Multijacketed, Jacketed,Insulated, and Pre-Insulated TubingInstallation InstructionsThese instructions provide the user with information forthe installation of Swagelok single-jacketed tubing,multijacketed tubing, insulated tubing, and pre-insulatedtrace tubing bundles. For additional information, see theSwagelok Multijacketed Tubing, Jacketed Tubing andInsulated Tubing catalog, MS-02-188 and Swagelok PreInsulated Tubing Bundles catalog, MS-02-316. CautionAll installations must be done in accordancewith applicable local codes.ContentsGeneral InformationKeep all exposed ends of the tubing and insulationsealed at all times during storage, handling, andinstallation. Temporary methods may use a combinationof water resistant plastic tape, caps, or bags. Permanentinstallations should use one of the methods described inthese instructions. CautionNever allow insulation to get wet.Determining Required LengthGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . 11. Determine the length of tubing required.Determining Required Length . . . . . . . . . . . . . . . . . . 12. Measure along the path of installation. Measure tightor square into corners. Add sufficient length in orderto make connections at each end.Uncoiling and Straightening . . . . . . . . . . . . . . . . . . 1-2Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Special Installation Instructions for MultijacketedTubing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Uncoiling and StraighteningBundle Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5There are four methods for uncoiling and straighteningtubing depending on the type of tubing product andavailable equipment. Refer to the table to select theappropriate method of for your application.Single-Jacketed Tube Bending . . . . . . . . . . . . . . . . . 5Installation and Support . . . . . . . . . . . . . . . . . . . . . . . 6Preparing Multijacketed Tubing for Breakout . . . . . . . 7MethodNumberUncoilingMethodStraighteningMethod1By handUnroll on floorSmall coil ofsingle-jacketed ormultijacketed tubing2By handUse secondsmaller spoolSpool ofsingle-jacketed ormultijacketed tubing3By handFive-rollstraightenerCoil of singletubingTracer Connections . . . . . . . . . . . . . . . . . . . . . . 124Center Line Tool for Pre-InsulatedTubing Bundles . . . . . . . . . . . . . . . . . . . . . . 12SpoolstandFive-rollstraightenerSpool ofsingle tubing5Breakout Tool for Multijacketed Tubing . . . . . . . . . . . 8Cutting Jacketed Tubing . . . . . . . . . . . . . . . . . . . . . . 9Heat Shrink Adhesive-Lined Sleeve Installation . . . .10Heat-Shrink End-Seal Boot Installation forInsulated and Pre-Insulated Tubing . . . . . . . . . . 11Self-Bonding Silicone Sealing Tape . . . . . . . . . . . . . 11Pre-insulated Tubing Bundles . . . . . . . . . . . . . . . . . 12Determining Required Length . . . . . . . . . . . . . . 12Heat-Shrink Entry-Seal Boot Installation Kitfor Pre-Insulated Tubing Bundles . . . . . . . 13Combination spool stand/bundle straightenerType of TubingSpool ofsingle-jacketed ormultijacketed tubingSilicone Sealant Installation forPre-Insulated Tubing Bundles . . . . . . . . . . 13Jacket Patch Kit Installation forPre-insulated Tubing Bundles . . . . . . . . . . 14Power Connection Installation forPre-insulated Tubing Bundles . . . . . . . . . . 15Temperature Sensor Installation forPre-Insulated Tubing Bundles . . . . . . . . . . 15MS-CRD-ITUB, RevENovember 2018,

Method 1: Unroll the coil on the floor or other flat surface.Straighten by hand and remove any bows.Method 2: Use a second smaller spool to straighten theproduct as it is taken off of the larger shipping spool.Method 4: Mount spool on spool stand with five-rollstraightener attachment.1. Use a ramp to lift spool into place.2. Adjust straightener position.Method 3: Use theSwagelok five-roll tubestraightener to straightenbare and jacketed tubingin sizes from 1/8 in. to1/2 inSee Swagelok instruction,MS-CRD-0147, for moredetails3. Adjust straightener to straighten tube.4. Pull tube to create straight section of required length.2MS-CRD-ITUB, RevENovember 2018, CP

Method 5: Mount spool on combination spool stand/bundle straightener.1. Install support spindle through center hole in spooland install collars.5. Rotate roller assembly towards operator.2. Use ramp to load spool and fit spindle into C-bracketon stand. Install safety pins through holes inC-bracket to secure spool in stand.6. With a steady motion, pull tubing through rollerassembly.3. Pull tubing from bottom of spool.7. Continue to pull tubing through rollers to desiredlength.CuttingAfter tubing has been straightened and pulled to desiredlength, cut tubing with appropriate tool (hack saw orband saw).4. Thread tubing between rollers.MS-CRD-ITUB, RevENovember 2018, CP3

