DEF - STAN 02-772 Iss.2

Defence Standard 02-772
Issue 2 Date: 14/11/2020

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Welding and Fabrication of Pipework,
Machinery and Engineering
Components for HM Submarines and
Surface Ships not in Class
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This Page Intentionally Left Blank
DEF STAN 02-772 Issue 2
Section 1
Foreword
Defence Standard Structure
Section 1 (Generated by the StanMIS toolset)
• Revision Note
• Historical Record
• Warning
• Standard Clauses
Section 2 (Technical information provided by Subject Matter Expert)
• Title
• Introduction (optional)
• Table of Contents
• Scope
• Technical Information to include Tables and Figures
• Annexes (as required)
Section 3 (Generated by StanMIS toolset)
• Normative References
• Definitions
• Abbreviation
REVISION NOTE
This revised standard specifies the minimum requirements for the welding and fabrication of pipework,
machinery and engineering components for HM Submarines and Surface Ships not in Class
HISTORICAL RECORD
This standard supersedes the following:
Def Stan 02-772 Issue 1dated 7th September 2007
WARNING
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work. Many Defence Standards set out processes and procedures that could
be injurious to health if adequate precautions are not taken. Adherence to those processes and procedures in
no way absolves users from complying with legal requirements relating to Health and Safety at Work.
STANDARD CLAUSES
a) This standard has been published on behalf of the Ministry of Defence (MOD) by UK Defence
Standardization (DStan).
b) This standard has been reached following broad consensus amongst the authorities concerned with its
use and is intended to be used whenever relevant in all future designs, contracts, orders etc. and whenever
practicable by amendment to those already in existence. If any difficulty arises which prevents application
of the Defence Standard, DStan shall be informed so that a remedy may be sought.
c) Please address any enquiries regarding the use of this standard in relation to an invitation to tender or to
a contract in which it is incorporated, to the responsible technical or supervising authority named in the
invitation to tender or contract.
d) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations
imposed upon them.
e) This standard has been devised solely for the use of the MOD and its contractors in the execution of
contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all liability whatsoever
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and howsoever arising (including, but without limitation, liability resulting from negligence) for any loss or
damage however caused when the standard is used for any other purpose.
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Def Stan 02-772 Issue 2
Section 2
Title: Def Stan 02-772
Welding and Fabrication of Pipework, Machinery and Engineering Components for

