Ministry of Defence

Defence Standard 02-743 (NES 743)

Issue 1 Publication Date 01 April 2000

Pipe Manipulation
Part 5
Brazing

Incorporating NES 743 Category 2

Issue 1 Publication Date April 1989

AMENDMENT RECORD
Amd No

Date

Text Affected

REVISION NOTE
This standard is raised to Issue 1 to update its content.
HISTORICAL RECORD
This standard supersedes the following:
Naval Engineering Standard (NES) 743 Part 5 Issue 1 dated April 1989.

Signature and Date

Ministry of Defence

Naval Engineering Standard

NES 743

Part 5

Issue 1 (Reformatted)

PIPE MANIPULATION
PART 5
BRAZING

April 1989

This NES Supersedes

DGS/PS/9019.1

Record of Amendments
AMDT

INSERTED BY

Incorporated

Incorporated

3
4
5
6
7
8
9
10

DATE

NAVAL ENGINEERING STANDARD 743

PIPE MANIPULATION
PART 5
ISSUE 1 (REFORMATTED)
BRAZING

The issue and use of this Standard

is authorized for use in MOD contracts
by MOD(PE) Sea Systems and
the Naval Support Command

ECROWN COPYRIGHT
Published by:
Director of Naval Architecture
Procurement Executive, Ministry of Defence
Sea Systems, Foxhill, Bath BA1 5AB
i

ii

NES 743
Part 5
Issue 1 (Reformatted)

SCOPE
1.

This NES defines the requirements for design and production of capillary brazed joints for
piping systems in Surface Ships and Submarines. It does not apply to reactor plant primary
system pipework.

2.

It covers only the material combinations listed. The general requirements of the NES may be
applied to other materials approved by MOD but not yet included in the NES.

3.

The design temperature for piping systems with brazed joints covered by this NES is not to
exceed 220 C (see Annex B.)

iii

NES 743
Part 5
Issue 1 (Reformatted)

iv

NES 743
Part 5
Issue 1 (Reformatted)

FOREWORD
Sponsorship
1.

This Naval Engineering Standard (NES) is sponsored by the Procurement Executive, Ministry
of Defence, Chief Naval Architect (CNA) Section NA 133.

2.

It is to be applied as required by any Ministry of Defence contract for brazing piping systems
and is applicable to Surface Ships and Submarines.

3.

This NES comprises:

PIPE MANIPULATION
Part 1

Bending of Pipes

Part 2

Extrusions

Part 3

Swaging

Part 4

Welding

Part 5

Brazing

4.

If it is found to be technically unsuitable for any particular requirement the Sponsor is to be

informed in writing of the circumstances with a copy to Chief Naval Architect (CNA), NA 145
for Ship Systems and Equipment.

5.

Any user of this NES either within MOD or in outside industry may propose an amendment
to it. Proposals for amendments which are:
a.

not directly applicable to a particular contract are to be made to the Sponsor of the NES;

b.

directly applicable to a particular contract are to be dealt with using existing procedures
or as specified in the contract.

6.

No alteration is to be made to this NES except by the issue of a formal amendment.

7.

Unless otherwise stated, reference in this NES to approval, approved, authorized or similar
terms, means by the Ministry of Defence.

8.

Any significant amendments that may be made to this NES at a later date will be indicated
by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line
intervals.

Conditions of Release
General
9.

This Naval Engineering Standard (NES) has been prepared for the use of the Crown and of
its contractors in the execution of contracts for the Crown. The Crown hereby excludes all
liability (other than liability for death or personal injury) whatsoever and howsoever arising
(including but without limitation, negligence on the part of the Crown, its servants or agents)
for any loss or damage however caused where the NES is used for any other purpose.
v

NES 743
Part 5
Issue 1 (Reformatted)

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 NES without consulting
or informing any holder.

MOD Tender or Contract Process

12.

This NES is the property of the Crown and unless otherwise authorized 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 NES 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 local MOD(PE) Quality Assurance Representative or the Authority named in the tender
or contract.

14.

When NES are incorporated into MOD contracts, users are responsible for their correct
application and for complying with contracts and any other statutory requirements.
Compliance with an NES does not of itself confer immunity from legal obligations.

Related Documents
15.

In the tender and procurement processes the related documents listed in each section and
Annex A can be obtained as follows:
a.

British Standards

British Standards Institution,

389 Chiswick High Road,
London W4 4AL

b.

Defence Standards

Directorate of Standardization and Safety Policy,

Stan 1, Kentigern House, 65 Brown Street,
Glasgow G2 8EX

c.

Naval Engineering Standards

CSE3a, CSE Llangennech, Llanelli,

Dyfed SA14 8YP

d.

Other documents

Tender or Contract Sponsor to advise.

Note: Tender or Contract Sponsor can advise in cases of difficulty.

16.

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.

17.

Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.

Health and Safety

Warning
18.

This NES may call for the use of processes, substances and/or 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 the 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.
vi

NES 743
Part 5
Issue1 (Reformatted)

CONTENTS
Page No

TITLE PAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sponsorship . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Conditions of Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOD Tender or Contract Process . . . . . . . . . . . . . . . . . . . . . . . . . .
Related Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

v
v
v
v
vi
vi
vi
vi

CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

SECTION

1.
1.1
1.2

GENERAL REQUIREMENTS . . . . . . . . . . . . . . . . .
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1
1.1
1.1

SECTION

2.
2.1
2.2
2.2.1
2.2.2

DESIGN REQUIREMENTS . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.1 JOINTS USING ALLOY INSERT
RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2.2 FACE FEED JOINTS . . . . . . . . . . . . .
FIGURE 2.3 BRAZED FLANGE JOINTS . . . . . . .
Ultrasonic Examinations . . . . . . . . . . . . . . . . . . . . . .
Surface Finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Alloys and Fluxes . . . . . . . . . . . . . . . . . . . . .

2.1
2.1
2.1
2.1
2.1

QUALIFICATION REQUIREMENTS . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualification of Brazing Alloys, Fluxes and
Combinations thereof . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Procedure Information . . . . . . . . . . . . . . . .
Changes in Brazing Procedures . . . . . . . . . . . . . . . .
Automatic Brazing Equipment . . . . . . . . . . . . . . . . .
Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualification Approval . . . . . . . . . . . . . . . . . . . . . . .
Requalification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Responsibilities of the Organization . . . . . . . . . . . . .
Qualification Test Pieces . . . . . . . . . . . . . . . . . . . . . .
Qualification of Procedures . . . . . . . . . . . . . . . . . . . .
TABLE 3.1 PROBABLE NUMBERS OF TEST
PIECES REQUIRED FOR EACH POSITION
(HORIZONTAL AND VERTICAL) . . . . . . . . . . . . .

3.1
3.1

2.2.3
2.2.4
2.3
2.4
SECTION

3.
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.10.1

vii

2.2
2.3
2.4
2.5
2.5
2.5
2.5

3.1
3.2
3.3
3.3
3.3
3.4
3.4
3.4
3.5
3.5
3.5

NES 743
Part 5
Issue1 (Reformatted)

3.5
3.6
3.6
3.6
3.6
3.7

3.12

TABLE 3.2 EXTENT OF QUALIFICATION . . . .

Qualification of Personnel . . . . . . . . . . . . . . . . . . . . .
Retests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualification of Automatic Brazing Equipment . . .
Requirements for Qualification Tests . . . . . . . . . . . .
FIGURE 3.1 QUALIFICATION TEST PIECES . .
FIGURE 3.2 QUALIFICATION TEST
ARRANGEMENTS FOR RESTRICTED ACCESS
Examination of Completed Test Pieces . . . . . . . . . . .

SECTION

4.
4.1
4.2
4.3
4.4
4.5
4.6
4.6.1
4.6.2
4.6.3
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.15
4.16
4.17
4.18
4.19
4.20
4.21
4.21.1
4.21.2
4.21.3
4.21.4
4.21.5
4.22
4.23

BRAZING REQUIREMENTS . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Alloys and Fluxes . . . . . . . . . . . . . . . . . . . . .
Preparation of Fittings . . . . . . . . . . . . . . . . . . . . . . . .
Preparation of Pipes . . . . . . . . . . . . . . . . . . . . . . . . . .
Cutting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fluxing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing of Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nitrogen Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Face Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Marking of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Treatment after Brazing . . . . . . . . . . . . . . . . . .
Cleaning after Brazing . . . . . . . . . . . . . . . . . . . . . . . .
Examination of Brazed Joints . . . . . . . . . . . . . . . . . .
Repair of Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording of Repairs . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Treatment of Repairs . . . . . . . . . . . . . . . . . . . .
Reuse of Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reuse of Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1
4.1
4.1
4.1
4.1
4.1
4.3
4.3
4.3
4.3
4.4
4.4
4.5
4.5
4.6
4.6
4.6
4.6
4.6
4.7
4.7
4.7
4.7
4.7
4.7
4.7
4.8
4.8
4.8
4.8
4.8
4.8

SECTION

5.
5.1
5.2
5.2.1
5.3
5.3.1

INSPECTION AND TEST REQUIREMENTS . . . .

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Braze Inspections . . . . . . . . . . . . . . . . . . . . . . . . .
Joint Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Examination of Fittings before Brazing
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1
5.1
5.1
5.1
5.1
5.1

3.10.2
3.10.3
3.10.4
3.11

viii

3.8
3.9

NES 743
Part 5
Issue1 (Reformatted)

5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.4
5.5
5.5.1
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.7
5.7.1
5.7.2
5.8
5.8.1
5.9
5.9.1
5.9.2
5.9.3
5.9.4
5.9.5
5.10
5.10.1
5.10.2
5.11
5.12

SECTION

6.
6.1
6.2
6.3
6.4
6.5
6.5.1
6.5.2

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Search Sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Examination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brazing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspections during Brazing for Joints using Insert
Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection of Completed Joints . . . . . . . . . . . . . . . . .
Visual Examination of Brazed Joints . . . . . . . . . . . .
Ultrasonic Examination of Brazed Joints . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method, Search Sensitivity and Calibration . . . . . .
Examination of Joints with External Hexagonal
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Radiographic Examination of Brazed Joints . . . . . .
Inspection of Used Fittings Salvaged for Reuse . . . .
Inspections before Reuse . . . . . . . . . . . . . . . . . . . . . .
Inspections after Brazing . . . . . . . . . . . . . . . . . . . . . .
Inspection of Used Pipe Salvaged for Reuse . . . . . .
Inspections before Reuse . . . . . . . . . . . . . . . . . . . . . .
Inspection of Qualification Test Pieces . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prebraze Inspections . . . . . . . . . . . . . . . . . . . . . . . .
Inspections During Brazing for Joints with Insert
Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual Examination of Completed Test Pieces . . . . .
Bond Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peel Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Tests required only for Qualification of
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5.1 MECHANICAL PEEL TEST
SPECIMENS AND REDUCED SECTION
TENSILE TEST SPECIMENS . . . . . . . . . . . . . . . . .
FIGURE 5.2 FULL SECTION TENSILE TEST . .
ACCEPTANCE STANDARDS FOR BRAZED PIPE
JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faying Surfaces of Pipes . . . . . . . . . . . . . . . . . . . . . .
Faces of Joints using Insert RingsBefore Face
Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faces of Joints after Face Feeding . . . . . . . . . . . . . .
Joint Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Examination of Brazed Joints . . . . . . . .
General Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix

5.2
5.2
5.2
5.2
5.2
5.2
5.2
5.2
5.3
5.3
5.3
5.3
5.3
5.3
5.3
5.4
5.4
5.4
5.4
5.4
5.4
5.4
5.4
5.4
5.5
5.5
5.5
5.5
5.5
5.6
5.6
5.7
5.8
6.1
6.1
6.1
6.1
6.1
6.1
6.1
6.1

NES 743
Part 5
Issue1 (Reformatted)

6.8.4

TABLE 6.1 BOND ACCEPTANCE STANDARDS

Fittings Salvaged for Reuse . . . . . . . . . . . . . . . . . . . .
Visual Examination . . . . . . . . . . . . . . . . . . . . . . . . . .
Dye Penetrant Examination . . . . . . . . . . . . . . . . . . .
Pipe Salvaged for Reuse . . . . . . . . . . . . . . . . . . . . . . .
Qualification Test Pieces . . . . . . . . . . . . . . . . . . . . . .
Faces of Joints using Insert Rings, before Face
Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Examination . . . . . . . . . . . . . . . . . . . . . . .
Peel Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 6.2 MINIMUM ACCEPTANCE
STANDARDS FOR PERCENTAGE BOND IN
PEEL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tensile Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2
6.3

ANNEX

A.

RELATED DOCUMENTS . . . . . . . . . . . . . . . . . . . .

A.1

ANNEX

B.

ABBREVIATIONS AND DEFINITIONS . . . . . . . .

B.1

ANNEX

C.