Special Installation Instruction for Multijacketed TubingWhen the installation requires the multijacketed tubing to change elevation, that is to be bent into a different plane(horizontal to vertical or vertical to horizontal), follow the steps below for best results.1. Twist bundle 90 to bend on flat side.3. Twist bundle back 90 in the opposite direction as instep 1.4. When working with more than one multijacketedbundle, overlap the twisted bundles through theelevation transition.2. Make the bend with the flat side of the multijacketedtubing bundle following the radius of the tubing tray.Bundle BendingBend the tubing using a bundle bending tool (Fig. 1) or amandrel such as a small spool (Fig. 2) with a radius of atleast 8 in. (203 mm). If the bundle is oval in shape, makethe bend with the wide side of the bundle against thetool or mandrel (Fig. 3).Bundle Bending Tool Ordering InformationBundled TubingBend RadiusSwagelok BundleBending ToolOrdering Number8 in. (203 mm)MS-BBT12 in. (305 mm)MS-BBT-12Note: A bundle bending tool with a 12 in. (305 mm)radius must be used when the bundle has any ofthese characteristics: The bundle contains two or more 3/4‑in.(18 mm) OD tubes. The smallest bundle dimension is 1.75 in.(44.4mm) The bundle contains a tube 1 in. (25.4 mm) ODWhen using a bundle bending tool:Fig. 1Fig. 2Fig. 3Fig. 41. Place the hook around the bundle towards the endof the bundle that you need to move during the bend(Fig. 3).2. Rotate the handle towards the stationary end of thebundle until the desired bend is achieved. If a bendgreater than 90 is required, reposition the bendingtool and make additional bends.4MS-CRD-ITUB, RevENovember 2018, CP

Bundle Bending, continuedFor multi-jacket tubing only:To make a lateral bend (Fig. 4):1. Make the initial bend (Fig. 5).2. Twist the bundle (90 maximum), and make the otherbend (Fig. 6).Fig. 5Fig. 6Single-Jacketed Tube Bending1. Calculate bending as normal. See Swagelok TubeFitter's Manual, MS-13-03.4. Make sure that shoe of bender is sliding over jacket.2. Liberally lubricate jacket before bending with siliconespray or light oil to prevent tearing of the jacket.5. Bend tubing to required angle.3. Use tube bender one size larger than tube OD toaccommodate jacket thickness.6. After bend is complete, inspect the condition of thebend to make sure jacket is intact.MS-CRD-ITUB, RevENovember 2018, CP5

Installation and Support To permanently install the tubing, remove temporaryend seals and install the heat-shrink boot. See HeatShrink End Seal Boot Installation, page 11. Route tubing along existing structures, such ascolumns, beams, tubing struts, or tubing trays toprovide support. Support jacketed tubing as you would bare tubing,except use the appropriately sized mounting clips. SeeSwagelok Multijacketed Tubing, Jacketed Tubing, andInsulated Tubing catalog, MS-02-188, for mountingclip ordering numbers. Support tubing every 6 ft (1.8 m) for horizontal runs,Tubing TrayMultijacketed tubingSingle-jacketed tubingand every 15 ft (4.6 m) for vertical runs. For offshoreapplications in cable tray or ladder rack support,distance should be a maximum of every 36 in. or1 meter for both horizontal and vertical runs. Supports and hangers must have a large surface areaand be designed so they cannot be overtightened tocrush the jacketed tubing. Do not use U-bolts as supports. Tubing may be strapped into an angle iron for support.Place the tubing in an angle iron that is 1/2 in. (12.7 mm)larger than the widest dimension of the bundle, andsecure it with metal or plastic straps.Cushioned clamp tube supportsRefer to Swagelok Stainless Steel Seamless Tubingand Tube Support Systems catalog, MS-01-181, foradditional information.Multijacketed tubing mounting clips6MS-CRD-ITUB, RevENovember 2018, CP

Preparing Multijacketed Tubing for BreakoutUse a utility knife with a hook blade for best results.4. Cut and remove the polyester film wrap.1. Cut outer jacket of multijacketed tubing todesired length. Do not cut into the tubingjacket on the individual tubes.5. Score the aluminum stiffening plate with a knifeand break off or cut with tin snips to remove.2. Slice outer jacket axially and remove.6. Apply silicone sealant to the cut seam wherethe outer jacket was removed.3. Cut and remove the foam wrap.MS-CRD-ITUB, RevENovember 2018, CP7

