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है”ह”ह

IS 8119 (1976): Copper brazed steel tubing [MTD 19: SteelTubes, Pipes abd Fittings]

IS : 8119 - 1976

Indian Standard SPECIFICATION FOR

COPPER BRAZED STEEL TUBING

( First Reprint OCTOBER 1990 )

UDC 621.643.2:669.146.9-462.2:669.387:621.791.36

0 Copyright 1976

BUREAU OF INDIAN STANDARDS

MAKAK BtlAVAN. 9 BAHADUR SHAH ZAFAR MARG

NtiW DELHI 1 loo02

Gt3 Odober 1976

J

IS I 8119 - 1976

Indian Standard ’

SPECIFICATION FOR COPPER BRAZED STEEL TUBING

Steel Tubes, Pipes and Fittings Sectional Committee, SMDC 22

Chairman Representing

SHRI J. G. KESWANI Indian Tube Co Ltd, Calcutta

Members

SHRI S. C. ANAND Bharat Steel Tubes Ltd, New Delhi SHIU K. C. SRIV~ST~VA ( Alternnte )

SHRI E. ANANDA RAO Tube Products of India, Madras SHRI T. SIV~SHANKAR ( Alternate )

ASSISTANT DIRECTOR STANDARDS Ministry of Railways

s;R$“,;Hz;xNow Hindustan Steel Ltd, Rourkela

S&I C. Das GVPTA ( Alternate ) SHRI B. B. CHAKRAVERTI Superintendence

Calcutta Co of India ( Private ) Ltd,

SHRI A. K. SHOME ( Alternate ) DR R. K. DUBEY National Metallurgical

Jamshedpur Laboratory ( CSIR ),

EXECUTIVE ENOINEER, CENTRAL Central Public Works Department, New Delhi STORES DIVISION No. 1

SHRI S. K. GUPTA Indian Tube Co Ltd, Jamshedpur SHRI D. DUTTA ( Alternate )

SHRI T. N. JH~ Central Boilers Board. New Dellti SHRI JACOB JOHN Kalinga Tubes Ltd, Calcutta

SHRI AJIT MOHaPATRA ( &&?I& ) SHRI M. T. KANSE Directorate General of Supplies & Disposals

( Inspection Wing ), New Delhi SKRI S. C. KAPUR ( Alternate )

SHRI B. Kul1.4~ Stewarts & Lloyds of India Ltd, Calcutta SHRI P. N. CHOWRANCHI (_Alternale )

CDR V. N. ~IADHAV RAO Defence Metallurgical Research Hyderabad

Laboratory,

S+rnr S. MITT.~L Indian Oil Corporation Ltd, Bombay SHRI R. K. AIRY ( Alternnte)

SHRI S. NEELAKANTAN Zenith Steel Pipes Ltd, Khopoli SHRI B. A. D~s.41 ( Alternate )

SIIKI GOP~L J. PATEI. Gu,jarat Steel Tubes Ltd, Ahmadabad SHIII SHAILESH V. SHAH ( Alternate )

SHJ~I N. B. ROY CHOWDH~:TRY Burmah-Shell Refineries Ltd, Bombay SHW S. L. ARANJIA ( Alternate )

( Continued on pn ge 2 )

@ Copyright 1976

BUREAU OF INDIAN STANDARDS This publication is protected under the Indian Copyright Act ( XIV of 1957 ) and. reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act.

IS : 8119 - 1976

( Continued from page 1 )

Members

&RI J. L. SET-I

Represeriting

Public Works Department ( Public Health Branch ), Government of Haryana, Chandigarh

SHP.I A. N. MEHESDALE ( Alternote ) SHRI s. SRIXIVASAN Hindustan Shipyard Ltd, Visakhapatnam

&Rx M. C. KEW~VA RAO ( Altern& ) SHRI .A. SRINIVASULU Bharat Heavy Electric& Ltd, Tiruchirapalli

SIIJLI C. R. R_~NA RAO, Director General, IS1 ( Ex-oBcio Member ) Director ( Strut & Met ) ( SecretmY )