MATERIALS FOR WHICH DATA IS INCLUDED

IN THE ANNEXES . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE C.1 MATERIAL COVERED IN THE
ANNEXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.6
6.6.1
6.6.2
6.7
6.8
6.8.1
6.8.2
6.8.3

6.1
6.2
6.2
6.2
6.2
6.2
6.2
6.2
6.2

C.1
C.1

ANNEX

D.

FLUXES AND BRAZING ALLOYS . . . . . . . . . . . .

TABLE D.1 FLUXES . . . . . . . . . . . . . . . . . . . . . . . .
TABLE D.2 BRAZING ALLOYS . . . . . . . . . . . . . .

D.1
D.1
D.2

ANNEX

E.

HEAT TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE E.1 HEAT TREATMENT OF FITTINGS

E.1
E.1

ANNEX

F.

CLEARANCES FOR CAPILLARY BRAZED

JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE F.1 RADIAL CLEARANCES AT ROOM
TEMPERATURE FOR PIPES USED WITH
INTERNAL FITTINGS . . . . . . . . . . . . . . . . . . . . . . .
TABLE F.2 RADIAL CLEARANCES AT ROOM
TEMPERATURE FOR PIPES USED WITH
EXTERNAL FITTINGS . . . . . . . . . . . . . . . . . . . . . .

ANNEX

SECTION

G.

H.

CONSUMABLES AND CLEARANCES FOR

ALUMINIUM NICKEL SILICON BRASS
(AlNiSi BRASS) PIPING USED WITH
ALUMINIUM SILICON BRONZE
(AlSi BRONZE) FITTINGS . . . . . . . . . . . . . . . . . .
TABLE G.1 BRAZING ALLOYS AND FLUXES
FOR USE WITH AlSi BRONZE FITTINGS AND
AlNiSi BRASS PIPES . . . . . . . . . . . . . . . . . . . . . . .
TABLE G.2 CLEARANCES (RADIAL) AT ROOM
TEMPERATURE (AlNiSi BRASS PIPING WITH
AlSi BRONZE FITTINGS) . . . . . . . . . . . . . . . . . . .
HEALTH PROTECTION AND SAFETY
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ALPHABETICAL INDEX
x

F.1
F.2
F.3

G.1
G.2
G.2
H.1

NES 743
Part 5
Issue 1 (Reformatted)

1.

GENERAL REQUIREMENTS

1.1

Drawings
a.

1.2

The drawing or contract is to state the method and extent of any

non-destructive examinations required, and the acceptance standards.

Production
a.

Organizations working to this NES are responsible for meeting all

requirements in the NES.

b.

Any conflict between this NES, the drawings, the procedures and the contract
is to be referred in writing to the QAR.

c.

Approval is required for any deviation from the requirements of this NES.

d.

The QAR is to be given access and facilities at all reasonable times to ensure that
the requirements of this NES are being met.

e.

The QAR has the right to reject any production work which cannot be proved
to meet the requirements of this NES.

1.1

NES 743
Part 5
Issue 1 (Reformatted)

1.2

NES 743
Part 5
Issue 1 (Reformatted)

2.

DESIGN REQUIREMENTS

2.1

General
a.

It is not intended that this NES should exclude any design, manufacturing
procedure, material or process that can be proved to meet the quality
requirements. Approval must be obtained before any design, procedure etc not
covered by this NES is issued for production.

b.

Drawings are to indicate the location of each brazed joint, the level of the
system and, when appropriate the approved brazing procedure. The various
system levels are defined in Annex B.

c.

Each brazed joint is to be designed so that with a perfect braze but with the
maximum end clearances allowed (see FIGURE 2.1, FIGURE 2.2 and
FIGURE 2.3) the joint, under axial loads, is 1.8 times as strong as the weaker
of the pipe and fitting and is also sufficiently strong to carry any bending loads
which may be applied.

d.

A realistic rule of thumb is:

(1)

The total length of faying surfaces are to be between three and four times
the thickness of the thinner component, with a minimum practical length
of 3mm and a maximum length of 20mm for each faying surface, ie when
one alloy insert ring is used, the total faying surface can consist of two
lengths of 20mm, one on each side of the insert ring groove. When face
feeding is used, the total faying surface is not exceed 20mm in length;

(2)

Under normal conditions, silver brazing alloy will not flow more than
20mm through a capillary gap.

e.

Systems containing brazed joints are to be designed so that wherever possible,

brazing is carried out in the workshop. Brazing in situ is to be kept to a
minimum.

f.

Adequate access is to be allowed for assembly, brazing, inspection and repair.

Particular care is required to facilitate any brazing in situ.

2.2

Joint Design

2.2.1

General

2.2.2

a.

Permanent joints in brazed piping systems are to be socket or sleeve joints as

shown in FIGURE 2.1 and FIGURE 2.2.

b.

Sleeve and socket joints are to use alloy insert rings unless specific approval for
an alternative design has been obtained. Any sleeve or socket joint which is not
designed to use pre-inserted alloy rings is to be individually identified as such
on the drawings.

c.

Fittings designed for face feeding are not to be machined to take insert rings
without approval.

d.

Joints in brazed piping systems which may need to be dismantled are to be

flanged joints as shown in FIGURE 2.3.

Clearances
a.

The clearances required at the brazing temperature vary from alloy to alloy and
are usually specified by the alloy manufacturers. This variation and the
variation in melting temperatures between different alloys need to be taken into
account when calculating the cold clearances required to give the correct
clearances at brazing temperatures. It is also necessary to allow for differential
expansion when pipe and fitting are of different materials.
2.1

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. Dimensions in mm.
2. For pipe below 25mm OD, G is not to exceed 1mm. For pipe 25 OD and over, G is
not to exceed 3mm.
FIGURE 2.1 JOINTS USING ALLOY INSERT RINGS

2.2

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. Dimensions in mm.
2. For pipe below 25mm OD, G is not to exceed 1mm. For pipe 25 OD and over, G is
not to exceed 3mm.
FIGURE 2.2 FACE FEED JOINTS

2.3

NES 743
Part 5
Issue 1 (Reformatted)

Note:

For flange and pipe materials and for design requirements, refer to BR 3013(1) for
Imperial sizes and BR 3013(2) for Metric sizes.
FIGURE 2.3 BRAZED FLANGE JOINTS

2.4

NES 743
Part 5
Issue 1 (Reformatted)

b.

Fittings are to be designed for the largest diameter of pipe which could be
supplied, within the limits of the pipe specification, for the nominal pipe size
called up. The bore of the pipe recess is to allow acceptable clearances, as
specified in Annexes F. and G., with the largest pipe that can be supplied against
the nominal pipe size called up.

Note:

2.2.3

c.

Joint design is to be checked to ensure that correct cold clearances can be

obtained by acceptable enlargement of any diameter of pipe which could be
supplied within the limits of the pipe specification for the nominal size called
up. The enlargement is not to exceed 1 per cent for pipes over 25mm OD or
0.5mm for pipes of 25mm OD or less.

d.

Where cold clearances are to be specified on a drawing and Annexes F. and G.

do not contain the required information, any proposed clearances are to be
proved by qualifying a brazing procedure as laid down in Section 3.

Ultrasonic Examinations
a.

Fittings for use with pipe of 12mm OD or larger are to be designed to allow full
ultrasonic examination of the faying surfaces as laid down in Section 5.

Note:

b.

2.2.4

(1)

pipe OD is not less than 12mm;

(2)

pipe wall is not less than 1.5mm;

(3)

fitting is cylindrical adjacent to the pipe, concentric with it, not less than
15mm OD extending to at least 6mm beyond the end of the pipe with a
surface finish on the OD equivalent to 6.3 micrometres or better and free
from waviness or burrs.

To allow accurate assessment of the results of ultrasonic examinations of brazed

joints, it is necessary to carry out an ultrasonic examination of the fitting before
brazing, as laid down in Section 5., in order to locate any defects in the fitting
which could hamper or prevent adequate ultrasonic examination of the
completed joint. Ultrasonic examination of brazing fittings is to be specified on
the drawing. The examination may be carried out by the manufacturer provided
that he meets the requirements in Section 5.

The faying surfaces of brazing fittings are to be fine turned as this finish
produces a better joint than smooth or polished surfaces. Cold drawn surfaces
also produce satisfactory joints.

Heat Treatment
a.

2.4

Ultrasonic examination of a brazed joint is practicable only when the:

Surface Finish
a.

2.3

In production, the ends of pipes below the maximum diameter will be

enlarged before brazing to give the correct clearance.

Drawings are to contain adequate instructions and sufficient information to

ensure that the required heat treatment is correctly carried out as laid down in
Annex E.

Brazing Alloys and Fluxes

a.

Brazing alloys or fluxes specified on the drawing, are to be selected from the list
of approved brazing materials in Annex D.

b.

Materials not listed are not to be used without specific approval. Tests may be
required to prove and qualify the materials and the brazing procedure before
approval is given.
2.5

NES 743
Part 5
Issue 1 (Reformatted)

2.6

NES 743
Part 5
Issue 1 (Reformatted)

3.

QUALIFICATION REQUIREMENTS

3.1

General

3.2

a.

Organizations working to this NES are to establish and maintain control of

procedures, equipment and personnel which form part of production, repair,
inspection, or required safety precautions. Equipment, essential processing
environments, procedures and personnel qualifications are to be subject to
approval or certification to the satisfaction of the QAR.

b.

All brazing is to be carried out by suitably qualified brazers in accordance with

written brazing procedures.

c.

Manual brazing equipment will not normally require qualification tests.

Automatic brazing equipment is to be qualified by practical qualification tests
as detailed later in this Section.

d.

All brazing equipment, when used by qualified personnel working to approved

procedures, is to be capable of consistently producing joints to the required
standards. Equipment is to be regularly inspected and tested as part of an
approved planned maintenance programme.

e.

Brazers will normally qualify by producing test pieces which meet the specified
Acceptance Standards as laid down in Clauses 3.6a.3.11c.

f.

Personnel currently qualified to meet the brazing requirements of a recognized

authority may, at the discretion of the QAR, be granted exemptions in respect
of brazer qualification. The QAR will state clearly in writing the extent of any
exemption granted.

g.

A brazing procedure is qualified by proving that acceptable sample joints can

be produced on standard test pieces, using the procedure. The test pieces are to
be prepared, examined and tested as described later in this Section. The test
results and, if requested, test pieces and test specimens are to be submitted and
approved by an Authority acceptable to the QAR. The test results may be in the
form of a laboratory report. Qualification of the procedure automatically
qualifies the person who brazed the test piece and the equipment used for the
test.

h.

Organizations may be exempted from procedure qualification tests if, during

the previous three years, brazed pipe joints similar to those covered by this
Standard have been successfully brazed to an acceptable quality. Supporting
documentation such as written procedures, test data, letters of approval, etc are
to be made available to the QAR on request.

Qualification of Brazing Alloys, Fluxes and Combinations thereof

a.

Brazing alloys, fluxes and combinations of these already approved for brazing
to this Standard are listed in Annex D. Details of other approved consumables
may be obtained from NA 133.

b.

If the proposed alloy/flux combination specified in the brazing procedure is not

already approved, it is to be tested and approved before use in production. In
certain cases long term corrosion tests may be necessary. Proposals for
qualification of new materials or material combinations are to be submitted, in
writing, to the QAR.
3.1

NES 743
Part 5
Issue 1 (Reformatted)

3.3

Brazing Procedure Information

a.

Each brazing procedure is to include the following information where

applicable:
(1)

Base metals:
(a)

Pipe material, wall thickness and thermal condition;

(b)

Fitting type, material and thermal condition;

in addition, brazing qualification procedures are to indicate clearly the

range of wall thickness qualified by each test piece;
(2)

(3)

Brazing materials:
(a)

Brazing alloy type, specification and brand;

(b)

Flux type, specification and brand;

Brazing process and details:

(a)

torch brazing:

fuel gas;
type of flame;

(b)

furnace brazing:

atmosphere;

(c)

induction brazing:

frequency and source of high

frequency current.

(4)

Brazing position (brazing qualification procedures only);

(5)

Safety precautions against:

(a)

solvents used for cleaning;

(b)

brazing materials;

(see Annex H.)

(6)

Joint design;

(7)

Joint fit-up:
(a)

clearances (see Annexes F. and G.);

(b)

reference marks (see Section 4.);

(8)

Placement of brazing alloy: insert ring or face feed;

(9)

Jigs and fixtures;

(10) Cleaning of faying surfaces and adjacent areas:

(a)

extent of cleaning;

(b)

cleaning methods and equipment;

(c)

degreasing methods and agents;

(11) Method of cooling;

(12) Post-braze cleaning requirements;
(13) Post-braze heat treatment requirements;
(14) Non-destructive examinations and acceptance standards;
(15) Destructive tests (normally only in qualification procedures) and
acceptance standards.
3.2

NES 743
Part 5
Issue 1 (Reformatted)

3.4

3.5

3.6

Changes in Brazing Procedures

a.