HM Submarines and Surface Ships not in Class
Contents
1 Scope 2-4
2 Quality 2-4
3 General 2-4
4 Materials 2-4
5 Preparation of Work to be Welded 2-5
6 Cleanliness 2-5
7 Thermal Treatment 2-5
8 Equipment and Facilities 2-5
9 Welding Requirements 2-6
9.1 General 2-6
9.2 Preparation of Base Material 2-6
9.3 Assembly Alignment 2-7
9.4 Control of Distortion 2-7
9.5 Root Pass Welding and Backing 2-7
9.6 Purging 2-8
9.7 Welding Practice 2-8
9.8 Consumable Control 2-9
9.9 Post Weld Heat Treatment 2-9
9.10 Defect Removal 2-10
9.11 Repair Welding 2-10
9.12 Identification and Marking 2-11
9.13 Test Pieces for Pressure Vessels 2-11
9.14 Cladding 2-12
10 Qualification 2-12
10.1 General 2-12
10.2 Qualification of Welding Procedures 2-12
10.3 Qualification of Welders 2-13
10.4 Restricted Access 2-13
10.5 Sleeve and Socket Welds 2-13
10.6 Mechanised/Semi-Automatic and Automatic Welds 2-13
10.7 Supplementary Requirements 2-13
11 Inspection Requirements 2-14
11.1 Scope 2-14
11.2 General 2-14
11.3 Interstage Inspection 2-14
11.4 Visual Inspection 2-14
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11.5 Liquid Penetrant or Magnetic Particle Inspection 2-14
11.6 Radiographic Inspection 2-14
11.7 Ultrasonic Inspection 2-15
11.8 Leak Test Examination 2-15
11.9 Cladding 2-15
12 Acceptable Welded Joint Designs 2-15
12.1 Scope 2-15
12.2 General Requirements 2-15
12.3 Holes in Welded Structures 2-16
12.4 Branch Welds 2-16
12.5 Sleeve and Socket Joints 2-16
12.6 Bulkhead Penetration Passing Pipes and Seal End Connectors 2-16
12.7 Pipe Flanges 2-17
12.8 Design Limitations 2-17
12.9 Proximity of Welds 2-17
12.10 Welding on Bends 2-17
13 Pipe Sleeve and Socket Welds 2-17
13.1 General 2-17
13.2 Acceptable Welded Joint Designs 2-18
13.3 Qualification Requirements 2-18
13.4 Weld Procedure Test Assemblies 2-18
13.5 Welder Qualification Test Pieces 2-18
13.6 Examination of Sleeve and Socket Welded Joints 2-19
13.7 Retests 2-19
13.8 Confirmation and Revalidation of Qualification of Welders 2-19
14 Corporate Experience and Knowledge 2-19
14.1 Relaxation of Sleeve & Socket Weld Radiography Requirement 2-19
Tables
Table 1 - Weld Bead Diameter Maximum............................................................................................. 2-8
Figures
Figure 1 - Restricted Access Conditions .............................................................................................. 2-20
Figure 2 - Restricted Access Conditions .............................................................................................. 2-21
Figure 3 - Face and Fillet Welded Flange up to and Including 20 mm Thick ....................................... 2-21
Figure 4 - Face and Back Welded Flange above 20 mm Thick ........................................................... 2-22
Figure 5 - Face and Back Fillet Welded Flange ................................................................................... 2-22
Figure 6 - Matching of Welding Ends ................................................................................................... 2-23
Figure 7 - Welding Without Temporary Backing of Right Angled Set-On Branches ............................ 2-24
Figure 8 - Welding Without Temporary Backing of Sloping Set-On Branches ..................................... 2-25
Figure 9 - Welding With Temporary Backing of Right Angles Set-On Branches ................................. 2-26
Figure 10 - Welding With Temporary Backing of Sloping Set-On Branches ........................................ 2-27
Figure 11 - Branch Connection - Pintle Type ....................................................................................... 2-28
Figure 12 - Branch Connection Fillet Leg Lengths for Pintle Welds ..................................................... 2-29
Figure 13 - Branch Connection - Sleeve Type ..................................................................................... 2-30
Figure 14 - Branch Connection - Without Compensation ..................................................................... 2-31
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Figure 15 - Branch Connection - With Compensation .......................................................................... 2-32
Figure 16 - Permissible Types of Backing Ring ................................................................................... 2-33
Figure 17 - Single - U Butt Joint ........................................................................................................... 2-34
Figure 18 - Single - U Butt Joint (Backed) ............................................................................................ 2-34
Figure 19 - Single - U Butt Joint (Narrow) ............................................................................................ 2-35
Figure 20 - Single - U Butt Joint (Pressure Vessel) .............................................................................. 2-35
Figure 21 - Single - J End Joint ............................................................................................................ 2-36
Figure 22 - Double - U Butt Joint .......................................................................................................... 2-36
Figure 23 - Single - V Butt Joint ............................................................................................................ 2-37
Figure 24 - Single - V Butt Joint (Backed) ............................................................................................ 2-37
Figure 25 - Double - V Butt Joint .......................................................................................................... 2-38
Figure 26 - Double - V Machine Butt Weld ........................................................................................... 2-38
Figure 27 - Single - V Machine Butt Weld With Manual Backing Weld ................................................ 2-39
Figure 28 - Fillet Welds ......................................................................................................................... 2-40
Figure 29 - Nuclear Containment Boundary Passing Pipes ................................................................. 2-41
Figure 30 - Non-Nuclear Containment Boundary Passing Pipes ......................................................... 2-41
Figure 31 - Astute Class Sleeve Welded Joints ................................................................................... 2-42
Figure 32 - Astute Class Socket Welded Joints ................................................................................... 2-43
Figure 33 - Swiftsure, Trafalgar and Vanguard Class Sleeve Welded Joints ...................................... 2-44
Figure 34 - Swiftsure, Trafalgar and Vanguard Class Socket Welded Joints ...................................... 2-45
Annexes
A Inspection Checklist for Welding Processes ........................................................................... 2-46
B Weld History Sheet .................................................................................................................. 2-47
B.1 Weld History Sheet Part 1 .......................................................................................... 2-47
B.2 Weld History Sheet Part 2 .......................................................................................... 2-48
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1 Scope
1.1 This Defence Standard specifies the minimum requirements for the welding and fabrication of
pipework, machinery and engineering components for HM Submarines and Surface Ships not in Class
approved by the Approval Authority. In order to ensure that the maximum benefits are achieved from
the material(s) selected by design it is essential that fabrication practices do not compromise the
material(s) properties and through-life performance.
1.2 This Defence Standard covers the welding and associated heat treatment of any metallic material
(although principally designed for steel, nickel alloys, copper alloys and aluminium alloys) in any
product form as approved by the Approval Authority.
1.3 This Defence Standard is not applicable to nuclear primary and associated circuits, for which reference
is to be made to DGS GS 3003 'General Welding Specification for Nuclear Plant and Machinery'.
1.4 This Defence Standard is not wholly applicable for sleeve and socket welded joints fabricated at build
for submarines for which special contract arrangements have been agreed by MOD. These are
covered by a BAE Systems Marine Limited document Specification 9023 ‘Welding and Fabrication of
pipework, machinery and engineering components’.
2 Quality
The Fabricator shall have an established quality assurance system according to BS EN ISO 9001 and shall
be able to demonstrate compliance with the principles of BS EN ISO 3834-2. Third party approved certification
to BS EN ISO 3834-2 is not a mandatory requirement of this Standard.
3 General
3.1 The Approval Authority will define in the contract or relevant drawings the level of importance for each
system, using the following definitions as guidance:
a) Level 1 System. A system in which failure of welds would lead to uncontrollable flooding, the total
immobilisation of the vessel, or serious hazard to personnel;
b) Level 2 System. A system in which failure of welds would lead to severe but controllable flooding, the
serious disruption of weapon systems, main propulsion machinery or its attendant auxiliaries including
generators;
c) Level 3 System. A system in which failure of welds does not constitute an immediately significant
hazard;
d) Level 4 System. A system in which failure of welds does not constitute a hazard.
3.2 Each organisation shall ensure that fabrication details appertaining to the initial build, repair, refit and
testing of welded components are recorded. These records shall be retained in accordance with
contract conditions. At the end of the retention period the records may be destroyed or transferred to
the MOD nominated records authority for the 'Through-Life Record'. Destruction or transfer of records
will be as directed by the Approval Authority and in accordance with the requirements of Def Stan 02-
207 (dependent on contract requirements. Requirements listed in SSP 25 for Legacy Equipment).
3.3 A typical standard history, or weld record, is shown in Annex B.
4 Materials
4.1 Base materials shall comply with the relevant material specifications. Material weldability tests shall
be performed if required by the material specification or the Approval Authority.
4.2 Welding consumables shall comply with a designated specification. Where this requirement cannot
be satisfied, the manufacturer and/or the user organisation shall demonstrate the suitability of the
consumable. It is no longer MOD policy to approve weld consumables for Low Strength Steel of the
type used in naval surface ships and in some submarine secondary structures.
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5 Preparation of Work to be Welded
5.1 Preparation, assembly and welding (including the welding position) shall be in accordance with the
approved drawings, procedures and/or specifications.
5.2 Drawings are to indicate the location of each weld and, when available, the approved weld procedure.
The use of symbols on drawings is not a requirement but all welds will be suitably detailed. All symbols
and welding terms shall be in accordance with BS EN ISO 2553 and BS 499 and exceptionally as
directed by Approval Authority.
5.3 Designs and procedures shall ensure that welding is kept to a minimum, and as far as possible that
all welding shall be done in the shop in the flat or horizontal rolled welding position.
5.4 All dissimilar metal welds, branch welds and attachment welds shall be made in the shop where
practical.
