Ministry of Defence

Interim Defence Standard 02-743

Issue 2 Publication Date 21 January 2011

Pipe Manipulation

Part 1: Bending of Pipes

 Colin Cockburn
Standards Programme Manager 7

DStan, Room 1138

65 Brown Street Tel: 0141 224 3829
Glasgow, G2 8EX Fax: 0141 224 25003
File Ref: D/DStan/
E-mail:
DESSEDSTAN-SPM7@MOD.UK Date: 10 January 2011

INTERIM DEFENCE STANDARD - INVITATION TO COMMENT

Defence Standard Number: 02-743 Part 1 Issue 2 INTERIM

Title: Pipe Manipulation: Part 1, Bending of Pipes

The above Defence Standard has been published as an INTERIM Standard and is provisional because it
has not been agreed by all authorities concerned with its use. It shall be applied to obtain information and
experience on its application which will then allow users to submit observations and comments.

The purpose of this form is to solicit any beneficial and constructive comment that will assist the author
and/or working group to review the Interim Standard prior to its being converted to a normal Standard.

Please enter below your comments and any additional pertinent data which may also be of use in improving
the Standard. Comments should be attached to this form and returned to writer at the above address.

No acknowledgement to comments received will normally be issued.

NAME: Colin Cockburn BRANCH: DSTAN SPM 7

1. Does any part of the Standard create problems or require interpretation:

YES NO If “yes” state under section 3:

a. the clause number(s) and wording;
b. the recommendation for correcting the deficiencies.

2. Is the Defence Standard restrictive:

YES NO If “yes” state in what way under section 3.

3. Comments, general or any requirement considered too restrictive:
Page Clause Comments Proposed Solution

4. I/We agree that this Interim Standard, subject to my/our comments being taken into consideration, when
published in final form will cover my/our requirements in full. Should you find my/our comments at variance with
the majority, I/we shall be glad of the opportunity to enlarge upon them before final publication.

Signature .................................................................Representing .................................................

Submitted by (print or type name and address) Telephone/Fax number(s):

Email:

Date:

Our Ref:
INT DEF STAN 02-743 Part 1 Issue 2

Contents

Foreword ..........................................................................................................................................................iii
1 Scope ..................................................................................................................................................1
2 Warning ..............................................................................................................................................1
3 Normative References.......................................................................................................................1
4 Definitions ..........................................................................................................................................1
5 Condition of Tubes Prior To Bending .............................................................................................2
6 Methods ..............................................................................................................................................2
6.2 Cold Bending....................................................................................................................................2
6.3 Hot Bending......................................................................................................................................2
7 Degree of Bending.............................................................................................................................3
8 Tolerances..........................................................................................................................................3
9 Local Correction of Bends................................................................................................................3
10 Heat Treatment ..................................................................................................................................4
11 Cleaning & Preservation After Bending ..........................................................................................5
12 Inspection...........................................................................................................................................5
13 Rectification .......................................................................................................................................6
Annex A Requirements For Tight Radius Bends .......................................................................................8
A.1 Machine Bending Of Pipes .............................................................................................................8
A.1.2 Condition of Tubes prior to bending ...........................................................................................8
A.1.3 Procedure.......................................................................................................................................8
A.1.4 Procedure Approval ......................................................................................................................8
A.1.5 Acceptance Requirements for Bends below 3D ........................................................................8
A.1.6 Heat Treatment ..............................................................................................................................8
A.1.7 Inspection Requirements .............................................................................................................9
A.1.8 Rectification ...................................................................................................................................9

Figures

Figure 1 Determination of Time at Temperature .........................................................................................5

Figure 2 Acceptance of Flatness ..................................................................................................................5
Figure 3 Types of Defects..............................................................................................................................6
Figure 4 Areas of Measurement....................................................................................................................6

Tables

Table 1 Full Post Heat Treatment................................................................................................................4

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 INT DEF STAN 02-743 Part 1 Issue 2

Foreword
AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

REVISION NOTE

This standard is raised to Issue 2 to update its content.

