Pure Epoxies Vs Epoxy Mastics For Maintenance PDF

Ministry of Defence
Defence Standard 02-878

Issue 1 Publication Date 30 June 2011
Non-Ferrous Tubes and Pipes

for use in
HM Submarines and
Surface Ships not in Class
Category 2
DEF STAN 02-878 Issue 1
Contents
Foreword .........................................................................................................................................................vii
0 Introduction.............................................................................................................................................x
1 Scope.......................................................................................................................................................1
2 Warning ...................................................................................................................................................1
3 Normative References ...........................................................................................................................1
4 Terms and Definitions............................................................................................................................3
5 Design Requirements ............................................................................................................................4
5.1 General ...............................................................................................................................................4
5.2 Material Selection..............................................................................................................................5
5.3 Corrosion of Tube Materials ............................................................................................................7
5.4 Other Physical Properties ................................................................................................................9
5.5 Joining and Welding .......................................................................................................................10
5.6 Tube Wall Thickness.......................................................................................................................10
6 Information to be Supplied by the Purchaser ...................................................................................13
7 Tube Manufacture.................................................................................................................................13
8 Test Methods and Examination Requirements .................................................................................14
8.1 Selection of Originating Standards ...............................................................................................14
8.2 Destructive Tests ............................................................................................................................14
8.2.1 Sampling .....................................................................................................................................14
8.2.2 Chemical Analysis .....................................................................................................................14
8.2.3 Tensile Tests ..............................................................................................................................14
8.2.4 Hardness Tests ..........................................................................................................................14
8.2.5 Re-tests .......................................................................................................................................14
8.3 Non-destructive Tests.....................................................................................................................15
8.3.1 Visual Examination ....................................................................................................................15
8.3.2 Dimensional Inspection.............................................................................................................15
8.3.3 Leak Tightness Tests.................................................................................................................15
8.3.3.1 Eddy Current Test .................................................................................................................15
8.3.3.2 Hydrostatic Test ....................................................................................................................15
8.3.3.3 Pneumatic Test (Heat Exchanger Tubes only)...................................................................16
8.3.4 Pressure Proof Test ...................................................................................................................16
8.3.5 Magnetic Permeability ...............................................................................................................16
8.3.6 Ultrasonic Tests .........................................................................................................................16
9 Acceptance Standards.........................................................................................................................16
9.1 Destructive Tests ............................................................................................................................16
9.1.1 Chemical Analysis .....................................................................................................................16
9.1.2 Mechanical Properties Tests.....................................................................................................16
9.1.3 Hardness Test ............................................................................................................................16
9.2 Non-destructive Tests.....................................................................................................................17
9.2.1 Visual Examination ....................................................................................................................17
9.2.2 Dimensional Checks ..................................................................................................................17
9.2.3 Leak Tightness Tests.................................................................................................................17
9.2.3.1 Eddy Current Test .................................................................................................................17
9.2.3.2 Hydrostatic Test ....................................................................................................................17
9.2.3.3 Pneumatic Test (Heat Exchanger Tubes only)...................................................................17
9.2.4 Pressure Proof Test ...................................................................................................................17
9.2.5 Magnetic Permeability ...............................................................................................................17
9.2.6 Ultrasonic Tests .........................................................................................................................17
ii
9.3 Rejection ..........................................................................................................................................17

9.4 Summary of Tube Procurement Process .....................................................................................18
10 Quality Assurance Documentation ....................................................................................................19
10.1 General .............................................................................................................................................19
10.2 Certificate of Conformity ................................................................................................................19
10.3 Records ............................................................................................................................................19
11 Identification .........................................................................................................................................19
Annex A Test Methods Specific to this Defence Standard ........................................................................21
A.1 Scope.....................................................................................................................................................21
A.2 Flattening and Bend Tests for Copper Alloys ...................................................................................21
A.2.1 Flattening Test.................................................................................................................................21
A.2.2 Double Bend Test............................................................................................................................21
A.3 Non-destructive Test Procedures.......................................................................................................21
A.3.1 Eddy Current Test ...........................................................................................................................21
A.3.1.1 Method of Test............................................................................................................................21
A.3.1.2 Calibration ..................................................................................................................................22
A.3.1.3 Checking of Equipment .............................................................................................................22
A.3.2 Ultrasonic Test Method ..................................................................................................................22
A.3.2.1 Method of Test............................................................................................................................22
A.3.2.2 Equipment...................................................................................................................................23
A.3.2.3 Calibration Standards................................................................................................................23
A.3.2.4 Calibration and Checking of Equipment..................................................................................24
A.3.3 Ultrasonic Thickness Gauging ......................................................................................................24
A.3.3.1 Method of Test............................................................................................................................24
A.3.3.2 Calibration Standards................................................................................................................24
A.3.3.3 Calibration and Checking of Equipment..................................................................................24
Annex B Specific Requirements for Copper Tubes (previously covered by Def Stan 02-837) ..............25
B.1 Scope.....................................................................................................................................................25
B.2 Manufacture ..........................................................................................................................................25
B.2.1 Tube production ..............................................................................................................................25
B.2.2 Condition of Tubing ........................................................................................................................25
B.2.3 Supply Requirements .....................................................................................................................25
B.3 Specific Tests .......................................................................................................................................26
B.3.1 Destructive Tests ............................................................................................................................26
B.3.1.1 Mechanical Test Sampling ........................................................................................................26
B.3.1.2 Chemical Analysis .....................................................................................................................26
B.3.1.3 Mechanical Tests .......................................................................................................................26
B.3.2 Non-destructive Tests ....................................................................................................................26
B.3.2.1 Samples for Dimensional Checks ............................................................................................26
B.4 Acceptance Criteria..............................................................................................................................27
B.4.1 Chemical Analysis...........................................................................................................................27
B.4.2 Mechanical Tests.............................................................................................................................27
B.4.3 Non-destructive Tests ....................................................................................................................27
B.4.4 Rejection ..........................................................................................................................................27
B.5 Identification .........................................................................................................................................27
Annex C Specific Requirements for 70/30 Copper-nickel Alloy Tubes (previously detailed in Def Stan
02-780 Part 3) ........................................................................................................................................31
C.1 Scope.....................................................................................................................................................31
C.2 Tube Classification ..............................................................................................................................31
C.3 Manufacture ..........................................................................................................................................31
C.3.1 Tube Production..............................................................................................................................31
C.3.2 Condition of Tubing ........................................................................................................................31
C.3.3 Supply Requirements .....................................................................................................................31
C.4 Specific Tests .......................................................................................................................................32
C.4.1 Destructive Tests ............................................................................................................................32
C.4.1.1 Sampling for Destructive Tests ................................................................................................32
C.4.1.2 Chemical Analysis .....................................................................................................................32
C.4.1.3 Mechanical Tests .......................................................................................................................32
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C.4.2 Non-destructive Tests.....................................................................................................................32

C.4.2.1 Dimensional Inspection.............................................................................................................32
C.4.2.2 Ultrasonic Wall Thickness Checks...........................................................................................32
C.5 Acceptance Criteria..............................................................................................................................32
C.5.1 Destructive Tests ............................................................................................................................32
C.5.1.1 Chemical Analysis .....................................................................................................................32
C.5.1.2 Mechanical Tests .......................................................................................................................32
C.5.2 Non-destructive Tests.....................................................................................................................33
C.5.3 Rejection ..........................................................................................................................................33
C.6 Identification .........................................................................................................................................33
Annex D Specific Requirements for 90/10 Copper-nickel Alloy Tubes (previously covered by Def Stan
02-779 Part 3) ........................................................................................................................................39
D.1 Scope.....................................................................................................................................................39
D.2 Tube Classification ..............................................................................................................................39
D.3 Manufacture ..........................................................................................................................................39
D.3.1 Tube production ..............................................................................................................................39
D.3.2 Condition of Tubing ........................................................................................................................39
D.3.3 Supply Requirements .....................................................................................................................39
D.4 Specific Test Methods .........................................................................................................................39
D.4.1 Destructive Tests ............................................................................................................................39
D.4.1.1 Sampling for Destructive Tests ................................................................................................39
D.4.1.2 Chemical Analysis .....................................................................................................................39
D.4.1.3 Mechanical Tests .......................................................................................................................40
D.4.2 Non-destructive Tests.....................................................................................................................40
D.4.2.1 Dimensional Inspection.............................................................................................................40
D.4.2.2 Ultrasonic Wall Thickness Checks...........................................................................................40
D.5 Acceptance Criteria..............................................................................................................................40
D.5.1 Destructive Tests ............................................................................................................................40
D.5.1.1 Chemical Analysis .....................................................................................................................40
D.5.1.2 Mechanical Tests .......................................................................................................................40
D.5.2 Non-destructive Tests.....................................................................................................................40
D.5.3 Rejection ..........................................................................................................................................41
D.6 Identification .........................................................................................................................................41
Annex E Specific Requirements for Aluminium-nickel-silicon-brass Tubes (previously covered by
Defence Standard 02-749 Part 3) ........................................................................................................44
E.1 Scope.....................................................................................................................................................44
E.2 Tube Classification ..............................................................................................................................44
E.3 Manufacture ..........................................................................................................................................44
E.3.1 Tube Production..............................................................................................................................44
E.3.2 Condition of Tubing ........................................................................................................................44
E.3.3 Supply Requirements .....................................................................................................................44
E.4 Specific Tests .......................................................................................................................................44
E.4.1 Destructive Tests ............................................................................................................................44
E.4.1.1 Sampling for Destructive Tests ................................................................................................44
E.4.1.2 Chemical Analysis .....................................................................................................................45
E.4.1.3 Mechanical Tests .......................................................................................................................45
E.4.2 Non-destructive Tests.....................................................................................................................45
E.4.2.1 Dimensional Inspection.............................................................................................................45
E.4.2.2 Ultrasonic Wall Thickness Checks...........................................................................................45
E.5 Acceptance Criteria..............................................................................................................................45
E.5.1 Destructive Tests ............................................................................................................................45
E.5.1.1 Chemical Analysis .....................................................................................................................45
E.5.1.2 Mechanical Tests .......................................................................................................................45
E.5.2 Non-destructive Tests.....................................................................................................................45
E.5.3 Rejection ..........................................................................................................................................46
E.6 Identification .........................................................................................................................................46
Annex F Advisory Material Property Datasheets ........................................................................................48
iv
Tables
Table 1 – Specifications and Room Temperature Mechanical Properties of Possible Ferrous
Materials for Tubes .........................................................................................................................6
Table 2 – Specifications and Room Temperature Mechanical Properties of Possible Non-ferrous
Materials for Tubes .........................................................................................................................7
Table 3 – Comparative Corrosion Resistance of Tube Materials ................................................................8
Table 4 – Comparison of Corrosion Severity for Various Tube Service Environments............................9
Table 5 – Guideline Maximum Velocity Limits for Seawater........................................................................9
Table 6 – Comparative Costs for Possible Tube Materials ........................................................................10
Table A.1 – Ultrasonic Calibration Notch Depths........................................................................................23
Table B.1 – Metric Tube for Fresh Water, Oil and LP Air Systems for use at Working Pressures
up to 6 bar and Temperatures up to 75°C...................................................................................28
Table B.2 – Imperial Tube for: (a) Steam Systems at Working Pressures up to 10.5 bar and
Temperatures up to 187°C and (b) General use up to 12 bar and Temperatures up to
175°C ..............................................................................................................................................28
Table B.3 – Imperial Tube for: (a) Steam Systems at Working Pressures up to 17 bar and
Temperatures up to 208°C and (b) General use at Working Pressures up to 25 bar and
Temperatures up to 190°C............................................................................................................29
Table B.4 – Imperial Tube for: (a) Pressure Gauge Piping for use at Working Pressures up to 83
bar and Temperatures up to 75°C and (b) Steam Systems at Working Pressures up to
17 bar and Temperatures up to 208°C ........................................................................................29
Table B.5 – Metric Tube for Refrigeration Systems at Working Pressures up to 11 bar and
Temperatures to 75°C ...................................................................................................................29
Table B.6 – Imperial Tube for Refrigeration Systems at Working Pressures up to 11 bar and
Temperatures up to 75°C..............................................................................................................30
Table C.1 – Classification of Tubes ..............................................................................................................33
Table C.2 – 70/30 Copper-nickel Alloy Tubes - General Purpose (metric) ...............................................34
Table C.3 – 70/30 Copper-nickel Alloy Tubes. General Purpose (imperial): Dimensions,
classification and working pressures.........................................................................................35
Table C.4 – Chemical Composition...............................................................................................................36
Table C.5 – Room Temperature Mechanical Properties .............................................................................36
Table C.6 – Tolerances for General Purpose Tubes ...................................................................................37
Table C.7 – Tolerances for Condenser and Heat Exchanger Tubes .........................................................38
Table D.1 – Class 1-175 Imperial Tubes (working pressure 175 psi) ........................................................41
Table D.2 – Data for Class 1-10 Metric Tubes (working pressure 10 bar).................................................42
Table D.3 – Data for Class 1-16 Metric Tubes (working pressure 16 bar).................................................43
Table D.4 – Specified Annealed 90/10 Copper-nickel Room Temperature Mechanical Properties .......43
Table E.1 – Tube Sizes and Working Pressures. (* Non-preferred sizes).................................................46
Table E.2 – Specified Al-Ni-Si-Brass Room Temperature Mechanical Properties...................................46
Table E.3 – Permitted Tube Dimensional Tolerances .................................................................................47
Table F.1 – Copper-phosphorus Deoxidised Non-arsenical ......................................................................49
Table F.2 – 70/30 Copper-nickel ....................................................................................................................51
Table F.3 – 90/10 Copper-nickel ....................................................................................................................53
Table F.4 – Aluminium-nickel-silicon-brass ................................................................................................55
v
Table F.5 – Carbon, Carbon-manganese and Chromium-molybdenum Steels........................................57

Table F.6 – 18% Chromium 10% Nickel Austenitic Stainless Steel...........................................................59
Table F.7 – 18% Chromium 10% Nickel Titanium Austenitic Stainless Steel...........................................61
Table F.8 – 18% Chromium 10% Nickel Niobium Austenitic Stainless Steel ...........................................63
Table F.9 – 18% Chromium 12% Nickel 2% Molybdenum Austenitic Stainless Steel .............................65
Table F.10 – 20% Chromium 18% Nickel 6% Molybdenum Super Austenitic Stainless Steel ................67
Table F.11 – 22% Chromium 5% Nickel 3% Molybdenum Duplex Stainless Steel...................................69
Table F.12 – 25% Chromium 7% Nickel 3.5% Molybdenum Tungsten Super Duplex Stainless
Steel................................................................................................................................................71
Table F.13 – Nickel-chromium-molybdenum-niobium Alloy 625 ...............................................................73
Table F.14 – Nickel-copper Alloy 400 ...........................................................................................................75
Table F.15 – Titanium Alloy, Commercial Purity .........................................................................................77
Table F.16 – Aluminium-magnesium-manganese Alloy .............................................................................79
Table F.17 – Aluminium-2% magnesium alloy.............................................................................................81
vi
Foreword
AMENDMENT RECORD
Amd No Date Text Affected Signature and Date
REVISION NOTE
A new policy of having performance based standards for non-ferrous tubes and pipes replacing prescriptive
standards was agreed in the Defence Standards rationalization plan in the Sea Systems Group of the MOD.
Def Stan 02-878 is a new standard which has been produced to implement this new policy, and supersedes
the Defence Standards listed below.
HISTORICAL RECORD
This standard supersedes the following:
Defence Standard 02-749 Part 3 Issue 1 Apr 2000

Defence Standard 02-837 Issue 2 Oct 2005
Defence Standard 07-259 Issue 1 Apr 2000
NES 749 Part 3 Issue 2 May 1987
NES 779 Part 3 Issue 2 Dec 1998
NES 780 Part 3 Issue 2 Aug 1998
NES 831 Part 3 Issue 1 Mar 1989
NES 837 Issue 2 Dec 1998
DGS 233A Oct 1971
DGS 271B Jul 1974
DGS 312B Apr 1976
DGS 8556D Apr 1976
DGS 8557C Sep 1963
DGS 8558B Jun 1963
DGS 8559D Mar 1963
DGS 856B Nov 1963
DGS 8562F Jul 1967
AD Spec 1011 Apr 1958
EinC 3T103
EinC 4T104 Jun 1955
DNC C7
DNC C9
vii
Sponsorship
1. This Defence Standard (Def Stan) is sponsored by the Sea Systems Group, Defence Equipment and
Support, Ministry of Defence (MOD).
2. The complete Defence Standard 02-878 Issue 1 comprises:

Metallic tubes and pipes for fluid handling in HM Surface Ships and Submarines not in Class
3. If it is found to be unsuitable for any particular requirement the MOD is to be informed in writing of the
circumstances.
4. Any user of this Defence Standard either within MOD or in industry may propose an amendment to it.
Proposals for amendments that are not directly applicable to a particular contract are to be made to the
publishing authority DStan and those directly applicable to a particular contract are to be dealt with using
contract procedures.
5. No alteration is to be made to this Defence Standard except by the issue of an authorised

amendment.
6. Unless otherwise stated, reference in this Defence Standard to approval, approved, authorised or
similar terms, means the MOD in writing.
7. Any significant amendments that may be made to this Defence Standard at a later date will be
indicated by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line interval.
8. Extracts from British Standards within this Defence Standard have been included with the permission
of the British Standards Institution.
Conditions of Release
General
9. This Defence Standard has been devised solely for the use of the MOD, and its contractors in the
execution of contracts for the MOD. To the extent permitted by law, the Crown hereby excludes all liability
whatsoever and howsoever arising (including but without limitation, liability resulting from negligence) for any
loss or damage however caused when the Defence Standard is used for any other purpose.
10. This document is Crown Copyright and the information herein may be subject to Crown or third party
rights. It is not to be released, reproduced or published without written permission of the MOD.
11. The Crown reserves the right to amend or modify the contents of this Defence Standard without
consulting or informing any holder.
MOD Tender or Contract Process

12. This Defence Standard is the property of the Crown. Unless otherwise authorized in writing by the
MOD, it must be returned on completion of the contract, or submission of the tender, in connection with
which it is issued.
13. When this Defence Standard is used in connection with a MOD tender or contract, the user is to
ensure that he is in possession of the appropriate version of each document, including related documents,
relevant to each particular tender or contract. Enquiries in this connection may be made of the Authority
named in the tender or contract.
14. When Defence Standards are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contractual and other statutory requirements. Compliance with a Defence
Standard does not of itself confer immunity from legal obligations.
viii
Categories of Naval Defence Standard

15. The Category of this Maritime Defence Standard has been determined using the following criteria:
a) Category 1. If not applied, may have a Critical effect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
b) Category 2. If not applied, may have a Significant effect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through-life costs and support.
c) Category 3. If not applied, may have a Minor effect on the following:

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.
Related Documents
16. In the tender and acquisition processes the related documents in clause 3 can be obtained as follows:
a) British Standards British Standards Institution,

389 Chiswick High Road,
London,
W4 4AL
b) Defence Standards Defence Equipment and Support

UK Defence Standardization,
Kentigern House
65 Brown Street,
Glasgow,
G2 8EX
c) Other documents Tender or Contract Sponsor to advise.
17. All applications to Ministry Establishments for related documents are to quote the relevant MOD
Invitation to Tender or Contract Number and date, together with the sponsoring Directorate and the Tender
or Contract Sponsor.
18. Prime Contractors are responsible for supplying their sub-contractors with relevant documentation,
including specifications, standards and drawings.
Health and Safety
Warning
19. This Defence Standard may call for the use of processes, substances and procedures that may be
injurious to health if adequate precautions are not taken. It refers only to technical suitability and in no way
absolves either the supplier or any user from statutory obligations relating to health and safety at any stage
of manufacture or use. Where attention is drawn to hazards, the list of those quoted may not necessarily be
exhaustive.
20. This Defence Standard has been written and is to be used taking into account the policy stipulated in
JSP430: MOD Ship Safety Management System Handbook.
Additional Information
(There is no relevant information)
ix
0 Introduction
0.1 The Royal Navy has gained considerable experience in the use of pipework for the transport of liquids
and gases within HM Surface Ships and Submarines over many years. It is on the basis of this corporate
knowledge that the Admiralty Pipework Standards (BR 3013) and the various system design Defence
Standards have evolved to their current status. The text of this particular Standard has also drawn on this
body of knowledge when citing general requirements, material selection, material corrosion performance,
etc.
0.2 A formal selection method for tube materials and sizes as part of a design process has been defined
in this Defence Standard, permitting the use of materials to commercial standards not previously codified by
Defence Standards or the preceding Naval Engineering Standards. This process includes defining the tube
non-destructive test requirements necessary to ensure the desired performance and component quality
assurance for naval applications.
0.3 Previous Defence Standards and Naval Engineering Standards have compiled standard tube
geometries used in Royal Navy vessels. To ensure “like-for-like” replacement of parts on vessels built to
these earlier Standards, the necessary test requirements and dimensions from these earlier Standards have
been included in this Defence Standard as a series of Annexes.
0.4 Where previous Defence Standards for tubes, such as Def Stan 02-831 covering aluminium alloy
tubes, have been found not to contain performance critical requirements or important component sizing data,
these standards have not been included as Annexes of this Defence Standard. Any naval requirement for
aluminium tubes for fluid or gas applications can be addressed using the general test methods and
acceptance criterion stated in clauses 13 and 14 of this Standard.
0.5 Previous naval experience, as embodied by the various material Annexes, has found the following
tube material / service combinations effective:
a) 90/10 and 70/30 copper-nickels for general seawater supply piping. The 70/30 copper-nickel alloy
offers somewhat greater strength, being particularly used for higher pressure components in HM
Submarines, but at a greater price than 90/10 copper-nickel. Both copper-nickel alloys show very high
resistance to stress corrosion cracking in seawater service.
b) Seawater cooler heat exchanger tubing has traditionally used 70/30 copper-nickel tube. This material
provides some anti-fouling effects to limit macro-fouling of tubes, and has the best erosion-corrosion
resistance of the copper alloys commonly used in naval tubing.
c) Aluminium-nickel-silicon-brass has provided a low magnetic permeability, higher strength and lower
price alternative to 70/30 copper-nickel for high pressure air and hydraulic pipework.
d) Titanium tubing has proved corrosion resistant in seawater heat exchanger applications, with greater
erosion-corrosion resistance than the copper-nickel alloys. The increased material cost may be offset
in part against the use of thinner tubes, based on the minimal corrosion rate of the titanium and its
greater strength.
0.6 Industrial experience, especially in offshore oil and gas applications, has also indicated some effective
tube material / service combinations:
a) Super duplex and super austenitic stainless steels have both been used for tubular products with
seawater up to 40°C.
b) Titanium tubes are being adopted for oil rig fire main systems, to avoid previous corrosion problems
with mild steel and copper-nickel materials.
x
c) Nickel-chromium-molybdenum alloys such as Alloy 625 can show high resistance to pitting and
crevice corrosion in seawater at elevated temperatures.
0.7 Some examples of the necessity to carefully select the material and tube size for a particular system
are given for illustrative purposes:
a) Submarine steam drains were for many years manufactured from mild steel. However these were
particularly susceptible to corrosion in this wet steam environment. This necessitated frequent
replacement and the resulting costs and non-availability of the platform. The selection of a more
corrosion resistant alloy (nickel-chromium-molybdenum Alloy 625) removed the need for repeated
replacement, reducing maintenance costs and increasing platform availability.
b) Erosion-corrosion due to excessive seawater flow velocities has caused failure of copper-nickel tubes.
These alloys are also susceptible to sulphide polluted waters and Microbial Influenced Corrosion
(MIC) during the initial period after installation. Def Stan 02-781 has been revised in Issue 2 to
improve the corrosion performance of such copper-nickel tubes.
c) An additional restriction on the iron content of 90/10 copper-nickel to between 1.5 and 2.0% has been
proposed to improve the seawater erosion-corrosion resistance of the alloy (see clause D.5.1.1).
d) Aluminium-nickel-silicon-brass can become susceptible to stress corrosion cracking if excessively cold

worked or over-heated, leading to over-aging of the alloy.
e) Non-copper based alloy tubes handling seawater can become rapidly clogged by marine organism
growths if not cleaned or treated by biocides / antifoulants such as chlorine.
f) Heat exchanger tubes can suffer corrosion accelerated fatigue due to flow induced tube vibration if of
insufficient rigidity.
g) The poor thermal conductivity of titanium compared to copper-nickel heat exchanger tubes can be
compensated for by the use of thinner tubes, utilising the greater corrosion and erosion-corrosion
resistance of titanium.
xi
Blank Page
xii
Non-Ferrous Tubes and Pipes for use in HM Submarines and

Surface Ships not in Class
1 Scope
This Standard is to advise and inform the selection of tubes and pipes for the transport of liquids and gases
within HM Submarines and Surface Ships not in Class. It specifies the requirements, inspection and testing
for non-ferrous tubes and pipes. The Standard replaces five specific alloy Standards (Def Stans 02-749
Part 3, 02-779 Part 3, 02-780 Part 3, 02-831 Part 3 and 02-837) but retains the procurement aspects of
these documents in appropriate Annexes. Def Stan 02-831 covering aluminium alloy tubes, has been found
not to contain performance critical requirements or important component sizing data and so these Standards
have been superseded by this Defence Standard, but not replaced by separate Annexes of this Defence
Standard. Requirements for the procurement of steel tubes and pipes are specified in Def Stan 02-864. Def
Stan 02-878 only applies to non-nuclear systems.
2 Warning
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that
could be injurious to health if adequate precautions are not taken. Adherence to those processes and
procedures in no way absolves users from complying with legal requirements relating to Health and Safety at
Work.
3 Normative References
3.1 The publications shown below are referred to in the text of this Standard. Publications are grouped
and listed in alpha-numeric order.
ASME B31 Code for pressure piping
ASTM A269 Seamless and welded austenitic stainless steels tubing for general service
ASTM A789 Seamless and welded ferritic / austenitic (duplex) stainless steel tubing for general
service
ASTM B165 Nickel-copper alloy (UNS N04400) seamless pipe and tube
ASTM B338 Seamless and welded titanium and titanium alloy tubes for condensers and heat
exchangers
ASTM B444 Nickel-chromium-molybdenum-columbium alloys (UNS N06625) and nickel-chromium-

molybdenum-silicon alloy (UNS N06219) pipe and tube
ASTM G36 Evaluation stress-corrosion-cracking resistance of metals and alloys in a boiling

magnesium chloride solution
ASTM G38 Practice for making and using C-ring stress-corrosion test specimens
BR 1326 Regulations for atmosphere control in submarines
BR 3008 Materials and processes (Mechanical Engineering).

Chapter 1 Metals
1
BR 3013 (1) and (2) Admiralty pipework standards: Imperial and metric
BR 3021 (2) Shock manual
BR 8470 Shock and vibration manual
BS 3074 Nickel and nickel alloys: seamless tube
BS EN 755-2 Aluminium and aluminium alloys - Extruded rod / bar, tube and profiles
Part 2 Mechanical properties
BS EN 10216 Seamless steel tubes for pressure purposes. Technical delivery conditions
Part 1 Non-alloy steel tubes with specified room temperature properties
Part 2 Non-alloy and alloy steel tubes with specified elevated temperature
properties
Part 5 Stainless steel tubes
BS EN 12449 Copper and copper alloys- seamless, round tubes for general purposes
BS EN 12451 Copper and copper alloys- seamless, round tubes for heat exchangers
BS EN 13445-1 Unfired pressure vessels

Part 1 General
BS EN 13480-3 Metallic industrial piping

Part 3 Design and calculation
BS EN ISO 6507-1 Metallic materials - Vickers hardness test

Part 1 Test method
BS EN ISO 6892-1 Metallic materials. Tensile testing

Part 1 Method of test at ambient temperature
BS MA 18 Salt water piping systems in ships
Def Stan 02-329 Requirements for heat exchangers for HM Surface Ships and Submarines
Def Stan 02-719 Sea Water Systems for H M Surface Ships
Def Stan 02-729 Requirements for non-destructive examination methods

Part 3 Eddy Current
Part 5 Ultrasonics
Def Stan 02-772 Welding and fabrication of pipework, machinery and engineering components for HM
Submarines and Surface Ships not in Class
Def Stan 02-781 Protection of Seawater System Pipework and Heat Exchanger Tubes in HM Surface
Ships and Submarines
Def Stan 02-797 Pipework Engineering

Part 1 General
Def Stan 02-864 Carbon, Carbon-Manganese, and Chromium-Molybdenum Steel Pipes and Tubes for
Pressure Purposes
Def Stan 07-247 The selection of materials on the basis of their fire characteristics
Part 1 The selection of materials on the basis of their fire characteristics
Def Stan 08-120 Requirements for determining the shock strength of equipment (Restricted)
2
MAP 01-109 Metals and corrosion guide
JSP 430 Ship Safety Managements System Handbook
SSP 25 Quality Assurance for Safety in Submarines (Restricted)
3.2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. For some standards the most recent editions shall always apply due to safety and regulatory
requirements. Examples of these are Flight Order AvP 67 and Statutory Instruments (SI’s)
3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Responsibility for the correct application of standards rests with users.
3.4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
4 Definitions
For the purpose of this standard the following definitions apply.
4.1
Acceptance Authority
This is as specified in the tender, contract document or order. Where this is not known, enquiries are to be
directed to MOD.
4.2
Annealed
Fully softened material, achieved by heating to a suitable temperature and holding at that temperature for a
time which is dependent on the thickness of the tube wall.
4.3
Batch
A number of tubes, maximum 300, of the same nominal dimensions manufactured from the same cast by the
same process and heat treated to the same standard in the same furnace at the same time.
4.4
Billet
A mass of metal produced from a single cast intended for further processing.
4.5
Cast
A cast is:
a) the product of one furnace melt, or
b) the product of one crucible melt, or
c) the product of a number of furnace or crucible melts where such are aggregated prior to sampling, or
d) in continuous casting 2000 kg or fraction thereof of metal poured.
4.6
Contractor
The Firm, Company, Organisation or Establishment working within the scope of this Defence Standard.
4.7
Design Authority
The approved firm, MOD establishment or branch responsible for the detailed design of materiel to approved
specifications and authorized to sign a certificate of design or certify sealed drawings.
3
4.8
Design Pressure
The maximum designed operating pressure of a tube system. Previously termed the Working Pressure in
Naval Engineering Standards.
4.9
First Level
Safety critical components and systems, as defined in SSP 25.
4.10
Originating Standard
A recognised standard used to define tubes by material and / or tube size, falling under the additional
requirements of this Defence Standard.
4.11
Ovality
The ratio of maximum external to minimum external diameter of the tube.
4.12
Pipe
For the purposes of this Defence Standard, pipe and tube are equivalent terms. Tube is used in preference
throughout this Defence Standard.
4.13
Tube
A hollow product of uniform wall thickness, produced from billet by hot extrusion, piercing or pilgering
followed by cold reduction and / or cold drawing processes.
5 Design Requirements
5.1 General
a) The form and material selection of tubes under this Standard shall be sufficient to meet the following
requirements, imposed by the design intent of the system for which the tubes are being selected:
1) Resistance to maximum Design Pressure, at maximum and minimum operating temperature.
NOTE Minimum temperature for refrigerant systems and compressed gas systems undergoing rapid de-
pressurisation may be below ambient air temperature.
2) Strength to sustain external loading (including self mass of pipework and contained fluids).
3) Tolerance of cyclic loading and resistance to fatigue cracking, as appropriate.
4) Resistance to deleterious corrosion and related deterioration from contained fluid or gas (i.e.
internal environment).
5) Resistance to deleterious corrosion and related deterioration from installation environment (i.e.
external environment).
6) Tolerance of excursion operating or environmental conditions.
7) Affordability.
8) Compatibility with pipe system fabrication and joining processes.
9) Fire resistance / shock resistance, if required.
4
10) Special functional properties (e.g. antifouling, thermal conductivity, non-magnetic etc), if
required.
b) These requirements for a particular system determine the following properties:
1) Sizing of tubes (wall thickness and internal diameter).
2) Minimum mechanical properties of the selected tube material, including hardness.
3) Corrosion resistance of tube material to the appropriate chemical/environments, including

velocity related erosion and erosion-corrosion.
4) Methods of tube material fabrication and joining.
5) Acceptable tube material cost.
c) The sequence of design and selection choices for tubes is shown schematically in Figure 1.
d) Additional guidance on pipework design is given in Def Stan 02-719 and 02-797 Part 1.
5.2 Material Selection
a) Materials for tubes shall be selected based on the intended equipment operating requirements, as
detailed in clause 5.1. Transient conditions must be considered, such as operating condition upsets
and installation or testing processes and procedures.
b) Specified mechanical properties of materials previously employed for Royal Navy tube applications
and likely alternatives are listed as material data sheets in Annex F and compared in Tables 1 and 2.
c) Materials shall be selected to meet the system requirements of clause 5.1 from materials of defined
composition and mechanical properties as described by recognised national or international
standards. Preferred sources are: Euronorm Standards (EN), British Standards (BS), American
Society for Testing and Materials (ASTM) and the attached Annexes of this Standard for those
materials previously specified for naval purposes in Naval Engineering Standards (NES) and their
relevant replacement 02-series Defence Standards.
d) Tube materials shall be identified as complying either with:
1) A stated commercial Originating Standard, or
2) Annexes B to E of this Defence Standard, detailing the requirements of the replaced Defence
Standards.
e) To ensure a tolerance of deformation for tubes materials and based on the requirements of BS EN
13480-3, the elongation to failure for ferrous and non-ferrous materials (excluding aluminium alloy) for
tubes must be >16% (longitudinal, at the design tube wall thickness and at the minimum tube
operating temperature).
f) Elongation to failure for aluminium alloys must be >14% (longitudinal, at the design tube wall thickness
and at the minimum tube operating temperature) for tubes subject to cold forming, or >10% for tubes
not subject to cold forming.
5
Table 1 – Specifications and Room Temperature Mechanical Properties