Any alteration in a brazing procedure is to be covered by an authorized change

to the procedure issued in writing.

b.

Any change in items in Clause 3.3a.(8) to 3.4b.(7) will normally require a new
procedure and qualification of the new procedure and personnel except:
(1)

in production procedures, changes of pipe wall thickness within the range

already qualified;

(2)

changes in consumables where the new consumable is supplied to the

same specification as the original;

(3)

changes in fuel gas;

(4)

changes in frequency or source of high frequency current for induction

brazing;

(5)

changes in fit-up clearances which do not allow the clearances to exceed

the limits laid down in Annexes F. and G.;

(6)

changes affecting only the reference marks;

(7)

changes where one material is replaced by another which, although not

identical, has similar characteristics and its use without requalification
is approved by the QAR.

Automatic Brazing Equipment

a.

Automatic or mechanized brazing equipment is to be qualified by test brazes in

accordance with an approved, preliminary or proposed brazing procedure.

b.

The Organization is required to demonstrate the reproducibility of machine

brazed joints. The production brazing procedure is to state the level and
frequency of any additional inspections necessary to meet this requirement.

Personnel
a.

The Organization is responsible for qualifying each brazer and for ensuring that
he is capable of working strictly to brazing procedures and of brazing under
production conditions to the specified acceptance standards.

b.

Personnel currently qualified to meet the brazing requirements of a recognized

authority may, at the discretion of the QAR, be granted exemptions in respect
of brazer qualification. The QAR will state clearly in writing the extent of any
exemption granted.

c.

A brazer who carries out a satisfactory brazing procedure qualification test also
qualifies himself for production brazing using that procedure.

d.

An unqualified brazer may qualify by producing acceptable sample brazed test

pieces using an approved brazing qualification procedure. The procedure is to
include the inspection requirements and acceptance standards. The test pieces
are to be examined and tested as described later in this Section.

e.

If a brazer is required to braze pipe joints in locations where access is difficult

or restricted, he is first to qualify for brazing under conditions of restricted
access as laid down later in this Section.
3.3

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. Access is defined as restricted when a panel or other surface passes
within 150mm of the joint, the surface extending for 70 or more around
the joint and obstructing the access for the torch or brazing rod.
2. A typical case of restricted access occurs when a joint is required in a pipe
run close to an inside corner. This condition is used later in this Section
in qualification tests for brazing with restricted access.

3.7

Qualification Approval
a.

3.8

Requalification
a.

To avoid needless expense the Organization must apply to the QAR for a waiver
when a proposed change is considered not to require requalification.

b.

Requalification is not required for subsequent components or order, provided

that:

c.

d.

3.9

The procedures, test reports and, if requested, test pieces and test specimens are
to be submitted to the QAR for approval. The test results may be in the form
of a laboratory report. Test pieces and specimens are to be retained until written
approval is obtained.

(1)

the QAR is satisfied that the approved conditions are unchanged;

(2)

the QAR is satisfied that the brazing equipment is producing acceptable

welds;

(3)

requalification is not required for any other reason.

Requalification of brazers is required if:

(1)

the QAR or Approving/Certification Authority has reason to believe that

the production workmanship is not consistently of the required standard;

(2)

a period of six months has elapsed since the brazer was last engaged on this
work.

Subject to the approval of the QAR, in exceptional circumstances, qualification

or requalification tests may be modified or waived for selected brazers subject
to full non-destructive examination of the first production braze, or as
otherwise specified by the QAR.

Responsibilities of the Organization

a.

Each Organization working to this NES is to carry out all necessary

qualification tests at its own expense. The QAR will require adequate notice of
each test so that the tests may be witnessed.

b.

The Organization is to certify that tests are conducted in accordance with the
preliminary, proposed or approved brazing procedure. When a test is intended
to qualify simultaneously any combination of procedure, equipment and
personnel, this must be clearly stated when notifying the QAR and again when
submitting details for approval.

c.

The Organization is to keep up-to-date records of qualifications. The records are

to include details of all tests carried out including failures as well as passes. The
records are to include at least the following information:
(1)

Brazer identification;

(2)

Date of test and result;

(3)

Procedure;
3.4

NES 743
Part 5
Issue 1 (Reformatted)

3.10

All test reports;

(5)

Letter or other signed form of approval.

d.

Records for personnel qualifications are to be retained until the person leaves
the Organization.

e.

Records for procedure and equipment qualifications are to be retained in

accordance with the Contract Documents.

Qualification Test Pieces

a.

3.10.1

(4)

The same test piece is used for qualification of brazers, procedures and
equipment.

Qualification of Procedures
a.

To qualify a brazing procedure, a minimum of two test pieces are to be brazed,

one in a vertical position and one in a horizontal position, as shown in
FIGURE 3.1. The test pieces are to be fixed so that the pipes cannot rotate once
brazing has started.

b.

To ensure that sufficient test specimens can be produced to meet the

examination requirements in Section 5., it is often necessary to braze more than
one test piece in each position. The actual number of test pieces to be brazed in
each position will depend on the size of pipe selected for the test pieces.
TABLE 3.1 gives some guidance on the probable minimum numbers required.
The exact requirements will depend on the method of preparation of the test
specimens and are to be decided by the responsible Organization before the tests
commence.
Test Pieces required for Tests for
each position

Pipe
p OD

or

No of Test Pieces to be Brazed in

each position

Tensile
Tests

Mechanical
Peel Tests

Machined
Peel Tests

Tests
A+B

Tests
A+C

Tests
A+US

75 max

Over 75 to
110

Over 110

One test piece can provide all of the

test specimens

Note:

Peel tests are not required if the brazed joints are ultrasonically (US)
examined before the destructive tests.
TABLE 3.1 PROBABLE NUMBERS OF TEST PIECES REQUIRED FOR EACH
POSITION (HORIZONTAL AND VERTICAL)

c.

Successful qualification of a procedure using pipe of wall thickness t will

qualify the brazer, the equipment and the production procedure for use with a
range of pipe wall thicknesses defined in TABLE 3.2. The qualification covers
pipe of any diameter.

Wall thickness t of pipe brazed in Test Range of pipe wall thickness covered by
qualification
Piece
Up to and including 9mm

0 to 2t

Over 9mm to 18mm inclusive

9mm to 2t

Over 18mm

18mm to 2t

TABLE 3.2 EXTENT OF QUALIFICATION

3.5

NES 743
Part 5
Issue 1 (Reformatted)

3.10.2

3.10.3

Qualification of Personnel
a.

To qualify a brazer a minimum of two test pieces are to be brazed, one in a

vertical position and one in a horizontal position, as shown in FIGURE 3.1 or
FIGURE 3.2. The test pieces are to be fixed so that the pipes cannot rotate once
brazing has started.

b.

For normal qualification of brazers, the test piece arrangement shown in

FIGURE 3.1 is to be used, but if the brazer is required to be qualified for brazing
where access is restricted, then the test piece arrangement shown in
FIGURE 3.2 is to be used.

c.

A successful qualification test using pipe of wall thickness t will qualify the
brazer for brazing pipes with a range of wall thicknesses defined in TABLE 3.2.

Retests
a.

If a brazer qualification test piece fails to meet the acceptance standards, retests
are permitted as follows:
(1)

One retest may be made for each test piece that failed without further
training;

(2)

A second retest may be made for each test piece that failed provided that
before the retest, the brazer receives at least eight hours of training or
practice designed to prevent the defects which caused the failures.

If the brazer fails the second retest he is not to be retested for brazing to this
standard until he has undergone a full retraining programme approved by the
QAR.
3.10.4

3.11

Qualification of Automatic Brazing Equipment

a.

To qualify automatic equipment, a minimum of two test pieces are to be brazed,

one in a vertical position and one in a horizontal position, as shown in
FIGURE 3.1 or FIGURE 3.2.

b.

A successful qualification test using pipe of wall thickness t will qualify the
equipment for brazing pipes with a range of wall thicknesses defined in
TABLE 3.2.

Requirements for Qualification Tests

a.

These requirements are to be read in conjunction with Section 4. In addition to

the requirements described below, the requirements of Section 4. are to be met,
omitting any requirement of Section 4. which is not compatible with the
requirements of this section.

b.

Repair of test pieces is not permitted.

c.

Supplementary face feeding and filleting are not permitted in qualification tests
using automatic brazing systems unless face feeding would always be possible
under production conditions.

d.

In qualification tests for manual brazing using fittings with alloy insert rings,
supplementary face feeding and filleting are permitted only after an inspection
of the joint has shown that the braze resulting from the melting of the insert
rings meets the appropriate acceptance standards in Section 6.
3.6

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. H is to be not less than 150mm. It is necessary to check that the dimension H is
sufficient for any tensile tests required.
2. Test pieces to be fixed to prevent rotation.
FIGURE 3.1 QUALIFICATION TEST PIECES

3.7

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. Dimensions in mm.
2. To be read in conjunction with FIGURE 3.1.

FIGURE 3.2 QUALIFICATION TEST ARRANGEMENTS FOR RESTRICTED ACCESS

3.8

NES 743
Part 5
Issue 1 (Reformatted)

3.12

Examination of Completed Test Pieces

a.

After brazing, the test piece is to be heat treated, if required, in accordance with
Annex E. as specified in the brazing procedure and then examined as laid down
below.

b.

Examinations are to be carried out as required in Section 5. under Inspection

of Qualification Test Pieces. Inspection and testing are to be fully detailed in the
qualification brazing procedure or in associated procedures called up in the
brazing procedure.

3.9

NES 743
Part 5
Issue 1 (Reformatted)

3.10

NES 743
Part 5
Issue 1 (Reformatted)

4.

BRAZING REQUIREMENTS

4.1

General
a.

4.2

Brazing Processes
a.

b.

4.3

Brazing may be carried out by one of the following processes:

(1)

Manual torch brazing;

(2)

Mechanical torch brazing.

Approval is required for the use of any other process.

Fittings
a.

4.4

Whenever practicable, brazing is to be carried out in the workshop.

The following types of fitting may be used:

(1)

Socket and sleeve types as shown in FIGURE 2.1 and FIGURE 2.2;

(2)

Flange types as shown in FIGURE 2.3.

b.

All brazed fittings other than flange types are to be designed for use with
pre-inserted alloy rings unless otherwise specified on the drawing.

c.

Fittings designed for face feeding are not to be modified to take insert rings.

Brazing Alloys and Fluxes

a.

The brazing alloy and flux, where not specified on the drawing, are to be selected
from the approved materials listed in Annex D. as suitable for use with the pipe
and fitting material combination.

Note:

4.5

The fluxes listed have a limited life at brazing temperature. When a joint
is heated above 600 C the effective working life of the listed fluxes is about
25 minutes.

Preparation of Fittings
a.

Before brazing, wrought fittings are to be annealed and cast fittings are to be
stress relieved. Fittings are normally purchased annealed or stress relieved, as
appropriate. Should the certification not cover this (see Section 5.) the fittings
are to be heat treated as laid down in Annex E.

b.

If a suitable certificate of ultrasonic examination is not supplied with any fitting

for use with pipe of 12mm OD or larger, (see Clauses 5.2.1a.5.2.1c.), an
ultrasonic examination is to be carried out before brazing, as laid down in
Section 5.

c.

In order to permit satisfactory ultrasonic examination, the outer surface of the

fitting is to be smooth and uniform. If the outer surface is not suitable, the
fitting is to be rejected unless a concession and repair procedure has been
approved to allow machining of the fitting.

d.

If fittings are to be plated before brazing, carry out the plating as laid down in
the Brazing Procedure and in Annex G.
4.1

NES 743
Part 5
Issue 1 (Reformatted)

4.6

Preparation of Pipes

4.6.1

Cutting
a.

4.6.2

4.6.3

Pipe ends are to be square, free from burrs, parallel and within specified
dimensional limits before expansion. Care is required when cutting to avoid
reducing the pipe wall thickness and forming a taper on the end of the pipe.

Sizing
a.

Pipe ends are to be cylindrical and may be enlarged, using suitable parallel pipe
expanders, to eliminate ovality and obtain the required clearances.

b.

Pipe ends are to be sized to provide a joint clearance that will promote capillary
flow of the molten brazing alloy in the gap between the pipe and fitting at the
brazing temperature.

Clearances
a.

The clearances required at the brazing temperature vary from alloy to alloy.
This variation and the variation in melting temperatures between different
alloys need to be taken into account when calculating the cold clearances to give
the correct clearances at the brazing temperatures. It is also necessary to allow
for any differential expansion between pipe and fitting.

b.

Clearances required at brazing temperatures are normally recommended by the

manufacturers of the alloys. Recommended cold clearances are listed in
Annexes F. and G. Clearances for combinations and sizes not listed in these
Annexes are to be proved by qualifying the proposed brazing procedure as laid
down in Section 3.