Panel for Copwr Brazed Steel Tubes, SMDC-22 : P22

Conoener

SHRI D. DUTTA Indian Tube Co Ltd, Jamshedpur

Member

DR A. P. I\/IAIiADEVIN Bundy Tubing of India Ltd, Vadodara SHRI S. SWAIINATRAN ( Alternate )

2

IS r 8119 - 1976

Indian Standard SPECIFICATION FOR

COPPER BRAZED STEEL TUBING

0. FOREWORD

0.1 This Indian Standard was adopted by the Indian Standards Institution on 15 July 1976, after the draft finalized by the Steel Tubes, Pipes and Fittings Sectional Committee had been approved by the Structural and Metals Division Council.

0.2 There has been a long felt need for copper brazed steel tubes used specially in automotive, refrigeration and stove industries for fuel lines, brake lines, oil lines and in heating and cooling units. It is hoped that this standard will give necessary guidance to the industry and users.

0.3 In the preparation of this standard assistance has been derived from ASTM : A 254-1970 ‘ Specification for copper brazed steel tubing ’ issued by the American Society for Testing and Materials.

0.4 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, express- ing the result of a test or anaLyysis, shall be rounded off in accordance with IS : 2-1960*. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

1. SCOPE

1.1 This standard covers two classes of copper brazed steel tubes suitable for general engineering uses, particularly inthe automotive, refrigeration, and stove industries for fuel lines, brake lines, oil lines, heating and cool- ing units, etc.

2. SUPPLY OF MATERIAL

2.1 General requirements relating to the supply of copper brazed steel tubes shall conform to IS : 1387-19671_.

*Rules for rounding off numerical values ( revised ). jGenera1 requirements for the supply of metallurgical materials (first revision ).

lS:8119-1976

3. MANUFACTURE

3.1 The steel shall be aluminium-killed, rimming or capped Steel and shall be made by the open hearth, electric furnace, basic oxygen or a combination of these processes.

3.2 The tubing shall be made by rolling electrolytically copper plated steel strip in the form of tubes and subsequently brazing in a reducing atmosphere.

3.3 Class 1 brazed tubes shall be constructed as shown in Fig. 1.

3.4 Class 2 brazed tubes shall be constructed as shown in Fig. 2.

0 0 SINGLE STRIP TYPE DOUBLE STRIP TYPE

FIG. 1 CLASS 1 BRAZED TUBES DOUBLE WALL 360” BRAZED CONSTRUCTION

BUTT @RAZED tYPE BEVEL.BRAZED TVPE t(w .

Fro. 2 CLASS 2 BRAZED TUBES SINGLE WALL CONSTRUCTION

4

IS t 8119 - 1976

4. CHEMICAL REQUIREMENTS

4.1 The steel when analyzed in accordance with relevant parts of IS: 228; shall conform to the following requirements:

Element Percent, Max

Carbon 0.10

Manganese 0’50

Phosphorus 0’035

Sulphur 0.035

4.2 Each heat shall be analyzed by the steel manufacturer to determine the percentages of the elements specified in4.1. The chemical composition thus determined shall be reported to the steel purchaser, or his represcn- tative, and shall conform to the requirements specified.

5. MECHANICAL REQUIREMENTS

5.1 Tensile Test -Test pieces shall be taken from the ends of tubes (prior to cold-work) and tested in accordance with IS : 1894-19727 and shall comply with the following requirements:

Tensile strength 290 N/mma, Min

Yield strength 180 N/mm”, Min

Elongation on a gauge 25 percent, Min length of 5 65 4A

5.2 Flattening Test-The test shall be conducted in accordance with 1s : 2328-1963:. A ring not less than 65 mm in length, cut from one end of each selected tube shall, when cold, be flattened between two parallel flat surfaces without showing any crack or flaw, until the inside walls are in contact. In case of Class 2 tubes, the seam shall be located so as to receive the maximum deformation upon flattening.

5.3 Expansion Test - It shall be carried out in accordance with IS : 2335-19635. A section of tube approximately 50 mm in length shall withstand being expanded over a tapered mandrel or cone having an included angle of 30” until the outside diameter at the eipanded end is increased 20 percent without cracking or otherwise showing flaws. Prior to expansion test, tubes shall be cut off, square edge crowned and deburred. The tube and cone shall remain concentric during expgdsion tests.

