EMBU KMTC UPGRADING DIPLOMA IN MEDICAL ENGINEERING R.

Video tutorial link: https://youtu.be/llaqTszbh9M

FLARE JOINTS IN RAC, AND PIPING

Flared Joints

While copper tube is usually joined by soldering or brazing, there are times when a mechanical joint may
be required or preferred. Flared fittings (Figures 9.1 and 9.2) are an alternative when the use of an open
flame is either not desired or impractical. Water service applications generally use a flare to iron pipe
connection when connecting the copper tube to the main and/or the meter. In addition, copper tube
used for Fuel Gas (Liquefied Petroleum (LP), Propane Gas or Natural Gas may be joined utilizing flared
brass fittings of single 45º-flare type, according to NFPA 54/ANSI. Z223.1 National Fuel Gas Code. All
National Model Codes permit the use of flare joints, but it is important to check with the authority
having jurisdiction (AHJ) to determine acceptance for a specific application in any particular jurisdiction.

A flare joint should be made with an appropriate tool such as those supplied by a number of
tubing/piping tool manufacturers. Make sure to use a tool that matches the outside diameter of the
tube being flared and that has the appropriate flare angle, commonly 45º (the physical characteristics of
which should be in accordance with the Society of Automotive Engineers SAE J533 Standard - Flares for
Tubing). The tool usually consists of flaring bars with openings for various tube sizes and a yoke that
contains the flaring cone and a clamp to grip the flaring bars.

When flaring Types L or K copper tube, annealed or soft temper tube should be used. It is possible to
flare Types K, L or M rigid or hard temper tube, though prior to flaring it is usually necessary to anneal
the end of the tube to be flared. The copper tube must be cut square using an appropriate tubing cutter.
After cutting, the tube must be reamed to the full inside diameter leaving no inside burr (Figure 9.3).
Tube that is out of round prior to flaring should be resized back to round.
 EMBU KMTC UPGRADING DIPLOMA IN MEDICAL ENGINEERING R.M

Failure to complete either of these steps can, lead to an inadequate seal of the flared joint and,
ultimately, to joint failure. Dirt, debris and foreign substances should be removed from the tube end to
be flared by mechanical cleaning. This can be accomplished with the use of an abrasive cloth (screen
cloth, sand cloth, emery cloth or nylon abrasive cloth).

Now, place a flare nut over the end of the tube with the threads closest to the end being flared. Insert
the tube between the flaring bars of the flaring tool in the appropriate opening for the diameter of the
tube being flared. Adjust the height of the tube in the opening in accordance with the tool
manufacturer's instructions, to achieve sufficient length of the flare. Position the yoke with the flaring
cone over the tube end and clamp the yoke in place. Turn the handle of the yoke clockwise (Figure 9.4).
This lowers the flaring cone and forces the lip of the tube against the base of the flaring bar to create an
angled flare that will mate securely with a corresponding flare-type fitting. Care should be taken not to
over-tighten the cone and cause cracking or deformation of the tube and/or the tool. Some tools also
provide a setting for ironing or burnishing the flare, as a final step to achieve a more consistent flare. The
final flared tube end should have a smooth, even, round flare of sufficient length to fully engage the
mating surface of the flare nut without protruding into the threads (Figure 9.5).
 EMBU KMTC UPGRADING DIPLOMA IN MEDICAL ENGINEERING R.M

No material (e.g., pipe joint compound) should be applied to the mating surfaces of the flare fitting and
the flared tube end before attaching the flare nut to the fitting body.

Objective:

The objective of this lab is to understand and practice the process of making flare joints specifically for
applications involving medical gases and refrigeration piping. Flare joints are critical in these applications
for ensuring leak-free connections and maintaining system integrity.

To Identify the three main components of the flare fittings; the body, the ferrule, and the nut. These
three parts work together to create a metal-to-metal seal when the nut draws the flared tubing, sleeve,
and fitting body together.

Draw, and make a structural sound flare joint.

Theory

Flare joints are mechanical connections used to join pipes or tubing in various applications, providing a
secure and leak-proof seal. They are commonly employed in industries such as plumbing, automotive,
refrigeration, and medical gas systems. Understanding the theory behind flare joints is crucial for
ensuring their effectiveness and reliability in different environments. Below are the key theoretical
aspects of flare joints:

1. Design and Construction:

Flare joints typically consist of two main components: the pipe or tubing and the fitting. The pipe or
tubing end is flared outwards to create a conical shape, while the fitting is designed to accept the flared
end snugly.

The flare angle, which is the angle at which the tubing is flared, is standardized to ensure compatibility
between components. Common flare angles include 45 degrees and 37 degrees.

The fitting may feature a cone-shaped seat or a tapered surface that matches the flare angle of the
tubing. This design helps distribute the force evenly and create a tight seal when the joint is assembled.
 EMBU KMTC UPGRADING DIPLOMA IN MEDICAL ENGINEERING R.M

2. Sealing Mechanism:

The sealing mechanism of a flare joint relies on mechanical compression and friction between the flared
end of the tubing and the fitting.