Note:

Radial clearances are quoted in the tables in Annexes F. and G., whereas
checking is normally and most easily carried out by measuring the
diametrical clearance with feeler gauges when the fitting and pipe are in
contact diametrically opposite the point at which the measurement is
taken.

c.

The maximum diametrical enlargement of pipes resulting from the use of pipe
expanders or other devices is not to exceed 0.5mm for pipes up to 50mm OD or
1% of the diameter for pipes over 50mm OD.

d.

Pipes with tapered ends may be used only if the taper is insufficient to cause the
clearances to be outside the specified limits anywhere along the faying surfaces.
To check for taper, the pipe may be inserted about 3mm into the fitting and the
clearance measured with feeler gauges, followed by a second measurement with
the pipe fully inserted.

e.

Where clearances are excessive, brazing alloy may still enter the joint
adequately due to gravity provided that the joint orientation is suitable. Such
joints are uneconomic, the joint strength is usually lower than that of a similar
capillary fed joint and they are to be avoided. If, nevertheless, a gravity fed
brazed joint is proposed, it is to be qualified, together with the proposed brazing
procedure, as laid down in Section 3.

4.2

NES 743
Part 5
Issue 1 (Reformatted)

4.7

Cleaning
a.

Before brazing, the faying surface, the end face and the insert ring groove of the
fitting, the brazing ring if used, the outside of the pipe and the end of the pipe
are to be cleaned to bright metal. The end of the pipe is to be cleaned over a
length equal to not less than twice the maximum depth of insertion of the pipe
into the fitting to allow for filleting and to avoid unnecessary degradation of the
flux. The insert ring, if fitted, is to be removed to facilitate cleaning of ring and
groove. Any brazing rods to be used for face feeding are also to be similarly
cleaned.

b.

Cleaning will generally involve the following processes although some

commercial cleaning solutions may provide satisfactory cleaning in one process:
(1)

Degrease with acetone, alcohol or other approved degreasing agent;

(2)

On fittings which are not copper plated for brazing, remove scale, oxides
and other firmly adhering contaminants by the use of abrasive cloth,
stainless steel wire brushes or stainless steel wire wool. Cleaning of copper
plated fittings is limited to (1) and (3);

(3)

Finally wipe clean with lint-free wipers soaked in degreasing agent or

damped with water.

Note:

4.8

Cleaned surfaces are not to be touched with bare hands and are not to be
allowed to come into contact with the skin or any other source of
contamination. Natural body oils and acids transferred during contact
with the skin will seriously affect the quality of the brazed joint.

Fluxing
a.

After cleaning, the faying surfaces are to be fluxed before brazing. If the surfaces
are not fluxed within eight hours of cleaning, they are to be recleaned as laid
down above before fluxing.

b.

Brazing flux is to be applied evenly to the faying surfaces in the form of a smooth
stiff paste. If the joints are not assembled immediately, the fluxed surfaces are
to be protected so that the flux is neither contaminated nor inadvertently
removed. If the flux dries before the joint is assembled, the old flux is to be
removed and fresh flux applied.

c.

If the joint is in a system or at a location where soaking and flushing cannot be

used to clean the joint after brazing, only sufficient flux to make a proper joint
is to be applied. The flux is to be applied evenly to the faying surfaces not more
than five minutes before the joint is due to be assembled. Non-faying surfaces
are to be wiped clean either before or after assembly, depending on accessibility.
Excess flux is to be removed. During brazing a nitrogen purge is required as
described later.

4.3

NES 743
Part 5
Issue 1 (Reformatted)

4.9

4.10

Assembly
a.

To facilitate assembly and inspection, where the inside of a joint will not be
accessible after brazing, a reference mark is to be made on the outside of the pipe
at a distance of 2L+10mm, say, from the end to be brazed, where L is the socket
depth or half of the sleeve length as shown in FIGURE 2.1 and FIGURE 2.2.
(The figure of 10mm is only a suggestion and may be altered if required). The
distance from the end of the pipe to the reference mark is to be measured and
recorded. The reference mark is to be located so that it is clearly visible after
brazing and may be used for measurement on final inspection. The method of
marking is to be such that the mark will not act as a stress raiser. In cases where
the pipe bends too close to the joint to allow the mark to be located as suggested
above, it may be located closer to the joint provided that it meets all of the other
requirements.

b.

When assembling a socket-type joint, the pipe end is to be inserted into the
socket so that nowhere does the distance between the end of the pipe and the
bottom of the socket exceed the limits laid down in FIGURE 2.1.

c.

The radial clearance between the pipe and socket is to be within the limits laid
down in Annex F. and G., or in an approved brazing procedure.

d.

When assembling a sleeve-type joint, the pipe ends are to be inserted into the
sleeve so that:
(1)

the pipes are located within the limits laid down in FIGURE 2.2;

(2)

nowhere does the distance between the ends of the pipes inside the sleeve
exceed the limits laid down in FIGURE 2.2.

e.

The radial clearance between each pipe and the sleeve is to be within the limits
laid down in Annex F. and G., or in the approved brazing procedure to be used.

f.

Before brazing, the pipe supports are to be checked to ensure that they are
adequate and sufficiently flexible to accommodate the expansion and
contraction resulting from the heating and cooling. Supports which are too rigid
can impose excessive stresses on the pipes and joint during the brazing cycle.

Brazing of Valves
a.

Before brazing connection to valves, the valves are to be dismantled if possible

and all separable parts removed, particularly soft seats, packings, seals etc,
which are easily damaged by heat. Non-removable items, (eg fixed valve seats,
seat housings, integral threads etc) are to be protected from oxidation by
applying a film of flux or other protective medium.

b.

Valves which are to be brazed while still assembled are to be kept as cool as
possible, particularly the bonnets. Before brazing, the valve is to be fully opened
and then closed by a quarter of a turn. Gaskets, O rings, seals and packings
which could be damaged by the heat are to be removed. Controlled heating and
cooling techniques are to be used. Proprietary heat protective paste is to be used.

4.4

NES 743
Part 5
Issue 1 (Reformatted)

4.11

Nitrogen Purge
a.

4.12

Tacking
a.

4.13

4.14

Tacking of joints is permitted only with specific approval of the QAR for each
application. If tacking is to be used, the brazing alloy used is to be the same as
that in the insert ring or that to be used in final assembly of face fed joints.
Tacking is to be limited to the minimum required to maintain alignment. No
more than 4 tacks are to be used, evenly distributed around the joint. Heating
is to be uniform to reduce the possibility of cracking.

Heating
a.

Brazing torches are to be oxy-fuel gas types. The sulphur content of any fuel gas
used is not to exceed 0.009 gram per cubic metre. The flame is not to be applied
directly to the brazing alloy or flux. Only the outer envelope of the flame is to
be applied. The inner cone of the flame is not to come into contact with the
assembly. The torch is to have sufficient capacity and the flame is to be adjusted
to neutral or slightly reducing.

b.

Overheating is to be avoided. Fittings of gunmetal and phosphor bronze in

particular are not to be heated above 800 C. Heating and cooling rates are to
be controlled to prevent cracking.

c.

Temperatures may be measured with contact thermometers, or optical

pyro-meters.

d.

Heat input is to be carefully controlled to ensure even distribution of heat

around the joint.

e.

Before brazing, large, thick walled fittings are to be preheated by raising the
temperature slowly and uniformly to 500 C in order to minimize thermal shock.

f.

The temperature of the assembled pipes and fitting is to be raised uniformly to

the brazing temperature to optimize the capillary flow of the molten brazing
alloy.

Priming
a.

4.15

If the joint to be brazed is in a system or at a location where soaking and flushing

cannot be used to clean the joint after brazing, a nitrogen supply is to be
connected to one end of the system and sufficient nitrogen blown through the
system to remove all the air. After the initial purge has removed the air, the
nitrogen flow is to be reduced until the nitrogen emerging from the discharge
end can just be felt with the palm of the hand. The purge is to be maintained
during brazing and until the joint has cooled below 120 C. When the purge is
removed the ends of the system are to be sealed to maintain an inert
atmosphere.

Priming with flux of pre-inserted alloy joints is permitted, provided that all
other requirements have been met. Priming with brazing alloy is NOT
permitted, as it will prevent any check of the brazing alloy flow round the joint
circumference.

Face Feeding
a.

When the initial flow of the brazing alloy from the insert ring has been checked
by the Inspector it is recommended that the joint should be face fed, while still
hot, to complete the joint, make up for any recession of the brazing metal on
cooling and ensure that a small circumferential fillet of alloy is present when
the joint has cooled.
4.5

NES 743
Part 5
Issue 1 (Reformatted)

Note:

4.16

Cooling
a.

4.17

4.20

Where required, completed joints are to be marked to identify the brazer.

Heat Treatment after Brazing

a.

4.19

After completion of the joint, the assembly is to be allowed to cool in still air.

Marking of Joints
a.

4.18

Large fillets are unnecessarily expensive and do not increase the joint
strength.

Some materials are to be heat treated after brazing. These materials and the
heat treatment required are listed in Annex E.

Cleaning after Brazing

a.

After cooling, all accessible surfaces are to be cleaned to remove scale and flux
residues. Internal surfaces are to be soaked for a minimum period of 12 hours
in cold water, or for two hours in hot water (at least 60 C). Subject to the
approval, some material combinations may be cleaned by soaking in hot to
boiling caustic soda solution (10% by weight) for at least one hour. For the
standard of cleanliness required for particular systems in submarines see
NES 341.

b.

Brazed joints made in situ are to be cleaned with water. The system is to be
soaked for a period of at least twelve hours, and flushed in accordance with the
requirements for that system. Where soaking and flushing is not permitted in
a particular system, a nitrogen purge is used for brazing and the system is to be
filled with nitrogen and sealed as Clause 4.11a.

Examination of Brazed Joints

a.

After completion of the brazing, the newly brazed joints, together with any
other brazed joints within 75mm of a new joint are to be examined as laid down
in Section 5. and are to meet the acceptance standards for brazed joints in
Section 6.

4.21

Repair of Joints

4.21.1

General
a.

Unless otherwise approved by the QAR, the brazing alloy used for repairs is to
be the same as that originally used in brazing the joint.

b.

Before starting any repair, the end face of the fitting adjacent to the faying
surfaces and the adjacent pipe surface are to be cleaned to bright metal and
fluxed as laid down in Clauses 4.7a.4.8c.

c.

Repairs are not permitted if the joints have been exposed to fluids other than:
(1)

clean water;

(2)

approved cleaning solutions;

(3)

nitrogen;

(4)

pure refrigerant.

If the joint has been exposed to refrigerant which cannot be guaranteed pure,
the joint is not to be repaired.
4.6

NES 743
Part 5
Issue 1 (Reformatted)

4.21.2

4.21.3

Repair Techniques
a.

Repairs to improve the percentage bond, repair leaks, or to correct the

alignment may be carried out by reheating the joint until the brazing alloy
melts, rotating the fitting or pipe if required, followed by addition of flux, face
feeding of alloy and filleting as required.

b.

No more than two attempts at repair are permitted on any one joint.

Examination
a.

4.21.4

4.21.5

Recording of Repairs
a.

Each repair attempt is to be recorded, either by marking up the ships drawings

or by marking the fitting in accordance with the Contract Documents.

b.

Where required, repaired joints may be marked also to identify the brazer
carrying out the repair. The method of marking is to be in accordance with the
Contract Documents.

Heat Treatment of Repairs

a.

4.22

4.23

After completion of the repairs, all brazed joints within 75mm of a repair,
together with the repaired joints, are to be examined as laid down in Section 5.
and are to meet the acceptance standards in Section 6.

Some materials are to be heat treated after repair. These materials and the heat
treatment required are listed in Annex E.

Reuse of Fittings
a.

Fittings may be reused, provided that the fittings are examined as laid down in
Section 5. and meet the acceptance standards in Section 6.

b.

If necessary the faying surfaces of the fitting and any insert ring grooves may
be machined, provided that the dimensions of the fitting after machining are
still within the specific limits. Hand grinding is not permitted.

c.

Reference marks used for previous ultrasonic examinations need not be

removed.

d.

Brazing procedures for joints made with reused fittings are to be the same as
for joints made with new fittings but, if required, insert rings may be slightly
rounded on the outer corners to fit the insert grooves.

e.

Reused fittings are to be marked or records kept to show that they have been
re-used. Where the location and reuse of the fitting is to be recorded on the ships
drawings, provided that the number of previous heatings is also recorded,
marking of the fitting may be omitted.

Reuse of Pipe
a.

Pipes of materials other than 70/30 CopperNickel (Cu Ni), 90/10 Cu Ni and
Aluminium NickelSilicon brass (AlNiSi brass) may be reused without
formal inspection unless otherwise specified.

b.