-_-___ *Methods of chemical analysis of pig iron, cast iron, and plain carbon low alloy steels

( rcviscd ). +Methods for tensile testing of steel tubes (Jirst r~$~n ). fMethod for flattening test on steel tubes. OMethod for drift expanding test on steel tubes.

5

IS:8119-1976

5.4 Bend Test -The test sludl be carried out in accordance with IS : 2Y29-1Wi3*. The tube selected ~for test. shah withstand bending arolmd a cylindrical former through 360”, with the joint line at 90’- to the plane of bending. The diameter of the former shall be six times the outside diameter. The test piece shall withstand this test without kinking, cracking or developing other flaws.

5.5 Bending Shear Test - If a cut piece of tube bent by hand in the form of a hair pin (seam on inner side) shears-by reverse bending at bending radius in a direction perpendicular to the axis of the bend, neither should the walls of the tube separate nor should the seam get cracked.

5.6 Non-destructive Testing - The tubes shall be checked 100 per- cent for brazing and surface defects by non-destructive testing during production ( see IS : 4853-19687 and Is : 7343-1974:).

6. HYDRAULIC TEST

6.1 Each tube shall be capable of withstanding hydraulic test for a period of 5 seconds with no evidence of failure, at a pressure calculated by the follo\ving equation:

p22! D

where

P = hydraulic pressure in N/mm?;

S = allowable stress of material, that is;

1 IO N/mm? for Class I 45 N/mm2 for Class II;

t = wall thickness of tube in mm; and

D = outside diameter of tube in mm.

7. INSIDBURFACE CLEANLINESS

7.1 \Vhen specified by the purchaser, tubes for certain uses, such as refrigeration condensers, shall conform to the following requirements for internal cleanliness.

7.1.1 When a length of tube is washed, internally with redistilled chloroform or redistilled trichloroethylene, the residue remaining upon evaporation of the solvent shall not exceed 0.194 g/m*of internalsurface.

*Method for bend test on steel tubes. tRecommended practice for radiographic examination of fusion welded circumferen-

tial joints in steel pipes. $Code of practice for ultrasonic testing of welded pipes and tubular products.

6

Es t 8119 - 1976

To perform the test, pour 100 ml of solvent through the tube and collect. The total length of tube tested shall be not less than 12.2 m, although this total length may be obtained by washing several separate lengths .and pouring the same solvent through each in succession. Evaporate the solvent on a steam-bath or hot water-bath and dry at 110°C until the vapours are completely removed.

7.2 To maintain this level of cleanliness in shipping, handling, and storage, the purchaser may request the manufacturer to seal tube ends with caps or closures.

8. DIMENSlONAL TOLERANCES 8.1 Tubes shall conform to permissible variations indimensions as speci- fied below:

Outside Diameter

Below 4.8 mm f 0.05 mm 4.8 mm up to and including 95 mm f 0’08 mm Over 9.5 mm up to and including 15.9 mm f 0’10 mm

Wall Thickness

0.50 mm up to and including 0.76 mm Over~0.76 mm up to and including 1.25 mm

Length

Up to and including 0.5 m Over 0.5 m up to and including 1.0 m Over 1.0 m up to and including 20 m

Over 2.0 m up to and including 3.0 m

f 0.08 mm f 0.09 mm

f 0’75 mm f 1’5 mm f 3’0 mm h 6.0 mm

Over 3-O m + 25’0 mm - 0’0 mm

9. WORKMANSHIP l

9.1 Finished tubes shall be clean, smooth and round, both inside and outside and shall be free from rust, scale and defects which impair pro- cessing and serviceability. Finished tubes shall be reasonably straight.

10. SUPPLEMENTARY RIQUiREMENTS

10.1 FlareTest -Class 1 tubes shall stand being double flared to the dimensions shown in Tables 1 and 2. The double flaring shall be done on square, deburred tube ends, using a hand tool or powered press, in two stages. Jn the first stage a tool forms the upset (see Fig. 3A ), while in the second stage another tool gives the final shape ( see Fig. 35).