of Possible Ferrous Materials for Tubes
Minimum 0.2% Tensile Minimum

Hardness
Material Specification Proof or Yield Strength Elongation
(HV)
Stress (MPa) (MPa) (%)
BS EN 10216-1/2 ‡
P235GH (1.0345) 235 360-500 25 –
Carbon / low
P265GH (1.0425) 265 410-570 23 –
alloy steel
20MnNb6 (1.0471) 355 500-650 22 –
13CrMo4-5 (1.7335) 290 440-590 22 –
BS EN 10216-5
X5CrNi18-10 (1.4301) 195 500-700 40 –
Austenitic X2CrNiMo17-12-2 (1.4404) 190 490-690 40 –
stainless steel
ASTM A269 316L annealed 170 >485 40 <220
BS EN 10216-5
Super austenitic
X1CrNiMoCuN20-18-7 (1.4547)
stainless steel 300 650-850 35 –
(PREN>40)
ASTM A269 UNS: S31254
Super duplex BS EN 10216-5

stainless steel 550 800-1000 20 –
X2CrNiMoCuWN 25-7-4 (1.4501)
(PREN>40)
Note ‡ Alternative ASTM material may be used, see Def Stan 02-864.
g) Tube materials shall comply with the requirements of Def Stan 07-247 Part 1 and BR 1326, as
applicable.
h) For severe corrosive service, such as seawater piping or heat exchangers, some materials must be
excluded based on insufficient corrosion resistance. The following materials shall not be used for
seawater service tubes under this Standard without special additional corrosion prevention measures
approved by the Acceptance Authority:
1) Carbon or low alloy steels (including galvanised steel).
2) Brasses (copper-zinc based alloys) with less than 75% copper content.
3) Stainless steels or nickel-chromium alloys with a Pitting Resistance Equivalent Number (PREN)
of less than 40.
4) Stress corrosion cracking susceptible austenitic stainless steels at temperatures above 60°C.
NOTE PREN = %chromium + (3.3 x %molybdenum) + (16 x %nitrogen), where %element is the minimum
content of stainless steel or nickel-chromium alloy in the specification.
i) For exposure to marine atmospheres, the following materials shall not be used due to risk of stress
corrosion cracking:
1) Brasses (copper-zinc based alloys) with less than 75% copper content.
2) Susceptible austenitic stainless steels at temperatures above 60°C.
6
j) Stress corrosion cracking susceptibility is defined as an inability to resist ASTM G36 test conditions for
1000 hours when C-ring samples (to ASTM G38) of the tube are loaded to 90% of material minimum
specified proof stress.
Table 2 – Specifications and Room Temperature Mechanical Properties

of Possible Non-ferrous Materials for Tubes
Minimum
0.2% Proof Tensile Strength Hardness
Material Specification Elongation
stress (MPa) (MPa) (HV)
(%)
Pure copper BS EN 12449 Cu-DHP CW024A >110 >200 40 40-65

Def Stan 02-878 Annex C
>140 >400 35 <110
70/30 Copper- Annealed (class 2-4, 6, 7 and 9)
nickel BS EN 12449 CuNi30Mn1Fe,
>120 >370 35 85-120
CW354H annealed
Def Stan 02-878 Annex D
>110 >310 35 <95
90/10 Copper- Annealed
nickel BS EN 12449 CuNi10Fe1Mn,
>90 >290 30 75-110
CW352H annealed
Aluminium- Def Stan 02-878 Annex E >230 >450 40 125-140
nickel silicon BS EN 12449 CuZn13Al1Ni1Si1
brass >220 >430 40 120-140
CW700R R430/H120 condition
Ni-Cr-Mo Alloy BS 3074 NA21 cold worked and
>415 >830 30 –
625 annealed
BS 3074 NA13 cold worked and
>275 >690 30 –
annealed
Nickel-copper
BS 3074 NA13 cold worked and
>195 >480 35 –
solution treated
NES 310 (Obsolete) 270-400 400-530 25 –
CP (commercial
purity) titanium ASTM B338 Grade 1 170-310 >240 24 –
ASTM B338 Grade 2 275-450 >345 20 –
BS EN 755-2, AlMg4.5Mn0.7 AW-
Aluminium 5083 >125 >270 10 –
5083, annealed condition
BS EN 755-2, AlMg2
Aluminium 5251 >60 >160 14 –
AW-5251, extruded condition
5.3 Corrosion of Tube Materials
a) Weakening of tube materials by general corrosion and local corrosion (pitting), reductions in wall
thickness by erosion-corrosion, stress corrosion cracking or corrosion fatigue from internal and
external environments shall be considered.
b) Reduction in effective tube wall thickness through-life due to corrosion must be considered in
specifying tube wall thickness, with the possible addition of a corrosion allowance thickness above the
minimum pressure determined wall thickness. Any such corrosion allowance must be determined by
the specific corrosive conditions and the design life of the system.
c) The galvanic (dissimilar metals) corrosion interactions of tube materials with other pipe system
component materials shall be considered in estimating the corrosion implications of a given material
selection.
d) Guidelines on tube material corrosion susceptibilities and corrosion rates are detailed in Annex F,
BR 3008 and MAP 01-109. Tables 3 and 4 provide comparative advisory listings of material corrosion
resistance and corrosion severity for various tube applications.
7
e) Corrosion allowances may not be required for low severity conditions. Corrosion resistant materials or
protective coatings can be specified to reduce or avoid the requirement for wall thickness corrosion
allowances. The durability of any such coatings must also be considered.
f) Water velocity limits apply for some materials. Excessive velocity can result in rapid loss of wall
thickness for certain materials due to erosion-corrosion. Suggested maximum permissible seawater
velocities for different tube materials are listed in Table 5.
g) Seawater velocity should always be at least 1m/s to prevent the settlement of surface deposits and
possible localised corrosion.
Table 3 – Comparative Corrosion Resistance of Tube Materials
Material Corrosion resistance Notes
Poor in aqueous fluids and

Vulnerable to erosion-corrosion.
Carbon / low alloy steel moist atmospheres without
Vulnerable to galvanic corrosion
coatings or other measures
Corrosion resistance varies with alloy composition.
Moderate to poor resistance to
Vulnerable to galvanic corrosion when coupled with
Aluminium alloys seawater, good to moderate in
most other metals. Can suffer stress corrosion
freshwater and atmosphere
cracking
Moderate in seawater, good in
Copper Vulnerable to erosion-corrosion in seawater
freshwater
High zinc brasses at risk of dezincification in
Moderate in seawater and
corrosive waters. Limits on acceptable seawater
Brasses some atmospheres, good in
velocity. Can suffer stress corrosion cracking in
freshwater
waters or marine atmosphere
Vulnerable to sulphide contamination, limits on
Copper-nickel alloys Good
acceptable seawater velocity
Can suffer pitting in stagnant seawater if not coupled
Nickel-copper alloys Good
to less noble alloys
Alloys with PREN<40 are at risk of rapid crevice
Stainless steels and Nickel- corrosion and pitting in low temperature seawater. If
Very good, except for localised
chromium-molybdenum PREN>40, high resistance to pitting and crevice
corrosion in seawater
alloys corrosion in seawater at moderate temperatures.
Possible stress corrosion cracking above 60°C
Titanium alloys Very good Very resistant to seawater and aqueous fluids
8
Table 4 – Comparison of Corrosion Severity for Various Tube Service Environments
Service environment Corrosion severity
Seawater
Open circuit (oxygenated) boiler feed High
External maritime atmospheric conditions
Compressed air
Freshwater
Fuel oil / diesel Medium
Saturated steam
Un-conditioned internal atmospheric conditions
Hydraulic oil
Lubricating oil
Refrigerants Low
Superheated steam
Closed circuit (deaerated / inhibited) boiler feed
Table 5 – Guideline Maximum Velocity Limits for Seawater
Material Velocity limits (m/s)
Aluminium brass 3.0
90/10 copper-nickel 3.5
70/30 copper-nickel 4.0
Stainless steels / nickel-based alloys /

>5.0-10.0
titanium alloys
NOTE These maximum velocities are for sea water system pipework of internal
diameter of 100mm or greater, and for heat exchanger tubing. Maximum
velocity limits for seawater system pipework less than 100mm or where
hydrodynamic conditions in heat exchanger tubes are less than ideal should be
reduced. Def Stan 02-719 Def Stan 02-781 Issue 2 Annex B and BS MA 18
provide additional guidance.
5.4 Other Physical Properties
a) The following properties may be required when selecting materials for tubes:
1) Resistance to fatigue and corrosion-fatigue where cyclic loading / vibration is significant.
2) Thermal conductivity, for heat exchanger tubes.
3) Antifouling properties of copper-alloy tubes in untreated seawater.
4) Magnetic permeability, where low ferromagnetic signature is required.
5) Shock resistance, if required, according to Def Stan 08-120, BR 3021 (2) and BR 8470.
b) Advisory values for some of these properties are detailed in Annex F.
9
c) Indications of relative material price (approximate at date of publication) compared to mild steel are
listed in Table 6.
Table 6 – Comparative Costs for Possible Tube Materials
Relative cost, per unit Relative cost, per unit

Material
mass strength
Mild steel / low alloy steel x1-2 x1
5000 and 6000 series

x10 x6
aluminium alloys
Low PREN stainless steels x6 x7
Pure copper x5 x9
Copper-nickel alloys x8-15 x15-20
High PREN stainless steels x10-20 x5-15
Ni-Cr-Mo alloys x25-30 x12-18
Titanium alloys x25-30 x12-15
d) Cost comparisons for complete tube applications must take into account that:
1) Typically, the through life costs of tubes that require periodic replacement due to corrosion
exceeds those of initially more expensive materials that do not require tube replacement.
2) The lower density of titanium and aluminium alloy reduces the effective cost per component.
3) Higher strengths and corrosion resistances may permit economic use of more expensive
materials through reduced tube wall thicknesses.
5.5 Joining and Welding
a) The joining and weldability of tubes shall be evaluated in selecting tube materials. Mixed metal joints
should be avoided wherever possible.
b) Requirements for compatibility with mechanical couplings and expansion into heat exchanger tube
plates may place limits on acceptable tube hardness.
c) Welding shall be in accordance with Def Stan 02-772 unless otherwise agreed by the Design
Authority.
5.6 Tube Wall Thickness
a) The tensile strength properties of the tube material and the maximum design pressure shall be used to
calculate the minimum tube wall thickness following the procedures of a recognised pipe design code
or pressure vessel design standard. Examples of such standards are BS EN 13445-1, BS EN 13480-
3 and ASME B31.
b) The final tube wall thickness shall be the next highest wall thickness found in commonly commercially
available tube size which is greater than the sum of the minimum wall thickness (from clause 5.6a)
and any allowance for corrosion or other factor.
c) Sizes of tube defined in BR 3013 and the previous Defence Standards now superseded in Annexes B
to E of this Standard shall also be acceptable without detailed design calculation, if fully compliant with
the specific stated material requirements and operating system limitations of these Annexes.
10
d) Tube wall thicknesses shall be sufficient to ensure resistance to buckling and ease of tube expansion,
joining by welding or metallic compression couplings, as appropriate.
e) If bending of tubes is desired, a bending allowance thickness should be added to the minimum wall
thickness, calculated as follows:
D
B= ×t
2.5r
Where:
B is bending allowance.
D is tube outside diameter.
r is centreline radius of bend.
t is tube wall thickness.
11
Define system operating

requirements (Clause 5.1)
Eliminate materials with

inadequate strength or
unsuitable for service
temperature (Clause 5.2)
Eliminate materials
unsuitable for corrosion risk
(Clauses 5.2 and 5.3)
Consider any special properties

required (magnetic/ antifouling /
thermal etc.)? (Clause 5.4)
Consider tube joining

requirements (Clause 5.5)
Select material with

required properties
Select Originating
Standard (Clause 5.2d))
for material
Choose tube size and weight

based on material properties
(Clause 5.6)
Acceptable Procure and inspect

tube cost? to selected
(Clause 5.4) Originating Standard
(Clauses 8 & 9)
NO YES
Figure 1 – Schematic Flowchart for Tube Material Selection Process
12
6 Information to be Supplied by the Purchaser

a) The following information shall be supplied by the purchaser:
1) The number of this Defence Standard.
2) Quantity (mass, total length and / or number of tubes).
3) Tube dimensions (outside diameter and wall thickness).
4) Tube material specification, as defined in an Annex of this Standard or another Originating

Standard.
5) The design pressure of the application for which the tubes are intended.
6) Any optional / additional testing required according to this Standard or related documents.
7 Tube Manufacture
a) The method of tube manufacture shall avoid local material inhomogeneity that adversely affects the
required mechanical or corrosion properties.
b) Tubes for pressure systems (steam, boiler, compressed air and hydraulic systems etc), or containment
of corrosive fluids, such as seawater, shall be seamless.
c) Billets or hollows shall be released for production of tubes only when a certificate of conformity or an
analysis shows that they meet the specified requirement.
d) Tubes are not to be redrawn from used tubing.
e) All heat treatment is to be carried out in a furnace operating with an atmosphere sulphur content less
than 0.005g/m3.
f) Surface defects may be removed by grinding, machining or filing with a clean file, provided that the
material thickness does not go below the allowable tolerance. Dressed areas are to be faired
smoothly into the surrounding material and the bottom radius of the dressed area is to be at least
three times the depth of the defect. Surface imperfections such as handling marks, straightening
marks, tight mandrel, die or roll marks and scale pattern are not to be considered as damaging defects
provided that they do not reduce the wall thickness below the specified tolerance. Surface features
that result in the detachment of metallic flakes from the wall thickness during subsequent bending /
forming shall be considered surface defects.
g) All tubes are to be cleaned to remove all contamination and moisture. After cleaning, the tube ends
are to be suitably sealed to prevent ingress of moisture and contamination during transport and
storage.
h) Unless otherwise stated in the contract documents, all tubes are to be supplied in straight random
lengths of not more than 6.0 metres. 90% or more of tubes in each batch are to have a minimum
length of 3.5 metres. The remainder may be supplied in shorter lengths down to a minimum of 2
metres.
13
8 Test Methods and Examination Requirements
8.1 Selection of Originating Standards
a) Tubes supplied to this Defence Standard shall be defined by material and dimensions in accordance
with an internationally recognised Originating Standard (as defined in clause 5.2d).
b) Examples for 70/30 copper-nickel tubing:
1) Originating Standard: BS EN 12449, Material: CuNi30Mn1Fe / CW345H, Condition R370, OD:

20mm, Wall thickness: 3.5mm.
2) Originating Standard: Annex C of this Defence Standard, Class 2, OD: 20mm, Wall thickness:
3.5mm.
c) The design decisions and assumptions, as outlined in clause 5.1, used to select a given tube size and
material from a chosen Originating Standard shall be formally recorded.
8.2 Destructive Tests
Tubes shall be tested and accepted according to the requirements of the chosen Originating Standard.
These requirements must address the issues detailed below, as applicable.
8.2.1 Sampling
Samples need to be taken from material representative of the supplied product, both in terms of
compositional origin and of the processing history to the final product form. When large amounts of tubing
are supplied from different production batches, samples may be required from each batch to ensure
uniformity of properties. Sampling from each production batch / cast is required for First Level components.
8.2.2 Chemical Analysis
Required to confirm compliance of the supplied material with the Originating Standard. Deviations in this
composition may affect tube performance in ways not otherwise detected by other acceptance testing.
Chemical analysis per batch / cast is required for all First Level components.
8.2.3 Tensile Tests
Required to confirm that the mechanical properties of the supplied tubes meet the design assumptions used
to select the tube dimensions. Deviations in mechanical properties may indicate that the wider tube
performance will not be as assumed in the original design decision. Tensile testing per batch is required for
all First Level components.
8.2.4 Hardness Tests
Required to ensure that tube surface mechanical properties do not deviate significantly from tensile test
results obtained from full wall thickness sample. Excessive hardness, especially in surfaces, can make
tubes more difficult to install / assemble and prevent effective use of mechanical couplings which use
metallic teeth or edges to engage the tube surface. If hardness values are specified in the Originating
Standard, First Level components require the hardness testing of each batch.
8.2.5 Re-tests
The repeat testing of a batch of tubes which initially fail to meet the specified performance levels must be
limited to a reasonable level to ensure that any passing test result is truly representative of the tube
performance.
14
8.3 Non-destructive Tests
The following non-destructive testing shall be required for all tubing meeting the requirements of this
Defence Standard. These tests and examinations ensure that manufactured tubes meet the high integrity
and safety requirements of applications in HM Submarines and Surface Ships not in Class.
8.3.1 Visual Examination
The surface of each tube is to be inspected, including internal surfaces where visible from the tube ends.
Magnification optics (up to x 5) may be used if required.
8.3.2 Dimensional Inspection
a) Each tube is to be checked for dimensional accuracy as follows:
1) The outside diameter of each tube is to be measured in two directions at 90° in the same plane,
at positions approximately 75 mm from both ends of the tube.
2) The wall thickness is to be measured at two positions 180° apart at one end of each tube,
unless otherwise specified in Annexes B to E.
8.3.3 Leak Tightness Tests
a) Each tube shall be tested for defects by one of the following methods at the option of the supplier,
unless otherwise stated in the order:
1) Eddy current test.
2) Hydrostatic test.
3) Pneumatic test (heat exchanger tubes only).
8.3.3.1 Eddy Current Test
The test is to be carried out in accordance with the procedure described in clause A.3.1
8.3.3.2 Hydrostatic Test
a) Non-heat exchanger tubes are to be hydrostatically tested at room temperature at a test pressure as
defined below, or at 69 bar, whichever is lower:
S×T
Test pressure P (bar) = 20
D
Where:
D is the specified outside diameter of the tube (mm).
T is the specified wall thickness of the tube (mm).
S is the stress (MPa) - corresponding to 70% of the specified minimum yield strength or
proof strength for the tube material concerned at room temperature.
b) The test pressure is to be maintained for at least 30 seconds. During the test the tube is to be
inspected along its entire length.
15
8.3.3.3 Pneumatic Test (Heat Exchanger Tubes only)
Each heat exchanger tube is to be subjected to a pneumatic test. The test pressure is to be 4 bar. The test
duration is to be at least 30 seconds.
8.3.4 Pressure Proof Test
a) Each general purpose tube (not heat exchanger tube) shall be pressure proof tested to indicate
suitability for the operating pressures to be employed. The test pressure is to be:
1) times the system Design Pressure if this is less than or equal to 70 bar, or
2) 1.5 times the system Design Pressure if greater than 70 bar.
b) The test pressure is to be maintained for at least 30 seconds. During the test the tube is to be
inspected along its entire length.
c) Where the leak tightness tests (clause 8.3.3) selected is a hydrostatic test (clause 8.3.3.2) requiring a
test pressure greater than the system-based proof test pressure defined in clause 8.3.4a), a
successful hydrostatic test shall be considered to also meet the requirements of this pressure proof
test.
8.3.5 Magnetic Permeability
This is only to be measured when stipulated in the contract documents, using the stipulated method.
8.3.6 Ultrasonic Tests
After acceptance of the leak tightness and pressure tests, each tube for First Level applications is to be
subjected to an ultrasonic test. Ultrasonic testing of Non-First Level tubes shall also be carried out if
stipulated by the contract documents. The test is to be carried out in accordance with the procedure
described in clause A.3.2.
9 Acceptance Standards
Tubes shall be accepted in accordance to their Originating Standard (as defined in 5.2d) and 8.1) and with
the following requirements, where additional:
9.1 Destructive Tests
9.1.1 Chemical Analysis
The analysis of each cast and batch of tubes is to conform to the chemical composition in the material
standard specified under clause 8.1. Only the result of the tube analysis is to appear on the quality
assurance documentation.
9.1.2 Mechanical Properties Tests
The mechanical properties established from the tensile tests under clause 8.2.3 are to conform to the
material standard specified under clause 8.1.
9.1.3 Hardness Test
The hardness value is to conform to material standard specified under clause 8.1, as applicable.
16
9.2 Non-destructive Tests
9.2.1 Visual Examination
a) The external and internal surfaces of each tube is to be clean, smooth, bright and free from visible
defects, contamination and moisture. Dressed areas are to be faired smoothly into the surrounding
material, in compliance with clause 7f) and the relevant minimum tolerance on tube dimensions.
b) All tube ends are to be clean cut and square with the axis and are to be free from burrs.
c) All tubes are to be free from local bends or kinks.
9.2.2 Dimensional Checks
Tubes shall comply with the dimensions specified by the standard selected under clause 5.2d). Deviations
from circularity (such as ovality and off-centre bore) shall be acceptable if such tubes comply with the
required wall thickness and outside diameter values at all points of their circumference.
9.2.3 Leak Tightness Tests
9.2.3.1 Eddy Current Test
No tube is to cause a signal which is equal to or greater than that caused by the standard reference specified
in clause A.3.1. Tubes giving rise to signals in excess of the agreed calibration level are to be rejected
without the need to record the location, extent and signal amplitude.
9.2.3.2 Hydrostatic Test
Each general purpose tube is to withstand the test pressure without leaking, bulging or revealing any other
defect.
9.2.3.3 Pneumatic Test (Heat Exchanger Tubes only)
Each condenser and heat exchanger tube is to show no evidence of leakage.
9.2.4 Pressure Proof Test
Each general purpose tube is to withstand the test pressure without leaking, bulging or revealing any other
defect.
9.2.5 Magnetic Permeability
The magnetic permeability is to conform to the requirements of the contract.
9.2.6 Ultrasonic Tests
No tube is to cause a signal which is equal to or greater than that caused by the standard reference specified
in clause A.3.2. Tubes giving rise to signals in excess of the agreed calibration level are to be rejected
without the need to record the location, extent and signal amplitude.
9.3 Rejection
Tubes failing to meet any of the requirements of clauses 9.1 and 9.2 are to be rejected.
17
9.4 Summary of Tube Procurement Process
A schematic of the tube selection and procurement process is shown in Figure 2.
NO Replacing YES Select Def Stan 02-878

Identify tube system
requirements (including existing tubes Annex equivalent to
pipe diameter) on like-for-like superseded Def Stan or
NES of original tubes
basis?
Select tube material for Select appropriate tube

strength, corrosion, cost dimensions from those
and other properties listed in Annex
(Clause 5.1c))
Select Originating Test tubes for

Standard (Clause 8.1), compliance with Annex
either commercial or requirements
Def Stan 02-878 Annex
Calculate minimum wall

thickness based on Add any
Design Pressure and bending/corrosion
minimum strength of allowances to minimum
specified material wall thickness
(Clause 5.6)
Record design process

decisions and
assumptions for future
reference
Select next available

tube size greater than
calculated wall
thickness requirement
Test tubes for

compliance with
Originating Standard
Test tubes for

compliance with Non- Accept tubes for use
Destructive tests and prepare QA records
detailed in Clauses
8.3 and 9.2
Figure 2 – Schematic Flowchart for Tube Procurement Process
18
10 Quality Assurance Documentation
10.1 General
a) Unless otherwise specified in the order or contract, each consignment of tubes is to be accompanied
by quality assurance documentation giving the actual results of the compositional, tensile and
hardness tests required by clauses 8.2.2, 8.2.3 and 8.2.4, and other information and results required
by the Originating Standard.
b) The quality assurance documentation which accompanies First Level Quality Assured tubes is to
satisfy all the requirements of SSP 25.
c) The documentation is to include a certificate of conformity.
d) Documentation is to be forwarded to the consignee in a separate enclosure.
10.2 Certificate of Conformity
a) Each certificate is to include a statement that the material complies with all the requirements of this
Defence Standard, supported by the signature of an authorized inspector.
b) Each certificate is to carry a reference number or sufficient other information to positively relate the
certificate with the relevant tubing.
10.3 Records
Records sufficient to prove adequate quality control, full material traceability and the relevant results of
analyses and tests are to be retained by the contractor for at least 5 years after delivery. After the 5 year
period destruction of the records shall be as defined in the contract.
11 Identification
a) Each box of tubes prepared for delivery is to be indelibly marked with the following (in the stated
order):
1) The manufacturers’ name or identification mark.
2) The Originating Standard, with Annexes of the Defence Standard marked e.g. “ABCD- Def Stan
02-878-Annex Y” as appropriate.
3) Description i.e. Size (outside diameter and wall thickness) and maximum Proof Test Pressure
(as per clause 8.3.7). The Class of tubes ordered to Annexes C to E of this standard shall also
be included.
4) NATO Stock Number (if applicable).
5) Contract Number.
6) Quantity.
7) A reference number or sufficient other information to positively relate the tubing to the relevant
certificate of conformity.
19
b) Unless otherwise stated in the order or contract, each tube is to be identified with the information
specified in clause 11a) 2), 3) and 7) by the contractor by printing directly onto the outside surface of
the tube using an ink which will not have a deleterious effect on the material. The markings are to be
not less than 5 mm high and are to be repeated along the entire length of the tube. The maximum
distance between markings is not to exceed 300 mm.
c) Metal stamping or vibro-etching shall not be used for identification marking, unless otherwise specified
by the contract.
20
Annex A
Test Methods Specific to this Defence Standard
A.1 Scope
This Annex details the specific test requirements of tubes procured under this Defence Standard, in addition
to those test methods used by the Originating Standard.
A.2 Flattening and Bend Tests for Copper Alloys
A.2.1 Flattening Test
a) This test applies to tubes not exceeding 108 mm outside diameter. The test pieces shall be annealed
before flattening unless the tubes are supplied in the annealed condition.
b) The test pieces shall be flattened down until the interior surface meets as shown below:
c) The test piece shall show no visible evidence of cracks or flaws.
A.2.2 Double Bend Test
a) This test applies to round tubes of over 108 mm outside diameter. The test pieces shall be annealed
before flattening unless the tubes are supplied in the annealed condition.
b) A test piece 50 mm wide shall be cut longitudinally from the tube. The longer edges shall be carefully
rounded and smoothed longitudinally so that a cross section has approximately semicircular ends.
The test piece shall be flattened and shall have its ends bent through 180° in opposite directions and
doubled up close as shown.
c) The test piece shall show no visible evidence of cracks or flaws.
A.3 Non-destructive Test Procedures
A.3.1 Eddy Current Test
A.3.1.1 Method of Test
a) All inspections are to be carried out in accordance with Def Stan 02-729 Part 3.
21
b) The method of test is to be chosen to ensure complete inspection of the whole of the tube wall as
supplied. If the ends of tubes cannot be satisfactorily inspected, the un-inspected areas may be cut-
off.
A.3.1.2 Calibration
a) The sensitivity of the equipment is to be set using a calibration standard.
b) In each case the calibration standard is to consist of 3 holes of not more than 0.80mm diameter drilled
completely through the tube wall. The holes are to be displaced circumferentially at 120° from one
another and sufficiently far apart axially to ensure that signals from each one can be easily resolved
and are not influenced by signals from either of the other two holes or by end effects.
c) The holes are to be drilled cleanly and the diameter is not to be enlarged in any way e.g. by deburring
operations on the external or internal surfaces.
A.3.1.3 Checking of Equipment
a) The control equipment is to be set so that it is triggered by the signal from each hole every time the
calibration standard is put through.
b) The speed at which the calibration standard passes the test coil is to be the same as will apply to
production testing.
c) Calibration checks are to be carried out at intervals not exceeding one hour and at the beginning of
each shift.
d) If on checking, any of the standard holes are not detected, all tubes tested since the last calibration
check are to be re-tested after normal operation has been re-established.
e) All equipment, techniques and procedures for the inspection of tubes to this Standard are to be
approved by the acceptance authority.
A.3.2 Ultrasonic Test Method
a) Testing shall be conducted on each tube, after leak tightness tests, pressure testing and magnetic
permeability (if required) tests have been completed.
b) All inspections are to be carried out in accordance with Def Stan 02-729 Part 5.
a) During testing, the tubes or search units are to be moved so that the probes traverse the tube surface
in a helix. The pitch of the helix is to be related to the effective beam width and the minimum flaw to
be positively located such that the whole of the tube wall is effectively scanned. The frequency and
transducer size used is to be compatible with the material and the thickness of the tube being
inspected.
b) The speed of movement of the probe relative to the tube surface is to be limited to give optimum
inspection conditions.
c) The probe assembly is to be so arranged that 100% of the internal and external surfaces of the tube is
scanned for both circumferential and longitudinal defects.
d) The standard immersion technique of using a compression wave probe operated to achieve shear
wave examination is permitted.
22
A.3.2.2 Equipment
Probes up to a maximum dimension of 25 mm diameter are permitted for use. All equipment, techniques
and procedures for the inspection of tubes to this Standard are to be approved by the Acceptance Authority.
A.3.2.3 Calibration Standards
a) The ultrasonic equipment is to be calibrated using a longitudinal and transverse standard notch on the
outside and inside surfaces of a tubular test piece of the same specification as the tubes for
inspection, in the “as supplied” condition.
b) External and internal standard notches are to be sufficiently separated axially as to be completely
distinguishable.
c) For tubes 12 mm bore and below, the internal notch may be omitted. In the absence of an internal
notch, bore defects will be identified by reference to the “depth range” of position of the cathode ray
tube display. The alarm monitor is to be positioned to include the “depth range” at which bore defects
will be indicated, i.e. at the midway position between the first and second outside surface defect
positions. The alarm monitor sensitivity is to be set to the level defined by the outside surface notch.
d) The standard notch is to comply with the following:
1) Manufacture - the notch is to be formed either by machining or spark erosion.
2) Shape - the cross section of the notch is to be nominally of rectangular section; other sections
are to be adopted only by agreement with the Acceptance Authority.
3) Length - standard longitudinal notch 25 mm maximum. Standard transverse notch may extend
fully round the circumference.
4) Width - standard notch width - 1mm maximum.
5) Depth - the standard notch depth is to be 3% of the specified wall thickness or 0.1 mm,
whichever is greater, unless otherwise agreed between the acceptance authority and the
Contractor. There is to be no positive tolerance on the depth of notch. The internal notch is not
to be used when the outside diameter to thickness ratio is less than 4. For outside diameter to
thickness ratios between 5 and 4, the internal standard notch depth is to be in accordance with
Table A.1.
Table A.1 – Ultrasonic Calibration Notch Depths
Ratio of Outside Diameter to Ratio of Internal Notch Depth to

Thickness External Notch Depth
5 1
4.75 to 4.99 1.6
4.50 to 4.74 1.9
4.25 to 4.49 2.2
4.00 to 4.24 2.5
23
A.3.2.4 Calibration and Checking of Equipment
a) The ultrasonic equipment is to be set so that it is triggered by the signals from both the internal and
external standard notches every time the calibration standard notch is used. The relative rotational
speed between the tube containing the standard notch and the search unit during calibration is to be
the same as will apply during testing.
b) Calibration checks are to be carried out at intervals not exceeding one hour and at the beginning of
each shift.
c) If on checking during production testing either or both standard notches are not detected, then all
tubes tested since the previous check are to be re-tested after the instrument has been recalibrated.
A.3.3 Ultrasonic Thickness Gauging
All inspections are to be carried out in accordance with Def Stan 02-729 Part 5.
a) During testing the tubes or search units are to be moved so that the probes traverse the tube surface
in a helix. The pitch of the helix is to be determined by the application of clause A.3.2.1a).
b) The speed of movement of the probe relative to the tube surface must be limited to give optimum
inspection conditions.
c) Variations in tube wall thickness are to be inspected by a longitudinal wave technique.
d) The frequency and transducer size used is to be compatible with the material and the thickness of the
tube being inspected.
A.3.3.2 Calibration Standards
The ultrasonic equipment is to be calibrated using a tube of known thickness with areas of minimum and
maximum wall thickness.
A.3.3.3 Calibration and Checking of Equipment
a) The ultrasonic equipment is to be set so that it is triggered by the signals from the minimum and
maximum wall thickness every time the calibration standard is used. The relative rotational speed
between the calibration standard tube and the search unit during calibration is to be the same as will
apply during testing.
b) Calibration checks are to be carried out at intervals not exceeding one hour and at the beginning of
each shift.
c) If on checking during production testing, the minimum or maximum wall thicknesses are not detected,
then all tubes tested since the previous check are to be retested after the instrument has been
recalibrated.
d) All equipment, techniques and procedures for the inspection of tubes to this Standard are to be
approved by the acceptance authority.
24
Annex B
Specific Requirements for Copper Tubes
(previously covered by Def Stan 02-837)
B.1 Scope
This Annex specifies the specific requirements for the manufacture, inspection, testing and supply of copper
tubes formally covered by Def Stan 02-837. The copper tubes meet the requirements for phosphorus
deoxidised non-arsenical copper conforming to the chemical composition of BS EN 12449, Material Symbol
Cu-DHP, Material Number CW024A (referred to as BS EN 12449 – CW024A throughout this standard) and
does not cover any other Material Symbol or Material Number listed in BS EN 12449.
B.2 Manufacture
B.2.1 Tube production
Unless otherwise stated in the contract documents, all tubes are to be made to the dimensions detailed in
Tables B.1 to B.6.
B.2.2 Condition of Tubing
a) Straight tube may be supplied in the R200, R250, R290 or R360 condition and Coiled tube shall be
supplied in the R200 (Annealed) condition in accordance with the requirements of BS EN 12449 –
CW024A.
b) If required by operational conditions, Bright Annealing (R200) may be specified on the order.
c) To satisfy hydrostatic pressure test requirements, materials of a higher tensile strength (R250, R290 or
R360) may be specified. Improved material properties may be achieved by cold drawing post the
annealing process. This condition has previously been referred to as the ‘Half-hard’ condition.
B.2.3 Supply Requirements
a) The order or contract shall state the form of tubing that shall be supplied if different from the normal
forms of supply detailed below.
b) Tubes up to and including 10 mm Outside Diameter (OD) shall be supplied in coils. Coiled tube shall
be supplied in bunched coils in accordance with the requirements of BS EN 12449.
c) Tubes larger than 10 mm shall be supplied in straight lengths in accordance with the requirements of
BS EN 12449.
d) Unless otherwise specified in the order or contract or agreed between purchaser and supplier, straight
tube shall be supplied in random lengths of not less than 3.5 metres and not more than 6.0 metres.
e) Unless otherwise specified in the order or contract or agreed between purchaser and supplier, coils
shall be approximately 750 mm outside diameter.
f) Tubes supplied for refrigeration systems must be supplied dehydrated and with sealed ends.
25
B.3 Specific Tests