Preparing Multijacketed Tubing forBreakout, cont'dBreakout Tool for Multijacketed TubingThe breakout tool is used to separate individually jacketedtubes. Use 1/2 in. square drive ratchet to apply torque tomake a 2 in. (50 mm) bend radius in 1/4 , 3/8, and1/2 in. (6, 10, and 12 mm) tubes.Follow the steps below for best results.7. Apply silicone sealant between individual tubes,on both sides, to ensure a good seal is created.1. Slide tool bracket between tubes so that desired tubeis between tool bracket and bending shoe.8. Center the heat shrink sleeve over the cut seamwhere outer jacket was removed.2. Use groove in bending shoe which best fits thetubing. Holding tubing securely, use 1/2 in. squaredrive ratchet to rotate shoe and bend tubing to desiredangle.9. Use a heat gun to shrink the sleeve over thetubing. Move the heat source back and forthover the sleeve applying heat evenly.3. After initial breakout, use Swagelok tube bender of thenext larger size to accommodate jacket thickness.8MS-CRD-ITUB, RevENovember 2018, CP

Cutting Jacketed Tubing4. Hold knife blade flat against the surface of the tubeto cut jacket away from tube. A small hook blade canbe used to cut jacket without danger of scratchingthe tubing.1. Mark jacket where tube should be cut.2. Measure jacket cut-back according to chart.5. Pull the jacket back to expose tube.Cut-BackJacket Cut-Back ChartTube Dia.mmMinimumCut-Backmm1/43/813/1682215/16101/2251 3/1612296. Mark the location of the cut on the tube.7. Cut the tube with a Swagelok tube cutter orappropriate tool, then deburr the end of the tube.3. Roll knife over jacket to cut. DO NOT draw it acrosstube.MS-CRD-ITUB, RevENovember 2018, CP9

Heat-Shrink Adhesive-Lined Sleeve Installation1. Slide the sleeve over the tube before making theconnection. Sleeve contains heat-activated adhesiveon the inside surface.4. Use a heat gun to shrink the sleeve over the tube andfitting. Keep the heat moving so you do not scorch orburn the sleeve or jacket.2. Install the fitting.5. Start applying heat at the center of the sleeve andmove out to the end. Repeat pattern to seal other end.3. Heat shrink sleeves are 5 in. (125 mm) long. Mark thetube to center the sleeve over the fitting. The sleeveshould overlap the jacket on the tube by a minimumof 1 in. (25 mm).106. When complete the sleeve should be uniform andthere should be a small line of adhesive visiblebetween the heat shrink sleeve and the jacket.MS-CRD-ITUB, RevENovember 2018, CP

Heat-Shrink End-Seal Boot Installation for Insulated and Pre-Insulated Tubing1. Cut back the insulation and jacket, leaving sufficientlength of tubing exposed in order to make thenecessary connections.2. Slip the heat-shrink boot over the end of the tubing.Do not nick or cut the boot.3. Use a heat gun to shrink the boot over the tubing.Move the heat source back and forth over the boot,applying heat evenly. Once the boot has assumedthe shape of the tubing, stop applying heat. Furtherheating will not make the boot shrink any more tightly.Note: I f the boot does not assume the shape of thetubing, pinch the boot with pliers while hot andhold until cool to reduce the leg diameter. WarningDo not overheat tubing when applying aheat-shrink boot to a product with plastictubing. Excessive heat could damage thetubing.Self-Bonding Silicone Sealing Tape Self-bonding tape is applied after the fitting isinstalled. Among other applications it can be used toprotect and seal unions, tees, crosses, jacket ends,and small valves. Self-bonding silicone tape is applied in layers with aminimum of 50 % overlap. Each fitting or installationshould have a minimum of four (4) layers for fullprotection. Simulated installation on a bulkhead union is used forillustration.4. When applying the tape, keep the backing in placeas long as possible. If the tape comes in contact withitself it will bond immediately.1. For the first layer, use a length of 8 to 10 in. (200 to250 mm). DO NOT REMOVE THE BACKING LAYER !2. Pull back about 2 in. (50 mm) of backing and stretchthe silicone tape 2 to 3 times the normal length.5. A second layer should be applied in the oppositedirection of wrapping.3. Start the tape on the jacket a minimum of 1 in. (25 mm)from the end of the jacket and wrap it around thetube and fitting keeping it stretched 2 to 3 times itsnormal length. Overlap each layer by at least 50 %.6. For the finishing layer, cut a length of 6 to 8 in.(150 to 200 mm) long.7. Stretch this layer 25 to 50 % and apply it in theopposite direction of the previous layer.8. Inspect tape for any gaps or voids and flatteningthem with your hand. If this is not successful, applyan additional layer of tape.MS-CRD-ITUB, RevENovember 2018, CP11