7

IS t 8119 - 1976

The tubes shall not split through the wall at the major diameter of the flare. A separation of the outer lap joint is permissible on the flared end of the tube only in area A (see Fig. 3 ). This separation shall not exceed 3’0 mm in length and shall be confined to outer thickness only. Seam separation is not permitted in the following areas:

a) Area B (the flare seat, defined as the surface within the 90”’ included angle): conical surface shall be smooth and free from cracks or other irregularities that could cause leaks after assembly.

b) Area C ( the surface beyond the length of the double thickness cracked by the flare ).

3A First Stage in Double Flare Formation

38 Second Stage in Double Flare Formation

FIG. 3 DOUBLE FLARE TEST

8

IS: 8119- 1976

TABLE 1 DIMENSIONS OF 45” FLARES

NOMINAL OUTSIDE DIAMETER

(‘1 3~18 476 6.35 7.94 9.52

11.11 12.70 14.29 15.88

( Clause 10.1 and Fig. 4 )

All dimensions in millimetres.

DOUBLE FLAIW DIA, B, Corsw LENGTH, _-h--- C,, Min A4a.v .Min

(2) (3) (4) 5.4 5.0 1 7.1 6.7 9.1 8.7 :

10.8 10.4 1.6 12;7 12-3 1% 14.5 14.1 16.3 15.9 ::;

18.1 17.7 1.6 19.6 19.2 1.6

2 ‘I IMES ACTUAL WALL THICKNESS 2 o t>,,,m WALLS TO’BE IN INTIMATE CONTACl OVER ENTIRE SEAT LENGTH

ACTUAL TUBE ID+oaa

All dimensions in millimetres.

FIG. 4 DOUBLE 45” FLARES FOR TUBES

NOXINAL OUTSIDE

DIAMETER

(1) 3’18 4.76 6’35 7.94 9.52

12.70 15.88

TABLE 2 DIMENSIONS OF 37” FLARES

( C’lause 10.1 and Fig. 5 )

All dimensions in millimetres.

DOUBLE FLARE DIA, B, RADIUS, c__-__~ RI

Max Min

(2) (3) (4) 5.1 7’1

12 12.4 16’7 20.0

4.6 0.8 f 0.5 6.6 0.8 & 0’5 8.6 0.8 f 0.5

10.2 0.8 & 0.5 11.7 1.0 + 0.5 16.0 1.5 ? 0.5 193 1’5 f 0.5

WALL THICKNESS,

D,, Max

(5) 0.63 0.71 0.88 0’88 1.24 1.24 1.24

IS:8119-1976

WALLS TO BE CONTACT OVE SE AT LENGTH

ACTUAL TUBE IO +0.25

All climcnsions in millimetres.

FIG. 5 DOUBLE 37” FLARES FOR TUBES

10.2 External Coating -The outside surface of the tubes shall have a coating of hot-dipped lead-tin alloy-coating or electroplated zinc as specified by the purchaser. Weight and other requirements of coating shall be agreed upon between the manufacturer and the purchaser.

10.3 End Finish -When so specified by the purchaser, finished tubes shall have smooth ends free of burrs.

11. MARKING

11.1 The following information shall be marked on a tag or label securely attached to the bundles or boxes in which the tubes are dispatched:

a) Manufacturer’s name or trade-mark,

b) Size, and

c) Class of tubes.

11.1.1 The tubes may also be marked with the ISI Certification Mark. NOTE - The use of the ISI Certification Mark is governed by the provisions of the

Indian Standards Institution ( Certification Marks) Act and the Rules and Regulations made thereunder. The ISI mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well-defined system of inspection, testing and quality control which is devised and supervised by ISI and operated by the producer. IS1 marked products are also continuously checked by IS1 for conformity to that standard as a further safe- guard. Details of conditions under which a licence for the use of the IS1 Certification Mark may be granted to manufacturers or processors, may be obtained from the Indian Standards Institution.