5.5 Site welds shall be kept to a minimum, and adequate access for assembly, welding, thermal treatment,
inspection and repair shall be provided.
6 Cleanliness
Cleanliness shall be maintained through all stages and at all times in accordance with Clause 6 hereof or
Def Stan 02-341 as appropriate.
7 Thermal Treatment
7.1 Thermal treatment shall be in accordance with the relevant material specifications and/or the approved
weld procedure and/or heat treatment procedure.
7.2 Approved and calibrated temperature controlled heating equipment shall be used for all thermal
treatments.
7.3 Full thermal treatment history shall be recorded and retained. The minimum recorded information shall
include the following:
a) Method and rate of heating;
b) Maximum temperature and duration at temperature;
c) Furnace atmosphere, if applicable;
d) Method and rate of cooling.
7.4 For detailed requirements refer to Clause 7.
8 Equipment and Facilities
8.1 Welding to this Defence Standard shall be performed by organisations retaining or having access to
the following minimum facilities:
a) Suitable and validated welding equipment;
b) Suitable facilities for the fabrication of the components being manufactured;
c) Suitable and validated heat treatment facilities including recording equipment;
d) Suitable and validated equipment for non-destructive examination and pressure testing;
e) Adequate facilities for mechanical testing and metallurgical examination.
8.2 All equipment to be used shall conform to the requirements of the Health and Safety at Work Act 1974
and all subsequent amendments.
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8.3 Welding power sources shall be maintained and calibrated in accordance with a written procedure.
For arc welding this is covered by BS EN 50504.
8.4 Bronze or lead hammers and chains, slings, or straps having a lead or zinc coating shall not be used.
8.5 Wire brushing, when required, shall be carried out using brushes compatible with the base material
and as specified in the approved weld procedures. The brushes shall not have been previously
contaminated by other incompatible material.
8.6 Grinding, filing or deburring operations shall be carried out only with tools which will prevent
contamination of weld and base material. Rubber or resin bonded aluminium oxide or silicon carbide
wheels and carbide files or deburring tools will not normally require approval.
9 Welding Requirements
9.1 General
9.1.1 Where possible, mechanised, semi-automatic and automatic processes should be used in preference
to manual processes.
9.1.2 Wherever practicable, in order to minimise site welding, welding should be performed in a shop
environment.
9.1.3 The surface condition of the finished weld shall be to the relevant drawing which shall comply with Def
Stan 02-773 or the contract applicable acceptance criteria.
9.1.4 Care shall be taken to avoid undesirable arcing or adherent spatter on the component being welded.
Arc strikes on the base material beyond the joint preparation shall be treated as defects (see
Clause 9.10). Base materials whose specifications require impact tests, i.e. notch sensitive materials,
shall be inspected after those defects have been removed to demonstrate that hard zones and notch
propagating effects caused by the arc strikes have been eliminated. The inspection methods used
may include chemical etching.
9.1.5 Arc strikes on the joint preparation and all starts and stops and craters in the weld shall be examined
visually and removed if defective.
9.1.6 The welding sequence shall be such that distortion is avoided or kept to a minimum.
9.1.7 Peening of welds is not permitted without prior written approval from Approval Authority.
9.1.8 Any welding process or any combination of welding processes can be used provided they satisfy the
qualification requirements of Clause 10 of this Defence Standard.
9.2 Preparation of Base Material
9.2.1 Prior to welding, all materials shall have been heat treated in accordance with the relevant material
specification to the condition required on the approved weld procedures.
9.2.2 Thermally cut material shall be subject to the following:
a) All scale, gouges or surface irregularities on the cut surface shall be removed by machining or grinding;
b) For high alloy steels and non-ferrous alloys, not less than 1.5 mm of metal shall be removed by
machining or grinding from the surface after cutting by air-arc and plasma, and not less than 3 mm
after cutting by any process using oxygen;
c) The method of weld preparation shall not cause physical or metallurgical damage to material.
9.2.3 Heat treatment before and after thermal cutting shall be in accordance with an approved procedure
and/or the relevant material specification as appropriate. Cut edges shall be dressed and visually
examined.
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9.2.4 It is essential that the base material is not subjected to local damage such as hammer marks. Every
precaution shall be taken to avoid such occurrences in handling and during all operations. Care shall
be taken to avoid the formation of notches or other sharp changes of contour likely to cause stress
concentrations.
9.2.5 In order to eliminate the dangers of contamination of parent metal and weld metal by sulphur, copper,
tin or lead, the following precautions shall be observed:
a) Materials supplied in the electro-plated condition shall be pickled to remove those deposits before hot
manipulation, heat treatment, welding or thermal cutting;
b) Ferrous and non-ferrous material shall be segregated from each other to preclude contamination.
9.2.6 Weld preparations shall be finally machined or ground to the profile on the approved weld procedure
or drawing. If any other method of preparation is proposed, prior written approval from Approval
Authority shall be obtained.
9.2.7 The joint surfaces and consumables shall be cleaned prior to heating or welding. Cleaning requires
the removal of all moisture, oxides, scale, grease, dirt, paints, cutting fluids and embrittling agents
such as zinc, copper, tin, lead, sulphur or phosphorus bearing compounds or other contaminants, for
at least 25mm either side of the joint. The final surfaces shall be clean, dry, smooth, and free from
irregularities.
9.2.8 Base materials, in particular copper and nickel base alloys, are susceptible to sulphur contamination
arising from any source and particular attention is drawn to the requirement to remove films arising
from other processes prior to any thermal operations.
9.3 Assembly Alignment
9.3.1 Parts may be assembled using jigs and fixtures.
9.3.2 The use of tack welds shall be avoided wherever possible; when used they shall be made in
accordance with this Defence Standard and an approved weld procedure, and the least practicable
number used. Tack welds shall be visually examined in accordance with Def Stan 02-773. Cracked or
broken tack welds or those of poor quality shall be removed by an appropriate method. Acceptable
tack welds shall be dressed before incorporation into the final weld.
9.3.3 Alignment devices shall be such that the welds to be made are readily accessible.
9.3.4 Welded temporary alignment devices shall be avoided if possible. Where they are used, the conditions
for welding shall be the same as for the parent metal and approved weld procedure. The surface finish
of the component shall be restored after the fixture has been removed and treated as defects (see
Clause 9.10).
9.3.5 Removal of welded temporary alignment devices by hammering or forcible release is prohibited.
9.4 Control of Distortion
9.4.1 Distortion through welding shall be minimised as far as possible. The welding sequence shall be such
that distortion in any component is kept to a minimum.
9.4.2 The circularity of welded pressure vessels after heat treatment shall be such that the difference
between maximum and minimum diameters at any section does not exceed one percent of the
designed internal diameter. Any departure from circularity shall be gradual and there shall be no local
flat in any welded seams.
9.5 Root Pass Welding and Backing
9.5.1 Consumable inserts are the preferred method for the root pass welding of pipe butt welds or similar
configurations.
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9.5.2 Temporary backing rings and strips may be used for assembly and welding. They shall be of the same
material as the base material or as stated in the weld procedure. Any joints in backing rings and strips
shall be welded to form a continuous ring or strip. Any temporary backing ring or strip design may be
used which will result in a weld which meets the quality requirements of this Defence Standard. The
diametrical clearances between the backing ring and pipe need not be limited.
9.5.3 Attachment of backing rings by tack welding shall be made by welding in the root gap; the tack welds
shall not bridge the root gap.
9.5.4 On completion of welding, backing rings or strips shall be removed by machining or grinding and the
weld root non-destructively examined in accordance with Def Stan 02-729 and Clause 11 of this
document, if appropriate.
9.5.5 Permanent backing rings or strips shall not be used without prior, written Approval Authority approval.
9.5.6 If the Approval Authority specifically approves not removing the backing ring or strip:
a) The backing rings shall be in accordance with Figure 16 A - F and H;
b) Backing rings shall be solid. Split type backing rings, if required for proper fitting, shall be welded to
form a solid ring after fitting and prior to final insertions in the pipes;
c) The diametrical clearances between the backing ring and the pipe shall not exceed 0.5mm.
9.6 Purging
9.6.1 To ensure adequate purging, welding shall not commence until both the moisture and oxygen content
of the emerging gas does not exceed the following limits:
a) For copper and nickel alloys: 800ppm moisture and 1% oxygen.
b) For carbon and low alloy steels: 800ppm moisture and 1% oxygen in build no moisture measurement
and 1% oxygen in re-fit.
c) For stainless steels: 5000ppm moisture and 1% oxygen.
d) For materials other than the above a), b) and c) the allowable oxygen and moisture content will be
specified in the approved weld procedure.
9.7 Welding Practice
9.7.1 For manual welding string beading is preferred but, where weaving is used, the width of the resultant
weld bead shall not exceed the diameter of the electrode core/filler wire multiplied by the following
factors (unless otherwise approved by weld procedure qualification).
Table 1 - Weld Bead Diameter Maximum
Material Type
Welding
Process Carbon/Low Stainless Copper or
Alloy Steels Steel Nickel Alloys
MMA x6 x4 x3
TIG x5 x5 x5
MIG x15 x15 x15
FCAW x15 x15 x15
9.7.2 Joints to be welded from both sides shall have the root of the first side weld deposit examined in
accordance with the approved weld procedure and any defective areas shall be removed prior to
welding on the second side.
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9.7.3 Each pass of deposited weld metal shall be cleaned free from slag, dirt, oxide etc., before the next
pass is deposited. Defects appearing at the surface of any weld deposit shall be removed before the
next pass is deposited.
9.7.4 Control of preheat and interpass temperature will be as specified in the approved weld procedure.
9.7.5 Preheating techniques and preheat and interpass temperature measure shall be such as to ensure
that the full thickness of the weld joint preparation and adjacent base material is at the specified
temperature. When flame heating is used, only a neutral flame shall be employed in order to avoid
local reduction or oxidation. The minimum preheat temperature shall be in accordance with the
approved weld procedure.
9.7.6 Temperatures shall be determined by optical or surface contact pyrometers, or thermocouples in