Pipes of 70/30 Cu Ni, 90/10 Cu Ni and AlNiSi brass are to be inspected as

laid down in Clause 5.10.2a. and are to meet the acceptance standards in
Section 6.

c.

Pipes to be reused are to be prepared for reuse as laid down in Clauses

4.6.1a.4.8c.

d.

Should pipe ends be oversize when the clearances are checked, the pipe OD may
be reduced with emery paper, used carefully to avoid causing ovality, provided
that the pipe wall is not reduced below the specified minimum thickness.
4.7

NES 743
Part 5
Issue 1 (Reformatted)

4.8

NES 743
Part 5
Issue 1 (Reformatted)

5.

INSPECTION AND TEST REQUIREMENTS

5.1

General
a.

Inspections are to be carried out in accordance with NES 729.

b.

The extent of examination and testing required on any brazed system is to be

related to the level of the system. The level of each system or part of a system
is to be stated in the contract or on the relevant drawing which will specify also
the required examinations and acceptance standards. The various system levels
are defined in Annex B.

c.

Crack detection is to be carried out using dye penetrant examination

techniques.

d.

Dye penetrant and ultrasonic examinations are to be carried out by qualified

personnel using approved equipment and working to approved procedures.

5.2

Pre-Braze Inspections

5.2.1

Joint Components
a.

Before brazing, each pipe and fitting is to be inspected to check that:

(1)

the materials of the pipe and fitting are as required by the drawing and
the approved brazing procedure;

(2)

the fittings have been correctly heat treated as laid down in Annex E.;

(3)

fittings for 12mm OD pipe and over are suitable for ultrasonic
examination after brazing and have been ultrasonically examined as
required by Section 4. and as laid down later in this Section;

(4)

the distance from the end of each pipe to the reference mark, if required,
has been accurately measured and recorded;

(5)

when pipe and fitting are assembled, the joint clearances are within the
limits laid down in Annexes F. and G., the drawing or approved brazing
procedure for the materials and alloy combination being used.

b.

The faying surfaces of each pipe plus an adjacent pipe length of at least 10mm
are to be examined using dye penetrant. The surfaces are to meet the acceptance
standards in Section 6.

c.

The brazing alloy is to be checked to ensure that it meets the requirements of

the drawing and the brazing procedure.

5.3

Ultrasonic Examination of Fittings before Brazing

5.3.1

General
a.

Ultrasonic examination of brazed joints using external fittings is practicable

only when pipes are 12mm OD or over and used with fittings of wall thickness
1.5mm or over. When internal fittings are to be used, the fitting is to be 12mm
OD or over and the pipe wall is to be 1.5mm or over. The following clauses are
written to cover external fittings. Where internal fittings are to be used, the pipe
wall is to be examined before brazing instead of the fitting. The procedure is
identical.

b.

In order to obtain reliable results from ultrasonic examinations of brazed joints

it is necessary to carry out an ultrasonic examination of each fitting before
brazing, in order to locate and record sub-surface defects which could interfere
with ultrasonic examinations after brazing.
5.1

NES 743
Part 5
Issue 1 (Reformatted)

5.3.2

5.3.3

Setting Up
a.

The ultrasonic equipment is to be calibrated and qualified as laid down in

NES 729.

b.

Probes are to be combined double compressional wave of test frequency 5MHz.

Where the material of the fitting has a high attenuation factor, probe
frequencies down to 2.5MHz may be used. Full probe details are to be included
in the ultrasonic examination report.

c.

Focussed probes are to be preferred where material thickness permits.

d.

All examinations are to be made using a couplant whose film integrity is to be

maintained at all times.

e.

The reject control is to be adjusted to the minimum setting consistent with a

clean trace.

Search Sensitivity
a.

5.3.4

Examination
a.

5.3.5

The certification of the gas to be used for torch brazing is to be checked to ensure
that the sulphur content does not exceed the limit laid down in Section 6.

Brazing Procedure
a.

5.4

The ultrasonic examination report is to be included with the paperwork for the
fitting and form part of the certification.

Gas
a.

5.3.8

Any fitting containing defects which would interfere with the ultrasonic
examination of the joint after brazing is unacceptable and is to be rejected.

Report
a.

5.3.7

The search scan is to be along parallel lines separated by not more than 90% of
the diameter of the probe crystal, to ensure complete coverage of the faying
surfaces.

Assessment
a.

5.3.6

The examination is to be carried out with the attenuator set to give 100% full
scale deflection (FSD) for the first back wall echo (BWE).

The brazing procedure is to be checked to ensure that only approved procedures

are used for production.

Inspections during Brazing for Joints using Insert Rings

a.

After the alloy insert ring has been melted and capillary flow has taken place,
the joint is to be inspected before any face feeding is permitted, in order to check
that adequate capillary flow has occurred. The joint is to meet the acceptance
standards for capillary flow in Section 6.

5.2

NES 743
Part 5
Issue 1 (Reformatted)

5.5

Inspection of Completed Joints

5.5.1

Visual Examination of Brazed Joints

a.

After brazing or repair each joint is to be inspected for:

(1)

evidence of brazing alloy at the face of the fitting;

(2)

correct depth of insertion and correct clearance between the end of each
pipe and the bottom of its socket in socket-type fittings, or between the
ends of the pipes in sleeve-type fittings;

Note:

(3)

When the inside of the joint is inaccessible, the insertion depth and
clearances can be checked by measuring the distance from the face of the
fitting to the reference mark placed on the pipe before assembly;
Correct alignment to drawing.

b.

Each joint is to meet the acceptance standards in Section 6. In multi-socket

fittings each joint is to be similarly re-examined after completion of the last
brazing operation on the fitting.

c.

After completion or repair of a joint, every other brazed joint within 75mm is
to be similarly re-examined.

5.6

Ultrasonic Examination of Brazed Joints

5.6.1

General
a.

The extent of ultrasonic examination required is to be stated in the contract or

drawing. When the requirement is not stated, the extent of ultrasonic
examinations is to be as follows:
Level
Level
Level
Level

1 systems
2 systems
3 systems
4 systems

100%;
100%;
10% minimum;
Nil.

Where part of a system has a different level from the rest, the two parts are to
be treated as separate systems for the purpose of deciding the extent of
ultrasonic examination.
Note:

5.6.2

5.6.3

Method, Search Sensitivity and Calibration

a.

To be in accordance with NES 729.

b.

The average percentage bond is to be calculated for each joint and this is to meet
the acceptance standards in Section 6.

Examination of Joints with External Hexagonal Configuration

a.

5.6.4

Ultrasonic examination of brazed joints is feasible only when the pipe is

12mm OD or over and the wall thickness of the fitting is 1.5mm or over.
All fittings for use with pipes of 12mm OD or over are to be suitable for
ultrasonic examination as laid down in Section 2.

Each of the six sides is to be examined and the average percentage bond
calculated. The percentage bond is to meet the acceptance standards for
hexagonal fittings in Section 6.

Radiographic Examination of Brazed Joints

a.

When radiographic examination of joints is specified in the drawing or contract

as a check of fit-up, unless otherwise specified, a minimum of 2% of the joints
are to be radiographed by qualified personnel using approved equipment and
working to an approved procedure.
5.3

NES 743
Part 5
Issue 1 (Reformatted)

5.7

Inspection of Used Fittings Salvaged for Reuse

5.7.1

Inspections before Reuse

a.

5.7.2

Each fitting is to be inspected to check that:

(1)

sufficient of the old brazing alloy has been removed to meet the acceptance
standards in Section 6.;

(2)

the dimensions meet the acceptance standards in Section 6.;

(3)

the fitting has not been heated more than twice before, for brazing or
repairing. If there are no markings on the fitting, the drawings are to be
checked for the information.

b.

The fitting is to be inspected using dye penetrant examination and is to meet

the acceptance standards in Section 6.

c.

The fitting is also to be fully inspected as laid down earlier in this Section under
Pre-braze Inspections.

Inspections after Brazing

a.

Each reused fitting is to be inspected to check that the fitting has been marked
to show the additional brazing operation due to its reuse. Where approval has
been obtained to record the reuse on the ships drawings, these are to be
inspected to check that the location and reuse have been recorded and that the
total number of previous reheats is also recorded.

5.8

Inspection of Used Pipe Salvaged for Reuse

5.8.1

Inspections before Reuse

a.

Before reuse, the ends of used pipes of 70/30 Cu Ni, 90/10 Cu Ni and AlNiSi
brass are to be inspected using dye penetrant examination over a minimum
length P where P is equal to the socket depth plus 50mm. The areas inspected
are to meet the acceptance standards in Clause 6.1a. This inspection may be
omitted for pipes of other materials.

5.9

Inspection of Qualification Test Pieces (See Clause 3.12b.)

5.9.1

General
a.

5.9.2

Prebraze Inspections
a.

5.9.3

Qualification test pieces are to be examined and tested as laid down in Clauses
5.9.2a. to 5.11d. and are to meet the acceptance standards for qualification test
pieces in Section 6.

Before brazing, qualification test pieces are to be inspected as stated in Clauses

5.2.1a.5.2.1c.

Inspections During Brazing for Joints with Insert Rings

a.

After the insert ring has melted and capillary flow has taken place, each joint
is to be inspected before any face feeding is permitted, in order to check that
adequate capillary flow has occurred.

Notes:
1. Face feeding is not permitted during qualification tests using automatic
brazing on joints with insert rings unless face feeding would always be
possible under production conditions.
2. Repairs to test pieces are not permitted.
5.4

NES 743
Part 5
Issue 1 (Reformatted)

5.9.4

Visual Examination of Completed Test Pieces

a.

5.9.5

After completion, qualification test pieces are to be inspected as stated in Clause

5.5.1a.

Bond Assessment
a.

The bond in qualification test pieces is to be assessed either by ultrasonic

examination or by peel tests as laid down in Clauses 5.12a.5.12b. Ultrasonic
examinations are not feasible on pipes below 12mm OD and for these pipes, peel
tests are to be carried out.

5.10

Ultrasonic Examination

5.10.1

General
a.

5.10.2

When ultrasonic examination is specified, every test piece produced for a

particular qualification is to be examined as stated in Clauses 5.6.1a. and 5.6.2a.

Peel Tests
a.

Peel tests are to be carried out using one of the two methods described below:
(1)

(2)

b.

Method 1. Mechanical Peel Test:

(a)

Peel test specimens are to be as shown in FIGURE 5.1. When the

pipe is 51mm OD or larger, the test specimens are to be 40mm wide,
measured round the OD of the pipe outside the joint. When the pipe
is less than 51mm OD, each test specimen is to be a 90 segment of
the test piece;

(b)

The specimens are to be separated along the line of the brazing alloy
by peeling the filling material from the pipe or vice versa. To
facilitate separation, the test specimen may be heated to 550 C or,
after removing the fillet of alloy from the face of the fitting, the
specimen may be cooled with dry ice or liquid nitrogen. The total
area of defects, unbrazed areas and flux inclusions is to be measured
and recorded.

Method 2. Peel Test by Machining.

(a)

The fitting is to be parted off just clear of the end of the pipe. The
test specimen is then to be prepared by machining the OD until the
wall of the fitting remaining is 0.2 to 0.3mm thick. Then with the
tube set true in a lathe the fitting wall is to be turned down carefully,
taking successive cuts of 0.010.05mm. After each cut the surface
is to be inspected carefully for bubbling of the metal surface caused
by separation of the fitting from the brazing alloy or by separation
of the brazing alloy from the pipe. All areas of separation are to be
plotted on one scale plan, together with areas of flux inclusions and
other defects. Continue machining until all of the brazing alloy has
been removed;

(b)

The total unfused area is to be taken as the sum of the areas plotted
on the scale plan, with any overlapping areas counted only once.

The percentage bond is to be calculated for each joint as follows:

5.5

NES 743
Part 5
Issue 1 (Reformatted)

(1)

Mechanical Peel Test:

For each joint, calculate the total area of faying surface of the fitting in the
two test specimens (F). Calculate also the total defective area in the two
test specimens (A):
Then percentage bond = FA 100
F
The percentage area examined (E) is to be calculated as follows:
E=

(2)

F
100
Total area of faying surface of socket

Peel Test by Machining:

Calculate the total area of faying surface in the socket (F):
Percentage bond = FA 100 where A is the total unfused
F
area determined earlier.

5.11

5.12

Additional Tests required only for Qualification of Procedures

a.

For qualification of procedures, two tensile tests are to be carried out on test
specimens from both the horizontal and vertical brazing positions (four tests in
all).

b.

Tensile test specimens are to be full section as shown in FIGURE 5.2 when the
Pipe is less than 75mm OD. When the pipe is 75mm OD or larger, reduced
section tensile test specimens are to be prepared as shown in FIGURE 5.1.

c.

The load at failure and the location of the break are to be recorded for each
tensile test.

d.

