Level 1, Unit 5, Section 1 – 1.2 Tools, Piping Materials & Drawings

Unit 5 — Pressure Testing, Tubing, and Piping

Section 1 — Piping & Tubing

1.2 — Tools, Piping Materials, and Drawings

Correct tool selection and material identification are foundational skills for any piping and tubing task. This lesson covers the specialized tools used to cut, form, and join tubing; the types of refrigeration piping and fittings encountered in the trade; the properties of common pipe materials; and how to read drawings and job documentation.

Hand Tools Copper Tubing Pipe Materials Drawings 313A / 313D

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1.2.1 — Specialized Tools and Equipment

Identifying the correct tool for each piping task reduces defects such as cracks, flattened bends, misalignment, and leaks. Each tool below is designed for a specific operation; using an improper substitute can compromise joint integrity or damage the tubing permanently.

Heat Sources

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Air-Fuel Torch

Used for soldering and some brazing tasks. Effective operation depends on correct tip selection, a stable fuel supply, and controlled heating of the joint rather than chasing the flame. Air-fuel torches reach lower temperatures than oxy-fuel systems and are well-suited for soft-solder work on smaller copper fittings.

Typical use: soft soldering (< 450 °C / 840 °F)
Fuel: propane, MAPP, or butane depending on model
Heat the fitting body, not the filler — draw filler into the joint by capillary action

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Oxy-Fuel Torch

Provides higher heat intensity and is used for brazing, cutting, and welding where temperature and heat input must be achieved quickly and precisely. The oxygen-fuel mixture allows a controllable neutral, carburizing, or oxidizing flame.

Typical use: brazing (> 450 °C / 840 °F), cutting, and welding
Common fuels: acetylene (highest temperature), propane, natural gas
Requires proper flashback arrestors on both hose lines

Cutting and Forming Tools

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Pipe / Tube Cutter

Produces a square, clean cut with minimal burr when used correctly. A square cut improves fit-up and allows the filler metal to wet and flow evenly around the joint. Over-tightening the cutter wheel work-hardens the cut edge and leaves a heavy internal burr; always ream the inside diameter after cutting.

Tighten the feed screw only slightly per revolution
Ream the ID thoroughly — burrs restrict flow and trap flux
Replace worn cutter wheels promptly to avoid ragged cuts

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Flaring Tool

Forms a controlled 45° (or SAE-specified) flare on tubing ends so a mechanical flare fitting can seal under pressure without cracking the tubing. The flare must be concentric, smooth, and free of cracks. Annealing (softening) hard-drawn tubing before flaring reduces the risk of split flares.

Always deburr and clean before flaring
Slide the flare nut onto the tube before forming the flare
Do not over-drive — splits are not repairable; cut and re-flare

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Swaging Tool (Manual and Hydraulic)

Expands a tube end to accept another tube of the same nominal size, enabling a socket-style joint. Proper swaging improves alignment and brazing capillary action. Hydraulic swaging tools provide more consistent results on larger diameters and harder tubing than manual drivers.

Expand to the correct depth — typically one tube OD in depth
Clean both surfaces before assembling for brazing
Hydraulic tools required for tubing above approximately 1-1/8″ OD

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Lever Bender and Ratchet Bender

Benders support the tube wall as it is formed to the required radius, reducing kinking and ovalization. Maintaining the tube’s cross-sectional area is essential for preserving flow capacity and structural strength through the bend.

Lever benders: used for smaller-diameter soft copper (up to approx. 5/8″)
Ratchet benders: used for larger or harder tubing; allow controlled incremental bending
Use the correct size shoe — undersized causes kinking; oversized causes ovalization

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Crimping Tool / Mechanical Press Tool

Press and crimp systems join compatible tubing and fittings using manufacturer-specific tooling and jaw profiles. Joint integrity depends on correct jaw selection, proper insertion depth, and a visual verification step after pressing. These systems are not interchangeable between manufacturers.

