per International Codes and standards for Commercial Buildings, Plants and Refinery Projects.

Copper Tubing & Fittings Installation Checklist and Commissioning

Material Receiving General Checklist for Instrumentation & Control

Tubing Installation

  1. “Design Pressure and Temperature Ratings:
  3. The tubing system components specified in this Material Specification are suitable for the following conditions: [PIP PCSIP 001 Sec 4.1.1]”
  4. Tubing Dimensions:
    • 1/4-inch outside diameter (OD) + 0.003-inch, 0.030-inch wall
    • 3/8-inch OD + 0.003-inch, 0.032-inch wall
    • 1/2-inch OD + 0.003-inch, 0.035-inch wall [PIP PCSIP 001 Sec 4.1.2.2]
  5. Supports: All tubing shall be supported to avoid vibration, sags, and vapor/liquid traps. Comment: Tubing supports should be spaced not more than four feet apart.
    Comment: In locations where mechanical damage is likely, tubing may be installed in structural channel, angle, or in trays, even though not required for normal support.
    Comment: Tubing should be supported on walls or structural steel whenever possible. [PIP PCCIP 001 Sec 3.2.1 – Lib drawing DC 950040, 41& 42]
  6. When tube bundles or preinsulated/traced tubing are used, the manufacturer’s recommendations for bend radius, support methods, spacing and thermal expansion allowances shall be used as the basis for design and installation. [PIP PCCIP 001 Sec 3.2.2 – Lib drawing DC 950040, 41& 42]
  7. Tubes and tube bundles and their support channels and trays shall not be supported from process or utility piping. Tubing channels or trays shall not be supported by bolting to transmitter brackets or control valves. Comment: Tubing may be supported from structural members and instrument stands. [PIP PCCIP 001 Sec 3.2.3- Lib drawing DC 950040, 41& 42]
  8. Stainless steel straps or clamps shall be used to attach bare metal tubing to structural angle, channel and cable trays. Tube bundles shall be secured with metal straps and clamps or plastic tie-down straps.
  9. Plastic tie-down straps shall be ultraviolet resistant and of a suitable material for the ambient conditions. Comment: Tubing installed in raceways shall be firmly attached to the support at intervals not exceeding 10 feet. [PIP PCCIP 001 Sec 3.2.4- Lib drawing DC 950040, 41& 42]
  10. All instrument piping and tubing to equipment or process piping shall be properly supported to avoid strain on equipment, piping connections, and instruments. Thermal expansion and vibration of the process piping or equipment to which an instrument is connected shall be considered in designing and installing the supports. [PIP PCCIP 001 Sec 3.2.5 – Lib drawing DC 950040, 41& 42]
  11. The tube fittings to be Brass, flareless compression type. The fitting nomenclature shall be in accordance with ISA RP 42.1.
    [PIP PCSIP 001 Sec 4.1.3 – Lib drawing DC 950040, 41& 42]”
  12. Tubing to and from non-indicating instruments shall have a plugged tee or equivalent test point for calibration and testing purposes.
  13. All incoming and outgoing interconnection lines shall terminate in bulkhead fittings. The lines shall be marked with the tag numbers of the corresponding instruments.
  14. All tubing shall be installed in a neat manner with no signs of crimping, flattening, or bends with radius too small. Tubing shall not be marked or scored. On offshore facilities, scratches may lead to corrosion of 316SS tubing from salt water pitting. [HOKE instrument tube manufacturers manual- PIP PCCIP 001 Sec 3.3.1 – Lib drawing DC 950040, 41& 42]
  15. Tube Benders:On applications where bending is required, a tube bender must be used. Follow the tube bender manufacturer’s instructions to assure good bends. Either compression or draw type hand benders should be used for tubing up to 1/2 inches. Above this size hydraulic tools are recommended. [HOKE instrument tube manufacturers manual- PIP PCSIP 001 Sec 4.1.1 – Lib drawing DC 950040, 41& 42]
  16. MINIMUM STRAIGHT LENGTHS: To ensure proper insertion depth into compression fittings minimum straight lengths of tubing are needed. The following information may be used as a reference for the bending radius and for the minimum straight length before the bend for proper installation.
    · If the tubing O.D. is 1/2 inches or less, provide at least 25mm straight length.
    · If the tubing O.D. is greater than 1/2 inches provide at least 50mm straight length. If the straight length is not possible, an elbow should be used. [HOKE instrument tube manufacturers manual – PIP PCCIP 001 Sec 3.3.2 – Lib drawing DC 950040, 41& 42].”
  17. All open tubing shall be capped to keep out dust, dirt, moisture, and other foreign matter. [PIP PCCIP 001 Sec 3.3.3 – Lib drawing DC 950040, 41& 42]
  18. Instrument connections for process service shall be in accordance with Appendix 1 (Attachment 1). Threaded connections shall be tapered per ASME B1.20.1.
  19. Flanged connections shall conform to ASME B16.5. The rating shall be equal to or exceed the equipment or line design pressure and temperature, but be at least ANSI Class 150, RF, except for PZV and control valves.

Commissioning

“All pneumatic instrumentation shall pass:
a) Leakage test of all piping and tubing”
“All pneumatic instrumentation shall pass:
b) Functional test of all pneumatic instruments”
“All pneumatic instrumentation shall pass:
c) Functional test of all pneumatic control loops”
“All electric/electronic instruments and systems shall undergo:
a) Functional test of all electronic instruments after testing for short circuits, cable continuity, ground insulation with a “”megger””, and ground faults.”
“All electric/electronic instruments and systems shall undergo:
b) Functional test of all electronic control loops verifying a proper response to a simulated input signal.”
Pneumatic Tests: Instrument process tubing shall be tested pneumatically to 1.1 times design pressure starting at the root valve and ending at the instrument.

International Standard and Codes for Copper Tubing & Fittings Installation

Copper Tubing, Brass Fittings, and Valves for Instrument Service

3. SAES-J-200 – Pressure, 18 May 2008
4. 34 SAMSS 831 – Instrumentation for Packaged Units, 5 April 2008
5. Process Industry Practices Process Control (PIP) PCSIP001 – Instrument Piping and Tubing Systems Specifications – Oct. 2002
6. Process Industry Practices Process Control (PIP) PCCIP001 – Instrument Piping and Tubing Systems Criteria – Oct. 2002
7. O Brien Tracepak Instructions. http://www.obcorp.com/WebPages/literatu.htm
8. Swagelok Tubing data. Http://www.swagelok.com

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