Tests shall be in accordance with clause 8, with the following additional specific requirements.
B.3.1 Destructive Tests
B.3.1.1 Mechanical Test Sampling
a) Straight Tube - Mechanical test samples shall be selected at the minimum rate of one tube in every
1300 kg of tubing or a minimum of one tube in every 300 tubes of the same size, whichever gives the
larger number of samples.
b) Coiled Tube - Mechanical test samples shall be taken from coils selected at the minimum rate of one
coil in every 1300 kg of tubing of the same size.
c) All Tube - Where a production run contains less than 1300 kg of tubing or less than 300 straight tubes
of the same size, one straight tube or part of one coil shall be selected as a test sample for each size
of tubing.
B.3.1.2 Chemical Analysis
a) A full chemical analysis shall be made from a sample taken from each cast and from each material
taken from each tube or coil selected for mechanical tests.
b) If no material is available from the tube or coil used for mechanical tests, one further sample tube or
coil shall be similarly selected and used for analysis.
B.3.1.3 Mechanical Tests
a) Tensile properties are to be determined in accordance with BS EN ISO 6892-1.
b) Hardness properties are to be determined in accordance with BS EN ISO 6507-1.
c) Retests shall be conducted as described in BS EN 12449.
B.3.2 Non-destructive Tests
These shall be performed as specified in clause 8.3.
B.3.2.1 Samples for Dimensional Checks
a) For tubing up to and including 75 mm OD, sample tubes shall be selected for dimensional
examination. Sampling shall be carried out at the minimum rate of one in every 300 tubes or a
minimum of one tube in every production run of less than 300 tubes.
b) For tubing over 75 mm OD every tube shall be examined.
26
B.4 Acceptance Criteria
B.4.1 Chemical Analysis
As specified in BS EN 12449 – CW024A.
B.4.2 Mechanical Tests
a) Tensile properties are to comply with stated material grade in BS EN 12449 – CW024A.
b) Hardness properties are to comply with stated grade in BS EN 12449 – CW024A.
B.4.3 Non-destructive Tests
a) Visual examination of the tube surfaces shall meet the requirements of clause 9.2.1. All tubes shall be
free from local bends and kinks.
b) Dimensions shall meet the tolerances of BS EN 12449 and Tables B.1 to B.6.
c) Leak tightness and pressure tests shall meet the requirements of clause 9.2.3.
B.4.4 Rejection
Tubes failing to meet the requirements of clause B.4 shall be rejected.
B.5 Identification
Material description in addition to requirements of clause 11 shall be “BS EN 12449-CW024A –Def Stan 02-
878 Annex B”.
27
Table B.1 – Metric Tube for Fresh Water, Oil and LP Air Systems for use at
Working Pressures up to 6 bar and Temperatures up to 75°C
Tube Dimensions based on BS EN 12449 (mm)

Nominal size
(mm) Outside Diameter Wall Thickness
Max Min Nom Max Min
6 6.06 5.94 0.8 0.92 0.68

8 8.06 7.94 0.8 0.92 0.68
12 12.08 11.92 0.8 0.92 0.68
15 15.08 14.92 1.0 1.15 0.85
22 22.12 21.88 1.2 1.356 1.044
28 28.12 27.88 1.2 1.356 1.044
35 35.15 34.85 1.5 1.695 1.305
42 42.15 41.85 1.5 1.695 1.305
54 54.20 53.80 2.0 2.26 1.74
76.1 76.30 75.90 2.0 2.26 1.74
Table B.2 – Imperial Tube for: (a) Steam Systems at Working Pressures up to 10.5 bar and
Temperatures up to 187°C and (b) General use up to 12 bar and Temperatures up to 175°C
Tube Dimensions based on BR 3013 (1),

Parts 1 and 2 (inches)
Nominal Size
Outside Diameter Wall Thickness
Bore (inches)
Max Min Nom SWG Max Min
0.125 See Table B.3
0.25 See Table B.4
0.375 See Table B.3
0.5 0.596 0.593 16 0.070 0.058
0.75 0.846 0.843 16 0.070 0.058
1.0 1.112 1.109 15 0.078 0.066
1.25 1.362 1.359 15 0.078 0.066
1.50 1.612 1.609 14 0.090 0.070
2.0 2.128 2.125 13 0.102 0.082
2.5 2.628 2.622 12 0.114 0.094
3.0 3.144 3.138 11 0.126 0.106
4.0 4.184 4.178 9 0.157 0.131
5.0 5.455 5.445 7 0.189 0.163
28
Table B.3 – Imperial Tube for: (a) Steam Systems at Working Pressures up to
17 bar and Temperatures up to 208°C and (b) General use at Working
Pressures up to 25 bar and Temperatures up to 190°C

Parts 1 and 2 (inches)
Nominal Size
Bore (inches) Outside Diameter Wall Thickness
Nom
Max Min Max Min
SWG
0.125 0.205 0.202 18 0.054 0.042
0.25 See Table B.4
0.375 0.471 0.468 16 0.070 0.058
0.5 0.596 0.593 15 0.078 0.066
0.75 0.847 0.843 13 0.102 0.082
1.0 1.112 1.109 12 0.114 0.094
1.25 1.362 1.359 11 0.126 0.106
Table B.4 – Imperial Tube for: (a) Pressure Gauge Piping for use at Working Pressures
up to 83 bar and Temperatures up to 75°C and (b) Steam Systems at Working
Nominal Size Parts 1 and 2 (inches)
Bore Outside Diameter Wall Thickness
(inches)
Nom
Max Min Max Min
SWG
0.25 0.346 0.343 16 0.070 0.058
Table B.5 – Metric Tube for Refrigeration Systems at Working

Pressures up to 11 bar and Temperatures to 75°C
Tube Dimensions based on BS EN 12449 (mm)

Nominal Size
(mm) Outside Diameter Wall Thickness
Max Min Nom Max Min
6 6.06 5.94 1.0 1.15 0.85
12 12.08 11.92 1.0 1.15 0.85
15 15.08 14.92 1.0 1.15 0.85
28 28.12 27.88 1.0 1.15 0.85
29
Table B.6 – Imperial Tube for Refrigeration Systems at Working

Tube Dimensions (inches)

Nominal Size
(inches) Outside Diameter Wall Thickness
Nom
Max Min Max Min
SWG
0.188 0.190 0.186 20 0.040 0.032
0.250 0.252 0.248 20 0.040 0.032
0.375 0.377 0.373 20 0.040 0.032
0.5 0.502 0.498 20 0.040 0.032
0.625 0.627 0.623 20 0.040 0.032
0.750 0.752 0.749 19 0.044 0.036
0.875 0.877 0.874 18 0.053 0.043
1.125 1.127 1.124 16 0.070 0.058
30
Annex C
Specific Requirements for 70/30 Copper-nickel Alloy Tubes
(previously detailed in Def Stan 02-780 Part 3)
C.1 Scope
a) This Annex specifies the requirements for the manufacture, inspection, testing and supply of 70/30
copper nickel alloy tubes previously covered by Def Stan 02-780 Part 3.
b) The tubes supplied against this Annex are for general purpose and heat exchanger / condenser use
only. Where tubes are required for a special purpose, e.g. an oxygen clean system, this should be
specified in the contract documents together with any special cleaning requirements and the required
acceptance standards.
c) 70/30 copper-nickel alloy tubes are placed in eight classifications (Classes 2-9 inclusive) dependent
upon material condition, usage, and wall thickness. The classification does not denote the level of
quality assurance.
C.2 Tube Classification

a) The classification of tubes is according to usage, dimensional units and material condition and is
defined in Table C.1. Any subsequent stroke number denotes maximum working pressure in either
psi for imperial tubes or bar for metric tubes.
b) All tubes are to be designated by class, outside diameter, wall thickness and length.
C.3 Manufacture
C.3.1 Tube Production
Tables C.2 and C.3. For condenser and heat exchanger tubes the requirements of Def Stan 02-329 must
also be met.
C.3.2 Condition of Tubing
a) General purpose tubes are to be supplied in the fully annealed condition.
b) Condenser and heat exchanger tubes are to be supplied in either the hard or the annealed condition,
dependent upon the requirements of the contract documents. When the hard condition is specified,
i.e. Class 5 and 8, the tubes are to be given a low temperature stress relieving treatment.
c) All tubes are to be cleaned to remove all contamination and moisture. After cleaning, the tube ends
are to be suitably sealed to prevent ingress of moisture and contamination during transport and
storage.
C.3.3 Supply Requirements
Unless otherwise stated in the contract documents, all tubes are to be supplied in straight random lengths of
not more than 6.0 metres. 90% or more of tubes in each batch are to have a minimum length of 3.5 metres.
The remainder may be supplied in shorter lengths down to a minimum of 2 metres.
31
C.4 Specific Tests

C.4.1 Destructive Tests
C.4.1.1 Sampling for Destructive Tests
Tests shall be made on a test sample taken from each batch of tubes in the “as supplied” condition.
C.4.1.2 Chemical Analysis
A full chemical analysis shall be made from a sample taken from each cast and from batch of tubes in the “as
supplied” condition.
C.4.1.3 Mechanical Tests
c) A flattening or double bend test shall be carried out as detailed in clause A.2.
d) Retests shall be conducted as described in BS EN 12449.
C.4.2 Non-destructive Tests
These shall be performed as specified in clause 8.3, in addition to:
C.4.2.1 Dimensional Inspection
The wall thickness at both ends of each tube is to be measured at four positions 90° apart.
C.4.2.2 Ultrasonic Wall Thickness Checks
Additional ultrasonic thickness testing to clause A.3.3 may be optionally required and stated in the contract
documents.
C.5 Acceptance Criteria
C.5.1 Destructive Tests
C.5.1.1 Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to Table C.4.
C.5.1.2 Mechanical Tests
a) The specified tensile tests shall conform to the values in Table C.5.
b) The specified hardness test shall conform to the values in Table C.5.
c) In the flattening or bending test the tubing is to show no visible evidence of cracks or flaws.
32
C.5.2 Non-destructive Tests
b) Dimensions shall meet the requirements of Tables C.2 to C.3 and the tolerances of Tables C.6 to C.7.
All condenser and heat exchanger tubes are to have ends cut clean and square to within ±1mm.
d) Ultrasonic testing is to comply with the requirements of clause 9.2.6.
e) If ultrasonic wall thickness gauging is required, tube is to be rejected where the wall thickness is
outside the thickness tolerance (Tables C.6 to C.7), without the need to record where the thickness
approaches the minimum tolerance on good or rejected tubes.
C.5.3 Rejection
Tubes failing to meet the requirements of clause C.5 shall be rejected.
C.6 Identification
Material description in addition to requirements of clause 11 shall be “70/30 CuNi –Def Stan 02-878
Annex C” and shall also detail the Class and Test Pressure.
Table C.1 – Classification of Tubes
Dimensions
Class Material Usage Condition
Metric Imperial
1 See Annex D: Requirements for 90/10 copper-nickel alloy tubes
General Purpose (Sea

2 70/30CuNi 3 3 ANNEALED
Water Systems)
General Purpose (High

3 70/30CuNi 3 ANNEALED
Pressure > 1000psi)
Condenser & Heat

Exchanger
Condenser & Heat

5 70/30CuNi 3 HARD
Exchanger
General Purpose (High

Pressure > 70 Bar)
Condenser & Heat

Exchanger
Condenser & Heat

8 70/30CuNi 3 HARD
Exchanger
General Purpose (Thin

Wall For MCMV’s)
33
Table C.2 – 70/30 Copper-nickel Alloy Tubes - General Purpose (metric)

Tube Classification
Nominal (Class-Working pressure in bar)
External
Diameter 2-28 2-69 6-207 6-280 9-10 9-16
(mm)
Wall Thickness (mm)
6 – – 1.0 1.0 0.8 1.0

8 1.5 1.5 1.5 1.5 0.8 1.0
10 2.0 – – – – –
12 2.5 2.5 2.5 2.5 0.8 1.0
12 (butt welded
3.0 3.0 3.0 3.0 – –
applications)
16 3.0 – 3.0 3.0 1.0 1.5
20 3.5 3.5 3.5 3.5 1.0 2.0
25 – – – – 1.5 2.0
30 2.5 4.0 4.0 5.0 1.5 2.0
38 2.5 4.0 5.0 6.5 1.5 2.0
44.5 3.0 4.0 – 8.0 1.5 2.0
50 3.0 – 6.5 8.5 – –
57 3.0 5.0 7.5 9.5 1.5 2.0
76.1 3.5 6.0 10.5 13.0 2.0 2.5
88.9 4.0 – – – 2.5 3.0
100 – – – – 2.5 3.0
108 4.0 7.5 – – 2.5 3.0
133 4.5 9.0 – – 2.5 3.0
162 – 11.0 – – – –
34
Table C.3 – 70/30 Copper-nickel Alloy Tubes. General Purpose (imperial):

Dimensions, classification and working pressures
Tube Classification
Outside Nominal Actual (Class-Working Pressure in psi)
Diameter Bore Bore 2-200 2-350 2-700 3-3000 3-4000 3-4500
(inches) (inches) (inches)
Wall Thickness (inches)
0.250 – 0.035 0.049 0.058
0.346 ¼ 0.064 0.062
1
0.405 /8 0.065
3
0.471 /8 0.064
0.500 – 0.035 0.072 0.109 0.134
0.540 ¼ 0.065 0.072 0.109 0.134
0.548 – 0.078
0.596 ½ 0.064 0.086
3
0.675 /8 0.065 0.072 0.083 0.120 0.165
0.721 – 0.064
0.840 ½ 0.065 0.072 0.083 0.148 0.180
0.846 ¾ 0.064
0.900 – 0.072
1.050 ¾ 0.065 0.095 0.165 0.220
1.112 ¾ 0.172
1.112 1 0.080
1.315 1 0.065 0.095 0.109 0.203 0.259
1.362 1 0.210
1.362 1¼ 0.092
1.612 1½ 0.092
1.660 1¼ 0.072 0.095 0.120 0.238 0.340
1.900 1½ 0.072 0.109 0.134 0.259 0.340
2.128 2 0.080 0.116 0.144 0.318
2.375 2 0.120 0.300 0.425
2.628 2½ 0.080 0.116 0.160
2.875 2½ 0.134 0.380
3.144 3 0.092 0.128 0.176
3.660 3½ 0.092 0.144 0.192
4.000 – 0.165
4.184 4 0.104 0.160 0.212
4.955 4½ 0.116 0.176 0.252
5.384 5 0.116 0.192 0.252
5.563 – 0.203
6.424 6 0.128 0.212 0.300
7.464 – 0.144 0.232 0.348
8 0.144 0.252
9 0.160 0.276
10 0.300
11 0.375
35
Table C.4 – Chemical Composition
Per Cent by Weight

Element
Not Less Than Not More Than
Nickel 30.0 32.0

Manganese 0.5 1.5
Iron 0.6 1.0
Copper Remainder
Impurities
Aluminium – 0.03
Bismuth – 0.002
Boron – 0.02
Carbon – 0.06
Lead – 0.01
Phosphorus – 0.01
Silicon – 0.05
Sulphur – 0.02
Total Impurities – 0.30
Table C.5 – Room Temperature Mechanical Properties
Minimum Minimum Minimum Hardness

