BRITISH STANDARD BS 4870-3:1985Incorporating Amendment No. 1

Specification for

Approval testing of welding procedures —

Part 3: Arc welding of tube to tube-plate joints in metallic materials

UDC 621.791.001.4:[669-462:621.791.75]

BS 4870-3:1985

This British Standard, having been prepared under the direction of the Welding Standards Committee, was published under the authority of the Board of BSI and comes into effect on 29 March 1985

© BSI 12-1999

The following BSI references relate to the work on this standard:Committee reference WEE/36Draft for comment 83/79158 DC

ISBN 0 580 14365 1

Committees responsible for this British Standard

The preparation of this British Standard was entrusted by the Welding Standards Committee (WEE/-) to Technical Committee WEE/36, upon which the following bodies were represented:

Aluminium FederationAssociated Offices Technical CommitteeAssociation of Consulting ScientistsBritish Constructional Steelwork AssociationBritish Gas CorporationBritish Railways BoardElectricity Supply Industry in England and WalesEngineering Equipment and Materials Users’ AssociationHeating and Ventilating Contractors’ AssociationMinistry of DefenceNational Coal BoardPower Generation Association (BEAMA Ltd.)Process Plant AssociationSociety of Motor Manufacturers and Traders LimitedStainless Steel Fabricators’ Association of Great BritainUnited Kingdom Atomic Energy AuthorityWater-tube Boilermakers’ AssociationWelding InstituteWelding Manufacturers’ Association (BEAMA Ltd.)Coopted member

Amendments issued since publication

Amd. No. Date of issue Comments

6292 February 1990

Indicated by a sideline in the margin

BS 4870-3:1985

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Contents

PageCommittees responsible Inside front coverForeword ii1 Scope 12 Definitions 13 Items in a welding procedure test 14 Changes affecting approval 25 Extent of approval 36 Test pieces 47 Examination and testing 48 Statement of results 5Figure 1 — Test piece for tube ends on triangular pitch 6Figure 2 — Test piece for tube ends on triangular pitch when push-out tests are required 7Figure 3 — Test piece for tube ends on square pitch 8Figure 4 — Test piece for tube ends on square pitch when push-out tests are required 9Figure 5 — Typical examples of macro-examination specimens 9Figure 6 — General arrangement of push-out test pieces for front face and back face welds 10Table 1 — Grouping system for welding steels 3Table 2 — Grouping for joints between similar steels 4Table 3 — Acceptance levels 11Publications referred to Inside back cover

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Foreword

This Part of BS 4870 has been prepared under the direction of the Welding Standards Committee to cover the particular requirements for the approval testing of welding procedures for tube to tube-plate joints. While there is no limitation on the metallic materials to be used, extra considerations not covered in this standard may need to be taken into account for some materials.This Part of BS 4870 is one of a series of standards on the approval testing of welders and welding procedures, the latter having a bearing on the former for certain applications. This link has been used as a means of arranging the Parts of the standards for tube to tube-plate joints into:

a) approval testing of welding procedures;b) welder approval when approval of the welding procedure is required (see BS 4871-3).

It should be appreciated that the non-destructive testing acceptance levels given in this standard are for the purposes of approval testing of welding procedures and as such are not necessarily the same as those which might be specified for work on which approved welding procedures will be employed.Depending upon the emphasis placed on quality control in the production of welded components, the approval of welding procedures covered in this series of standards may be administered in one of several ways which should be stipulated at the enquiry and/or order stage. The alternatives currently employed are the following:

1) each individual contractor (or sub-contractor) may have proved, by actual test pieces, every weld form he wishes to use, in every thickness and material; or2) each individual contractor (or sub-contractor) may have proved, by actual test pieces, a set of welds representative on a group basis of all the various thicknesses and materials to be used in production; or3) each individual contractor (or sub-contractor) need not make procedure test pieces provided he can prove by appropriate authentic documentation of an independent nature that he has previously satisfactorily welded the type of joint and material in question.

In respect of 1) and 2) it should be appreciated that once the welding procedure tests have been approved, they need never be repeated unless there is a change in certain variables. As an extension beyond 3), it may be possible by agreement between the contracting parties for fully documented welding procedures, developed independently of the particular contractor, to be employed without the need for further approval tests.The need for a welding procedure to be approved in accordance with this standard should be specified in the application standard or be agreed between the contracting parties. Although a welding procedure may already have been approved, each manufacturer should accept responsibility for the procedure used on a contract and for the ability of the welders to apply the procedure.It has been assumed in the drafting of this British Standard that the execution of its provisions is entrusted to appropriately qualified and experienced people.A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application.