accordance with approved procedure. Other means of measurement shall be as approved by Approval
Authority.
9.7.7 No welding is to be carried out on base material whose temperature is lower than 5°C and the pre-
and interpass-heating shall ensure that the weld joint preparation and adjacent material is maintained
within the specified temperature range of the approved weld procedure.
9.8 Consumable Control
9.8.1 Welding consumables shall be treated in accordance with Manufacturer’s instructions and good
working practices.
9.8.2 When drying with heating ovens, electrodes shall be dried in accordance with Manufacturer’s
recommendations.
9.8.3 Consumable fillers which have been contaminated or which have damaged coatings shall not be used.
9.9 Post Weld Heat Treatment
9.9.1 Any stress relief or heat treatment of base material on completion of welding will be carried out in
accordance with an approved heat treatment procedure.
9.9.2 Post weld heat treatment for pipework shall be carried out in accordance with ASME B31.3 or the
contract specification.
9.9.3 Where final post weld heat treatment of welds is required, this shall be affected by uniformly heating
(in accordance with an approved heat treatment procedure):
a) The completed structure; or
b) The sub-assembly containing the weld; or
c) The entire weld and the adjacent areas of the base material including the heat affected zone.
9.9.4 Before being heat-treated, all parts shall be clean and free from surface contamination.
9.9.5 The approved heat treatment procedure shall state the furnace atmospheric conditions if applicable.
The furnace atmosphere for all high alloy steels, and nickel base alloys, shall be neutral or slightly
oxidising.
9.9.6 The fuel used for any thermal treatment of high alloy austenitic steels and nickel base alloys shall
have a sulphur content not exceeding:
a) Gas: 0.23 grams per cubic metre;
b) Oil: 0.5 percent by weight (W/W).
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9.9.7 During thermal treatment, sufficient thermocouples shall be attached by an approved method e.g.
temporary localised weld deposits, with drilled thermocouple pockets which are subsequently removed
by machining or grinding.
9.9.8 Thermocouple junctions and wires shall be protected from flame impingement. To prevent direct
radiation from the heating elements on the hot junction when electrical resistance heating is used,
thermocouples shall be covered with a protective wrapping.
9.9.9 To prevent harmful stresses arising from temperature gradient within heavy sections, controlled
heating and cooling rates shall be used.
9.9.10 For materials which require furnace cooling, the rate of cooling may be accelerated if required when
the temperature of the part has fallen to 300°C and the temperature difference between the furnace
and the part does not exceed 150°C. The part may be removed from the furnace or local heating
stopped when the maximum temperature of the part has fallen to 250°C.
9.9.11 During furnace heating and cooling, the temperature difference between any two points on the part
shall not exceed 60°C, and during the holding time at the specified temperature, the difference
between any two points on the part shall not exceed the tolerance specified for the particular
temperature used or ± 20°C of the average temperature used when a range of temperature is allowed.
9.9.12 Where parts are locally heat treated in situ, the temperature of the weld area shall not vary from the
approved temperature by more than ± 20°C.
9.9.13 Where approved, local stress relief of circumferential joints in pipes shall be by heating a band having
a width on each side of the centre line of the weld of not less than three times the width of the finished
weld. The portion outside the heated band shall be protected so that the temperature gradient is not
harmful.
9.9.14 Local stress relief of cylindrical vessels containing welded nozzles or attachments, where approved,
shall be by heating a circumferential band containing the welded nozzles or welded attachment that
require stress relief in such a manner that the entire circumferential band shall be brought up uniformly
to the right temperature, and held for the specified time. The circumferential band shall extend around
the entire vessel and shall include the welded nozzle or welded attachment and shall extend at least
six times the material thickness beyond the welding which connects the nozzles or other attachments
to the vessel. The portion of the vessel outside the circumferential band shall be protected so that the
temperature gradient is not harmful.
9.9.15 Local heat treatment shall not be used on air hardenable steels, high alloy steels or nickel base alloys
without prior written Approval Authority approval.
9.9.16 Post weld heat treatment carried out shall be within limits as specified in the approved weld procedures
and any departure requires prior written Approval Authority.
9.10 Defect Removal
9.10.1 Unacceptable defects shall be removed by machining or grinding. Thermal gouging is permissible
subject to the excavated area being treated in accordance with Clause 9.2.
9.10.2 The complete removal of such defects shall be verified by:
a) Visual inspection followed by;
b) Magnetic particle inspection, or liquid penetrant inspection as appropriate or visual inspection at x10
magnification; or
c) Repeating the inspection which originally disclosed the defect.
9.11 Repair Welding
9.11.1 The weld repair of any weld or base material defect shall be in accordance with this Defence Standard
and with an approved weld procedure.
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9.11.2 Unless otherwise approved by the Approval Authority, the preheat and post weld heat treatment
applied to weld repairs shall be the same as that applied to the original weld, or shall be in accordance
with an approved weld repair procedure.
9.11.3 Specific approval is required from the Approval Authority representative, for weld repairs following any
one, or a combination of the following:
a) Final heat treatment;
b) Final hydrostatic test;
c) Any weld repair where the repair welding cannot duplicate all pre-weld and post weld heat treatments
required by the original weld procedure or base material specifications;
d) Repeated repair of defects which recur in welds:
i) After the third cycle of repair;

ii) After each second cycle of repair for welds of the type that are heat-treated after each repair
cycle;
e) All base material weld repairs.
9.11.4 The joint surfaces and consumables shall be cleaned prior to heating or welding. Cleaning requires
the removal of all moisture, oxides, scale, grease, dirt, paints, cutting fluids and embrittling agents
such as zinc, copper, tin, lead, sulphur or phosphorus bearing compounds or other contaminants, for
at least 25mm either side of the joint. The final surfaces shall be clean, dry, smooth, and free from
irregularities.
9.11.5 Records shall be prepared in accordance with Clause 3.2. The records shall include the following as
a minimum:
a) Location of defective joint or base material;
b) Location of defect i.e. sketch or marked drawing or reference to film marker position number;
c) Description of defect including nature, size and maximum defects;
d) Approved weld procedure reference;
e) Details of the inspection before and after repair, and results thereof;
f) Identification of welder making repair and extent of relevant welder's approval.

Note: The above information shall be included on a weld history sheet similar to that shown in Annex B.
9.12 Identification and Marking
9.12.1 Positive identification of all welds during all operations shall be maintained.
9.12.2 Permanent marking when specified on the drawings will be made by any approved method and shall
be on the base material adjacent to the weld but outside the heat affected zone. Vibro-etching, electro-
chemical and engraving are approved methods.
9.12.3 Temporary markings shall not be injurious to the base material or weld metal and shall be removed
while still accessible. The surface shall be thoroughly cleaned before exposure to thermal treatment.
9.13 Test Pieces for Pressure Vessels
9.13.1 For items designated pressure vessels by design, welded coupons additional to those required to
demonstrate qualification and representing both longitudinal and circumferential joints shall be
provided either:
a) From the parent plate; or
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b) From a plate of similar chemical composition acceptable to the Approval Authority.
9.13.2 These test pieces are to be welded by the welder or welding operator, to the same procedure as for
the production weld.
9.13.3 Where a component has identical longitudinal and circumferential joint preparations and weld
procedures, test pieces from the longitudinal weld may be accepted for both seams.
9.13.4 Test pieces may be a continuation of the production assembly or separately attached test plates, so
that the weld metal in the test piece is, wherever practicable, a continuation of the weld on the
production assembly.
9.13.5 Where it is found impracticable to attach the test pieces to the work, the test piece may be welded
separately by the same personnel and equipment, and to the same weld procedure as that to be used
in production. The test piece should also be welded under similar environmental conditions to the
production weld.
9.13.6 Test pieces are to receive the same heat treatment as the production weld and are to be subjected to
non-destructive and destructive examination as for the weld procedure qualification test assemblies.
9.13.7 All test piece results are to be submitted to the Approval Authority for approval.
9.14 Cladding
Requirements for welded overlay or cladding are contained within Def Stan 02-875.
10 Qualification
10.1 General
10.1.1 All welding shall be carried out in accordance with the appropriate British Standards (BS) or ASME-IX
code; this includes welding personnel, welding equipment and weld procedures. All welding shall be
carried out according to a qualified Welding Procedure Specification (WPS) by qualified
welders/welding operators and be ‘fit-for-purpose’ as required by the Approval Authority. However, the
requirements of this Standard shall as a minimum apply.
10.1.2 All WPSs must be approved by the Approval Authority prior to use in production. To obtain approval
from the Approval Authority each WPS must be accompanied by the relevant Procedure Qualification
Records (PQRs).
10.2 Qualification of Welding Procedures
10.2.1 Weld procedures should be produced by manufacturers in accordance with BS documents (or
ASME-IX) and verification shall be carried out by a recognised third-party examining body. Approval
of the examining body will be granted by the Approval Authority. The Approval Authority will have the
opportunity to audit as part of the contract audit plan.
10.2.2 The following documents currently apply to this welding procedure qualification process:
a) General rules - BS EN ISO 15607;
b) Welding procedure specification:
i) BS EN ISO 15609-1 (arc welding);