HISTORICAL RECORD

This standard supersedes the following:

Def Stan 02-743 Part 1 Issue 1 dated 1 April 2000

Sponsorship

1. This Defence Standard (Def Stan) is sponsored by the FWE-MET-FSG, Defence Equipment and
Support Agency, Ministry of Defence (MOD).

2. The complete Def Stan Issue comprises:

Procedures for Pipe Manipulation (Cat 2)"

Part 1: Bending of Pipes

Part 3: Swaging

Part 5: Brazing

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 Ministry of Defence 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.

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INT DEF STAN 02-743 Part 1 Issue 2
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 authorised in writing by the MOD
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 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.

Categories of Naval Defence Standard

15. The Category of this Naval Defence Standard has been determined using the following criteria:

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

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.

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 INT DEF STAN 02-743 Part 1 Issue 2
Related Documents

16. In the tender and procurement processes the related documents in each Section 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 subcontractors 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 too 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, 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.

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 INT DEF STAN 02-743 Part 1 Issue 2

Pipe Manipulation: Part 1, Bending of Pipes

1 Scope
This Def Stan details the procedures and requirements for the bending of metallic pipes for all services
except those used in reactor plant systems in nuclear submarines.

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.

Def Stan 02-341 Requirements for Cleaning of Items, Components and Equipment for Fluid Systems
Part 1: Cleaning

Def Stan 02-729 Requirements for Non-Destructive Examination Methods

Part 1: Radiographic
Part 2: Magnetic Particle
Part 3: Eddy Current
Part 4: Liquid Penetrant
Part 5: Ultrasonic

JSP430 MOD Ship Safety Management System Handbook.

NES 25 Quality Assurance Documentation Requirements for Nuclear Submarines.

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.

3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue and amendment status 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 normative references documents are obtained from. Requests for
such information can be made to the DStan Helpdesk. How to contact the helpdesk is shown on the outside
rear cover of Def Stans.

4 Definitions
For the purpose of this Def Stan the following definitions apply:

Pipe A tube which has been cut, shaped or extruded to a specified length or profile to which flanges
or couplings may have been attached.

Tube Ferrous, non-ferrous or plastic material manufactured to thin walled circular cross-section, with
open ends, and to a specified diameter. Used to manufacture pipes.

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INT DEF STAN 02-743 Part 1 Issue 2
5 Condition of Tubes Prior To Bending

5.1 The tubes are to be examined and any showing defects which may prove harmful in service or affect
the final finish of the pipe after bending are to be rejected. The surfaces of tubes with wall thicknesses less
than 25mm are to be free from any grooves or pits having a depth equal to or greater than 3% of the nominal
wall thickness or 0.1mm whichever is the greater. For tubes with wall thicknesses of 25mm and above such
defects are to be not more than 0.75mm deep.

5.2 Ensure that the tube is in the heat treated condition required by the relevant material specification.

5.3 The surfaces of the tubes are to be free of all contamination by preservative, grease, oil, dirt, etc and
with all cut edges free of rags and burrs.

5.4 Care is to be taken that the surfaces of steel tubes are not contaminated with lead, zinc, copper,
cadmium, tin, sulfur or phosphorus. High pressure lubricants may contain such elements and if these are
used, care is to be taken to degrease the tubes before any heating is applied. Tubes supplied in the electro-
zinced condition are to be pickled to remove this deposit before welding or hot bending.

6 Methods

6.1 All bends in pipes 150mm nominal OD and below are to be made in an approved machine. Manual
hot bending is only to be used when specified or when the available bending machine will not produce the
required result.

6.2 Cold Bending

6.2.1 No preference is given for a particular bending machine provided that the following requirements are
met :
a) The formers, guides and mandrels will provide a finish to that specified in Clause 5.1.
b) Tools are of the correct size for the pipe being bent.
c) The lead in to the roller path is further guided by a wiper die, except where test pieces have shown this
to be unnecessary to prevent wrinkling of the inside bend of the pipe.
d) The tolerances, stated clause 8, are met.

6.2.2 When manual coppersmithing or press bending of copper or copper alloy pipes is unavoidable, pipes
are to be filled with either sodium thiosulphate (Hypo) or silica sand in accordance with Clause 6.3.8. All
traces of filler film are to be removed before pipes are heat treated.