Compliance with a British Standard does not of itself confer immunity from legal obligations.

Summary of pagesThis document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 12, an inside back cover and a back cover.This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover.

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1 ScopeThis Part of BS 4870 specifies requirements for the approval testing of welding procedures for the arc welding of tube to tube-plate joints in metallic materials by manual, semi-automatic, automatic or mechanized processes.The welder who successfully completes a welding procedure test in accordance with this Part of BS 4870 is approved to the extent given in clauses 5 and 6 of BS 4871-3:1985 without further testing.NOTE 1 This Part of BS 4870 does not cover welding processes such as explosive welding, laser welding or electron-beam welding. The parameters to be recorded and the acceptance levels for such processes would, therefore, have to be agreed between the contracting parties, but this Part of BS 4870 may be used as the framework for such agreement.NOTE 2 The titles of the publications referred to in this standard are listed on the inside back cover.

2 DefinitionsFor the purposes of this Part of BS 4870, the following definitions apply.2.1 welding procedurea specific course of action followed in welding, including a list of materials and, where necessary, tools to be used1)

2.2 welding procedure testthe making and testing of a welded joint, representative of that to be used in production, in order to prove the feasibility of a welding procedureNOTE This term is not usually applied to any tests that may have been made during the development of a welding procedure.

2.3 approved welding procedurea documented welding procedure that has been approved by an inspecting authority either by means of a welding procedure test or as a result of authentic documented experience gained with the welding of joints similar to that to which the welding procedure applies2.4 test piececomponents welded together in accordance with a specified welding procedure2.5 test specimena portion detached from a test piece and prepared as required for testing

2.6 inspecting authoritythat competent independent body or association which verifies compliance with this standard

3 Items in a welding procedure test3.1 General

The items listed in 3.2 and the items in 3.3 relevant to the particular welding process shall be recorded for each welding procedure test.NOTE Not all of these items need be included in the approved welding procedure documentation.

3.2 Items for all welding processes

Details relating to the following items shall be recorded for all welding processes:

a) welding process, or processes when more than one is used in making a complete joint;b) tube-plate specification and thickness and details of any cladding and its thickness;c) tube specification, thickness and outside diameter;d) pitch type (square or triangular) and ligament dimension;e) joint geometry and fit-up tolerances (sketch);f) cleaning and degreasing;g) jigging or tacking, roller expansion and backing;h) tube-plate position (including welding direction for vertical tube-plates);i) make, trade name, type and specification of welding consumables;j) filler material composition, specification and size (diameter);k) pre-heating and interpass temperature, including method of control;l) travel speed (mechanized or automatic welding);m) approximate number and arrangement of runs and weld dimensions (sketch);n) welding sequence;o) post-weld heat treatment, including method and control;p) when applied, the temperature and time adopted for drying/baking of welding consumables before use;q) any special features, including heat input control requirements, any heat sinks or post-weld tube expansion.

1) This definition is taken from BS 499-1.

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3.3 Items for particular welding processes

Details relating to the items given in 3.3 a) to 3.3 d) shall be recorded for these particular processes, in addition to the items in 3.2.

a) Manual metal-arc welding1) a.c. or d.c. and polarity;2) current.

b) MIG and MAG welding, solid wire or cored wire, with or without separate gas shield

1) shielding gas and flow rate;2) nozzle diameter;3) arc voltage;4) wire feed speed or current;5) for pulsed welding, the pulse time and interval, pulse current and background current.

c) TIG welding1) tungsten electrode diameter, type and tip included angle;2) shielding gas and flow rate;3) nozzle diameter;4) a.c. or d.c. and polarity;5) current;6) for pulsed welding the pulse time and interval, pulse current and background current;7) whether filler metal is used;8) length of filler metal used per run when dilution is an important factor.

d) Mechanized or automatic welding1) all the items in b) or c) above;2) arc length or arc voltage;3) where filler metal is used its rate of addition or wire feed speed;4) other pre-programmed welding variables such as:

i) pre- and post-gas purge times;ii) changes in current level;iii) current slope up and down rates;

5) welding travel speed and degree of overlap;6) when considering front face welding, the following additional information:

i) radius of electrode rotation;ii) electrode angle relative to the tube axis;

7) when considering back face bore welding, the following additional information:

i) if a flux is used at the back of the joint its type or specification and amount;ii) if a shielding gas is used at the back of the joint its composition and flow rate;iii) electrode axial position.