The extent of the qualification obtained by a test is to be as shown in TABLE 3.2.

Hydraulic Testing
a.

Hydraulic testing of brazed pipe systems is to be carried out in accordance with

pressures given in the relevant system Naval Engineering Standard or Contract
Documents.

b.

All leaks are to be repaired.

5.6

NES 743
Part 5
Issue 1 (Reformatted)

Notes:
1. Dimensions in mm.
2. For test pieces brazed in the horizontal position, AA is to be the horizontal axis.
3. For pipes below 51 OD, peel test specimens are to be 90 segments.
4. For pipes over 75 OD, all test specimens for one brazing position may be taken from
the same joint, provided that the specimens are taken from the correct positions
as shown.

FIGURE 5.1 MECHANICAL PEEL TEST SPECIMENS AND REDUCED SECTION TENSILE
TEST SPECIMENS

5.7

NES 743
Part 5
Issue 1 (Reformatted)

FIGURE 5.2 FULL SECTION TENSILE TEST

5.8

NES 743
Part 5
Issue 1 (Reformatted)

6.

ACCEPTANCE STANDARDS FOR BRAZED PIPE JOINTS

6.1

Faying Surfaces of Pipes

a.

6.2

Faces of Joints using Insert RingsBefore Face Feeding

a.

6.3

Capillary flow of alloy from the melted insert ring is acceptable when, before any
face feeding of alloy has taken place, alloy can be seen at the face of the fitting,
extending round at least 75% of the circumference of the joint.

Faces of Joints after Face Feeding

a.

6.4

All faying surfaces and adjacent areas of pipe are to be inspected using dye
penetrant and are to be free from cracks, linear defects and similar faults.

The joint face is acceptable when a small fillet of alloy is visible round the whole
of the circumference of the joint.

Joint Geometry
a.

In joints using socket-type fittings, the depth of insertion of each pipe into its
socket is to be such that the clearance between the end of the pipe and the
bottom of the socket does not exceed the limit specified in the drawing or in
FIGURE 2.1.

b.

In a joint using sleeve-type fittings, the depth of insertion of each pipe into the
sleeve and the clearance between the end of the pipes are to be within the limits
specified in the drawing or in FIGURE 2.1 and FIGURE 2.2.

c.

The alignment of the pipes and joints is to be as shown on the drawing.

6.5

Ultrasonic Examination of Brazed Joints

6.5.1

General Fittings
a.

6.5.2

The average bond of new joints is not to be less than 50%. Joints which have been
in service and on inspection are found to have an average bond of 40% or
greater are acceptable for further service. For Nuclear Submarines refer to DPT
1306 Specification.

Special Fittings
a.

TABLE 6.1 acceptance standards may be used for fittings which are not suitable
for full ultrasonic examination of the faying surfaces and for the use of which
special approval has been obtained from the QAR.

b.

Fittings with cylindrical exterior surfaces which are too small to allow
examination of all of the faying surfaces are to meet the acceptance levels in
TABLE 6.1. Where the area available for examination lies between the values
quoted in the table, use the lower area figure in the table (which will require a
higher acceptance standard).
Percentages of faying surfaces
examined

Acceptable % Bond

50

80

60

75

70

70

80

65

90

55

100

50

TABLE 6.1 BOND ACCEPTANCE STANDARDS

6.1

NES 743
Part 5
Issue 1 (Reformatted)

c.

For fittings with hexagonal exterior surfaces the average bond for the joint is
to be not less than 80%.

6.6

Fittings Salvaged for Reuse

6.6.1

Visual Examination

6.6.2

a.

The fittings are to be clean and free from brazing alloy except that traces of alloy
remaining in the corners of the insert ring groove may be allowed to remain.

b.

The dimensions of the fitting are to be within the limits laid down in the
drawings except that a small increase in the interior diameter of the faying
surfaces is acceptable provided that it does not require an unacceptable degree
of enlargement of the pipe to provide the correct clearances for brazing (see
Section 4.) The radius of the internal corners of the insert ring groove is to be
not less than 0.4mm.

Dye Penetrant Examination

a.

6.7

The fitting is to be free from cracks, linear defects and similar faults.

Pipe Salvaged for Reuse

a.

The pipe ends and adjacent areas are to be free from cracks, linear defects and
similar faults.

6.8

Qualification Test Pieces

6.8.1

Faces of Joints using Insert Rings, before Face Feeding

a.

6.8.2

Ultrasonic Examination
a.

6.8.3

Capillary flow of alloy from the melted insert ring is acceptable when, before any
face feeding of alloy has taken place, alloy can be seen at the face of the fitting,
extending round at least 75% of the circumference of the joint and any gap in
the brazing alloy around the circumference is less than 10% of the
circumference.

The average percentage bond for any joint is to be not less than 70%. For Nuclear
Submarines refer to DPT 1306 Specification.

Peel Tests
a.

When mechanical peel tests are used the percentage bond for any joint is to be
not less than stated in TABLE 6.2. Where the percentage area examined falls
between the figures listed in the table, use the acceptance standard for the next
lower figure of percentage area examined.
g Area Examined
Percentage
%
50

Minimum Average
g Bond
%
80

40

90

30 or less

100

TABLE 6.2 MINIMUM ACCEPTANCE STANDARDS FOR PERCENTAGE BOND IN

PEEL TESTS
b.

When peel tests are carried out by machining, the percentage bond for any joint
is to be not less than 70%.
6.2

NES 743
Part 5
Issue 1 (Reformatted)

6.8.4

Tensile Tests
a.

If the failure occurs in the brazing alloy, the stress in the pipe at failure is to be
not less than the minimum ultimate tensile stress for the annealed pipe.

b.

If the pipe or fitting fractures then the stress in the fractured material at failure
is to be not less than 90% of the minimum ultimate tensile stress for annealed
material.

6.3

NES 743
Part 5
Issue 1 (Reformatted)

6.4

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX A.
RELATED DOCUMENTS
A.1

Reference is made to:

Referred to in
Clause, Fig and
Annex
BS 499

Welding terms and symbols

Pt 1 Glossary for welding, brazing and
thermal cutting

Annex B.

BS 1845

Filler metals for brazing

BS 2874

Copper and copper alloys, rods and

sections (other than forging stock)

Annexes D.
and G.
Annex C.

BS 3072

Nickel and nickel alloys: sheet and plate

Annex C.

BS 3073

Nickel and nickel alloy: strip

Annex C.

BS 3074

Nickel and nickel alloy: seamless tube

Annex C.

BS 3075

Nickel and nickel alloy: wire

Annex C.

BS 3076

Nickel and nickel alloy: bar

Annex C.

NES 341

Requirements for the Cleaning of Items

Components and Equipment for Fluid
Systems

4.19a.

NES 729

Requirements for Non-Destructive

Examination Methods
Requirements for
AluminiumNickelSilica Brass
Pt 3: Tubes

5.1a., 5.3.2a.,
5.6.2a.
Annex C.,
Annex E.

NES 779

Requirements for 90/10 CopperNickel

Alloy Material
Pt 3: Tubes

Annex C.,
Annex E.

NES 780

Requirements for 70/30 CopperNickel

Alloy Material
Pt 3: Tubes

Annex C.,
Annex E.

BR 3013

Admiralty Pipework Standard

FIGURE 2.3

DPT 1306

Nuclear Submarines Acceptance

6.5.1a., 6.8.2a.
(Specification Issue 2 1974) Standards for
The Ultrasonic Inspection of Brazed
Joints

NES 749

A.1

ANNEX A.

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX A.

A.2

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX B.
ABBREVIATIONS AND DEFINITIONS
B.1

Brazing nomenclature and definitions are to conform generally to BS 499, Part 1 with
the additions below.

B.2

For the purpose of this NES the following additional abbreviations and definitions
apply:
ADQA/IND

Assistant Director Quality Assurance/Industry;

Approval

Written approval from the QAR or other authorized

MOD local representative acting on behalf of and in
consultation with the Design Authority;

Approved

Having written approval;

Brazer

An individual who is producing brazed joints;

Brazing Procedure

A written instruction containing the essential

information for brazing to this standard;
The phenomenon which causes molten brazing alloy to
be drawn along the gap between the faying surfaces;

Capillary Flow
Clearance
Consumables

The radial gap between pipe and fitting when located

concentrically;
Brazing alloy and flux;

Design Authority

The section within MOD(PE) Sea Systems Controllerate

which carries overall responsibility for the system
concerned;

Design Temperature

The maximum temperature for which the piping system

is designed, which is not to be exceeded;
A fitting designed so that the pipe is inserted into a
socket in the fitting and brazed into place;

External Fitting
Face Feeding
Faying Surfaces
Filleting

Manual addition of brazing alloy at the intersection of

fitting and pipe;
Machined surfaces of fitting that will form the capillary
joint with the pipe;
Addition of brazing alloy at the intersection of fitting
and pipe after the initial brazing operation to ensure
that a fillet of alloy is present around the inter-section;

Fitting

A pressure-containing component of a piping system

such as a tee, elbow etc or a valve, flange, strainer, sleeve
etc;

Insert Rings

Rings of brazing alloy for insertion, before assembly of

the joint, into a groove prepared in the fitting wall
adjacent to the faying surfaces;

Internal Fitting

A fitting designed to be inserted into the pipe bore and

brazed into place;
See System Levels;

Level
Organization
Peel Test

The Contractor or responsible Authority at the site

where brazing to this standard is to be carried out;
A destructive test to allow a visual assessment of the
bonded area in a joint;

B.1

ANNEX B.

NES 743
Part 5
Issue 1 (Reformatted)

Priming

Manual addition of a small amount of flux at the

intersection of fitting and pipe to help break surface
tension and promote alloy flow from the insert ring;

Qualified

Approved as required by this standard;

QAR

The MOD local Quality Assurance Representative or

other authorized MOD representative usually
ADQA/IND;

Repairing

Reheating the joint to melt the brazing alloy in order to

seal leaks, improve percentage bond or correct
alignment. Includes supplementary face feeding where
required;

Special Fittings

These fittings have an undesirable profile and require an

alternative U/T examination and % bond acceptance
standard. Examples being hexagon and two land joints
where only one land joint is accessible;

Supplementary Face
Feeding

Addition of brazing alloy at the intersection of fitting

and pipe after the initial brazing operation. Usually used
with insert rings;

System Levels:
Level 1

Level 2

A system in which failure of brazed joints could lead to

severe but controllable flooding, serious disruption of
weapon systems, main propulsion machinery or
important auxiliaries;

Level 3

A system in which failure of brazed joints does not

constitute an immediate significant hazard;
A system in which failure of brazed joints does not
constitute a hazard.

Level 4

ANNEX B.

A system in which failure of brazed joints could lead to

uncontrollable flooding, immobilization of the vessel or
serious hazard to personnel;

B.2

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX C.
MATERIALS FOR WHICH DATA IS INCLUDED IN THE ANNEXES
C.1

The following materials are covered by data included in these Annexes:

Material (see Note 4)

Specification or Standard

Copper

0.0000195 (1)

70/30 CuNi

NES 780 Part 3

0.00001 (2)

90/10 CuNi

NES 779 Part 3

0.0000171 (2)

NiCu

BS 3072 to 3076NA 13

0.0000168 (1)

AlNiSi Brass

NES 749 Part 3

0.0000195 (1)

Al Brass

0.0000185 (2)

AlSi Bronze

0.0000194 (1)

Phosphor Bronze

BS 2874PB102

0.0000180 (2)

Naval Brass

0.0000212 (2)

Gunmetel (88/10/2)
Notes
1.
2.
3.
4.

Coefficient of Linear Thermal

Expansion
mm per mm per C

0.0000182(2)

Average coefficient over range 0700 C or 01300 F

Average coefficient over range 0300 C
Unqualified data. Temperature range not known
Cu = Copper
Al = Aluminium
Ni = Nickel
Si = Silicon
TABLE C.1 MATERIAL COVERED IN THE ANNEXES

C.2

Clearances in Annex F. TABLE F.1, TABLE F.2 and Annex G. TABLE G.2 are based
on the coefficients of expansion quoted in TABLE C.1. Coefficients covered by Note 1
in the table may be regarded as reliable and the clearances listed in later tables may
be used without reservation. Clearances not based on coefficients covered by Note 1
are to be checked by qualification of the procedure before use in production. The
qualification is to include at least one test piece with clearances at the upper limit of
the proposed range and at least one test piece with clearances at the lower limit of the
proposed range.

C.3

Other materials may be acceptable but the correct data is to be determined for each
material before use. Each proposed procedure is to be qualified, including the
requirements laid down earlier in this Annex.

C.1

ANNEX C.

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX C.

C.2

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX D.
FLUXES AND BRAZING ALLOYS
D.1

TABLE D.1 and TABLE D.2 list brazing alloys and fluxes approved for use with the
material combinations shown. (Material combinations including AlNiSi Brass are
covered in Annex G.).