6.3 Hot Bending

6.3.1 Hot bending is only to be permitted when the machines available will not produce the bend required .
It is not permitted for copper nickel alloy or aluminium silicon brass pipes.

6.3.2 Carbon and low alloy steel pipes are to be heated to within the temperature range 950°C to 1100°C
in a suitable furnace, by oil or gas burners or by electrical methods. A uniform temperature throughout the
section is to be attained. No bending is to be done if the pipe temperature falls below 820°C. Carbon steel
pipes up to 75mm nominal bore and chrome molybdenum pipes up to 50mm nominal bore may be locally
heated by torch for bending or forging provided that precautions are taken to ensure gradual heating of the
section and to avoid local overheating. (See caution, Clause 5.4).

6.3.3 Copper pipes may be hot bent within the temperature range 600°C to 650 °C.

6.3.4 The furnace temperature is to be determined by the use of contact pyrometers, optical pyrometers or
thermometers.

6.3.5 During hot bending the heat is to be maintained by the use of Propane, Coal gas burners, or
electrical methods.

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 INT DEF STAN 02-743 Part 1 Issue 2
6.3.6 The atmosphere for all heating operations is to be neutral or slightly oxidizing.

6.3.7 When a filler is needed it is to be sand, which is free from moisture, carbonaceous matter, dirt, oil,
grease or any other contaminant such as metallic chips or dust. Sand used for non-ferrous pipe bending is
not be reused for ferrous pipe bending.

6.3.8 The sand is to comply with the following requirements:

Silica content 95% min
Grain Size 70% to 80% retained on BS sieve No 100,
100% shall pass through BS sieve No 16.

6.3.9 The sound is to be packed tightly in the pipe using non-metallic hammers.

7 Degree of Bending

7.1 The bend radius is to be measured at the neutral axis of the pipe.

7.2 The preferred minimum bend radius for all pipes for ships and submarines is 3D. It is accepted
however that, particularly in submarines, tighter radius bends are necessary. Such cases will be subject to
approved system design limitations and use of approved machines. The requirements for such bends are
stated in Annex A.

8 Tolerances

8.1 The percentage ovality of the pipe is to be calculated from the formula
100 ( a - b )
(2 (a + b)
respectively, at the bend.

8.2 Ovality is to be not greater than 10% for all bends.

8.3 The thickness of the bent pipe is to be not less than 87.5% of the specified minimum thickness of the
unbent pipe. This figure is derived from the wall thickness appropriate to the maximum pressure rating of the
pipe, plus a corrosion allowance where applicable. Departure from this requirement will be subject to specific
approval which will only be granted in exceptional circumstances.

8.4 Before production commences, a sample bend of each size of pipe per material specification is to be
pulled to the minimum centre line radius of the bending machine, sectioned and examined to ensure the
tolerance requirements of the specification are met for each size of pipe to be bent. Further sample bends
will be required only if the production bends produced by the machine fail to meet the programmed
inspection standards.

9 Local Correction of Bends

9.1 If it is necessary to correct bends to lessen the ovality, or to improve the contour, such work is to be
achieved by pressing, using formers shaped to the pipe contour. Hammering is to be severely restricted and
only permitted when wooden mallets are used or when full post heat treatment is arranged.

9.2 In the above case, and also where local correction of bends may be required on site, the pipes should,
if necessary, be annealed beforehand and given a subsequent stress relief heat treatment.

9.3 Bends may be corrected in a closing direction only to prescribed limits for wall thickness and ovality.

9.4 Bends requiring correction in an opening direction are to be stressed relieved if the angle of correction
exceeds 10% of the original bend angle.

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INT DEF STAN 02-743 Part 1 Issue 2
10 Heat Treatment

10.1 Except as stated below, all steel pipes are to be stress relieved after cold working. Copper alloy
pipes except aluminium nickel silicon brass, are to be annealed after manual coppersmithing or after bending
to a radius smaller than 3D. Aluminium nickel silicon brass, if bent to a smaller radius than 3D, is to be heat
treated in accordance with Clause 10.5.