Verify the jaw profile matches the fitting brand and size
Confirm the tube is fully inserted before pressing
Check the visual indicator (gap or witness mark) post-press to confirm complete engagement

1.2.2 — Types of Refrigeration Piping, Tubing, and Fittings

Material selection affects pressure capability, corrosion resistance, the joining method required, and code compliance. The table below summarizes the piping and tubing types most commonly encountered in refrigeration and HVAC/R mechanical work.

Type	Description	Key Considerations
ACR Copper (Type K & L)	Dehydrated and capped copper tube manufactured specifically for Air Conditioning and Refrigeration service. Type K has the thickest wall; Type L has a medium wall.	Selection depends on design pressure, environment, and project requirements. ACR tubing is sold by OD; plumbing tube is sold by nominal (ID) size — do not substitute without verifying dimensions and pressure ratings.
Soft (Annealed) Copper	Fully annealed copper coil that can be hand- or tool-bent without a bender in smaller sizes. Available as ACR or plumbing type.	Easier to bend than hard-drawn, which reduces fittings. Requires good support spacing and protection from vibration and abrasion. Not suitable where rigid support is critical.
Copper Drainpipe	DWV (Drain, Waste, and Vent) copper used for condensate and equipment drain lines.	Correct slope (typically 1:50 minimum), adequate support spacing, and sealed penetrations are essential to prevent leaks and water damage.
Plastic Drainpipe (PVC / CPVC)	Plastic pipe used for condensate drainage and some non-refrigerant drain lines depending on application and local code.	Verify temperature rating — standard PVC is limited to approximately 60 °C (140 °F); CPVC extends this range. Check local code acceptance.
Type M Copper	Thin-wall copper tube used in plumbing and HVAC hydronic applications. Thinner wall than Type K or L.	Verify allowable use against project specification and applicable code — Type M is not permitted for all refrigerant or high-pressure applications. Joining requirements are the same as other copper tube types.
XFR (Cross-linked / Specialty)	Specialty product designed for specific mechanical or refrigerant service. The exact product varies by manufacturer and application.	Confirm manufacturer’s joining requirements, pressure and temperature ratings, and code acceptance before installation. Do not assume standard copper fittings are compatible.
Stainless Steel Pipe	High-corrosion-resistance pipe used where refrigerant type, process fluid, or environmental conditions rule out copper or carbon steel.	Requires compatible fittings and filler metals. Joining methods include orbital welding, press fittings, and threaded connections. Verify material grade (e.g., 304 vs. 316) for the fluid service.
Schedule 40 Steel Pipe	Standard-wall carbon steel pipe widely used in HVAC hydronic systems, process piping, and some refrigerant applications where copper is not specified.	Joined by welding, threading, or grooved mechanical couplings. Requires corrosion protection (painting, galvanizing, or chemical treatment) when used with water systems.
Schedule 80 Steel Pipe	Heavy-wall carbon steel pipe with higher pressure rating than Schedule 40 at the same nominal diameter.	Used where higher working pressures, greater mechanical strength, or additional corrosion allowance is required. Joining as per Schedule 40; verify wall thickness at threaded connections.

1.2.3 — Pipe Materials, Fittings, and Accessories

Each pipe material has different joining methods and limitations. The correct choice depends on the working fluid (including refrigerant type), expected pressures, temperature range, chemical compatibility, and environmental exposure.

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Aluminum

Lightweight and corrosion-resistant in many environments. Used in micro-channel condensers and some evaporator coils. Requires aluminum-compatible brazing alloys; copper fittings must not be connected directly (galvanic corrosion risk).

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Brass

Commonly used for valves, fittings, and threaded connections. Compatible with copper tubing. Some brass alloys are not suitable for ammonia refrigerant systems — verify material compatibility when working with natural refrigerants.

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Copper

The dominant material for refrigerant piping in most HVAC/R systems. Excellent thermal conductivity, corrosion resistance in most refrigerant environments, and well-established brazing techniques. Not compatible with ammonia (R-717).