Where machine settings are quoted, these shall be backed up with documented calibration that enables the true value of the parameter to be assessed, e.g. wire feed setting shall be related to actual wire feed speed.

4 Changes affecting approval4.1 For manual or semi-automatic welding, a welding procedure test shall be carried out when any of the following changes are made to an approved welding procedure:

a) any change in welding process;b) any change in parent metal, tube pitch, tube or tube-plate thickness, cladding thickness or tube outside diameter, subject to the extent of approval given in clause 5;c) any change in joint geometry that would affect the welding procedure;d) any change in type2) or specification of the consumable electrode, filler metal, wire, flux or shielding gas;e) any change in type of welding current, e.g. from d.c. to a.c. or change in polarity;f) any change in pre-heating temperature except for an increase of not more than 100 °C;g) any change in post-weld heat treatment temperature range;h) the addition or deletion of filler metal, i.e. a change to or from autogenous welding;i) any change in tube-plate position.

4.2 For mechanized or automatic welding, a welding procedure test shall be carried out when there is a change to any of the items recorded in accordance with clause 3, subject to the extent of approval given in clause 5.4.3 Any change in make, trade name, drying/baking or size [other than as given in 4.1 d) or h)] of filler material or in the shielding or back purging gas shall be reported to the purchaser.NOTE By agreement between the contracting parties, re-approval of such changes may be waived.

2) In respect of a consumable electrode or filler material, “type” means the compulsory part of the classification according to the standard with which it complies, but a change to a consumable electrode or filler material with a different classification does not necessitate re-approval of the welding procedure if the change is agreed between the contracting parties on the evidence of available mechanical test data.

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Table 1 — Grouping system for welding steels

4.4 In the absence of any of the changes stated in 4.1, 4.2 or 4.3, the approved welding procedure shall remain in force indefinitely.

5 Extent of approval5.1 Parent metal

5.1.1 Grouping system. In order to minimize the unnecessary duplication of technically identical procedure tests, steels with similar metallurgical and welding characteristics shall be grouped for the purposes of welding procedure approval as shown in Table 1.In using the grouping system it shall be ensured that the requirements of clause 4 are met; in particular, it is emphasized that a change in the welding process, type of welding consumables or the post-weld heat treatment range requires the re-approval of a welding procedure.Separate welding procedure approval shall be obtained for any material not covered by the grouping system.NOTE Where the grouping system is being applied, a separate welding procedure sheet should be issued for each parent metal/welding consumable combination that is derived from an approved procedure.

5.1.2 Autogenous welds. For autogenous welds, separate welding procedure approval shall be obtained for each group of steels.NOTE In using autogenous welding, the parent metal chemical composition should be carefully studied. It does not necessarily follow that the successful welding of one steel within a group will result in a successful weld on a similar steel within the same group. A pre-production test may be desirable to substantiate the results of a previous procedure test.

5.1.3 Grouping for joints between similar steels when procedures involve filler metal addition. The grouping for joints between similar steels when procedures involve filler metal addition shall be as follows.

a) Approval on a steel within a particular group shall include approval for welding on any other steel within the same group.b) Approval on a group A2 steel shall include approval for welding in group A1 steels, but not the converse.c) Approval on a group B steel shall include approval for welding in groups A1 and A2 steels, but not the converse.d) Approval on a group K steel shall include approval for welding in groups A1 and A2 steels, but not the converse.e) Approval on a group D steel shall include approval for welding in group B steels, but not the converse.f) Approval on a group F steel shall include approval for welding in group E1 steels, but not the converse.