Tensile 0.2% Elongation on (HV)
Class
Strength Proof Stress 5.65 √So Gauge
(MPa) (MPa) length (%) Minimum Maximum
2, 3, 4, 6, 7 and 9 400 140 35 - 110
5 and 8 480 400 16 150 -
36
Table C.6 – Tolerances for General Purpose Tubes
Classes 2&6 (Metric)
Nominal Tube
Tolerance On
Size (mm)
Up to but
From not Outside Diameter (mm) * Specified Thickness
including
Plus Minus Plus Minus
3 20 0.05 0.04 15% 0%
20 35 0.06 0.03 15% 0%
35 55 0.07 0.01 15% 0%
Class 9 (Metric)
All dimensions
To be in accordance with requirements of BS EN 12449
All sizes
Classes 2&3 (Imperial)
Nominal Tube
Tolerance On
Size (inches)
Up to but
From not Outside Diameter (inches) * Specified Thickness
including
Plus Minus Plus Minus
0.250 1.660 0.000 0.003 15% 0%
1.660 5.384 0.000 0.006 15% 0%
5.384 7.500 0.010 0.000 15% 0%
* Maximum deviation at any point. The eccentricity of the bore relative to the outside diameter is not to
be greater than the thickness tolerance will permit.
37
Table C.7 – Tolerances for Condenser and Heat Exchanger Tubes
Classes 7&8 (Metric)
Dimension Range
Tolerance
Up to and including
Outside
50mm
Diameter
To be in accordance with requirements of
Thickness* All Sizes
BS EN 12451
Length** 30m
Classes 4&5 (Imperial)
Tolerance (inches)
Range
Dimension
Up to and including
Plus Minus
Outside
1½ inches 0.000 0.006
Diameter
Thickness* 17 SWG 0.004 0.004
Length** All Sizes 0.031 0.000
* The eccentricity of the bore relative to the outside diameter is not to be greater than the thickness
tolerance will permit, which is to be the maximum deviation at any point.
** The tolerance on straightness is to be 6mm total envelope in any 3m for metric tubes and 0.250
inches total envelope in any 10 feet for Imperial tubes.
38
Annex D
Specific Requirements for 90/10 Copper-nickel Alloy Tubes
(previously covered by Def Stan 02-779 Part 3)
D.1 Scope
a) This Annex specifies the requirements for the manufacture, inspection, testing and supply of 90/10
copper-nickel alloy tubes previously covered by Defence Standard 02-779 Part 3.
b) The tubes supplied against this Annex are for general purpose use only. Where tubes are required for
a special purpose, e.g. an oxygen clean system, this should be specified in the contract documents
together with any special cleaning requirements and the required acceptance standards.
D.2 Tube Classification

The tubes are Class 1 (see Table D.1). The class number denotes the usage and wall thickness. The
classification does not denote the level of quality assurance.
D.3 Manufacture
D.3.1 Tube production
Tables D.1 to D.3. For condenser and heat exchanger tubes the requirements of Def Stan 02-329 must also
be met.
D.3.2 Condition of Tubing
All tubes are to be supplied in the fully annealed condition.
D.3.3 Supply Requirements
D.4 Specific Test Methods

D.4.1 Destructive Tests
D.4.1.1 Sampling for Destructive Tests
Tests shall be made on a test sample taken from each batch of tubes in the “as supplied” condition.
D.4.1.2 Chemical Analysis
39
D.4.1.3 Mechanical Tests
c) A flattening or double bend test shall be carried out as detailed in clause A.2.
D.4.2 Non-destructive Tests
D.4.2.1 Dimensional Inspection
D.4.2.2 Ultrasonic Wall Thickness Checks
documents.
D.5 Acceptance Criteria
D.5.1 Destructive Tests
D.5.1.1 Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to BS EN 12449- CW352H, except
that for seawater applications the iron content shall be at least 1.5%. This increased iron content is to
ensure resistance to seawater erosion-corrosion.
D.5.1.2 Mechanical Tests
a) The specified tensile tests shall conform to the values in Table D.4.
b) The specified hardness test shall conform to the values in Table D.4.
c) In the flattening or bending test the tubing is to show no visible evidence of cracks or flaws.
D.5.2 Non-destructive Tests
b) Dimensions shall meet the requirements of Tables D.1 to D.3. All condenser and heat exchanger
tubes are to have ends cut clean and square to within ±1mm.
outside the thickness tolerance, without the need to record where the thickness approaches the
minimum tolerance on good or rejected tubes.
40
D.5.3 Rejection
Tubes failing to meet the requirements of clause D.5 shall be rejected.
D.6 Identification
Material description in addition to requirements of clause 11 shall be “90/10 CuNi –Def Stan 02-878
Annex D” and shall also detail the Class and Test Pressure.
Table D.1 – Class 1-175 Imperial Tubes (working pressure 175 psi)
Tube Dimensions (inches)

Nominal
Size Mean Outside
Wall Thickness
(inches) Diameter
Maximum Minimum Nominal Maximum Minimum
0.5 0.596 0.593 0.048 0.053 0.043
0.75 0.846 0.843 0.048 0.053 0.043
1.0 1.112 1.109 0.056 0.062 0.050
1.25 1.362 1.359 0.056 0.062 0.050
1.5 1.612 1.609 0.056 0.062 0.050
2.0 2.128 2.122 0.064 0.070 0.058
2.5 2.628 2.622 0.064 0.070 0.058
3.0 3.144 3.138 0.072 0.079 0.065
3.5 3.660 3.654 0.080 0.088 0.072
4.0 4.184 4.178 0.092 0.102 0.083
6.0 6.208 6.198 0.104 0.117 0091
8.0 8.208 8.198 0.104 0.117 0.091
41
Table D.2 – Data for Class 1-10 Metric Tubes (working pressure 10 bar)
Tube Dimensions (mm)

Nominal
Size Mean Outside
Wall Thickness
(mm) Diameter
6 6.045 5.965 0.8 0.88 0.72
8 8.045 7.965 0.8 0.88 0.72
12 12.045 11.965 0.8 0.88 0.72
16 16.045 15.965 1.0 1.1 0.9
20 20.055 19.975 1.0 1.1 0.9
25 25.055 24.975 1.5 1.65 1.35
30 30.055 29.975 1.5 1.65 1.35
38 38.070 37.990 1.5 1.65 1.35
44.5 44.570 44.490 1.5 1.65 1.35
57 57.200 57.120 1.5 1.65 1.35
76.1 76.300 76.150 2.0 2.2 1.8
88.9 89.150 89.000 2.5 2.75 2.25
108 108.25 108.00 2.5 2.75 2.25
133 133.50 133.25 2.5 2.81 2.19
159 159.50 159.25 2.5 2.81 2.19
193.7 194.50 194.25 3.0 3.38 2.625
219.1 219.90 218.30 3.0 3.38 2.625
267 268.00 266.40 3.0 3.38 2.625
42
Table D.3 – Data for Class 1-16 Metric Tubes (working pressure 16 bar)
Tube Dimensions (mm)

Nominal
Size Mean Outside Wall Thickness
(mm) Diameter
6 6.045 5.965 1.0 1.1 0.9
8 8.045 7.965 1.0 1.1 0.9
12 12.045 11.965 1.0 1.1 0.9
16 16.045 15.965 1.5 1.65 1.35
20 20.055 19.975 2.0 2.2 1.8
25 25.055 24.975 2.0 2.2 1.8
30 30.055 29.975 2.0 2.2 1.8
38 38.070 37.990 2.0 2.2 1.8
44.5 44.570 44.490 2.0 2.2 1.8
57 57.200 57.120 2.0 2.2 1.8
76.1 76.300 76.150 2.5 2.75 2.25
88.9 89.150 89.000 3.0 3.3 2.7
100 100.25 100.00 3.0 3.3 2.7
108 108.25 108.00 3.0 3.3 2.7
133 133.50 133.25 3.0 3.38 2.63
159 159.50 159.25 3.0 3.38 2.63
193.7 194.50 194.25 3.5 3.94 3.06
219.1 219.90 218.30 4.0 4.5 3.5
267 268.00 266.40 4.0 4.5 3.5
Table D.4 – Specified Annealed 90/10 Copper-nickel Room Temperature Mechanical Properties
Minimum tensile Minimum 0.2% Minimum elongation
Maximum hardness
strength proof stress on 5.65√S0 gauge
(HV)
(MPa) (MPa) length (%)
310 110 35 95
43
Annex E
Specific Requirements for Aluminium-nickel-silicon-brass Tubes
(previously covered by Defence Standard 02-749 Part 3)
E.1 Scope
This Annex specifies the requirements for the manufacture, inspection, testing and supply of aluminium-
nickel-silicon-brass tubes previously covered by Def Stan 02-749 Part 3.
E.2 Tube Classification

The tubes are placed in four classifications (see Table E.1). Class I to IV are in ascending order of pressure
rating.
E.3 Manufacture
E.3.1 Tube Production
Table E.1.
E.3.2 Condition of Tubing
a) All tubes are to be solution treated and precipitation hardened. For guidance:
1) Solution treatment consists of furnace heating the tubes to a temperature of 775°C ± 25°C for a
period of 15 minutes to 1 hour, followed by rapid water cooling.
2) Precipitation hardening consists of furnace heating the tubes to a temperature of 500-525°C for
a period of 1 hour, followed by cooling in still air.
E.3.3 Supply Requirements
E.4 Specific Tests

E.4.1 Destructive Tests
E.4.1.1 Sampling for Destructive Tests
Tests shall be made on a test sample taken from each cast and each batch of tubes in the “as finished and
44
E.4.1.2 Chemical Analysis
finished and supplied” condition.
E.4.1.3 Mechanical Tests
c) A flattening test shall be carried out as detailed in clause A.2.
E.4.2 Non-destructive Tests
E.4.2.1 Dimensional Inspection
E.4.2.2 Ultrasonic Wall Thickness Checks
documents.
E.5 Acceptance Criteria
E.5.1 Destructive Tests
E.5.1.1 Chemical Analysis
Chemical analysis of each cast and each batch of tubes shall conform to BS EN 12449- CW700R.
NOTE Tubing supplied in accordance with this chemical composition will have a magnetic permeability figure of
not more than 1.001.
E.5.1.2 Mechanical Tests
a) The specified tensile tests shall conform to the values in Table E.2.
b) The specified hardness test shall conform to the values in Table E.2.
c) In the flattening test the tubing is to show no visible evidence of cracks or flaws.
E.5.2 Non-destructive Tests
b) Dimensions shall meet the requirements of Table E.1 and the tolerances of Table E.3.
45
outside the thickness tolerance, without the need to record where the thickness approaches the
minimum tolerance on good or rejected tubes.
E.5.3 Rejection
Tubes failing to meet the requirements of clause E.5 shall be rejected.
E.6 Identification
Material description in addition to requirements of clause 11 shall be “AL-NI-SI-BR – Def Stan 02-878
Annex E”, in addition to stating the Class of tubes.
Table E.1 – Tube Sizes and Working Pressures. (* Non-preferred sizes)
Wall thickness (mm)

Tube size (mm)
Class I Class II Class III Class IV
8 – 0.8 – 1.0
9.5* – – – 1.0*
12 – 0.8 – 1.2
16 – 0.8 – 1.6
20 – 1.0 – 2.0
25 – 1.6* – –
30 – 1.5 2.5 3.0
38 – 1.5 3.0 4.0
50 – 2.0 4.0 5.0
57 – 2.0 4.5 6.0*
76.1 2.0* – 5.5 –
Working
7.5 70 207 280
Pressure (bar)
Table E.2 – Specified Al-Ni-Si-Brass Room Temperature Mechanical Properties
Minimum Tensile Minimum 0.2% Minimum Elongation

Hardness
Strength Proof Stress on 5.65√S0 Gauge
(HV)
(MPa) (MPa) Length (%)
450 230 40 125-140
46
Table E.3 – Permitted Tube Dimensional Tolerances
Outside diameter (mm) Wall thickness (%)

Tube size (mm)
Max. Min. Plus Minus
8 8.045 7.965
9.5 9.545 9.465
12 12.045 11.965
16 16.045 15.965
20 20.055 19.975
25 25.055 24.975 15 0
30 30.055 29.975
38 38.07 37.99
50 50.07 49.99
57 57.2 57.12
76.1 76.32 76.15
47
Annex F
Advisory Material Property Datasheets
F.1 The following data sheets outline the properties of some of the tube materials previously used for
naval fluid and gas applications and other materials in commercial use that might be considered for naval
tubes. These are for comparative and advisory purposes only, and do not constitute requirements under this
Defence Standard. These data sheets do not constitute MOD approval of the contents for design purposes.
F.2 The data contained in this Annex is based on BR 3008, Materials and Processes (Mechanical
Engineering). Chapter 1: Metals, with revisions and additional material from:
1) American Society of Materials Handbooks.
2) BS EN 10216-2, Seamless steel tubes for pressure purposes. Technical delivery conditions.
Part 2: Non-alloy and alloy steel tubes with specified elevated temperature properties.
3) BS EN 10216-5, Seamless steel tubes for pressure purposes. Technical delivery conditions.
Part 5: Stainless steel tubes.
4) Copper Development Association publications database.
5) Relevant manufacturers’ data sheets.
48
Table F.1 – Copper-phosphorus Deoxidised Non-arsenical

Specification(s) Annex B (formerly Defence Standard 02-837), BS EN 12449- CW024A.
Nominal
Copper 99.90 min, Phosphorous 0.013-0.040.
Composition, %
Melting range, °C 1083
3
Density, kg/m 8940
Thermal conductivity, W/mK 339
Electrical resistivity,
0.017
Physical μ ohm.m
Properties Coefficient of linear expansion,
17 Range 20-200°C
μ strain/K
Specific heat, J/kg K 386
Magnetic permeability, μ Less than 1.0001
Mechanical Properties at Room Temperature

Condition Tube, annealed Tube, 1/2 hard Tube, full hard
(condition R220) (condition R250) (condition R360)
0.2% Proof stress, MPa (min) 110 max. 150 320
Tensile strength, MPa (min) 200 250 360
Elongation, % on gauge 40 20 3
length = 5.65 √So (min)
Reduction of area, % – – –
Shear strength, MPa 154 168 –
Vickers hardness 40-65 70-100 110 min.
Modulus of elasticity, GPa 117 117 117
Modulus of rigidity, GPa 44 44 44
Poisson’s ratio 0.33 0.33 0.33
Fatigue Data Rotating limit in air, +/- MPa, 76 110 –
1x107 cycles
Impact Test Izod impact value, Joules – – –
Data
Condition Temperature, °C Stress, MPa Creep rate, %
per 1000 hours
Rod, 3.2mm diameter, 204 14.1 0.0039
annealed (32µm grain size) 204 21.0 0.0185
204 34.5 0.051
204 55.5 0.120
Creep
Properties
Rod, 3.2mm diameter, cold- 204 24.5 0.0152
worked 84% 204 34.8 0.038
204 62.4 0.224
204 103.4 2.70
49
Table F.1 (continued)
Free corrosion potential, VSCE -0.21
Corrosion rate, mm/year 0.075
Crevice corrosion, mm/year 0.15-0.30

Marine corrosion data (full
immersion) Compatible with most copper
Galvanic corrosion
based alloys
Form of galvanic attack Pitting
Impingement resistance, m/s 1.8
Soldering, brazing and TIG welding are excellent joining methods.

Joining Methods Gas welding can also produce good results but SMAW is not
recommended.
Suited to forming by hot and cold-working processes.
Fabricating Properties and Hot-working temperature range of 750-950°C.
Heat Treatment A 95% cold reduction between anneals is possible. Annealing
temperature range of 250-650°C.
General purpose tubes for hot and cold water services, evaporators
and heat exchangers; steam, air, water and oil lines.
Typical Uses
Also suitable for any equipment involving heating in reducing gases
either during joining processes or in service.
This metal is not susceptible to hydrogen embrittlement.
The conductivity is relatively low on account of the high phosphorus
Remarks content.
Copper-zinc alloys should not be used for brazing where resistance
to seawater corrosion is a requirement.
50
Table F.2 – 70/30 Copper-nickel
Annex C (formerly Def Stan 02-780 Part 3), BS EN 12449- CuNi30Mn1Fe CW354H, ASTM
Specification(s)
B111 C71500
Nominal Nickel 30.0-32.0, Manganese 0.5-1.5, Iron 0.6 -1.0, Total impurities 0.30, remainder
Composition, % Copper.
Melting range, °C 1170 - 1240
Density, kg/m3 8950
Thermal conductivity, W/mK 29.3
Physical 0.37
μ ohm.m
Properties
Coefficient of linear expansion,
16 Range 20-300°C
μ strain/K
Magnetic permeability, μ 1.0006
Condition Tube, classes 4 Tube, classes 5
and 7 and 8 (hard)
(annealed)
0.2% Proof stress, MPa (min) 140 450
Tensile strength, MPa (min) 400 480
Elongation, % on gauge length 35 16
= 5.65 √So (min)
Reduction of area, % 38 –
Shear strength, MPa 308 353
Vickers hardness 110 max. 150 min.
Modulus of elasticity, GPa 152
Modulus of rigidity, GPa 57
Poisson’s ratio 0.33
Fatigue Data Rotating limit in air, +/-MPa, 142 –
1x107 cycles
Impact Test Izod impact value, Joules – –
Data
Condition Temperature, °C Stress, MPa Creep rate, % per
1000 hours
Rod, 3mm diameter, annealed 149 138 0.0004
149 196 0.0010
204 109 0.0002
260 71 0.0005
260 107 0.0009
260 145 0.0037
Creep
260 182 0.0053
Properties:
260 209 0.0083
Rod, 3mm diameter, 84% cold 260 69 0.0011
worked 260 145 0.0016
260 282 0.0024
260 339 0.0030
260 407 0.0120
51
Corrosion rate, mm/year <0.025

Marine corrosion data (full Cathodic to most copper alloys
immersion) Galvanic corrosion and therefore tends to accelerate
corrosion of copper alloys
Pitting; sometimes dealloying,
Form of galvanic attack particularly at mildly elevated
temperatures
May be soft soldered, silver soldered and brazed.

