COPPER PRESSURE PIPING SYSTEMS

opper tube for T able 1 Design stress values (N/mm 2 ) for solid drawn copper tubes (See BS 1306 for copper alloy tubes) domestic water Values of design stress for metal temperatures services at temp- Material Designation EN 12449 Condition Tensile not exceeding (BS 6017) strength (Formerly eratures up to 110C (min.) BS2871-2) -200 to is manufactured to EN 1057. 100 C 150 C 175 C 200 C +50 C However, 110C is not the 2 Annealed O 200 41 40 34 26 18 maximum temperature to which copper can be subjected Light drawn 2 250 62 59 55 34 18 in service. Indeed, copper tube, Copper Cu-DHP 1/2H (EN 12449) and copper alloys, 2 As drawn M 280 70 69 55 34 18 correctly installed and jointed, are ideal materials to use for all irrespective of wall thickness generally These do not require the use of a flux as the following industrial and marine allow for a variance of 10% of any the phosphorus content will remove the pressure piping systems: specified wall thickness. oxide film. If 1/2H, or as drawn M, Where copper tube is to be used for condition tube is heated to temperatures - steam boiler, feed and hot water; steam or condenser water services at >600C during fabrication or jointing the - hydraulic (water or oil); temperatures of up to 205C and annealed, O condition values for design - oil fuel; working pressures of up to 17bar, stress should be used. - pneumatic and gas; suitable thicknesses are shown in Table 2. - refrigeration and cryogenic; T able 2 Copper tube for steam services with plain Joints at temperatures from -200C to ends EN12449 (Formerly BS 2871-2) Tube can be joined by +200C where required. welding, brazing, soldering Low pressure range High pressure or mechanical methods, (Table 5) range (T able 6) The specification for copper and copper provided the type of joint Working pressure Working pressure alloy pressure piping systems is BS 1306. used is suitable for the up to and including up to and including This standard covers the design, tube material, pipeline fluid 7 bar, max working 17 bar, max o installation and inspection of the systems carried, its pressure and temperature 205 C working Size of mentioned above. temperature, and has temperature 205 oC tube the mechanical strength (mm) Thickness (mm) Thickness (mm) Design pressure required under service 6 0.8 0.8 To determine the required wall thickness conditions. 8 0.8 0.8 for a particular diameter of straight tube, Brazing is often used the formula is: where the maximum 10 0.8 0.8 pd working temperature does 12 0.8 0.8 t = ----not exceed 200C. Socket 15 1.0 1.0 p+20F type capillary joints and 18 1.0 1.0 Where: flanges made from copper t is the minimum tube wall thickness alloy are brazed with 22 1.2 1.2 (mm); EN 1044 group AG silver 28 1.2 1.5 p is the design pressure (bar); brazing alloys as the filler 35 1.5 2.0 d is the outside diameter of the tube metal. This requires the 42 1.5 2.0 (mm); use of a suitable flux. F is the design stress (N/mm2), at the Where both fittings and 54 2.0 3.0 maximum working temperature, and is tube are made from 67 2.0 3.5 obtained from Table 1. copper, EN 1044 group 76.1 2.0 4.0 It should be noted, however, that CP copper-phosphorus 108 2.5 5.0 tube manufacturers tolerances brazing alloys can be used.

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nitrogen flow displaces the air and prevents oxidation. Loose flange in steel with slip on The flow should be copper alloy collar continued until the tube has cooled. Silver solder capillary fittings are usually recommended for oxygen Code 307 PN 6,10, PN 16 and medical gas applications. DN 10-1800 DN 10-250 Brazing should be in accordance with BS 1723 Hubbed slip-on flange in copper alloy Locking nut and joints should be visually with tube stop Locking ring inspected before carrying out Pressure ring a hydrostatic pressure test Nitrile rubber sealing ring for strength. This is followed by a pressure test for leakage Figure 3 Ring seal joint 15 to 159 mm diameter. using nitrogen or other Code 314 PN 6,10, PN 16 PN 25 DN 10-1800 DN 10-500 DN 10-700 suitable inert gas following the guidelines set out in HSE guidance The mechanical strength of the joint is Copper alloy Steel achieved by the housing having tapered note GS4. Refrigeration liquid lines are limited sides that enable it to lock into the rolled Figure 1 Typical flanges for brazing to a maximum of 25mm ID whilst grooves. Also recently introduced to the UK vapour lines can be up to 40mm ID. Jointing refrigeration tubing Screwed compression fittings are limited market is a Norwegian developed 'O' Oil, water and dirt should be kept to a maximum of 16mm ID. Flared ring fitting made from dezincification out of the bore of all pipelines during fittings are only suitable for use with resistant brass, see Figure 3. This uses a installation.This is especially important in annealed tubes and are limited to a locking nut (or bolted flange ring on the the case of refrigeration (and oxygen) maximum of 22mm OD in locations larger sizes) to compress a split locking pipelines. The tube used should be where joints remain exposed for visual ring on to the tube for mechanical strength whilst a nitrile rubber ring forms specially de-greased by the manufacturer inspection. and supplied with its ends sealed. Any Where there is any doubt regarding the seal. temporary open ends need to be the suitability of the materials for any blanked with rubber plugs during given application, reference should be Safety note Remember, all piping systems must installation. made to the relevant manufacturer. be depressurised and drained before It is important to prevent the disassembly and removal of any fitting! formation of oxide scale inside the tube De-mountable joints when brazing refrigeration pipelines. This Figure 1 illustrates typical flange joints is achieved by connecting a nitrogen for brazing and use where disconnection Cost and performance benefits of cylinder to one end of the pipeline via a is required. Traditional non-manipulative copper Good corrosion resistance and the regulator and passing a gentle flow of gas and manipulative compression joints can through the tube whilst heating. The also be used provided the manufacturers ability to carry a wide range of fluids figures for maximum make copper and its alloys suitable for all pipeline services. temperature and virtually working pressure are Furthermore, coppers high thermal conductivity makes it the ideal material not exceeded. New on the market for heat exchangers. Its high strength, are rolled-groove mech- wear and corrosion resistance and the anical joints for EN 1057 ability to be formed to close tolerances copper tube (formerly means that copper tube has a higher table X and Y). The carrying capacity when compared to principle having been other tube made from other materials. developed for use on The ease of fabrication of copper tube steel tube for sprinkler and the wide range of jointing and Ductile iron housing installations. Figure 2 bending methods that are available, the manufacture and shows a coupling, this simplifies EPDM gasket consists of an epoxy installation of pipeline services. coated ductile iron Furthermore, the intrinsic properties of Groove rolled into copper tube housing that compresses copper over its long, proven, working life an EPDM rubber gasket results in improved cost effectiveness Figure 2 Rolled groove mechancial joint to form a pressure seal. when compared to other materials.

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