c) Welding procedure test:
i) BS EN ISO 15614-1 (steels, nickel and nickel alloys);

ii) BS EN ISO 15614-2 (aluminium and aluminium alloys);
iii) BS EN ISO 15614-4 (finish welding of aluminium castings);
iv) BS EN ISO 15614-5 (titanium, zirconium and their alloys);
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v) BS EN ISO 15614-6 (copper and its alloys).
10.2.3 If the welded joint is outside the scope of these BS documents and ASME-IX, a course of action shall
be agreed between the Organisation and Approval Authority.
10.3 Qualification of Welders
10.3.1 ASME Welders shall be qualified by a valid and appropriate test of skill in accordance with either BS
standards or ASME IX code. The manufacturer shall be responsible for the qualification of welders
and is required to keep records of the welders' qualifications and, when required, furnish copies of
valid welders' certificates of test for review. Relevant standards are listed as follows:
a) BS EN ISO 9606-1 (steels);
b) BS EN ISO 9606-2 (aluminium and aluminium alloys);
c) BS EN ISO 9606-3 (copper and copper alloys);
d) BS EN ISO 9606-4 (nickel and nickel alloys);
e) BS EN ISO 9606-5 (titanium and titanium alloys, zirconium and zirconium alloys);
f) ASME IX.
10.4 Restricted Access
Where production welds are to be made under restricted access conditions, the welder shall be qualified by
welding test assemblies in a restricted access box as shown in Figure 1. Restricted access conditions are
considered to exist when the distance from the surface of the finished weld to any other surface is 300mm or
less.
10.5 Sleeve and Socket Welds
For sleeve and socket welds, welders shall be qualified in accordance with the specific written and approved
sleeve and socket weld procedures, unless otherwise agreed, see Clause 13.
10.6 Mechanised/Semi-Automatic and Automatic Welds
For mechanised and/or automatic welds, the extent of weld procedure approval will be restricted to the nominal
pipe diameter, thickness and position. Some relaxation of this rule may be allowed by application to the
Approval Authority.
10.7 Supplementary Requirements
10.7.1 Organisations which satisfy the above requirements may have approval withheld subject to
supplementary requirements of the Approval Authority being satisfied.
Note: For instance, in the case of a super duplex stainless steel, corrosion tests may be required which would not be specified
in the basic BS documentation or ASME-IX code - dialogue between organisations and the Approval Authority is therefore to
be encouraged.
10.7.2 The acceptance standard for weld procedure qualification and welder qualification will be Def Stan 02-
773 Class 1.
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11 Inspection Requirements
11.1 Scope
This section states the minimum requirements for the method and extent of inspection for fabricated
components covered by this Defence Standard. This shall not be construed as limiting any organisation from
performing more extensive inspection when required by the Approval Authority or for their own benefit.
11.2 General
11.2.1 To meet the requirements for Inspection Quality Control, the inspection check list, shown in Annex A,
gives guidance with respect to the significant points requiring checking and control.
11.2.2 All non-destructive examination shall be carried out in accordance with the methods specified in Def
Stan 02-729 parts 1 to 5. The extent of non-destructive examination shall be in accordance with the
relevant contract, drawings and/or applicable weld procedures. Applicable acceptance criteria are
contained in Def Stan 02-773.
11.2.3 The extent of non-destructive examination for various systems are contained in Def Stan 02-773.
11.2.4 Additional inspection of particular welds may be required by either the Design or Approval Authority.
11.2.5 Unless otherwise specified herein or specifically approved by the Approval Authority, final inspection
shall be performed on all welds in the finished surface condition as offered for acceptance.
11.2.6 Provided that Approval Authority approval has been obtained, examination of surface defects may be
performed before post weld heat treatment on those on which impact properties are not required to
be determined by the relevant material specification.
11.3 Interstage Inspection
Visual inspection shall take place on the root pass of welds where practicable using magnifying lenses (of x10
magnification) where appropriate. This is only to be carried out on welds subject to surface flaw examination
and not radiographed at the final weld stage.
11.4 Visual Inspection
11.4.1 The inner and outer surfaces of all welds when accessible shall be inspected. The visual inspection
shall precede any other means of non-destructive examination.
11.4.2 Aids such as magnifying lenses (of up to x10 magnification), daylight lamps, strong lights, mirrors,
intrascope, etc. may be used for visual inspection. Such aids should be used to verify defects for
acceptance purposes.
11.5 Liquid Penetrant or Magnetic Particle Inspection
Acceptance criteria shall be in accordance with Def Stan 02-773.
11.6 Radiographic Inspection
11.6.1 Welds shall be radiographically examined as required by acceptance criteria contained in Def Stan
02-773.
11.6.2 Acceptance criteria for radiographic examination of sleeve and socket welds, where appropriate, shall
be in accordance with Def Stan 02-773.
11.6.3 Additionally, radiography will not normally be required for the following welds:
a) Fillet welds (excluding socket and sleeve welds);
b) Support structural welds;
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c) Tube to tube plate welds;
d) Overlay cladding;
e) Where the results of such examinations would not be meaningful due to geometry or access, provided
that radiography is not required by the contract, drawing or approved weld procedure, e.g. boiler
generator tube welds. Superheater and economiser element welds inside the casting may be magnetic
particle or liquid penetrant examined in lieu of radiography;
f) Pintle bosses and branch welds below 25 mm nominal bore;
g) Vicolets.
11.6.4 Radiographic inspection shall be carried out on all welds in clad vessels before cladding.
11.6.5 Radiography may be carried out before machining when the subsequent reduction in thickness does
not exceed 20% of the thickness as radiographed or 6 mm, whichever is the greater.
11.6.6 Final radiographic inspection shall be carried out after PWHT where appropriate.
11.7 Ultrasonic Inspection
Where ultrasonic inspection is proposed for acceptance purposes, prior written Approval Authority approval
shall be obtained for each procedure as defined in Def Stan 02-729 Part 5.
11.8 Leak Test Examination
All tube to tube plate welds shall be leak tested in accordance with an Approval Authority approved procedure.
11.9 Cladding
Requirements for welded overlay or cladding are contained within Def Stan 02-875.
12 Acceptable Welded Joint Designs
12.1 Scope
12.1.1 This section contains acceptable weld joint designs. Figures 2 to 34 illustrate acceptable weld
preparation and assembly details for a range of typical joint configurations.
Note: Any stated multiplying factor shall not give dimensions less than the nearest mm e.g. if t is 6.02mm, 1.09t min. is 7mm
min, not 6.518mm, or, if t is 3.91mm, 1.09t min. is 4mm min. not 4.2619mm.
12.1.2 Weld joint designs not specified in this section may be employed if approved by the Approval Authority.
This approval may be obtained with approval of a weld procedure or a component drawing provided
that the weld procedure or component drawing states that the weld joint design is not included in this
Defence Standard.
12.2 General Requirements
12.2.1 All welded joints shall be located so that:
a) intensification of stresses to which the weld may be subjected as the result of pressure, fatigue,
thermal gradients, discontinuities, etc. shall be minimized as far as is reasonably practical;
b) the inspection requirements of this Defence Standard can be met, i.e. access is provided for non-
destructive inspection;
c) the effects of undesirable base material characteristics such as laminations and segregation of rolled
plate are minimized, i.e. edges of plates are sealed by the welded joint;
d) for manually welded joints, the entire weld groove is visible to the welder. If necessary, due to
obstructions impairing the welder’s visibility, aids (such as mirrors) may be used.
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12.2.2 Full penetration welded joints made and inspected in accordance with this Defence Standard may be
considered 100% efficient. The strength of welded joints shall be based on the strength of the weaker
member.
12.2.3 Abrupt change of section incorporating a butt weld is to be avoided. Where parts of different thickness
are to be butt welded, the thicker part shall be reduced in the vicinity of the butt to the thickness of the
thinner part with a taper ratio not less than 1 in 4, the size of the weld shall be taken to be the thickness
of the thinner member and is generally to be in accordance with Figure 6 or Figure 20.
12.2.4 When a flush surface is required, the butt weld shall be first built up and then dressed flush by
appropriate mechanical methods transverse to the weld to a fine finish in accordance with Def Stan
02-773.
12.2.5 The throat thickness of a fillet weld as deposited shall comply with the following requirements for a 90°
fillet weld as shown in Figure 28:
a) The throat thickness is not to be less than 0.7 times the specified leg length in the case of a normal
mitre fillet;
b) The throat dimension is to be not less than 0.6 times the specified leg length in the case of a concave
fillet, and not more than 0.9 times the specified leg length in the case of convex fillets;
c) For calculating the strength of a fillet weld, the throat is to be taken as 0.7 times the specified leg
length.
12.2.6 The throat thickness of a butt weld is taken as the thickness of the thinner part joined. When both parts
are of equal thickness the throat thickness is equal to the part thickness. Weld reinforcement is ignored
for design purposes.
12.3 Holes in Welded Structures
12.3.1 It is preferred that no manhole, handhole or any hole for a connection or mounting shall be located in
a welded joint of a pressure containment component.
12.3.2 Where rings and pads are attached by welding only, they are to be welded to the parent plates around
both the inner and outer circumference or as may be approved.
12.4 Branch Welds
12.4.1 Branches shall be of the 'set on' type, and shall conform generally to ASME B31.1, BS EN 13480-3,
BS 1113 or BS EN 12952. Proposals for attachment of branch welds shall be submitted to the Approval
Authority for approval.
12.4.2 Acceptable preparations for branch welds shall be in accordance with Figures 7 to 15 and shall
comply with ASME B31.1 or BS EN 13480-3 or equivalent, as appropriate. Alternative proposals for
such joints shall be submitted to the Approval Authority for approval.
12.4.3 The preparations for any 'set-on' type branch require varying angles of preparation due to the
curvature of the main pipe wall, and the angles shown in Figures 7 to 10 are for guidance only. The
preparations shown are for plain bevels but 'U' type preparations are acceptable where appropriate.
Extruded branches shall be welded as for butt welds.
12.5 Sleeve and Socket Joints
These types of joint are a special case and are covered in Clause 13.
12.6 Bulkhead Penetration Passing Pipes and Seal End Connectors
These joints are currently specific to Astute Class platforms and are not used on earlier submarine classes.
Such joint may be applied to earlier classes of submarines, with Approval Authority approval. Joint design and
fillet size to be in accordance with Figures 29 and 30.
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12.7 Pipe Flanges
The welding of 'neck' or 'tail' flanges comes within the requirements of pipe butt welds (see Figure 2). Plain
ring flanges shall comply with the requirements of Figures 3 to 5.
12.7.1 Welding Conditions
12.7.1.1 The flange is to be a good fit on the pipe, the clearance at any point not to exceed 1.5 mm where
dimensions permit, the end of the pipe is to be lightly expanded to fit the bore of the flange.
12.7.1.2 The welds are to be examined visually with the aid of approved crack detection methods.
12.7.1.3 Radiographic inspection is not a requirement.
12.7.1.4 External weld fillets may vary between the nominal 45° fillet shown to the nominal 1t x 2t fillet profile.
12.8 Design Limitations
12.8.1 The following types of welds shall not be used without specific approval of the Approval Authority:
a) Edge Welds;
b) Plug or Slot Welds;
c) Partial Penetration Welds;
d) Sleeve and Socket Welds;
e) Welds incorporating permanent backing rings or strips;
f) Intermittent fillet welds.
12.9 Proximity of Welds
The intersection or overlapping of welds and/or heat affected zones of welds shall wherever practicable be
avoided. Branch fittings and other attachments shall preferably not be located on or near circumferential or
longitudinal welded seams. Butt and sleeve/socket welds shall preferably be no closer than 4T, where T is the
thickness of joint or material.
12.10 Welding on Bends
12.10.1 Butt, socket or sleeve welding on bends should be avoided and is not permitted unless agreed by the
Approval Authority.
12.10.2 Welding attachments, i.e. pintles or stubs to bends, is not permitted unless agreed by the Approval
Authority.
13 Pipe Sleeve and Socket Welds
13.1 General
13.1.1 A butt welded joint is the preferred joint in the fabrication of pipe systems. Alternative joints for these
systems are sleeve or socket welded joints. However, sleeve or socket welded joints are non-preferred
joints, as they do not offer the same fatigue life as a butt welded joint.
13.1.2 There are specific characteristics of sleeve and socket welded joints that make it necessary for these
weld types to be considered separately.
13.1.3 The historical background to these joint types and the changes in MOD procurement policy and design
responsibilities has forced the sleeve and socket welded joint designs and procedures for the Astute
Class to be different from the other classes of submarine, i.e. Swiftsure, Trafalgar and Vanguard
Classes.
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13.2 Acceptable Welded Joint Designs
13.2.1 Sleeve and socket welded joints are non-preferred joints. Prior Approval Authority approval shall be
sought for their use in System Levels 1, 2 and 3.
13.2.2 For Astute Class, joints shall be restricted to 21.3mm outside diameter and below. Sleeve and socket
welded joints shall not be used in Submarine Reactor Compartments unless prior Approval Authority
approval is obtained. Sleeve welded joints shall show suitably scribed reference marks to ensure
accurate fit up. Joints shall conform to Figure 31 for Astute Class sleeve welded joints and Figure 32
for Astute Class socket welded joints.
13.2.3 For Swiftsure, Trafalgar and Vanguard Class, there were no size restrictions imposed at build. No
sleeve or socket welded joints are to be introduced into systems and locations not previously
containing these joint types without prior Approval Authority approval. All replacement joints on these
classes of submarines are to conform to Figure 33 for Swiftsure, Trafalgar and Vanguard Class sleeve
welded joints and Figure 34 for Swiftsure, Trafalgar and Vanguard Class socket welded joints, or
alternatively these replacement joints can conform to the equivalent Astute Class designs in Figure
31 and Figure 32.
13.2.4 Minimum insertion lengths and gap dimensions are stated in Figures 31 to 34.
13.2.5 The fit-up aspects contained in the Swiftsure, Trafalgar and Vanguard Class sleeve and socket welded
joint designs have been the subject of various studies conducted on behalf of MOD by DRA, DERA
and QinetiQ. The minimum insertion lengths and gap dimensions have been particular parameters
studied in cupro-nickel and steel sleeve and socket welded joints. (The sponsor has access to the
reports on these studies which include DERA/SMC/SM2/CR980055/1.0 for CuNi studies and
QINETIQ/06/02463 for studies on steel joints.)
13.2.6 For each sleeve or socket joint a record shall be kept of the sleeve or socket edge profile, i.e. square
faced or 22° bevel.
13.2.7 Where practicable, weld build-up for sleeve and socket welds should comprise a minimum of one root
pass plus two fill passes.
13.3 Qualification Requirements
The qualification of welding equipment, welders and welding procedures are to be in accordance with
Clause 10. As indicated in Clause 10.5, specific additional requirements may be stipulated within sleeve and
socket weld procedures. Any additional requirements stipulated in Clause 13 takes precedence over the more
general requirements stated in Clause 10.
13.4 Weld Procedure Test Assemblies
13.4.1 The Test Assembly is to be in accordance with the appropriate fit-up, clearance dimensions and fillet
dimensions as applicable for the joint design for which the weld procedure is intended. For Astute
Class designs, Figures 31 and 32 apply, for Swiftsure, Trafalgar and Vanguard Class designs,
Figures 33 and 34 apply.
13.4.2 Test Assemblies are to be prepared using the range of qualification based on outside diameter as
specified in BS EN ISO 15614-1 or ASME-IX.
13.4.3 The position of welding is to be “H-L045” in accordance with BS EN ISO 9606-1, or “6F” in accordance
with ASME-IX. The length of each test assembly shall be a total of 250 mm.
13.4.4 Macro specimens are to be prepared in order that visual examination of cross sections of weld and
heat affected zone show complete fusion and freedom from cracks. Small linear indications at the root
visible from macro specimens are permitted provided they do not exceed 1% of the pipe wall or fitting
thickness, whichever is least.
13.5 Welder Qualification Test Pieces
13.5.1 Welder qualification test pieces are to be similar to the production joints to be welded.
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13.5.2 Any restricted access conditions, confirmed by the site welding application, are to be additionally
represented in the welder qualification test. Where the production welds are to be made under
restricted access conditions, the welder shall be qualified by welding test assemblies in a restricted
access box consisting of a cube having a minimum of a top and bottom and two adjoining sides. The
test assembly shall be located to represent the most difficult position to be encountered in production
and the satisfactory performance of the test shall qualify the welder. In these cases, the welder test is
to be subject to the restricted access conditions of Figure 1.
13.6 Examination of Sleeve and Socket Welded Joints
13.6.1 Procedure and welder qualification test assemblies are to be examined non-destructively prior to the
taking of samples for any destructive testing. Leak testing is not to be preferred unless specifically
required.
13.6.2 Non-destructive examination of production and test assemblies are to comprise the following:
a) Visual Examination - The surfaces of all welds are to be inspected for quality and appearance. The
visual examination is to precede all other NDT methods and is to conform to Def Stan 02-773;
b) Surface Crack Detection - The surfaces of all new or repaired welds are to be examined to Def Stan
02-729 Part 2 or 4 as appropriate. All welds are to be in accordance with Def Stan 02-773. This
examination shall not be required for in-service inspections;
c) Radiographic Examination – 100% Radiographic examination of production assemblies shall be