Joining Methods Welding with gas welding, SMAW and GMAW processes is
practicable.
May be hot-worked in region 925-1050°C. No forging to be carried
out below 850°C.
Fabricating Properties and Cold worked by forming and bending. Anneal at 650-815°C.
Heat Treatment Avoid sulphurous atmospheres.
Alloy has limited formability in range 600-925°C, particularly at low
strain rates.
Tubes for heavy duty condensers, feedwater heaters and
Typical Uses
evaporators, including desalination plant.
Iron and manganese are added to improve corrosion resistance in
high velocity waters, including polluted seawater.
Remarks The alloy is insensitive to stress corrosion.
Alloy has tendency to suffer ‘hot spot corrosion' at locally heated
areas.
52
Table F.3 – 90/10 Copper-nickel

Annex D (formerly Def Stan 02-779 Part 3), BS EN 12449- CuNi10Fe1Mn Alloy CW352H,
Specification(s)
ASTM B111 C70600
Nominal
Nickel 10.0-11.0, Iron 1.0-2.0, Manganese 0.5-1.0, remainder Copper.
Composition, %
Melting range, °C 1100-1145
3
Density, kg/m 8940
0.19
Physical μ ohm.m
17 Range 20-300°C
μ strain/K
Magnetic permeability, μ 1.39 annealed, 1.01 hard rolled

Condition Tube, annealed
0.2% Proof stress, MPa (min) 110
Tensile strength, MPa (min) 310
Elongation, % on gauge length 35
= 5.65 √So (min)
Reduction of area, % –
Shear strength, MPa 277
Vickers hardness 95 max
Fatigue Data Rotating limit in air, +/-MPa, 92, cold worked 25%
1x107 cycles
Impact Test Izod impact value, Joules –
Data
per 1000 hours
Rod, 3mm diameter, annealed 149 102 0.0001
149 174 0.0002
204 63 0.0001
204 98 0.0007
Creep
204 132 0.0020
Properties
204 151 0.0028
260 63 0.0006
260 96 0.0017
260 126 0.0038
53

immersion) Slightly cathodic to most copper
Galvanic corrosion
alloys
May be soft soldered, silver soldered and brazed.

Joining Methods Welding with SMAW and GMAW processes are practicable. Gas
welding is not recommended.
Hot-worked in range 850-950°C.
Excellent cold formability characteristics with cold reduction between
Fabricating Properties and
annealing limited to 80%.
Heat Treatment
Annealing temperature range of 700-800°C. Avoid sulphurous
atmospheres.
Used in tube form for condensers, evaporators and heat
Typical Uses exchangers; also tubes carrying seawater for fire mains, cooling
water circuits and sanitary services.
Iron and manganese are added to improve corrosion resistance in
Remarks high velocity waters, including seawater.
The alloy is insensitive to stress corrosion.
54
Table F.4 – Aluminium-nickel-silicon-brass

Specification(s) Annex E (previously Def Stan 02-749 part 3); BS EN 12449 - CuZn13Al1Ni1Si1 CW700R
Nominal Copper 81.00-86.00, Aluminium 0.70-1.20, Nickel 0.80-1.40, Silicon 0.80-1.30, remainder
Composition, % Zinc.
3
Density, kg/m 8530
Electrical resistivity, 0.11
Physical μ ohm.m
19 Range 20-200°C
μ strain/K
Specific heat, J/kg K –

Condition Tube, heat
treated
= 5.65 √So (min)
Reduction of area, %
Vickers hardness 125-140
Fatigue Data Rotating limit in air, +/-MPa, 108
1x107 cycles
Impact Test Izod impact value, Joules 42
Data
Condition Temperature, °C Stress, MPa Creep rate,
% per 1000
hours
Creep – – – –
Properties
55

Crevice corrosion, mm/year 0.18
Marine corrosion data (full compatible with most copper
immersion) Galvanic corrosion
based alloys
Form of galvanic attack pitting
Welding by SMAW, GMAW and TIG processes is practicable with

Joining Methods the appropriate filler rods.
Brazing is the recommended method of joining.
The forging temperature range is 750-780°C and the annealing
range is 600-750°C.
Fabricating Properties and The alloy is suited to forming by most cold-working processes; alloy
Heat Treatment tubes should not be heated prior to bending.
Heat treatment (solution treatment and precipitation hardening) is
performed in accordance with the requirements of Annex F.
Used for high pressure hydraulic or gas systems on land and at sea.
Also on low pressure systems such as gas and steam turbine
Typical Uses lubrication lines where clean systems and fatigue resistance are
required.
Low magnetic permeability applications.
If very tight bends have been made or if the tube is going to be
subjected to considerable vibration, it is recommended that stress
relieving is performed by heating to 300°C for one hour followed by
Remarks gradual cooling.
Not recommended for seawater systems.
Some documentation refers to this material by a manufacturer’s
trade name “Tungum”.
56
Table F.5 – Carbon, Carbon-manganese and Chromium-molybdenum Steels

Specification(s) Def Stan 02-864, BS EN 10216-2 grades P235GH, P265GH, 20MnNb6 and 13CrMo4-5.
P235GH (Carbon steel): Carbon 0.16 max, Silicon 0.35 max, Manganese 1.2 max,
Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.3 max, Nickel 0.3 max.
P265GH (Carbon-Manganese steel): Carbon 0.20 max, Silicon 0.4 max, Manganese 1.4
max, Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.3 max, Nickel 0.3 max.
Nominal
Composition, % 20MnNb6 (Carbon-Manganese steel): Carbon 0.22 max, Silicon 0.15-0.35, Manganese
1.0-1.5, Phosphorus 0.025 max, Sulphur 0.020 max, Niobium 0.015-0.10.
13CrMo4-5 (Chromium-Molybdenum steel): Carbon 0.10-0.17, Silicon 0.35 max,
Manganese 0.4-0.7, Phosphorus 0.025 max, Sulphur 0.020 max, Chromium 0.70-1.15,
Molybdenum 0.40-0.60, Nickel 0.3 max.
Melting range, °C –
Density, kg/m3 7850
Thermal conductivity, W/mK 42.7-46.1
Physical 0.20-0.23
μ ohm.m
Properties
12.0-12.4 Range 20-100°C
μ strain/K
Specific heat, J/kg K 477-482
Magnetic permeability, μ Ferromagnetic
Condition Normalised P235GH P265GH 20MnNb6 13CrMo4-5
Yield strength (dependant on 215-235 245-265 335-355 280-290
thickness, to 60mm), MPa (min)
Tensile strength, MPa (min) 360-500 410-570 500-650 440-590
Elongation (longitudinal), % on 25 23 22 22
gauge length = 5.65 √So (min)
Reduction of area, % – – – –
Shear strength, MPa – – – –
Vickers hardness – – – –
Modulus of elasticity, GPa 205-212 all grades
Modulus of rigidity, GPa 80-83 all grades
Poisson’s ratio 0.27-0.28 all grades
Fatigue Data Rotating limit in air, +/-MPa, –
1x107 cycles
Impact Test Charpy impact value, Joules –
Data
Condition 0.2% Proof Stress, MPa, at temperature °C
100 200 300 400 450 500
P235GH 198 170 132 112 108 –
Elevated P265GH 226 192 154 134 128 –
temperature Normalised
properties 20MnNb6 312 264 219 186 174 –
13CrMo4-5 264 245 192 174 168 166
57
Free corrosion potential, VSCE about -0.69
Corrosion rate, mm/year 0.125-0.25
Crevice corrosion, mm/year 0.38-0.75 - pitting

immersion) Protected by zinc and aluminium
Galvanic corrosion
alloys
Readily welded using gas, GMAW and TIG processes. SMAW is

Joining Methods also practicable although preheating and post-heating may be
required.
P235GH and P265GH supplied normalized at 880-940°C, 20MnNb6
Fabricating Properties and normalized at 900-960°C, and 13CrMo4-5 normalized at 900-960°C
Heat Treatment and tempered at 640-720°C.
Some bending can be carried out during fabrication.
Pipes and tubes for steam system pipework (P235GH and P265GH
for temperatures up to 400°C and 13CrMo4-5 for temperatures of
Typical Uses 400-500°C).
Pipes and tubes for high pressure hydraulic system pipework
(20MnNb6).
Pitting corrosion can occur from condensed steam system fluids.
Remarks Outside of the pipework should be protected from corrosion.
These materials have specified elevated temperature properties.
58
Table F.6 – 18% Chromium 10% Nickel Austenitic Stainless Steel

BS EN 10216-5 X5CrNi18-10 EN No. 1.4301 (formerly BS 970: 304S31). ASTM A269
Specification(s)
S30400.
Nominal Carbon 0.07 max, Silicon 1.0 max, Manganese 2.0 max, Phosphorus 0.04 max, Sulphur 0.015
Composition, % max, Nitrogen 0.11 max, Chromium 17.0-19.5, Nickel 8.0-10.5.
3
Density, kg/m 7970
0.72
Physical μ ohm.m
17.2 Range 20-100°C
μ strain/K
Magnetic permeability, μ Non-magnetic (1.008), unless cold worked

Condition Annealed tube
Tensile strength, MPa (min) 500-700
= 5.65 √So (min)
Shear strength, MPa –
Vickers hardness –
Modulus of rigidity, GPa –
Poisson’s ratio –
1x107 cycles
Impact Test Charpy impact value, Joules 100 min, at room temperature
Data
Rupture time, hours Estimated average stress for rupture, MPa, at a
temperature, °C, of:
500 550 600 650 700 750
10 000 250 191 132 87 55 34
Stress rupture 100 000 192 140 89 58 28 15
values 200 000 176 125 78 43 22 –
59
Corrosion rate, mm/year Less than 0.025
Crevice corrosion, mm/year Up to 2.0 - pitting
Marine corrosion data (full Pitting Resistance Equivalent

18
immersion) Number (PREN)
Protected by aluminium alloys,
Galvanic corrosion
mild and low alloy steels.
Impingement resistance, m/s Greater than 9
May be soft soldered and silver soldered with appropriate fluxes.

Joining Methods
SMAW, GMAW and TIG processes satisfactory.
Fabricating Properties and Suited to hot and cold forming operations.
Heat Treatment Soften by rapid cooling from 1000-1100°C.
Typical Uses Applications involving moderately corrosive service.
Good corrosion resistance, weldable.
Remarks
Approximate maximum service temperature of 800°C.
60
Table F.7 – 18% Chromium 10% Nickel Titanium Austenitic Stainless Steel
BS EN 10216-5 X6CrNiTi18-10 EN No. 1.4541 (formerly BS 970:321S31). ASTM A269
Specification(s)
S32100.
Composition, % max, Chromium 17.0-19.0, Nickel 9.0-12.0, Titanium: 5 x %carbon up to 0.7 max.
3
Density, kg/m 7970
0.73
Physical μ ohm.m
16.6 Range 20-200°C
μ strain/K

Condition Annealed cold Annealed hot
finish tube finish tube
0.2% Proof stress, MPa (min) 200 180
Tensile strength, MPa (min) 500-730 460-680
Elongation, % on gauge length 35 35
= 5.65 √So (min)
Reduction of area, % – –
Shear strength, MPa – –
Vickers hardness – –
Modulus of elasticity, GPa 200 200
1x107 cycles
Data
550 600 650 700 750 800
Stress rupture 10 000 186 135 88 49 31 20
values 100 000 142 83 49 25 14 8
Elevated temperature
properties
Temperature, °C 300 400 500 600
1% proof stress, MPa 158 148 140 135
61

18
Galvanic corrosion

Joining Methods
No heat treatment required after welding unless for purposes of
stress relief.
Suited to forming by hot and cold-working.
Fabricating Properties and Normally supplied in heat treated condition which consists of a
Heat Treatment solution treatment achieved by heating the tubes uniformly to 1020-
1120°C then cooling rapidly in air or water.
Typical Uses For corrosion resistant boiler and superheater tubes.
This alloy is weldable and resistant to sensitization.
Remarks Good corrosion and oxidation resistance.
Approximate maximum service temperature 800°C.
62
Table F.8 – 18% Chromium 10% Nickel Niobium Austenitic Stainless Steel
BS EN 10216-5 X6CrNiNb18-10 EN No. 1.4550 (formerly BS 970:347S31). ASTM A269
Specification(s)
S34700.
Composition, % max, Chromium 17.0-19.0, Nickel 9.0-12.0, Niobium: 10 x %carbon up to 1.0 max.
3
Density, kg/m 7970
0.73
Physical μ ohm.m
16.6 Range 20-200°C
μ strain/K

= 5.65 √So (min)
1x107 cycles
Data
550 580 600 620 650 670 700
10 000 237 192 166 142 112 96 71
Stress rupture 100 000 172 135 115 97 74 61 –
values 200 000 156 122 102 86 64 51 –
250 000 136 – 86 66 – – –
Elevated Temperature, °C 300 400 500 600

temperature 1% proof stress, MPa 172 159 155 151
properties
63

18
Galvanic corrosion

Joining Methods
No heat treatment required after welding unless for purposes of
stress relief.
Suited to hot and cold forming operations. Machinability poor.
Drawability very good.
Fabricating Properties and Hot-working range 1100-1150°C (start), 900°C (finish).
Heat Treatment Normally supplied in heat treated condition which consists of a
solution treatment achieved by heating the tubes uniformly to 1020-
1120°C and then cooling rapidly in air or water.
Typical Uses For corrosion resistant boiler and superheater tubes.
This alloy is weldable and resistant to sensitization. Good corrosion
Remarks and oxidation resistance.
Approximate maximum service temperature 800°C.
64
Table F.9 – 18% Chromium 12% Nickel 2% Molybdenum Austenitic Stainless Steel
BS EN 10216-5 X2CrNiMo18-10 EN No. 1.4404 (formerly BS 970: 316S13). ASTM A269
Specification(s)
S31603.
Composition, % max, Nitrogen 0.11 max, Chromium 16.5-18.5, Nickel 10.0-13.0, Molybdenum 2.0-2.5.
3
Density, kg/m 7970
0.76
Physical μ ohm.m
17.2 Range 20-200°C
μ strain/K
Magnetic permeability, μ Non-magnetic (1.008).

= 5.65 √So (min)
1x107 cycles
Data
per 1000 hours
Bar softened 535 168 0.1
595 145 0.1
Creep
650 100 0.1
Properties
705 63 0.1
760 43 0.1
65
Crevice corrosion, mm/year Up to 1.5-1.75 - pitting

25
Galvanic corrosion

Joining Methods
Fabricating Properties and Suited to hot and cold forming operations.
Heat Treatment Solution treat by rapid cooling from 1020-1120°C.
Typical Uses Corrosion resistant tubing, but unreliable in seawater contact.
Good corrosion resistance, weldable.
Remarks
Approximate maximum service temperature of 800°C.
66
Table F.10 – 20% Chromium 18% Nickel 6% Molybdenum Super Austenitic Stainless Steel
Specification(s) BS EN 10216-5 X1CrNiMoCuN20-18-7, EN No. 1.4547. ASTM A269 S31254.
Carbon 0.02 max, Silicon 0.7 max, Manganese 1.0 max, Phosphorus 0.03 max, Sulphur 0.010
Nominal
max, Nitrogen 0.18-0.25, Chromium 19.5-20.5, Nickel 17.5-18.5, Molybdenum 6.0-7.0,
Composition, %
Copper 0.5-1.0.
3
Density, kg/m 8000
Physical 0.85
μ ohm.m
Properties
16.5 Range 20-100°C
μ strain/K
Magnetic permeability, μ Non-magnetic (1.01).
= 5.65 √So (min)
Modulus of rigidity, GPa 77.2
1x107 cycles
Data
per 1000 hours
Creep
–
Properties
67
Crevice corrosion, mm/year <0.01

Pitting Resistance Equivalent
Marine corrosion data (full 42
Number (PREN)
immersion)
Galvanic corrosion mild and low alloy steels and
copper alloys.

Joining Methods No heat treatment required after welding except for purposes of
stress relief.
Good cold-working properties.
Fabricating Properties and May be hot-worked in the temperature range 1000-1150°C.
Heat Treatment Solution anneal after hot-working by rapid cooling from 1140-
1200°C.
Corrosion resistant duties.
Typical Uses Used for equipment in contact with seawater such as heat
exchangers, condensers, cooling water pipes and similar
components, even in cases where stagnant conditions can occur.
Better resistance to pitting and crevice corrosion than conventional
Remarks stainless steels.
May be referred to by one manufacturer’s trade name “254SMO”.
68
Table F.11 – 22% Chromium 5% Nickel 3% Molybdenum Duplex Stainless Steel

Specification(s) BS EN 10216-5 X2CrNiMoN22-5-3, EN No. 1.4462. ASTM A789 S31803.
Composition, % max, Nitrogen 0.11-0.22, Chromium 21.0-23.0, Nickel 4.5-6.5, Molybdenum 2.5-3.5.
3
Density, kg/m 7805
Physical 0.85
μ ohm.m
Properties
13.7 Range 20-100°C
μ strain/K
Magnetic permeability, μ Ferro-magnetic.
= 5.65 √So (min)
1x107 cycles
Data
per 1000 hours
Creep
–
Properties
69
Crevice corrosion, mm/year 0.25-0.5 - pitting

Number (PREN)
immersion)
copper alloys.