D.2

Orders for the purchase of brazing alloys are to specify that the composition and
supply are to be in accordance with BS 1845 unless otherwise approved by the Design
Authority.

D.3

For plating of fittings, see Annex G.

Material Combination
Pipe

Copper
or
70/30
Cupro-Nickel

Working Range
C

Flux Type

Manufacturer

70/30
Cupro-Nickel
or
90/10
Cupro-Nickel
or
Nickel-Copper

Easy-flo
Flux Powder

Johnson Matthey
Metals Ltd

550800

or
Easy-flo
Flux Paste
or

Johnson Matthey
Metals Ltd

500800

Phosphor Bronze
or
Gunmetal
or
Naval Brass
or
Copper

Tenacity No 6

Johnson Matthey
Metals Ltd

500800

Thessco Ltd

530750

E Flux
or
ALP 3 Flux
or
Ultra Flux

Engelhard Ltd

550820

Engelhard Ltd

500840

Engelhard Ltd

500820

Easy-flo FluxAluminium
Bronze Grade

Johnson Matthey
Metals Ltd

500800

Fitting

or
90/10
Cupro-Nickel

or
Type Y Flux
or

Aluminium Brass

Note:

or
Thessco Ltd
550800
ABl Flux
or
Engelhard Ltd
550800
Aluminium
Bronze Flux
The fluxes listed above have a guaranteed useful life of only five minutes at
temperatures between 600 C and 700 C and a shorter garanteed life at higher
temperatures. For high temperatures (up to 1204 C) brazing use Black Flux supplied
by Engelhard Ltd.
TABLE D.1 FLUXES
D.1

ANNEX D.

NES 743
Part 5
Issue 1 (Reformatted)

Material Combination
Pipe

Copper
or
70/30
Cupro-Nickel
or
90/10
Cupro-Nickel

Fitting
70/30
Cupro-Nickel
or
90/10
Cupro-Nickel
or
Nickel-Copper
or
Phosphor
Bronze
or
Gunmetal
or
Naval Brass
or
Copper
or
Aluminium
Brass

Manufacturer

Silverflo 55

Johnson
Matthey Metals
Ltd

630
660

Thessco Ltd

630
660

Specification

BS 1845AG 14

or
BS 1845AG 14
Grade M25T
or

BS 1845AG 14

Silvaloy 5509

Engelhard Ltd

TABLE D.2 BRAZING ALLOYS

ANNEX D.

Melting
Range
C

Brazing Alloy

D.2

630
660

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX E.
HEAT TREATMENT
E.1

Fittings
Before brazing, all wrought fittings are to be fully annealed and cast fittings are to
be stress relieved. When necessary, heat treatment is to be carried out as indicated in
TABLE E.1.

E.2

Tubing
Before Brazing
Cupro-Nickel tubing is to be delivered in the fully annealed condition (Reference NES
779 Part 3 for 90/10 CuNi and NES 780 Part 3 for 70/30 CuNi).
AlNiSi Brass Tubing is to be delivered in the solution treated and precipitation
hardened condition (Reference NES 749 Part 3).
After Brazing
After brazing AlNiSi Brass tubing, a post-braze heat treatment (PBHT) is to be
carried out by raising the temperature of the relevant area to 500 C 25 C for one
hour followed by slow cooling in still air. PBHT can be accomplished either by local
heat treatment for example by using resistance or induction equipment or by heat
treatment in a furnace. Although PBHT of the complete pipe length will not have an
adverse effect on the pipe material, it is necessary to heat treat the pipe only up to
300mm from the braze.
Furnace Treatment
Where heat treatment is carried out in a furnace, the sulphur content of the
atmosphere is not to exceed 0.23g per cubic metre.
Preferred
Hardness after
Treatment

Soak
Temperature
C

Soak Time

8595 HV
105 max

800850

10 mins

140 HV max

870980

10 mins

Phosphor
Bronze

585 HV

500700

10 mins

Gunmetal

350

30 mins

Phosphor
Bronze

350

30 mins

AlSi Bronze

500

30 mins

Materials
70/30 CuNi
90/10 CuNi
Wrought
materials to be
Nickel-Copper
annealed

Cast materials
to be stress
relieved

Notes:
1.
Heat slowly and uniformly to the stated temperature.
2.
Cool slowly in still air to below 250 C. Below 250 C water quenching may
be used to accelerate cooling.
TABLE E.1 HEAT TREATMENT OF FITTINGS
E.1

ANNEX E.

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX E.

E.2

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX F.
CLEARANCES FOR CAPILLARY BRAZED JOINTS
(excluding material combinations with AlNiSi Brass which are covered in Annex G.)

F.1

The radial clearance at room temperature between a round pipe and a fitting is to be
within the limits specified in TABLE F.1 and TABLE F.2.

F.2

The cold clearances listed in the tables are calculated to produce, at the brazing
temperature, radial clearances of 0.05 to 0.13mmthe limits specified by the
manufacturersfor the brazing alloys listed in Annex D. The calculated clearances
are based on the coefficients of expansion listed in Annex C. Where these coefficients
are not average coefficients over 0 to 700 C or 0 to 1300 F the proposed clearances
are to be checked by qualification of the procedure before use in production. The
qualification is to include at least one test piece with clearances at the upper limit of
the proposed range of clearances and at least one test piece with clearances at the
lower limit of the proposed range.

F.3

Before using brazing alloys other than those listed in Annex D., the clearance required
at the brazing temperature is to be checked. Where this clearance or the brazing
temperature, differs from that specified for the alloys listed in Annex D., the cold
clearances are to be calculated and proved by qualification of the proposed procedure,
including the additional check for each end of the proposed range of clearances as
specified above.

F.4

When the pipe and fitting are of the same material, the clearance will remain constant
from room temperature to brazing temperature as long as there is no temperature
difference between the fitting and the pipe.

F.5

Where the minimum clearance shown in the tables is negligible or 0.00, the pipe is
to be enlarged so that it can be assembled to the fitting cold without hammering and
without undue force.

F.6

For the calculations, room temperature has been taken as 15 C.

F.1

ANNEX F.

NES 743
Part 5
Issue 1 (Reformatted)
Cold clearances (Radial)
Outer
Material
Pipe

Inner
Material
Fitting

Pipes
Above 20
up to 40
ID

Pipes
Above 40
up to 60
ID

Pipes
Above 60
up to 80
ID

Pipes
Above 80
up to 100
ID

Cupro-Nickel* 0.05 to
70/30
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

Cupro-Nickel* 0.05 to
90/10
0.13

0.06 to
0.13

0.06 to
0.13

0.06 to
0.14

0.07 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.06 to
0.13

0.06 to
0.13

0.07 to
0.14

0.08 to
0.16

0.09 to
0.17

0.10 to
0.18

Phosphor*
Bronze

0.05 to
0.13

0.06 to
0.14

0.07 to
0.15

0.08 to
0.16

0.09 to
0.17

Gunmetal*

0.06 to
0.13

0.07 to
0.14

0.08 to
0.15

0.09 to
0.16

0.10 to
0.17

Cupro-Nickel* 0.05 to
70/30
0.13

0.05 to
0.13

0.05 to
0.12

0.04 to
0.12

0.04 to
0.12

Cupro-Nickel* 0.05 to
90/10
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

Nickel-Copper 0.05 to
0.13
Cupro Nickel*
Nickel
90/10
Aluminium*
0.05 to
Brass
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.12

0.04 to
0.12

0.06 to
0.14

0.07 to
0.15

0.08 to
0.16

0.09 to
0.17

Nickel Copper
Cupro Nickel*
Nickel
70/30
Aluminium*
Brass

Copper

Pipes Up
to 20 ID

Phosphor*
Bronze

0.05 to
0.13

0.06 to
0.13

0.06 to
0.14

0.07 to
0.15

0.08 to
0.15

Gunmetal*

0.05 to
0.13

0.06 to
0.14

0.07 to
0.14

0.07 to
0.15

0.08 to
0.16

Naval Brass*

0.06 to
0.13

0.07 to
0.14

0.08 to
0.15

0.09 to
0.16

0.10 to
0.17

Cupro-Nickel* 0.04 to
70/30
0.12

0.03 to
0.10

0.01 to
0.08

0.00 to
0.07

0.00 to
0.05

Cupro-Nickel* 0.04 to
90/10
0.12

0.03 to
0.11

0.02 to
0.09

0.00 to
0.08

0.00 to
0.06

Nickel Copper

0.04 to
0.12

0.03 to
0.10

0.02 to
0.09

0.00 to
0.07

0.00 to
0.05

Aluminium*
Brass

0.06 to
0.13

0.04 to
0.12

0.04 to
0.11

0.03 to
0.11

0.02 to
0.10

Phosphor*
Bronze

0.05 to
0.12

0.04 to
0.12

0.03 to
0.11

0.02 to
0.10

0.01 to
0.09

Gunmetal*

0.05 to
0.13

0.04 to
0.12

0.03 to
0.11

0.02 to
0.10

0.02 to
0.09

Copper

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

* See Annex C. before using data

Dimensions in mm

TABLE F.1 RADIAL CLEARANCES AT ROOM TEMPERATURE FOR PIPES USED

WITH INTERNAL FITTINGS

ANNEX F.

F.2

NES 743
Part 5
Issue 1 (Reformatted)
Cold clearances (Radial)
Outer
Material
Pipe

Inner
Material
Fitting

Pipes
Above 20
up to 40
ID

Pipes
Above 40
up to 60
ID

Pipes
Above 60
up to 80
ID

Pipes
Above 80
up to 100
ID

Cupro-Nickel* 0.05 to
70/30
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

Cupro-Nickel* 0.03 to
90/10
0.13

0.05 to
0.13

0.05 to
0.12

0.04 to
0.12

0.04 to
0.12

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.12

0.03 to
0.11

0.02 to
0.10

0.01 to
0.09

0.00 to
0.08

Phosphor*
Bronze

0.06 to
0.13

0.05 to
0.12

0.03 to
0.11

0.02 to
0.10

0.01 to
0.09

Gunmetal*

0.06 to
0.13

0.05 to
0.12

0.04 to
0.11

0.03 to
0.10

0.02 to
0.09

Cupro-Nickel* 0.05 to
70/30
0.13

0.06 to
0.13

0.06 to
0.13

0.06 to
0.14

0.07 to
0.14

Cupro-Nickel* 0.05 to
90/10
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

Nickel Copper

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.06 to
0.13

0.06 to
0.14

0.06 to
0.13

0.05 to
0.12

0.03 to
0.11

0.02 to
0.10

0.01 to
0.09

Phosphor*
Bronze

0.05 to
0.13

0.04 to
0.12

0.04 to
0.12

0.03 to
0.11

0.03 to
0.10

Gunmetal*

0.05 to
0.13

0.04 to
0.12

0.03 to
0.11

0.03 to
0.11

0.02 to
0.10

Naval Brass*

0.05 to
0.13

0.04 to
0.11

0.03 to
0.10

0.01 to
0.09

0.00 to
0.08

Cupro-Nickel* 0.06 to
70/30
0.14

0.08 to
0.15

0.10 to
0.17

0.11 to
0.19

0.13 to
0.21

Cupro-Nickel* 0.06 to
90/10
0.14

0.07 to
0.15

0.09 to
0.16

0.10 to
0.18

0.12 to
0.19

Nickel Copper

0.06 to
0.14

0.07 to
0.15

0.09 to
0.17

0.11 to
0.19

0.13 to
0.20

Aluminium*
Brass

0.05 to
0.13

0.06 to
0.14

0.07 to
0.14

0.07 to
0.15

0.08 to
0.16

Phosphor*
Bronze

0.05 to
0.13

0.06 to
0.14

0.07 to
0.15

0.08 to
0.16

0.09 to
0.17

Gunmetal*

0.05 to
0.13

0.06 to
0.14

0.07 to
0.15

0.08 to
0.16

0.09 to
0.16

Copper

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

0.05 to
0.13

Nickel Copper
Cupro Nickel*
Nickel
70/30
Aluminium*
Brass

Cupro Nickel*
Nickel
90/10
Aluminium*
Brass

Copper

Pipes Up
to 20 ID

* See Annex C. before using data

Dimensions in mm

TABLE F.2 RADIAL CLEARANCES AT ROOM TEMPERATURE FOR PIPES USED

WITH EXTERNAL FITTINGS

F.3

ANNEX F.

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX F.

F.4

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX G.
CONSUMABLES AND CLEARANCES FOR ALUMINIUM NICKEL SILICON BRASS
(AlNiSi BRASS) PIPING USED WITH ALUMINIUM SILICON BRONZE (AlSi
BRONZE) FITTINGS
G.1

Consumables are listed in TABLE G.1. Although those listed provide acceptable
mechanical properties for pipe joints, at the time of preparation of this NES they have
not been fully evaluated for long term corrosion resistance.