10

IS t 8119 - 1976

12. INFORMATION TO BE SUPPLIED BY THE PURCHASER

12.1 The purchaser shall state in his enquiry or order:

a) the size ( outside diameter, wall thickness and length of tubes); b) the class of tube required;

c) the inside surface cleanliness where requir&d; d) the external coating where required; and e) special requirements, if any.

BUREAU OF INDIAN STANDARDS

Headquarters:

Manak Bhavan, 9 Bahadur Shah Zafar Marg. NEW DELHI 110002

Telephor;es: 331 01 31, 331 13 75 Telegrams: Manaksanstha ( Common to all Offices 1

Regional Offices: Telephone

Central : Manak Bhavan, 9 Bahadur Shah Zafar Marg,

I

331 01 31 NEW DELHI 110002 331 1375

*Eastern : l/l4 C. I. T. Scheme VII M, Y. I. P. Road. 36 24 99 Maniktola. CALCUTTA 700054

Northern : SC0 445-446, Sector 35-C, 21843 CHANDIGARH 160036 I 3 16 41

{

41 24 42 Southern : C. I. T. Campus, MADRAS 600113

t: f f :: tWestern : Manakalaya, E9 MIDC, Marol, Andheri ( East ), ,6 32 92 95

BOMBAY 400093

Branch Offices:

‘Pushpak’. Nurmohamed Shaikh Marg, Khanpur,

I

2 63 46 AHMADABAD 380001 2 63 49

+,Peenya Industrial Area 1 st Stage, Bangalore Tumkur Road 38 49 55 BANGALORE 560058

Gangotri Complex, 5th Floor, Bhadbhada Road, T. T. Nagar, I

38 49 56 667 16

8HOPAL 462003 Plot No: 82/83. Lewis Road, BHUBANESHWAR 751002 531’5. Ward No. 29, R.G. Barua Road, 5th Byelane,

GUWAHATI 781003

5-36 i7 3 31 77

5-8-566 L. N. Gubta Marg ( Nampally Station Road ), HYDERABAD 500001

23 1083

R14 Yudhister Marg. C Scheme, JAIPUR 302005

1171418 8 Sarvodaya Nagar, KANPUR 208005

i 634 71 6 98 32

I 21 68 76 21 82 92

Patliputra Industrial Estate. PATNA 800013 6 23 05 T.C. No. 14/1421. Unlversitv P.O.. Palayam /6 21 04

TRIVANDRUM 695035 16 21 17

inspection Offices ( With Sale Point ):

Pushpanjali. First Floor, 205-A West High Court Road, 2 51 71 Shankar Nagar Square, NAGPUR 440010

Institution of Engineers ( India ) Building, 1332 Shivaji Nagar, 5 24 35 PUNE 411005

*Sales Office in Calcutta is at 5 Chowringhse Approach, P. 0. Princep 27 68 00 Street. Calcutta 700072

tSaras Office in Bombay is at Novelty Chambers. Grent Road, 89 66 28 Bombay 400007

iSales Office in Bangalore is at Unity Building, Narasimharaja Square, 22 36 71 Bangalore 560002

Reprography Ud.t, BIS, New Delhi, In tia

AMENDMENT NO. 1 FEBRUARY 1984

TO

IS:8119-1976 SPECIFICATION FOR COPPER BRAZED STEEL TUBING

Alterations ------

(Page 5, dause 4.1) - Substitute the following for the existing clause:

'4.1 The steel when analyzed shall.conform to the following requirements:

Element Percent, Max

Carbon Manganese Phosphorus Sulphur

0.10 0.50 0.035 0 0035

4.1.1 !Phe analysis of steel shall be carried out either by the method specified in IS:228* and its relevant parts or any other established instrumental/ chemical method. In case of dispute the procedure given in 18:228* and its relevant parts shall be referee method. However, where the method is not given in 1s:228* and its relevant parts, the referee method shall be agreed to between the purchaser and the manufacturer.'

(Page 5_, foot-note with I+' mark) - Substitute the following for the existing foot-note:

'*Methods for chemical analysis of steels (issued in several parts).'

(SMDC 22)

Reprography Unit, BIS, New Delhi, India