Joining Methods Heat input should be kept low, and no pre- or post heat used.
Nitrogen added to shielding gas can be beneficial in maintaining the
duplex phase balance.
Good cold-working properties.
Heat Treatment Solution anneal after hot-working by rapid cooling from 1020-
1100°C.
Corrosion resistant duties requiring higher strength.
Typical Uses
Reverse osmosis plant pipework.
Better resistance to pitting and crevice corrosion than conventional
Remarks
stainless steels, but not immune to corrosion in seawater.
70
Table F.12 – 25% Chromium 7% Nickel 3.5% Molybdenum Tungsten Super Duplex Stainless Steel
Specification(s) BS EN 10216-5 X2CrNiMoCuWN25-7-4, EN No 1.4501. ASTM A789 S32760.
Carbon 0.03 max, Silicon 1.0 max, Manganese 1.0 max, Phosphorus 0.035 max, Sulphur 0.015
Nominal
max, Nitrogen 0.2-0.3, Chromium 24.0-26.0, Nickel 6.0-8.0, Molybdenum 3.0-4.0, Copper 0.5-1.0,
Composition, %
Tungsten 0.5-1.0.
3
Density, kg/m 7840
Physical 0.85
μ ohm.m
Properties
12.8 Range 20-100°C
μ strain/K
Magnetic permeability, μ Ferro-magnetic: 29
= 5.65 √So (min)
Vickers hardness 211-285
1x107 cycles
Data 70 at -46°C
Elevated Temperature, °C 100 200 250

temperature 0.2% proof stress, MPa 470 430 400
properties Tensile strength, MPa 700 670 650
71
Free corrosion potential, VSCE +0.1-0.3
Crevice corrosion, mm/year <0.01

Number (PREN)
immersion)
copper alloys.
Form of galvanic attack Pitting or general corrosion
SMAW, GMAW and TIG processes practicable.

Material should be in the solution treated condition before welding.
Pre-heat not required.
Joining Methods Matched consumable welded components should be solution treated
and quenched after welding.
Post-weld heat treatment not required if over-alloyed consumables
employed.
Suited to cold forming operations but because of the high proof
stresses requires more power than for ordinary stainless steels.
Fabricating Properties and May be hot-worked in the range 1100-1280°C. Avoid hot-working
Heat Treatment below 1050°C otherwise cracking may occur.
Solution treated at 1100-1120°C and water quenched after hot
working.
High strength components where good resistance to crevice
corrosion, wear, erosion and cavitation is required.
Typical Uses
Mainly used offshore for components in seawater piping, pumps,
valves, shafts, and seals.
Alloy has higher strength than austenitic stainless steels.
Remarks Good resistance to pitting, crevice corrosion and stress corrosion.
For reasons of microstructural stability, not to be used above 300°C.
May be referred to by one manufacturer’s trade name “Zeron 100”.
72
Table F.13 – Nickel-chromium-molybdenum-niobium Alloy 625

Specification(s) BS 3074- NA21. ASTM B444 N06625
Chromium 20.0-23.0, Iron 5.0 max, Molybdenum 8.0-10.0, Niobium+Tantalum 3.15-4.15,
Nominal Carbon 0.10 max, Manganese 0.50 max, Silicon 0.50 max, Phosphorus 0.015 max,
Composition, % Sulphur 0.015 max, Aluminium 0.40 max, Titanium 0.40 max, Cobalt 1.0 max, remainder
Nickel.
Density, kg/m3 8440
Physical 1.29
μ ohm.m
Properties
12.8 Range 20-100°C
μ strain/K
Condition Tube, cold
worked and
annealed
= 5.65 √So (min)
Fatigue Data Rotating limit in air, +/-MPa, 610 (330 in seawater)
1x107 cycles
Data
per 1000 hours
Annealed 650 88 0.01
Creep 650 182 0.1
Properties 760 30 0.1
815 10 0.1
Elevated Condition Temperature, °C 0.2 % Proof

temperature Stress, MPa
properties
Annealed 200 340
300 330
400 330
500 315
73
Crevice corrosion, mm/year Nil

immersion) Protected by aluminium alloys,
copper alloys
Impingement resistance, m/s Greater than 45.8
Alloy can be welded using SMAW, GMAW and TIG welding

processes.
Joining Methods
The alloy can be readily brazed.
Used as a weld overlay.
Alloy can be cold formed by standard processes.
It can also be fabricated by hot forming providing adequately
Fabricating Properties and powerful equipment is used. Hot-work in range 925-1175°C.
Heat Treatment Anneal 930-1040°C.
To guard against duplex grain structure, the work should be given
uniform reductions.
Mooring wire ropes/cables, propeller blades, turbine exhaust ducts,
underwater sheathing, steam line bellows, springs, seals, pump
components, pump shafts, canning, fasteners and seawater cooled
Typical Uses plate heat exchangers.
Also used for furnace parts at temperatures up to 1100°C.
Used as a weld overlay for tailshafts, stabiliser stocks and stern tube
liners.
The high nickel content provides immunity from chloride ion stress
Remarks corrosion cracking.
May be referred to by one manufacturer’s trade name “Inconel 625”.
74
Table F.14 – Nickel-copper Alloy 400

Specification(s) BS3074- NA13. ASTM B165 N04400
Nominal Nickel 63.0 min, Copper 28.0-34.0, Iron 2.5 max, Carbon 0.3 max, Silicon 0.5 max,
Composition, % Manganese 2.0 max, Sulphur 0.024 max.
Density, kg/m3 8830
Physical 0.51
μ ohm.m
Properties
13.9 Range 20-100°C
μ strain/K
Condition Cold worked
and annealed
= 5.65 √So (min)
Reduction of area, % 60
Vickers hardness 200
Fatigue Data Rotating limit in air, +/-MPa, 308 (146 in brackish water)
1x107 cycles
Data
Condition Temperature, °C Stress, MPa Creep rate, % per
1000 hours
Bar- hot or cold rolled and 400 139 0.01
annealed 400 209 0.1
430 108 0.01
Creep 430 169 0.1
480 108 0.1
540 23 0.01
540 62 0.1
Elevated Condition Temperature, °C 0.2 % Proof
temperature Stress, MPa
properties
Annealed 200 135
400 130
500 125
75
Crevice corrosion, mm/year 0.5 - pitting

immersion) Protected by aluminium alloys,
Galvanic corrosion
low alloy steels and copper alloys
Suitable for soft soldering, silver soldering or brazing with

phosphorus free filler but latter not advised in corrosive environment.
Joining Methods SMAW, GMAW and gas welding processes practicable with
appropriate fillers.
Used as a weld cladding material.
May be hot-worked in range 925-1180°C but is hot-short in range
650-925°C.
Alloy may be readily cold-worked. Anneal 870-980°C.
Heat Treatment
Avoid heating in sulphur bearing atmospheres and contamination
during processing with sulphur bearing cutting fluids.
Fasteners (nuts and washers), bellows, seawater pump shafts, valve
spindles and seals, pump sleeves, wear rings, propeller shafting,
Typical Uses and tubes for steam coils in calorifiers.
Also used as a cladding material.
Not suitable for use in sulphur bearing atmospheres above 370°C.
Alloy had a good reputation for seawater corrosion resistance but
Remarks this was in part due to galvanic protection by copper alloys to which
it was frequently coupled.
May be referred to by one manufacturer’ trade name “Monel 400”.
76
Table F.15 – Titanium Alloy, Commercial Purity

Specification(s) NES 310 (obsolete). ASTM B338 Grades 1 and 2
Titanium balance, Oxygen 0.18 max (dependant on grade), Nitrogen 0.03 max, Carbon
Nominal
0.1 max, Composition, % Iron 0.2 max, Hydrogen 0.008, other elements in total 0.1-0.3
Composition, %
max
Density, kg/m3 4510
0.50
Physical μ ohm.m
7.6 Range 20-100°C
μ strain/K
Specific heat, J/kg K 52.8

Condition Tube, annealed ASTM B338 ASTM B338
(NES 310) Grade1 Grade2
0.2% Proof stress, MPa 260-370 170-310 275-450
Tensile strength, MPa (min) 440-530 240 345
Elongation, % on gauge length 25 24 20
= 5.65 √So (min)
Vickers hardness 170
1x107 cycles
Data
per 1000 hours
20 288 0.1
100 179 0.1
Creep 150 140 0.1
Annealed
250 96 0.1
300 87 0.1
77
Crevice corrosion, mm/year Nil, unless >70°C
Marine corrosion data (full Protected by coupling to low alloy

immersion) / mild steels, aluminium and
Galvanic corrosion
copper alloys, and most stainless
steels and nickel alloys
Nil, but excessive cathodic
Form of galvanic attack protection can cause hydride
formation.
Titanium can be joined by GMAW, TIG, resistance, flash-butt,

pressure or friction welding processes.
Joining Methods Techniques are governed by the affinity of the metal for atmospheric
gases; equipment may need modification to protect the under
surface as well as the top surface of a weld run.
Limited ability for pressing, stretch forming and spinning.
Anneal at 650-700°C. Stress relief is complete after half an hour at
300-500°C.
Heat Treatment
Titanium can be contaminated by atmospheres containing free
hydrogen or hydrogen compounds.
Tubular and plate type heat exchangers for condensers, evaporators
etc. in marine vessels and water purification plants, for example
Typical Uses steam drain coolers, and main condenser U-tubes.
Also used for other specialist components in contact with seawater,
fasteners and in diesel exhaust systems.
Has very good marine corrosion resistance and the use of this metal
Remarks should be considered for applications where the cost of fabrication is
large in relation to the amount of material used.
78
Table F.16 – Aluminium-magnesium-manganese Alloy

Def Stan 02-831 (superseded), BS EN 755, Alloy EN AW-5083. This material
Specification(s)
supersedes BS 1470 N8.
Nominal Magnesium 4.0-4.9, Manganese 0.40-1.0, Chromium 0.05-0.25, Silicon 0.40 max, Iron
Composition, % 0.40 max, Copper 0.10 max, Zinc 0.25 max, Titanium 0.15 max remainder Aluminium.

3
Density, kg/m 2670
Physical 0.06
μ ohm.m
Properties
24.5 Range 20-100°C
μ strain/K
Specific heat, J/kg K –
Magnetic permeability, μ –

(O condition)
Elongation, % on gauge length 11-16
= 5.65 √So (min)
Vickers hardness 75
1x107 cycles
Data
Temperature, °C Stress, MPa Creep rate, %
per 1000 hours
Creep
–
Properties
79
Corrosion rate, mm/year 0.05, greater if cold worked

0.15 Prevented by use of
Crevice corrosion, mm/year
Marine corrosion data (full inhibited jointing compounds
immersion) Corroded by coupling to steels
Galvanic corrosion
and copper alloys
Pitting and intergranular
Form of galvanic attack
corrosion
This alloy can be easily welded by the normal GMAW and TIG
processes.
Joining Methods
Resistance, spot and seam methods should also give excellent
results.
May be formed, drawn or spun by normal cold-working processes
but this may adversely affect corrosion resistance when subjected to
Fabricating Properties and service temperatures in range 50-100°C.
Heat Treatment
During severe forming operations, this alloy will need interstage
annealing.
Salt water services and marine applications, cryogenics and welded
Typical Uses
pressure vessels.
After welding, the strength of the alloy is reduced to that of the
annealed (O) temper in the heat affected zone.
Remarks
Corrosion properties may be improved by anodizing and sealing.
Maximum service temperature 100°C.
80
Table F.17 – Aluminium-2% magnesium alloy

Def Stan 02-831 (superseded), BS EN 755, Alloy EN AW-5251. This material
Specification(s)
supersedes BS 1470 N4.
Nominal Magnesium 1.7-2.4, Manganese 0.1-0.5, Silicon 0.40 max, Iron 0.50 max, Copper 0.15
Composition, % max, Zinc 0.15 max, Chromium 0.15 max, Titanium 0.15 max, remainder Aluminium.

3
Density, kg/m 2690
Physical 0.05
μ ohm.m
Properties
24 Range 20-100°C
μ strain/K
Magnetic permeability, μ –

Condition Def Stan 02-831
Extruded tube
(F condition)
= 5.65 √So (min)
Modulus of rigidity, GPa 26.5
1x107 cycles
Data
Temperature, °C Stress, MPa Creep rate, %
per 1000 hours
65 62 0.013
65 123 1.20
150 38.5 0.015
Creep 150 54 0.083
Rolled plate
205 15.4 0.021
205 23 0.092
205 31 0.60
81
Crevice corrosion, mm/year Rarely experienced

immersion) Corroded by coupling to steels
Galvanic corrosion
and copper alloys
Pitting and intergranular
Form of galvanic attack
corrosion
Braze soldering practicable (poor corrosion resistance).

Can be welded by TIG and GMAW processes using filler containing
Joining Methods
Magnesium or 5% Silicon.
Resistance welding processes practicable.
Readily cold-worked by all normal processes.
Hot-work in range 260-510°C.
Heat Treatment
Anneal by heating to 345°C.
For applications where good workability, corrosion resistance
Typical Uses combined with moderate strength are required.
Used for pipes, fuel tanks and miscellaneous marine applications.
For good service in marine environments avoid contamination by
copper corrosion products.
Remarks
Corrosion properties may be improved by anodizing and sealing.
82
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Defence Standards are revised as necessary by an up issue or amendment. It is important that users of
Defence Standards should ascertain that they are in possession of the latest issue or amendment.
Information on all Defence Standards can be found on the DStan Website www.dstan.mod.uk, updated
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Ministry of Defence

Defence Standard 02-878

Non-Ferrous Tubes and Pipes

9.3 Rejection ..........................................................................................................................................17

C.4.2 Non-destructive Tests.....................................................................................................................32

Table F.5 – Carbon, Carbon-manganese and Chromium-molybdenum Steels........................................57

Amd No Date Text Affected Signature and Date

This standard supersedes the following:

Defence Standard 02-749 Part 3 Issue 1 Apr 2000

2. The complete Defence Standard 02-878 Issue 1 comprises:

5. No alteration is to be made to this Defence Standard except by the issue of an authorised

MOD Tender or Contract Process

Categories of Naval Defence Standard

a) Category 1. If not applied, may have a Critical effect on the following:

b) Category 2. If not applied, may have a Significant effect on the following:

c) Category 3. If not applied, may have a Minor effect on the following:

a) British Standards British Standards Institution,

b) Defence Standards Defence Equipment and Support

c) Other documents Tender or Contract Sponsor to advise.

Health and Safety

(There is no relevant information)

d) Aluminium-nickel-silicon-brass can become susceptible to stress corrosion cracking if excessively cold

Non-Ferrous Tubes and Pipes for use in HM Submarines and

ASME B31 Code for pressure piping

ASTM B444 Nickel-chromium-molybdenum-columbium alloys (UNS N06625) and nickel-chromium-

ASTM G36 Evaluation stress-corrosion-cracking resistance of metals and alloys in a boiling

BR 1326 Regulations for atmosphere control in submarines

BR 3008 Materials and processes (Mechanical Engineering).

BR 3021 (2) Shock manual

BR 8470 Shock and vibration manual

BS 3074 Nickel and nickel alloys: seamless tube

BS EN 13445-1 Unfired pressure vessels

BS EN 13480-3 Metallic industrial piping

BS EN ISO 6507-1 Metallic materials - Vickers hardness test

BS EN ISO 6892-1 Metallic materials. Tensile testing

BS MA 18 Salt water piping systems in ships

Def Stan 02-719 Sea Water Systems for H M Surface Ships

Def Stan 02-729 Requirements for non-destructive examination methods

Def Stan 02-797 Pipework Engineering

MAP 01-109 Metals and corrosion guide

JSP 430 Ship Safety Managements System Handbook

SSP 25 Quality Assurance for Safety in Submarines (Restricted)

1) Resistance to maximum Design Pressure, at maximum and minimum operating temperature.

3) Tolerance of cyclic loading and resistance to fatigue cracking, as appropriate.

6) Tolerance of excursion operating or environmental conditions.

8) Compatibility with pipe system fabrication and joining processes.

9) Fire resistance / shock resistance, if required.

b) These requirements for a particular system determine the following properties:

1) Sizing of tubes (wall thickness and internal diameter).

2) Minimum mechanical properties of the selected tube material, including hardness.

3) Corrosion resistance of tube material to the appropriate chemical/environments, including

4) Methods of tube material fabrication and joining.

5) Acceptable tube material cost.

5.2 Material Selection

d) Tube materials shall be identified as complying either with:

1) A stated commercial Originating Standard, or

Table 1 – Specifications and Room Temperature Mechanical Properties

Minimum 0.2% Tensile Minimum

ASTM A269 316L annealed 170 >485 40 <220

Super duplex BS EN 10216-5

1) Carbon or low alloy steels (including galvanised steel).

2) Susceptible austenitic stainless steels at temperatures above 60°C.

Table 2 – Specifications and Room Temperature Mechanical Properties