Pre-Insulated Tubing BundlesThis section contains additional instructions for pre-insulated tubing bundles.Determining Required Length1. Determine the length of tubing required.2. Allow at least 12 in. (305 mm) of straight tubing before connecting to fittings.3. For steam-traced tubing bundles, add enough length to connect the tracer to the supply connection and to thereturn system.4. For electric-traced tubing bundles, add enough length to connect the power supply. Include 6 in. (152 mm) for insidethe junction box. Include enough length of tracer to heat any other desired devices at the end of the bundle.Tracer ConnectionsElectric tracer kits must be connected and terminated using approved power connection and termination kits. Center Line Tool for Pre-insulated Tubing Bundles1. Cut the jacket and insulation, and remove to exposeprocess and tracer tubes.2. Insert the tube bundle through the seal boot.Outer bend shoe3. Unscrew center nut and remove center bend shoe.4. Insert tube bundle.5. Gently bend tubes against the outside shoes.6. Install center bend shoe and tighten center nut.7. Bend tubes against center shoe until tubes areparallel.8. Repeat step 3, and remove tubing bundle from tool.9. Seal bundle ends. See Heat-Shrink End SealBoot Installation for Insulated and Pre-InsulatedTubing, page 11, or Heat-Shrink Entry Seal BootInstallation for Pre-Insulated Tubing Bundles, page13.12Outer bend shoeCenter nutCenter bend shoeMS-CRD-ITUB, RevENovember 2018, CP

Heat-Shrink Entry-Seal Boot Installation Kit for Pre-Insulated Tubing BundlesKit Contents1. Place the threaded connector end into the pre-cuthole in an enclosure so the flanged end is on theinside of the enclosure. Threaded connector O-ring2. Place the O-ring over the threaded end and positionagainst outside of enclosure. Shrinkable bootPanelA, maximum panel thicknessO-ring3. Screw the shrinkable boot onto the connector, andtighten using a spanner wrench.4. Insert the insulated tubing into the shrinkable bootopening and make the necessary connections in theenclosure.BmountingholediameterCbundleOD5. Use a heat gun to shrink the boot over the tubing.Move the heat source back and forth over the boot,applying heat evenly. Once the boot has assumedthe shape of the tubing, discontinue heat application.Further heating will not make the boot shrink tighter.Note: I f the boot does not assume the shape of thetubing, pinch the boot with pliers while hot andhold until cool to reduce the leg diameter.MS-HSS-4-KITAB0.50 (12.7)2.00 (50.8)MS-HSS-4S-KITMS-HSS-5-KIT WarningDimensions, in. (mm)OrderingNumber2.38 (60.5)1.00 (25.4)MS-HSS-6X-KIT3.50 (88.9)4.50 (114)C0.75 to 1.60(19.0 to 40.6)0.75 to 2.10Do not overheat tubing when applying aheat-shrink boot to a product with plastictubing. Excessive heat could damage thetubing.(19.0 to 53.3)1.43 to 2.75(36.3 to 69.8)1.50 to 3.50(38.1 to 88.9)Silicone Sealant Installation for Pre-Insulated Tubing Bundles CautionSeal insulation ends to prevent contaminationof the insulation.1. Cut the jacket square and remove insulation, leavingthe desired length of tubing exposed.2. Bend the process tubing to the desired position.3/8 in. (9.5 mm)3. Cut and remove the insulation back under the jacketabout 3/8 in. (9.5 mm). Do not push back the insulation. It must beremoved as indicated.4. Fill the cavity end with silicone sealant, making surethat all exposed insulation is sealed.MS-CRD-ITUB, RevENovember 2018, CP13