required for;
i) Within or forming part of the Nuclear Reactor Plant containment boundary

(DGS GS 3003 specifies the requirements for nuclear plant and machinery);
ii) Within or forming part of the Naval Reactor Plant Boundary (NRPb);
iii) All joints in hot systems;
iv) All joints in other systems in areas subject to high cyclic loadings where a consequent risk of
fatigue exists. Such systems will be determined by the Approval Authority;
v) All Bi-metallic joints;
13.6.3 When radiographic examination is required, this shall be to Def Stan 02-729 Part 1 and in accordance
with Clause 11.6.2 and complete coverage of the weld shall be achieved by using at least three
radiographs. Fit up clearances for all joints are to be those for the particular class group as per
Clause 13.4.1. Defects revealed by radiography are not to exceed those permitted in Def Stan 02-
773.
13.6.4 Destructive examination is to comprise a macroscopic examination as per Clause 13.4.4.
13.7 Retests
Where a sleeve and socket welded joint welder qualification test fails, the retest shall be in accordance with
BS EN ISO 9606-1 or ASME-IX.
13.8 Confirmation and Revalidation of Qualification of Welders
BS EN ISO 9606-1 or ASME-IX shall apply when welders for sleeve and socket welded joints require
confirmation or revalidation of original qualification.
14 Corporate Experience and Knowledge
14.1 Relaxation of Sleeve & Socket Weld Radiography Requirement
14.1.1 Relaxation of Sleeve & Socket Weld Radiography Requirement (Clause 13.6.2c)) has been justified
based on the following evidence:
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a) SSMG investigation of leakage rates from sleeve and socket joints, reported in SUBIPT PowerPoint®
Presentation “Investigation into Relaxation of In-Service System Surveillance Requirements (SSR) for
Welded CuNi Sleeve & Socket Couplings” Dated 27th March 2007 (MoD File Reference
D/SSG/168/2/3/13);
b) US Navy practice as reported in “Sleeve & Socket Weld NDE Requirements. Visit Report - USA DoD
- NAVSEA - 1/2/07” Dated 29th March 2007 (MoD File Reference D/SSG/168/2/3/13);
c) SUBIPT DASS Policy Paper “Relaxation of the In-Service System Surveillance Requirements for
Welded Copper Nickel Sleeve and Socket Pipework Couplings” – SUBIPT/630/1845 dated 25th June
2007.
Note: Restricted access shall exist when the distance from the surface of the finished weld to any other surface is 300 mm or
less.
Figure 1 - Restricted Access Conditions
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20 °
Note 1: Dimension C may be increased as necessary to facilitate the use of automatic welding processes.
Note 2: For dimensions of flange, see Weld Procedure or applicable Technical Drawing.
Figure 2 - Restricted Access Conditions
Figure 3 - Face and Fillet Welded Flange up to and Including 20 mm Thick
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Dimensions:
A t but not less than 6mm
B t but not less than 5mm
C t but not less than 5mm for t = 0
to 37mm
2t for T above 37mm up to 62mm
2.5t for T above 62mm
D 1.5t but not less than 6mm (see
D)
E 1.5t but not less than 6mm (see
D)
F t but not less than 5mm (see D)
G t but not less than 5mm (see D)
Figure 4 - Face and Back Welded Flange above 20 mm Thick
For applications where

:-
1. Pipe size does
not
exceed 100mm
nominal size
2. Maximum
pressure
rating Class 300
Figure 5 - Face and Back Fillet Welded Flange
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Figure 6 - Matching of Welding Ends
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Figure 7 - Welding Without Temporary Backing of Right Angled Set-On Branches
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Figure 8 - Welding Without Temporary Backing of Sloping Set-On Branches
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Figure 9 - Welding With Temporary Backing of Right Angles Set-On Branches
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Figure 10 - Welding With Temporary Backing of Sloping Set-On Branches
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} = 3 mm for d less than 12 mm

} = 6 mm for d = 12 mm to 15 mm
d’
} = d – 10 mm for d >15 mm to 20 mm
} = d -12 mm for d >20 mm diameter
Note 1: Bore d to be continued through on completion of welding.
Note 2: Where the parent pipe o/d is less than 1.5 times the pintle o/d, welds of d/4 leg length are not achievable around the
full circumference of the Pintle. In these circumstances the weld fillet size should range from the maximum achievable to d/4.
See Figure 12.
Figure 11 - Branch Connection - Pintle Type
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Figure 12 - Branch Connection Fillet Leg Lengths for Pintle Welds
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Dimensions:
D 25mm minimum
d' D - 6mm
G 3mm minimum, 6mm maximum
E t or 10mm whichever is the greater
Note 1: Suitable for branches on superheated headers etc. where the diameter of branch is approximately not more than half
that of the drum header.
Note 2: Where possible, backing ring is to be removed by machining or grinding. Where backing ring is to be left in, it should
be shaped as shown dotted.
Note 3: Bevel on end of pipe to be machined and hand dressed as necessary to maintain correct gap and feather edge.
Figure 13 - Branch Connection - Sleeve Type
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Dimensions:
A t but not less than 10 mm
B 0.5t but not less than 3 mm
C1 7 mm to 9 mm
C2 6 mm to 7 mm
E C2 + 1.5 mm
R 3 mm to 4 mm
Note 1: Weld in the flat position.
Note 2: Root of outer weld to be chipped out to sound metal before inner weld is laid.
Note 3: Normally end of branch may be left square as shown, where it is to be shaped it is to be shaped as shown dotted.
Figure 14 - Branch Connection - Without Compensation
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Dimensions:
A t but not less than 10 mm
B 0.5t but not less than 3 mm
C1 7 mm to 9 mm
C2 6 mm to 7 mm
E C2 + 1.5 mm
R 3 mm to 4 mm
Note 1: Weld in the flat position.
Note 2: Root of outer weld to be chipped out to sound metal before inner weld is laid.
Note 3: Normally end of branch may be left square where it is to be shaped it is to be shaped as shown dotted.
Note 4: Thickness of compensating ring (tw) is to be calculated in accordance with BS 1113, BS EN 12952, BS EN 13480-3 or
ASME B31.1.
Figure 15 - Branch Connection - With Compensation
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Figure 16 - Permissible Types of Backing Ring
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Note 1: Joint to be welded in the flat position only.
Note 2: Root of weld to be chipped out to sound metal and at least two runs of weld metal laid to root side of weld.
Note 3: Top and bottom reinforcement to be dressed before radiographic examination.
Figure 17 - Single - U Butt Joint
Note 2: Where root of weld may be subjected to tension bending backing strip should be removed or alternatively edges of
baking strip should be sealed by full fillet welds.
Note 3: Where corrosive conditions exist, edges of backing strip should, where possible, be sealed as shown in sketch.
Note 4: Where backing strip is to be left on dimension W to be at least 6 mm more than maximum width of groove.
Figure 18 - Single - U Butt Joint (Backed)
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Note 2: Root of weld to be chipped out to sound metal and at least two runs of weld metal laid on root side of weld.
Note 3: Top and bottom reinforcement may be dressed before radiographic examination.
Note 4: To be welded with an electrode giving a concave finish, single running without weaving.
Figure 19 - Single - U Butt Joint (Narrow)
Note 2: Root of weld to be chipped out to sound metal and at least two runs of weld metal laid on root side of weld.
Figure 20 - Single - U Butt Joint (Pressure Vessel)
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Note 2: Where possible, an internal fillet weld is to be laid for sealing purposes at least two runs being deposited.
Note 3: For drum ends a recess 0.5 to 1.5 mm deep may be machined in the shell for locating purposes as shown at "X". End
to be a good fit in the recess.
Figure 21 - Single - J End Joint
Note 2: Root of weld to be chipped out to sound metal before root side is welded.
Note 3: Weld from alternate sides.
Note 4: Where desirable to reduce amount of internal welding in pressure vessels depth of inner weld may be reduced.
Figure 22 - Double - U Butt Joint
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Note 2: Root of weld to be chopped out to sound metal and at least two runs of weld metal laid.
Note 3: Top and bottom reinforcement to be machined or ground off before radiographic examination.
Figure 23 - Single - V Butt Joint
Note 1: Use only where joint cannot be welded from both sides, or where joint is to be welded on a backing structure.
Note 2: Where convenient, sides or backing structure of strip to be sealed as shown.
Figure 24 - Single - V Butt Joint (Backed)
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Note 1: Root of first run to be chopped out to sound metal before root side of joint is welded.
Note 2: It is preferred that joint be welded alternatively first from one side and then from the other.
Figure 25 - Double - V Butt Joint
Finishing Weld Backing Weld

T mm E mm
B mm C A mm D
12 3±1 90° 6 3±1 90°
14 5±1 90° 6 5±1 60°
18 6±1 90° 7 5±1 60°
22 7±1 90° 7 6±1 60°
25 9±1 90° 7 7±1 60°
28 9±1 90° 9 9±1 60°
31 12 ± 1 70° 9 9±1 60°
34 13 ± 1 60° 10 9±1 60°
37 14 ± 1 60° 10 10 ± 1 50°
40 14 ± 1 60° 12 12 ± 1 50°
43 14 ± 1 60° 12 14 ± 1 45°
46 18 ± 1 50° 12 14 ± 1 45°
50 18 ± 1 50° 12 18 ± 1 45°
57 25 ± 1 45° 12 18 ± 1 45°
Figure 26 - Double - V Machine Butt Weld
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Finishing Weld Manual Weld

T mm
B mm C A mm D
12 6±1 60° 3±1 90°
14 9±1 60° 3±1 90°
18 10 ± 1 60° 5±1 90°
22 13 ± 1 60° 5±1 90°
25 17 ± 1 60° 5±1 90°
28 17 ± 1 45° 5±1 GROOVE
31 17 ± 1 45° 10 ± 1 GROOVE
37 20 ± 1 45° 10 ± 1 GROOVE
37 24 ± 1 40° 10 ± 1 GROOVE
50 24 ± 1 40° 13 ± 1 GROOVE
Figure 27 - Single - V Machine Butt Weld With Manual Backing Weld
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Figure 28 - Fillet Welds
2-40
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Figure 29 - Nuclear Containment Boundary Passing Pipes
Figure 30 - Non-Nuclear Containment Boundary Passing Pipes
2-41
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Permitted Minimum Pipe Insertion Lengths

Minimum Pipe Insertion
Sleeve Size
Length
12 mm 8 mm
16 and 20 mm 8 mm
> 20 to 50 mm 11 mm
Note 1: Sleeve welded joints are non-preferred as they do not possess the same fatigue life for given stress levels as butt
joints.
Note 2: Where required, replacement Level 1 and Level 2 joints are to be radiographed in accordance with Clause 13.6.2c).
Note 3: Sleeve length and thickness to be as directed by Approval Authority. (Sleeve sizes for Astute Class submarines have
been amended to accommodate leg length sizes of 2.5t).
Note 4: Fillet face concavity is prohibited for Astute Class submarines.
Note 5: Where radiography is required, the assembly fit-up will be regarded as acceptable if after welding there is a clearly
discernible gap on the completed weld between the pipe ends. Subject to minimum pipe insertion lengths being met.
Note 6: Some irregularity in exposed edge of sleeve may be unavoidable in thinner wall sleeve welds due to melting away
during welding but is not cause for rejection unless excessive and affects weld throat thickness.
Figure 31 - Astute Class Sleeve Welded Joints
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Permitted Minimum Pipe Insertion Lengths