G.2

The radial clearance at room temperature between a round pipe and a fitting is to be
within the limits specified in TABLE G.2.

G.3

The cold clearances listed in the tables are calculated to produce, at the brazing
temperature, radial clearances of 0.05 to 0.13mmthe limits specified by the
manufacturers, for the brazing alloys listed in TABLE G.1. The calculated clearances
are based on the coefficients of expansion listed in Annex C.
Before using brazing alloys other than those listed in TABLE G.1, the clearance
required at the brazing temperature is to be checked. The same clearance will be
required at room temperature.

G.4

For these calculations, room temperature has been taken as 15 C.

Plating of Fittings

G.5

The faying surfaces of fittings may be copper plated to provide a barrier layer to
facilitate brazing to AlNiSi brass pipe.

G.6

In some literature a plating thickness of 0.005mm is recommended. A plating

thickness of 0.05mm on AlSi bronze fittings has been used successfully and this has
allowed the use of general purpose fluxes such as Thesscos Y flux paste, Johnson
Mattheys Easy-flo Flux Powder and Engelhards E flux, in conjunction with
brazing alloy to BS 1845AG14

G.1

ANNEX G.

NES 743
Part 5
Issue 1 (Reformatted)

Consumable

Manufacturer

Melting Range
C

BS 1845
Classification
Cl
ifi ti

Flux

Brazing Alloy

ABI

Thessco Ltd

550800

Easy-flo Flux,
Aluminium
Bronze Grade

Johnson
Matthey
Metals Ltd

550800

Aluminium
Bronze Flux

Englehard Ltd

550800

Silvaloy 550 S

Englehard Ltd

630660

AG 14

Silvaloy 420 Z

Englehard Ltd

690770

AG 5

M25T

Thessco Ltd

630660

AG 14

M13

Thessco Ltd

700775

AG 5

Silvaflo 55

Johnson
Matthey
Metals Ltd

630660

AG 14

Silvaflo 60

Johnson
Matthey
Metals Ltd

695730

AG 13

Silverflo 43

Johnson
Matthey
Metals Ltd

698778

AG 5

Note:

The brazing alloys and fluxes listed above provide acceptable

mechanical properties for pipe joints but long term corrosion resistance
etc have not been fully evaluated at the time of preparation of this NES

TABLE G.1 BRAZING ALLOYS AND FLUXES FOR USE WITH AlSi BRONZE
FITTINGS AND AlNiSi BRASS PIPES
Brazing Alloy
M25T
M13
Silverflo 55
Silverflo 60
1845AG5

Radial Cold Clearance between AlNiSi Brass Pipe

and AlSi Bronze Fittings
0.05 to
0.12
Because the difference in the coefficient
0.05 to
of thermal linear expansion for the two
0.20
materials
t i l (Al
(AlNiSi
Ni Si B
Brass/AlSi
/Al Si
0.05 to
Bronze)
is
insignificant,
the
cold
0.13
clearances required are the same as the
0.07 to
hot clearances specified by the
0.12
manufacturer of the brazing alloy.
0.10 to
0.20
Dimensions in mm

TABLE G.2 CLEARANCES (RADIAL) AT ROOM TEMPERATURE (AlNiSi BRASS

PIPING WITH AlSi BRONZE FITTINGS)

ANNEX G.

G.2

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX H.
HEALTH PROTECTION AND SAFETY PRECAUTIONS
H.1

When heated, brazing alloys containing cadmium, and cadmium plating on base
metals, may give rise to cadmium oxide fume, the inhalation of which can result in
acutely harmful effects.

H.2

Cadmium plating is to be removed from surfaces wherever possible before the

application of heat.

H.3

Only cadmium-free brazing alloys are to be used and are to be selected from the list
approved by MOD(PE) in Annexes D. and G.

H.4

All operations on cadmium plated items are to be undertaken with effective local
exhaust ventilation adjacent to the joint being brazed. Exhausted air is to be filtered
so that the concentration of cadmium at outlets within enclosed work areas is less
than 0.005 milligrams per cubic metre of exhausted air. Where these conditions
cannot be met, respiratory protection, as detailed in Paragraph H.5, is to be worn.
After completion of work processes the residual fume is to be exhausted to
atmosphere.

H.5

Appropriate respiratory protection is:

a.

for use in non-confined working areasRespirator VHE twin Vocab No 26928

fitted with cartridge filters FC6 Vocab No 26938;

b.

for use in confined areasRespirator mask airline Vocab No 26339.

H.6

Where acetone or alcohol is used for cleaning, operators hands are to be protected
with rubber gloves.

H.7

Chlorinated hydrocarbon type solvents, (eg 1,1,1trichloroethane) produce toxic

gases on contact with heated surfaces and are not to be used for cleaning.

H.8

In each brazing procedure, attention is to be drawn to the conditions likely to produce

health hazards during brazing operations.

H.1

ANNEX H.

NES 743
Part 5
Issue 1 (Reformatted)

ANNEX H.

H.2

NES 743
Part 5
Issue 1 (Reformatted)

ALPHABETICAL INDEX

A
Acceptance Standards
destructive tests, 6.2
non-destructive tests, 6.1
special fittings, 6.1
Access, 2.1
restricted, 3.3, 3.6, 3.8
Alloy rings, 4.1
Aluminium brass, C.1, F.1
Aluminiumnickelsilicon brass, 4.7, 5.4, C.1, E.1, G.1
Aluminiumsilicon bronze, C.1, E.1
Annealing, 4.1, E.1
Assembly, 4.4
Automatic brazing, 5.4
equipment qualification, 3.1, 3.3, 3.6

B
Bond, 6.1
Bond assessment, 5.5
Brazer, B.1
qualification, 3.1, 3.3, 3.4, 3.6
Brazing alloy, 2.5, 3.1, 3.2, 4.1, D.1, D.2, G.1, G.2
Brazing position, 3.2, 3.5, 3.6, 3.7, C.1
Brazing procedure, 4.7, 5.2
changes, 3.3, 4.7
information, 3.2, 3.3, 4.7
qualification, 2.5, 3.1, 3.3, 3.4, 3.5
requalification, 3.4
Brazing process, 3.2, 4.1
Brazing rods, 4.3

C
Capillary flow, 5.4, 6.1, 6.2, B.1
Cleaning, 3.2, 4.3, 4.6
Clearances, 2.1, 3.2, 3.3, 4.2, 5.1, 5.3, B.1, F.1, G.1
Coefficient of linear thermal expansion, C.1, F.1, G.1
Consumables, 3.3, B.1, G.1
Cooling, 3.2, 4.6, E.1
Copper, C.1, F.1
Crack detection, 5.1, 5.5
Cupro-nickel, 4.7, 5.4, C.1, E.1

INDEX.1

INDEX

NES 743
Part 5
Issue 1 (Reformatted)

D
Definitions, B.1
Design Authority, B.1
Design temperature, iii, B.1
Drawings, 1.1, 2.1, 2.5, 4.7, 5.3, 6.1
Dye penetrant examinations, 5.1, 5.4, 6.1, 6.2

E
Enlargement, 2.5, 4.2
Examination
during brazing, 5.2, 5.4
of brazed joints, 4.6, 5.3, 5.4
of qualification test pieces, 3.9, 5.4
of repairs, 4.7, 5.3
of used fittings, 4.7, 5.4
of used pipe, 4.7, 5.4
pre-braze, 5.1
Expansion, coefficient of thermal, C.1, F.1, G.1
Extent of qualification, 3.5, 3.6, 5.6

F
Face Feeding, 2.1, 2.3, 3.2, 3.6, 4.1, 4.5, 4.7, 5.4, 6.1, B.1
Faying surfaces, 2.1, 2.5, 3.2, 4.3, 5.1, 6.1, B.1
Filleting fillets, 3.6, 4.5, 6.1, B.1
Fitting, 4.1, B.1
external, B.1, F.1
internal, B.1, F.1
preparation, 4.1
Flanges, 2.1, 2.4, 4.1
Flux, 2.5, 3.1, 3.2, 4.1, 4.3, 4.5, D.1, G.1
Furnace atmosphere, E.1
Furnace treatment, E.1

G
Gas, 3.2, 3.3, 4.5, 5.2
Gravity joint, 4.2
Gunmetal, C.1, E.1, F.1

H
Hand grinding, 4.7
Health protection, H.1
Heat treatment, 2.5, 3.9, 4.6, 4.7, E.1
Heating, 3.2, 4.5, E.1
Hydraulic Testing, 5.6

INDEX

INDEX.2

NES 743
Part 5
Issue 1 (Reformatted)

I
Insert ring, 2.1, 3.2, 4.1, 4.3, 4.7, 5.2, 5.4, 6.1, B.1
Insert ring groove, 4.3, 4.7, 6.2
Inspection
during brazing, 5.2, 5.4
of brazed joints, 4.6, 5.3, 5.4
of qualification test pieces, 3.6, 5.4, 6.2
of repairs, 4.7, 5.3
of used fittings, 4.7, 5.4
of used pipe, 4.7, 5.4
pre-braze, 5.1, 6.1
Internal fitting, B.1, F.1

J
Joint design, 2.1, 3.2

L
Level of system, 2.1, 5.1, B.1
Linear thermal expansion coefficient, C.1

M
Marking of joints, 4.4, 4.6, 4.7, 5.4
Materials , C.1

N
Naval brass , C.1, F.1
NickelCopper , C.1, F.1
Nitrogen purge, 4.3, 4.5
Non-destructive examinations, 5.1, 6.1

O
Organization, 1.1, 3.1, 3.3, 3.4, B.1

P
Peel tests, 3.5, 5.5, 5.7, 6.2, B.1
Personnel, 3.1, 3.3, 3.6
Phosphor bronze, C.1, E.1, F.2
Pipe supports, 4.4
Plating of fittings, 4.1, 4.3, G.1
Preheating, 4.5
Preparation
of fittings, 4.1
of pipe, 4.2
Priming, 4.5, B.1
Procedure
changes, 3.3
information, 3.2
qualification, 2.5, 3.1, 3.3, 3.4, 3.5, 5.6
Production, 1.1
Purge nitrogen, 4.3, 4.5

INDEX.3

INDEX

NES 743
Part 5
Issue 1 (Reformatted)

Q
Qualification
approval, 3.4
cover, 3.5
exemption, 3.1
for restricted access, 3.3, 3.6, 3.8
of automatic brazing equipment, 3.6
of personnel, 3.6
of procedures, 2.5, 3.1, 3.3, 3.4, 3.5, 5.6
test pieces, 3.5, 3.6, 3.7, 3.9, 5.4, 5.5, 5.6, 6.2, 6.3
test requirements, 3.6
Qualified, B.1

R
Radiographic examination, 5.3
Reactor plant, iii
Records, 3.4, 3.5, 4.7
Reference marks, 3.2, 3.3, 4.4, 4.7, 5.1, 5.3
Repair of joints, 4.6, 4.7
Repairing, B.1
Requalification, 3.4
Responsibilities, 1.1, 3.4, 3.5
Restricted access, 3.3, 3.8
Retest, 3.6
Reuse of fittings, 4.7, 5.4, 6.2
Reuse of pipes, 4.7, 5.4
Room temperature, F.1, G.1

S
Safety precautions, 3.2, H.1
Sleeve type fittings, 2.1, 2.2, 2.3, 4.1, 4.4, 5.3
Socket type fittings, 2.1, 2.2, 4.1, 4.4, 5.3
Special fittings, 6.1, 6.2
Stress relief, 4.1, E.1
Supplementary face feeding, 3.6, 4.5, 5.4, 6.1, B.1
Surface finish, 2.5
System level, 2.1, 5.1, B.1

T
Tacking, 4.5
Temperature measurement, 4.5
Tensile tests, 5.6, 5.7, 5.8, 6.3
Test pieces, 3.5, 3.6, 3.7, 3.9
destructive tests, 5.5, 6.2
non-destructive examinations, 5.4, 5.5, 5.6, 6.2
Test specimens, 3.5, 5.5, 5.6, 5.7
Thermal expansion coefficient of, C.1

INDEX

INDEX.4

NES 743
Part 5
Issue 1 (Reformatted)

U
Ultrasonic examination, 5.1
design for, 2.5
limits, 2.5
of brazed joints, 5.3, 5.4, 5.5, 6.1, 6.2
of fittings before brazing, 2.5, 4.1, 5.1
of qualification test pieces, 5.4, 5.5, 6.2
of special fittings, 6.1, 6.2
Used fittings salvaged for re-use, 4.7, 5.4, 6.2
Used pipe salvaged for re-use, 4.7, 5.4

V
Valves, 4.4
Visual examination, 5.3, 5.4, 6.2

INDEX.5

INDEX

NES 743
Part 5
Issue 1 (Reformatted)

INDEX

INDEX.6

Inside Rear Cover

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