Jacket Patch Kit Installation for Pre-insulated Tubing BundlesKit ContentsFig. 1 Thermal insulation Self-sealing black rubber patch Fiberglass tapeTo install the jacket patch kit at a splice:1. Cut the jacket square and remove insulation, leavingdesired length of tubing exposed on both pieces(Fig. 1).Fig. 26 in. (152 mm)Maximum2. Use a Swagelok tube fitting to connect the tubes(Fig. 2).3. Wrap the area with thermal insulation until it is builtup to the outside diameter of the jacket (Fig. 3). Usethe fiberglass tape to hold the insulation in place.Fig. 3Insulation4. Cut the self-sealing black rubber patch so that itextends over the pre-existing tubing bundle jacketsby 1 in. (25 mm) on each side (Fig. 4).5. Remove the protective wax paper backing, and wrapthe patch around the area to be patched. Leave theclear protective layer in place and facing out.Fig. 4Patch1/2 in.6. Overlap the edges of the patch by at least 1/2 in.(12 mm) and press the patch into place (Fig. 4).(12 mm)7. Use the fiberglass tape to hold the patch in place andprevent separation of the seams until it cures.To install the jacket patch kit at a tubing end:1 in.1. Wrap insulation around the tubes and fittings until thediameter is built up to equal the outside diameter ofthe jacket (Fig. 5).2. Cut the patch material to extend over the jacket by 1in. (25 mm) and beyond the insulation on the individualtubes by 3/8 in. (10 mm) (Fig. 6).(25 mm)Fig. 53. Remove the protective wax paper backing, and wrapthe patch around the area to be patched. Leave theclear protective layer in place and facing out.4. Overlap the edges of the patch by at least 1/2 in.(12 mm), and press the patch into place.Fig. 63/8 in.(10 mm)1 in.(25 mm)5. Use the fiberglass tape to hold the patch in place andprevent separation of the seams.6. Fill the cavity end with a sealant, such as siliconesealant, making sure that all exposed insulation isprotected (Fig. 7).Fig. 714MS-CRD-ITUB, RevENovember 2018, CP

Power Connection Installation for Pre-insulated Tubing BundlesKit Contents Junction box and cover Mounting bracket 2 mounting straps Connection kitTo mount bundle:1. Cut the jacket and insulation to expose the processand tracer tubes to the length required to connect tothe power location.2. Seal the end of the bundle with a heat-shrink end sealboot or entry seal boot. See Heat-Shrink End-SealBoot Installation for Insulated and Pre-InsulatedTubing, page 11, or Heat-Shrink Entry-Seal BootInstallation for Pre-Insulated Tubing Bundles, page13.3. Cut the process tubing to length and makeconnections. CautionElectric Traced SystemsConsult installation instructions received with thekit. You may be required to make connections andterminations at a particular point on the tracer. If so,these points will need to be located prior to cuttingthe bundle to its final length. Failure to properlyinstall the electric tracer can lead to excessiveheating, tracer failure, and damage to the tubingbundle.4. See the manufacturer’s instructions for installing theconnection kit.Temperature Sensor Installation for Pre-Insulated Tubing BundlesThe purpose of this instruction is to provide generalguidance in the installation of a temperature sensingthermostat, an RTD, or thermocouple. Each thermostatis different and specific instructions may vary; see anyadditional instructions received with the specific product. C autionThe sensor should be in contact with theprocess tubes only and not the tracer. Contactwith the tracer could cause a false reading.1. Determine a suitable mounting location for thethermostat housing, and route the capillary along thebundle. C autionDo not place near heater or near processconnection in an enclosure. Doing so willcause the thermostat to register an inaccuratetemperature.2. Measure the sensor length and add an additional 2 in.(50 mm). This will be your slit length.5. Once the sensor is in place, hold the slit area togetherand place fiberglass tape every 1 1/2 in. (38 mm) overthe slit area.6. Secure the capillary to the bundle with the fiberglasstape at least 2 in. (50 mm) from the end of the slit.7. Apply a bead of silicone sealant along each side ofthe capillary.8. Using a jacket patch kit, wrap the bundle with therubber patch where the slit was made previously. SeeHeat-Shrink Entry-Seal Boot Installation Kit for PreInsulated Tubing Bundles, page 13, steps 4 to 7.Note: T he rubber patch should extend 2 in.(50 mm) past the slit on each side.Similar techniques can be used to install other sensingdevices. See any additional instructions provided by thedevice manufacturer.3. Slit the bundle lengthwise as determined in step 2,ensuring that the slit goes through the insulation andpolyester film, opposite the tracer, where the sensorwill be placed.4. Insert the sensor into the bundle. The sensor shouldtouch the process tubes only.MS-CRD-ITUB, RevENovember 2018, CP15

2004 - 2018 Swagelok CompanySwagelok — TM Swagelok CompanyNovember 2018, RevEMS-CRD-ITUB

the installation of Swagelok single-jacketed tubing, multijacketed tubing, insulated tubing, and pre-insulated trace tubing bundles. For additional information, see the Swagelok Multijacketed Tubing, Jacketed Tubing and Insulated Tubing catalog, MS-02-188 and Swagelok Pre-Insulated Tubing Bundles catalog, MS-02-316. Caution