Minimum Pipe Insertion
Socket Size
Length
12 mm 8 mm
16 and 20 mm 8 mm
> 20 to 50 mm 11 mm
Note 1: Socket welded joints are non-preferred as they do not possess the same fatigue life for given stress levels as butt
joints.
Note 3: Socket length and thickness to be as directed by Approval Authority. (Socket sizes for Astute Class submarines have
been amended to accommodate leg length sizes of 2.5t).
Note 4: Fillet face concavity is prohibited for Astute Class submarines.
discernible gap on the completed weld between the pipe end and the socket base. Subject to minimum pipe insertion lengths
being met.
Figure 32 - Astute Class Socket Welded Joints
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Note 1: Sleeve welded joints are non-preferred as they do not possess the same fatigue life for given stress levels as butt joints.
Note 3. The elongation of fillet weld to be within the tolerance 2t ± 0.25t and to blend smoothly into the pipe wall without undercut
or wall thinning.
Note 4: Profile of weld to approximate to ‘flat profile’ but reasonable concavity/convexity that sensibly maintains weld throat
thickness is acceptable.
discernible gap on the completed weld between the pipe end. Subject to minimum pipe insertion lengths specified in Note 8
being met.
Note 6: Profile of weld not to contain notches conducive to fatigue failure; reasonable weld ripples acceptable.
Note 7: Some irregularity in exposed edge of sleeve may be unavoidable in thinner wall sleeve welds due to melting away
during welding but is not cause for rejection unless excessive and affects weld throat thickness.
Note 8: There is a requirement that a certain length of each pipe must be inserted into the sleeve. For all new sleeve welded
joints this minimum insertion length shall be 8 mm for pipes up to 30 mm outside diameter, and 12 mm for pipes greater than
30 mm outside diameter.
Figure 33 - Swiftsure, Trafalgar and Vanguard Class Sleeve Welded Joints
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Note 1: Socket welded joints are non-preferred as they do not possess the same fatigue life for given stress levels as butt
joints.
Note 3: The elongation of fillet weld to be within the tolerance 2t ± 0.25t and to blend smoothly into the pipe wall without undercut
or wall thinning.
Note 4: Profile of weld to approximate to ‘flat profile’ but reasonable concavity/convexity that sensibly maintains weld throat
thickness is acceptable.
discernible gap on the completed weld between the pipe end and the socket base. Subject to minimum pipe insertion specified
in Note 7 lengths being met.
Note 6: Profile of weld not to contain notches conducive to fatigue failure; reasonable weld ripples acceptable.
Note 7: There is a requirement that a certain length of pipe must be inserted into the socket. For all new socket welded joints
this minimum insertion length shall be 8 mm for pipes up to 30 mm outside diameter, and 12 mm for pipes greater than 30 mm
outside diameter.
Figure 34 - Swiftsure, Trafalgar and Vanguard Class Socket Welded Joints
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Annex A
Inspection Checklist for Welding Processes
BEFORE AND DURING WELDING

1 Welder and/or machine qualification.
2 Procedure approval.
3 Correct heat treatment of the base material.
4 Correct joint geometry and fit up requirements of the approved weld procedure.
Correct use of holding fixtures and aligning clamps and, where temporary welding is used,
5 whether it was performed to an approved procedure and whether it complies with this Defence
Standard.
6 Whether base material has passed surface defect inspection.
That inspection has been carried out on all areas that become inaccessible as a result of the
7
operation.
8 The conditions of the approved weld procedure are being maintained, for example:
Cleanliness of joint
Preheat time and temperature
Correct welding rod or wire
Moisture removed from rod coating or flux
Gas backing at correct volume and pressure
Gas shielding at correct volume and purity
Correct arc stop and start techniques
Voltage control and setting
Current control and setting
Correct polarity
Satisfactory technique including weaving, angle of rod or wire, speed of travel, amount of feed,
etc.
Amount of penetration
Undercutting
Interpass temperature
Peening
In-process inspection
Removal of tack welds, if required by the Weld Procedure
Removal of craters at stops
Cleaning of pass before starting next pass, using non-contaminated brush or grinding wheel
Safe bonding of grinding wheel
Correct thickness of deposit
Identification of welder on each layer
Cover layer used if required
Whether the total weld thickness is satisfactory with no undercutting
For front and back welded joint, back chipping performed correctly to sound metal
Post heat or slow cool
AFTER WELDING
1 Size of legs and throat of fillet welds.
2 Contour and finish of outside surface of welds.
3 Contour and surface condition of inside surface where possible.
4 Degree of undercutting.
Evidence of mishandling, i.e. from centre punch or other impression marking, excessive
5
grinding etc.
6 Dimensional accuracy of the component.
7 Check bead size if weave technique used.
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Annex B
Weld History Sheet
B.1 Weld History Sheet Part 1
FORM NO. WELD RECORD SERIAL NO.

PART 1
SHIP NO. SYSTEM AND/OR COMPONENTS
DRAWING REFERENCE WELD IDENTITY
WELD PROCEDURE NO. SHOP SITE
BASE MATERIAL THICKNESS

FILLER MATERIAL WIRE
ELECTRODE
FLUX
GAS(ES)
PREHEAT TEMP °C METHOD OF MEASURE
HEAT TREATMENT INTERPASS TEMP °C METHOD OF MEASURE
POST WELD TEMP °C METHOD OF MEASURE
ROOT
WELDERS
COMPLETION
SURFACE CONDITION
JOINT DETAILS ‡
‡ For sleeve/socket welds this should include a statement of

whether the sleeve/socket was ‘Bevelled’ or ‘Square faced’ prior
to welding
REMARKS
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B.2 Weld History Sheet Part 2
PART 2 - INSPECTION RESULTS

VISUAL INSPECTION
SURFACE OF FINISHED WELD
AMOUNT OF UNDERCUT
NON-DESTRUCTIVE INSPECTION
METHOD REPORT NO. RESULTS PERSONNEL
REPAIRS
WELD ACCEPTED * / REJECTED *
APPROVAL AUTHORITY
SIGNATURE RANK OR DESIGNATION
* Delete as applicable
2-48
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Section 3
Normative References
1 The publications shown below are referred to in the text of this standard. Publications are grouped
and listed in alpha-numeric order.
Note: Def Stan’s can be downloaded free of charge from the DStan web site by visiting
<http://dstan.uwh.diif.r.mil.uk/> for those with RLI access or <https://www.dstan.mod.uk> for all other
users. All referenced standards were correct at the time of publication of this standard (see 2, 3 & 4 below for
further guidance), if you are having difficulty obtaining any referenced standard please contact the DStan
Helpdesk in the first instance.
Def Stans
Number Title
02-207, Pt 02, Iss Quality Management Framework and Requirements for Materiel Safety in Submarines -
02 Quality Requirements
02-341, Pt 01, Iss Requirements for Cleaning of Items, Components and Equipment for Fluid Systems -
02 Cleaning
02-729, Pt 01 Requirements for Non-Destructive Examination Methods - Radiographic
02-729, Pt 02 Requirements for Non-Destructive Examination Methods - Magnetic Particle
02-729, Pt 03 Requirements for Non-Destructive Examination Methods - Eddy Current
02-729, Pt 04 Requirements for Non-Destructive Examination Methods - Liquid Penetrant
02-729, Pt 05 Requirements for Non-Destructive Examination Methods - Ultrasonic
02-773, Iss 03 Minimum Non-Destructive Examination Acceptance Standards for Welds in HM

Submarines and Surface Ships not in Class
02-875, Iss 01 Weld Overlay Cladding and Hardfacing for Naval Applications
STANAGs
Number Title
Allied Publications
Number Title
Other References
Standard Type Standard Name
3-1
OFFICIAL
BS / BS EN / BS ASME B31.1 - Power Piping
ISO Standards
BS / BS EN / BS ASME B31.3 - Process Piping

ISO Standards
BS / BS EN / BS BPVC-IX: Welding, Brazing, and Fusing Qualifications

ISO Standards
BS / BS EN / BS BS 499: Welding terms and symbols Part 1: Glossary for welding, brazing and thermal
ISO Standards cutting
BS / BS EN / BS BS EN 12952: Water-tube boilers and auxiliary installations

ISO Standards
BS / BS EN / BS BS EN 13480: Metallic industrial piping Part 3: Design and calculation

ISO Standards
BS / BS EN / BS BS EN 50504: Validation of arc welding equipment

ISO Standards
BS / BS EN / BS BS EN ISO 15607: Specification and qualification of welding procedures for metallic

ISO Standards materials. General rules

ISO Standards materials. Welding procedure specification Part 1: Arc welding
BS / BS EN / BS BS EN ISO 15614 : Specification and qualification of welding procedures for metallic

ISO Standards materials. Welding procedure test Part 5: Arc welding of titanium, zirconium and their
alloys

ISO Standards materials. Welding procedure test Part 1: Arc and gas welding of steels and arc welding
of nickel and nickel alloys

ISO Standards materials. Welding procedure test Part 2: Arc welding of aluminium and its alloys

ISO Standards materials. Welding procedure test Part 4: Finishing welding of aluminium castings

ISO Standards materials. Welding procedure test Part 6: Arc and gas welding of copper and its alloys
BS / BS EN / BS BS EN ISO 2553: Welding and allied processes. Symbolic representation on drawings.