10.2 Carbon steel pipes of up to 0.26% carbon are to be heated to 600°C ± 20°C except that pipes 13mm
or less in wall thickness need not be so treated.

10.3 Carbon steel 0.26% to 0.4%C and low alloy steel pipes are to be stress relieved at 645°C ± 15°C.

10.4 Copper pipes are to be annealed at 600°C to 650°C 90/10 copper nickel at 750°C to 800°C, and
70/30 copper nickel at 800°C to 850°C for 10 minutes in a furnace operating with a sulfur free atmosphere or
with combustion conditions such as to prevent sulphide penetration of the pipes .

10.5 After bending of aluminium nickel silicon brass tubing to a radius smaller than 3D, heat treatment is
required by raising the temperature of the relevant area to 500°C ± 25°C for one hour followed by slow
cooling in air. Heat treatment can be accomplished by local treatment e.g. by using resistance/induction
equipment or by furnace methods. Although heat treatment of the complete pipe will not have any adverse
effect on the material it is only essential to carry this out within 300mm each side of the bend. Where heat
treatment is carried out by furnace methods the sulfur content of the atmosphere is not to exceed 10 grains/3
cubic metres.

10.6 Except as stated in Clause 10.5, furnace annealing is preferred but a hand held torch is a permitted
option. The flame is to be soft and bulbous, from a non-oxidizing gas torch. The pipe is to be heated evenly,
and the temperature maintained for five minutes. This is to be measured by a pyrometer until such time as
operators are experienced enough to gauge by colour. The use of sulfur bearing temperature gauging sticks
of fixed melting point is not permitted.

10.7 Ferrous pipes are to be finally heat treated after hot bending in accordance with Table 1:

Table 1 Full Post Heat Treatment

Carbon Steels Low Alloy Steels

Up to 0.26%C 0. 26% to 0.4%C 1%Cr 0.5%Mo

Wall Thickness 13mm or Less Over 13mm All All

Normalizing Temperature °C Not Required 900° to 950° 900° to 950° 950° to 975°

Tempering Temperature °C Not Required 620° to 650° 620° to 650° 630° to 660°

Time At Temperature Not Applicable See Fig 1

Cooling Method Not Applicable Air Cool

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 INT DEF STAN 02-743 Part 1 Issue 2

Figure 1 Determination of Time at Temperature

11 Cleaning & Preservation After Bending

Def Stan 02-341 is to apply.

12 Inspection

12.1 Pipe bends to a centre line radius of 3D and larger are to be visually inspected for evidence of
cracking, indentations, ovality, surface and internal tears. Where machines do not produce 2D or tighter radii
bends to an acceptable standard, 3D bends and larger are to be additionally inspected for ovality and wall
thickness on a sample basis of one bend every 6 months.

12.2 Flatness exceeding the following is not to be accepted.

Figure 2 Acceptance of Flatness

Note The combined length of flatness is not to be greater than 20% of the nominal pipe size
circumference.

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INT DEF STAN 02-743 Part 1 Issue 2
12.3 For carbon and low alloy steels, depressions are not to exceed 0.75mm in depth and are not to be
below the minimum permissible wall thickness. Removal will not be required if the bottom is visible, has a
radius greater than 3 times the depth and is free from stress concentration features.

12.4 All wrinkles with definite fold indications as shown in Fig 3A are to be removed.

Figure 3 Types of Defects

12.5 Dents and/or peen marks indicating the use of ball, peen or face hammers lead to rejection.

12.6 Humps, bumps and steps caused by improper location of mandrels are to be subject to local MoD
Quality Assurance Representative approval and may lead to rejection (See Fig 3B).

12.7 Non-destructive examination is to be in accordance with Def Stan 02-729.

13 Rectification

13.1 Unacceptable defects are to be removed by grinding or filing. On removal, if the wall thickness at the
bend or within the bend area is reduced below the minimum permitted thickness, or if the wall thickness
outside the bend area is reduced below 87.5% of the minimum specified thickness, the material is to be
subject to concession action.

13.2 The wall thickness in areas where defects have been removed in the sector shown shaded in Fig 4 is
to be measured .for acceptance after rectification has been completed.