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Copper-Iron Alloy

Specialty alloy used where enhanced strength or specific system requirements apply, such as in certain hermetic compressor discharge lines. Joining and handling procedures may differ from standard copper; confirm with the manufacturer’s specification.

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Plastics (PVC, CPVC, ABS, PE)

Used for drain lines, condensate piping, and some non-refrigerant services. Each plastic type has specific temperature limits, solvent-cement requirements, and code restrictions. Plastic pipe must not be used for refrigerant service under Canadian mechanical refrigeration codes.

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Stainless Steel

High corrosion resistance and strength. Used in ammonia systems, food-grade refrigeration, and corrosive environments. Requires stainless-compatible filler metals and tooling to avoid cross-contamination from carbon steel tools.

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Steel (Carbon Steel)

Used in ammonia refrigeration systems, process cooling, and HVAC hydronic systems. Commonly joined by welding or threading. Requires corrosion protection appropriate to the fluid service and environment (painting, galvanizing, or chemical inhibitors).

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Match Material to Refrigerant

Copper and brass are incompatible with ammonia (R-717). Steel and stainless steel are incompatible with many halogenated refrigerants (e.g., R-22, R-410A) due to moisture and corrosion concerns. Always confirm material compatibility with the refrigerant and lubricant in use before selecting pipe or fittings.

1.2.4 — Drawings, Specifications, and Job Documentation

Drawings and specifications communicate routing, sizes, materials, insulation, supports, and joining methods. Understanding how to read and use this documentation ensures that installation matches design intent and meets acceptance criteria.

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Characteristics Shown on Drawings

Piping and refrigeration drawings typically convey the following information:

Pipe routing and layout — plan view, elevation view, and isometric drawings show where each line runs, change direction, and connects to equipment
Pipe and tubing sizes — nominal diameter or OD is annotated on each line; size changes at reducers or branches are noted
Materials and schedule/type — material specifications (e.g., Type L copper, Schedule 40 carbon steel) are called out in notes, legends, or title blocks
Insulation — insulation type, thickness, and vapour-barrier requirements are shown as symbols or in the specifications section
Supports and hangers — hanger type, spacing, and attachment details are either drawn directly or referenced to a standard detail sheet
Joining methods — whether connections are brazed, welded, threaded, flanged, or mechanically coupled is indicated in notes or symbols
Valves and specialties — isolation valves, service valves, strainers, and instrumentation connections are shown with standard symbols defined in the drawing legend

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Job Documentation

Job documentation defines what must be installed, where, and to what acceptance criteria. It also creates the written record that work followed the required process and standards. Common documents encountered on a piping job include:

Weld procedure specifications (WPS) — define the approved parameters for each weld type; a welder must follow the applicable WPS, not deviate without authorization
Inspection and test records — pressure test logs, leak test reports, and visual inspection sheets that document system integrity before commissioning
Material certifications (Mill certs) — confirm that piping, fittings, and valves meet the specified material grade; required for pressure-code-registered systems
As-built drawings — updated drawings that reflect the actual installed configuration, including any field changes from the design drawings
Job safety analysis (JSA) / hot work permits — required before any torch or welding work begins; identifies hazards and control measures specific to the work location

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Reading a Piping Drawing — Practical Steps

Locate the title block first — it identifies the project, revision level, scale, and applicable specifications
Read the legend — confirm what each line type, symbol, and abbreviation means on this specific drawing
Identify pipe sizes and materials on each line before ordering materials or beginning work
Cross-reference the specifications document for joining methods, insulation type, and pressure test requirements
Check for revision clouds — shaded or clouded areas on recent revisions indicate what changed from the previous version; always confirm you are working from the current revision
Confirm elevation data — invert elevations for drain lines and pipe centreline elevations for process lines must be verified before hanging supports

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Drawings Show Intent — Site Conditions Govern Installation

Drawings are produced before construction begins and may not reflect every structural member, existing pipe, or field obstruction. When a conflict exists between the drawing and site conditions, stop work and consult the supervisor or engineer before proceeding. Do not improvise routing changes without authorization — changes must be documented on the as-built drawings.