ISO Standards Welded joints.
BS / BS EN / BS BS EN ISO 3834: Quality requirements for fusion welding of metallic materials Part 2:
ISO Standards Comprehensive quality requirements.
BS / BS EN / BS BS EN ISO 9001: Quality management systems. Requirements

ISO Standards
BS / BS EN / BS BS EN ISO 9606: Qualification test of welders. Fusion welding Part 2: Aluminium and
ISO Standards aluminium alloys
BS / BS EN / BS BS EN ISO 9606: Qualification test of welders. Fusion welding Part 1: Fusion welding.
ISO Standards Steels
3-2
OFFICIAL
BS / BS EN / BS BS EN ISO 9606: Qualification test of welders. Fusion welding Part 3: Copper and
ISO Standards copper alloys
BS / BS EN / BS BS EN ISO 9606: Qualification test of welders. Fusion welding Part 4: Nickel and nickel
ISO Standards alloys
BS / BS EN / BS BS EN ISO 9606: Qualification test of welders. Fusion welding Part 5: Titanium and
ISO Standards titanium alloys, zirconium and zirconium alloys
Other DGS GS 3003: General Welding Specification for Nuclear Plant and Machinery
Civilian/Industry
Standards
Other Specification 9023: Welding and Fabrication of Pipework, Machinery and Engineering
Civilian/Industry Components. BAE SYSTEMS Marine Limited.
Standards
Other SSP 25: Quality Assurance for Safety in Submarines (Superseded by Interim Def Stan
Civilian/Industry 02-207, Retained for Legacy Equipment)
Standards
2 Reference in this Standard to any normative references means in any Invitation to Tender or contract
the edition and all amendments current at the date of such tender or contract unless a specific edition is
indicated. Care should be taken when referring out to specific portions of other standards to ensure that they
remain easily identifiable where subsequent amendments and supersession’s might be made. For some
standards the most recent editions shall always apply due to safety and regulatory requirements.
3 In consideration of clause 2 above, users shall be fully aware of the issue, amendment status and
application of all normative references, particularly when forming part of an Invitation to Tender or contract.
Correct identification of standards is as defined in the ITT or contract.
4 DStan can advise regarding where to obtain normative referenced documents. Requests for such
information can be made to the DStan Helpdesk. Details of how to contact the helpdesk are shown on the
outside rear cover of Defence Standards.
3-3
OFFICIAL
Definitions
For the purpose of this standard, ISO/IEC Guide 2 ‘Standardization and Related Activities – General
Vocabulary’ and the definitions shown below apply.
Definition Description
Approval Authority The organisation responsible for approving Weld Procedures. For Weld Procedures
produced by a Prime Contractor, MOD (DES-SE-Sea-MT) will be the Approval Authority,
except where other arrangements are specified in the Contract. For Weld Procedures
produced by a sub-contractor, the Prime Contractor will be the Approval Authority. Other
arrangements for weld procedure approval may be specified in the Contract.
Design Authority The approved firm, MOD establishment or branch responsible for the detailed design of
material to approved specifications and authorized to sign a certificate of design to certify
sealed drawings.
Dissimilar Metal Welds between two metals which differ sufficiently in metallurgical and physical
Welds properties to require special consideration in procedure qualification and inspection.
Examining Body A recognised Classification Society e.g. Lloyds, DNV, Bureau Veritas, who verify that
the weld procedure approval testing has been carried out in accordance with the
applicable standard.
Flat or Essentially A surface in a single plane or a curved surface of 250 mm radius or over.
Flat Surfaces
Gas Purging Atmospheric conditioning within a component, to protect the weld and parent metal
during welding the initial passes or the completed weld thickness, dependent on material
and thickness being welded.
Gas Shielding Atmospheric conditioning local to the weld during the welding process.
Interpass In a multiple weld, the interpass temperature is the temperature range of the deposited
Temperature weld metal and adjacent base material, prior to subsequent weld deposition. Interpass
temperature shall be measured on the parent metal on the side from which welding will
be performed, within 25 mm of the edge of the weld preparation and along the joint for
a length equal to the proposed continuous deposit.
Metallographic Examination to reveal the constituents and structure of metals and their alloys. The
Examination object of the examination may require the development of less detail in some cases than
in others. The terms macroscopic and microscopic are used in this Defence Standard
to define the normal levels of examination required, which are macroscopic examination
up to x10 magnification, and microscopic examination up to a maximum magnification
of x100.
Naval Reactor The NRPb is defined as those systems/equipments/components that are categorised as
Plant Boundary Nuclear Safety Significant and/or Nuclear Safety Essential. The NRPb is defined,
(NRPb) approved and maintained by the Naval Reactor Plant Authorisee.
Organisation The Contractor or Establishment where work to this Defence Standard is carried out.
Post-Heating The application of heat to a weld subsequent to a welding or thermal cutting operation.
Pre-heating The application of heat to the base material(s) prior to a welding or thermal cutting
operation.
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OFFICIAL
Thermal Treatment Any process involving the controlled heating and cooling of materials.
Welder A person performing a manual, mechanised or semi-automatic welding operation.
Welder The demonstration by a welder of his/her ability to produce acceptable welds using a
Qualification proven weld procedure (WPS) and meeting prescribed standards. A welder who
performs a satisfactory weld procedure qualification test is concurrently qualified to
make production welds to that procedure within the limits of the welder approval and
welding procedure specifications.
Welding Operator A person who operates automatic welding equipment.
Welding Procedure A PQR is a record of the welding and test data raised to qualify the WPS. It contains the
Qualification welding variables used to produce the test weld, and also the non-destructive and
Record (PQR) destructive test results obtained from the test weld.
Welding Procedure A WPS is a written and qualified document incorporating all the essential elements and
Specification guidance necessary to produce welded joints in accordance with the applicable
(WPS) fabrication document.
3-5
OFFICIAL
Abbreviations
Abbreviation Description
ASME American Society of Mechanical Engineers
BS British Standard
Def Stan Defence Standard
DERA Defence Evaluation and Research Agency
DGS GS Director General Submarines: General Specification
EN European Normalisation
FCAW Flux Cored Arc Welding
HM Her Majesty's
ISO International Organization for Standardization
JSP Joint Services Publication
MIG Metal Inert Gas
MMA Manual Metal Arc
MOD Ministry of Defence
NDE Non-destructive Examination
NDT Non-Destructive Testing
NRPb Naval Reactor Plant Boundary
PCN Personnel Certification in Non-Destructive Testing
ppm Parts per million
PQR Procedure Qualification Record
PWHT Post Weld Heat Treatment
SSMG Submarine Support Management Group
SSP Sea Systems Publication
SSR System Surveillance Requirements
SUBIPT Submarine Support Integrated Project Team
T Thickness
TIG Tungsten Inert Gas
3-6
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USA DoD United States of America Department of Defence
W/W Percent by weight
WPS Welding Procedure Specification
3-7
OFFICIAL
©Crown Copyright 2020
Copying Only as Agreed with DStan
Defence Standards are published by and obtainable from:
Defence Equipment and Support
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
DStan Helpdesk
Tel: +44 (0) 141 224 2531
Internet e-mail: [email protected]
File Reference
The DStan file reference relating to work on this standard is 69/2/772.
Contract Requirements
When Defence Standards are incorporated into contracts, users are responsible for their correct
application and for complying with contractual and statutory requirements. Compliance with a Defence
Standard does not in itself confer immunity from legal obligations.
Revision of Defence Standards

Defence Standards are revised as necessary by an up-issue or amendment. It is important that users
of Defence Standards ensure that they are in possession of the latest issue or amendment. Information
on all Defence Standards can be found on the DStan Websites https://www.dstan.mod.uk and
http://dstan.uwh.diif.r.mil.uk/, updated weekly. Any person who, when making use of a Defence
Standard, encounters an inaccuracy or ambiguity is encouraged to notify UK Defence Standardization
(DStan) without delay in order that the matter may be investigated and appropriate action taken.

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Defence Standard 02-772

Issue 2 Date: 14/11/2020

Title: Def Stan 02-772

Welding and Fabrication of Pipework, Machinery and Engineering Components for

3.3 A typical standard history, or weld record, is shown in Annex B.

a) Method and rate of heating;

b) Maximum temperature and duration at temperature;

c) Furnace atmosphere, if applicable;

d) Method and rate of cooling.

7.4 For detailed requirements refer to Clause 7.

8 Equipment and Facilities

a) Suitable and validated welding equipment;

b) Suitable facilities for the fabrication of the components being manufactured;

c) Suitable and validated heat treatment facilities including recording equipment;

e) Adequate facilities for mechanical testing and metallurgical examination.

9.2 Preparation of Base Material

9.2.2 Thermally cut material shall be subject to the following:

9.3 Assembly Alignment

9.3.1 Parts may be assembled using jigs and fixtures.

9.4 Control of Distortion

9.5 Root Pass Welding and Backing

a) The backing rings shall be in accordance with Figure 16 A - F and H;

a) For copper and nickel alloys: 800ppm moisture and 1% oxygen.

c) For stainless steels: 5000ppm moisture and 1% oxygen.

9.7 Welding Practice

Table 1 - Weld Bead Diameter Maximum

9.7.6 Temperatures shall be determined by optical or surface contact pyrometers, or thermocouples in

9.8 Consumable Control

9.9 Post Weld Heat Treatment

a) The completed structure; or

b) The sub-assembly containing the weld; or

a) Gas: 0.23 grams per cubic metre;

b) Oil: 0.5 percent by weight (W/W).

9.10 Defect Removal

9.10.2 The complete removal of such defects shall be verified by:

a) Visual inspection followed by;

c) Repeating the inspection which originally disclosed the defect.

9.11 Repair Welding

a) Final heat treatment;

b) Final hydrostatic test;

d) Repeated repair of defects which recur in welds:

i) After the third cycle of repair;

a) Location of defective joint or base material;

c) Description of defect including nature, size and maximum defects;

d) Approved weld procedure reference;

f) Identification of welder making repair and extent of relevant welder's approval.

9.12 Identification and Marking

9.13 Test Pieces for Pressure Vessels

a) From the parent plate; or

10.2 Qualification of Welding Procedures

a) General rules - BS EN ISO 15607;

b) Welding procedure specification:

i) BS EN ISO 15609-1 (arc welding);

i) BS EN ISO 15614-1 (steels, nickel and nickel alloys);

10.3 Qualification of Welders

a) BS EN ISO 9606-1 (steels);

b) BS EN ISO 9606-2 (aluminium and aluminium alloys);

c) BS EN ISO 9606-3 (copper and copper alloys);

d) BS EN ISO 9606-4 (nickel and nickel alloys);