Figure 4 Areas of Measurement

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 INT DEF STAN 02-743 Part 1 Issue 2

13.3 The removal of defects by grinding or filing is to produce rectification areas with a length and width of
at least 8 times the depth of the defect, with a taper not less than 4 to 1. This is to be considered to be a well
faired or blended area.

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INT DEF STAN 02-743 Part 1 Issue 2
Annex A
Requirements For Tight Radius Bends

A.1 Machine Bending Of Pipes

A.1.1 This Annex applies to the machine bending of pipes to a radius of less than 3 x D. When these
requirements cannot be met by a pipe bending machine, the bends concerned are to be forged or cast as
appropriate. Manual hot bending is not permitted.

A.1.2 Condition of Tubes prior to bending

Clauses 5.1 to 5.4 apply and relate specifically to surface condition. That portion of the pipe forming the bend
is to be dressed free of any surface irregularities.

A.1.3 Procedure

Written and approved procedures are to exist for each machine and type of bend. The minimum
recommended distance between bends is 6 x pipe diameter. All traces of lubricant used during bending are
to be removed by thorough flushing with detergent, followed by clean water prior to any heat treatment being
carried out.

A.1.4 Procedure Approval

Machines are to be subject to the following procedure approval:

a) Sample bends are to be pulled as stated in Clause 8.4.

b) The bends are to be visually examined for freedom from cracks, wrinkles or other surface defects.

c) Ovality is to be within that specified in the acceptance requirements stated in Clauses 8.1 and 8.2.

d) The bends are to be sectioned and the minimum wall thickness at the outer curve is to be not less than
that specified in the acceptance requirements stated in clauses at 6.

A.1.5 Acceptance Requirements for Bends below 3D

a) The ovality expressed as a percentage and calculated from the formula given in Clause 0701, is to be
not greater than 10%.

b) The minimum wall thickness is to be determined by ultrasonic methods in accordance with Def Stan 02-
729 and is to be not less than 87.5% of the specified minimum thickness of the unbent pipe. Departure
from this requirement will be subject to specific approval which will only be granted in exceptional
circumstances. (Clause 8.3 also refers).

c) After manipulation, bends are to be examined for evidence of cracks, indentations or tears. Visual
inspection is to be supplemented by the use of an approved liquid dye penetrant on outer surfaces of the
bend, plus clamping area. For acceptance standards see Clause 5.1.

A.1.6 Heat Treatment

Clauses 10.1 to 10.7 apply.

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 INT DEF STAN 02-743 Part 1 Issue 2
A.1.7 Inspection Requirements

a) The first and last pipes in each batch being bent are to be inspected in accordance with the acceptance
requirements unless there is a need for greater coverage (e.g. 100% coverage is required for nuclear
submarine First Level pipework as defined in NES 25 and supporting documents).

b) Manually bent pipes are to have all bends examined in accordance with the acceptance requirements.

c) Clause 12.3 specifies acceptable limits of flatness. Wrinkles, humps, bumps, steps and dents referred to
in Clauses 12.5 to 12.7 will lead to rejection.

A.1.8 Rectification

Clauses 13.1 to 13.3 apply.

9
 ©Crown Copyright 2011

Copying Only as Agreed with DStan

Defence Standards are published by and obtainable from:

Defence Equipment and Support

UK Defence Standardization

Kentigern House

65 Brown Street

GLASGOW

G2 8EX

DStan Helpdesk

Tel: 44 (0) 141 224 2531/2

Fax: 44 (0) 141 224 2503

Internet e-mail: enquiries@dstan.mod.uk

File Reference
The DStan file reference relating to work on this standard is D/DStan/69/2/743/1.

Contract Requirements
When Defence Standards are incorporated into contracts users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.

Revision of Defence Standards

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 weekly and supplemented regularly by Standards in Defence News (SID News). Any person
who, when making use of a Defence Standard encounters an inaccuracy or ambiguity is requested to
notify UK Defence Standardization (DStan) without delay in order that the matter may be investigated
and appropriate action taken. Sponsors and authors shall refer to Def Stan 00-00 part 2 before
proceeding with any standards work.