When the flared end of the tubing is inserted into the fitting, it forms a tight seal against the mating
surface. The flare angle ensures uniform contact between the surfaces, minimizing the risk of leaks.

As the fitting is tightened, it compresses the flared end of the tubing against the mating surface,
increasing the sealing force and enhancing the integrity of the joint.

3. Materials and Compatibility:

Flare joints are commonly made from materials such as copper, stainless steel, brass, or aluminum,
depending on the application requirements.

It's essential to ensure compatibility between the materials of the tubing and the fitting to prevent
corrosion and chemical reactions that could compromise the joint's integrity.

In applications involving high pressure or extreme temperatures, materials with suitable strength and
resistance to corrosion are selected to ensure long-term reliability.
 EMBU KMTC UPGRADING DIPLOMA IN MEDICAL ENGINEERING R.M

4. Installation and Assembly:

Proper installation is critical to the performance of flare joints. This includes cutting the tubing to the
correct length, deburring the edges to remove roughness, and ensuring a clean mating surface.

Flaring tools are used to shape the end of the tubing into a flare with the appropriate angle and
dimensions. Careful attention to the flaring process is necessary to avoid deformities or irregularities in
the flare.

During assembly, it's essential to apply the correct amount of torque to the fitting to achieve a secure
seal without damaging the flare or the mating surface.

5. Testing and Inspection:

After assembly, flare joints should be subjected to pressure testing to verify their integrity and leak-
tightness.

Visual inspection, as well as the use of leak detection solutions or devices, can help identify any leaks or
defects in the joint.

Regular maintenance and inspection of flare joints are necessary to ensure continued reliability and
safety in operation.

In summary, flare joints provide a robust and versatile method of connecting pipes and tubing in various
industrial and commercial applications. Understanding the theory behind flare joints is essential for
proper design, installation, and maintenance, ensuring leak-free operation and system integrity.

Materials Required:

Copper tubing or pipe (for refrigeration piping)

Stainless steel tubing or pipe (for medical gases). We will use available copper tubing.

Flaring tool kit designed for medical gases and refrigeration applications

Tubing cutter appropriate for copper or stainless steel tubing

Deburring tool

Safety glasses

Gloves

Nitrogen (for purging refrigeration lines).

Leak detection solution (for testing joints)

Bench vice.

Procedure:

1. Prepare the Tubing:

a. For refrigeration piping (copper), measure and mark the point on the tubing where the flare will be
made.

b. For medical gas piping (stainless steel), ensure the tubing is clean and free from any debris or
contaminants.

2. Setup Flaring Tool:

a. Assemble the flaring tool according to the manufacturer's instructions, ensuring it is appropriate for
the material being used (copper or stainless steel).

b. Ensure the cone is clean and free from any debris.

c. Ensure you determine pipe size in inches and apply correct flare set inch selections.

3. Flare the Tubing:

a. Slide the flaring tool's yoke over the end of the tubing.

b. Insert the cone into the tubing until it rests against the tubing's end.

c. Tighten the flaring bar onto the cone until the tubing is securely held in place.

d. Rotate the flaring bar handle clockwise to flare the tubing. Apply gradual pressure until the desired
flare is achieved.

e. Once the flare is formed, loosen the flaring bar and remove the tubing from the tool.

f. Use bench vice, or proper reinforcement for firm grip of your tool, and workpiece handling.

4. Inspect the Flare:

a. Inspect the flare visually to ensure it is uniform and smooth.

b. Check the flare's dimensions using a flare gauge or calipers to ensure it meets the required
specifications.

5. Assembly and Testing:

a. Assemble the flare joint by connecting the flared end of the tubing to the appropriate fitting.

b. For refrigeration piping, purge the lines with nitrogen to remove any contaminants and ensure a clean
system.

c. Use a leak detection solution to test the flare joint for leaks. Apply the solution around the joint and
observe for bubbles indicating a leak.

d. If the joint passes the leak test, it is ready for installation.

Safety Precautions:

Always wear safety glasses and gloves when working with tools and materials.

Ensure proper ventilation when purging refrigeration lines with nitrogen.

Use caution when operating tools and equipment to avoid injury.

Follow manufacturer instructions and safety guidelines for all tools and materials used.

Conclusion:

Creating flare joints for medical gases and refrigeration piping requires attention to detail and adherence
to specific procedures. By following the steps outlined in this lab guide and observing safety precautions,
you can ensure the integrity and reliability of flare joints in these critical applications. Regular testing and
inspection are essential to maintain system safety and efficiency.

1. Discuss the purpose of ensuring clean debris free surface on the pipework before metal joining.
2. Discuss the purpose of purging after piping.
3. Discuss purpose and definition of tools used in the practical setup.
4. Outline the process of flaring.
5. Hand in your workpiece for flaw inspections.
6. Discuss the application of flare joints in pipe joining processes in medical gas, and refrigeration.
7. Draw the schematic representation of a flare joint, and necessary coupling used to make it a
complete mechanical joint.
8. Discuss characteristics of a good flared joint.