Group Type of steela

A1 C and C-Mn steel with minimum tensile strength in the specification up to and including 430 N/mm2

A2 C and C-Mn steel with minimum tensile strength in the specification over 430 N/mm2 b

B C-Mo steel

C Mo-B steel and Mn (Ni) Cr Mo V steel

D 1 – 1! Cr " Mo steel

E1 2 – 3 Cr 1 Mo steel, normalized and tempered

E2 2 – 3 Cr 1 Mo steel, quenched and tempered

F " Cr " Mo ! V steel

G 5 Cr " Mo steel

H 9 Cr 1 Mo steel

J 12 Cr Mo V steel

K 3" Ni steel

L 9 Ni steel

M 13 Cr ferritic stainless steel

N 17 – 20 Cr ferritic stainless steel

P and Q Reserved for future allocation of other steel groups

R 304 type austenitic stainless steelc

S 310 type austenitic stainless steel

T 316 type austenitic stainless steelc

U 321 type austenitic stainless steelc

V 347 type austenitic stainless steel

W to Z Reserved for future allocation of other steel groups

a Appendix A in BS 4870-1:1981 gives examples of generally recognized weldable steels in each group.b Care is required in the welding of BS 4360 grade 55 steel with respect to the attainment of the minimum tensile properties with the welding consumables used.c Warm-worked and nitrogen-bearing varieties are excluded from the grouping system. For such steels separate welding procedure approval has to be obtained.

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g) Approval on any austenitic stainless steel in group R, S, T, U or V shall include approval for any other austenitic stainless steel in groups R, S, T, U or V provided that appropriate filler metal is used3).

These requirements are summarized in Table 2.Table 2 — Grouping for joints between

similar steels

5.1.4 Grouping for joints between dissimilar metals. Separate welding procedure approval shall be obtained for each combination of dissimilar metals.

5.2 Tube pitch

The approval of a welding procedure using a particular pitch of tubes shall include approval for any other type or pitch provided that the ligament dimension (see Figure 1 to Figure 4) is not reduced to below that used in the approved procedure.

5.3 Cladding

Irrespective of the tube-plate thickness, when welding a clad tube-plate any reduction in nominal cladding thickness shall entail re-approval of the welding procedure.

5.4 Thickness and diameter

5.4.1 Mechanized or automatic welding. Each nominal thickness of tube or tube-plate and each nominal outside diameter of tube shall be separately approved, except that approval of a procedure on a tube-plate of thickness 35 mm or greater shall include approval for all tube-plate thicknesses 35 mm and above.5.4.2 Manual welding. Each nominal thickness of tube or tube-plate and each nominal outside diameter of tube shall be separately approved except that:

a) approval of a procedure on a tube of nominal thickness t above 3 mm shall include approval in the thickness range t to 2t;

b) approval of a procedure on a tube-plate of nominal thickness 35 mm or above shall include approval for all tube-plate thicknesses 35 mm and above;c) approval of a procedure on a tube-plate of nominal thickness T below 35 mm shall include approval in the thickness range T to 2T;d) approval of a procedure on a tube of nominal outside diameter 19 mm or larger shall include approval for all diameters 19 mm and above.

6 Test pieces6.1 General

Procedure test pieces shall be produced in accordance with 6.2 and shall simulate the joint geometry to be used in production or a similar geometry within the requirements of clauses 4 and 5.

6.2 Type of test joint

6.2.1 Tube ends welded on triangular pitch. Where tube end welds are involved on a triangular pitch, a minimum of seven tube ends shall be welded as shown in Figure 1. When push-out tests are required (see 7.6) 10 tube end welds shall be welded as shown in Figure 2.6.2.2 Tube ends welded on square pitch. Where tube end welds are involved on a square pitch, a minimum of nine tube ends shall be welded as shown in Figure 3. When push-out tests are required (see 7.6) 13 tube end welds shall be welded as shown in Figure 4.

6.3 Welding

Welding shall start at a position so that the macro-examination sections can be cut through two or three root run start positions (see Figure 1 to Figure 4).NOTE The test piece may need positioning to facilitate sectioning through start positions.

7 Examination and testing7.1 General

For a welding procedure to be approved the same test piece representing the welding procedure test shall comply with 7.2 to 7.5 and, when required, with the push-out tests described in 7.6.The existence of any defects or parameters outside the acceptance levels given in Table 3 shall be sufficient cause for rejection. Minor local defects, except cracks, which can be established as being due solely to the welder’s workmanship shall not be cause for rejection.

3) Guidance on the selection of filler metal is given in BS 4677.

Steel group of originally approved procedure

Steel group also approved

A1 A2 B E1 R, S, T, U or V

A2 X X — — —

B X X X — —

D — — X — —

F — — — X —

K X X — — —

R, S, T, U or V — — — — XNOTE 1 X indicates applicability.NOTE 2 Approval on any steel within a group includes approval on any other steel within the same group.

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If a test piece fails to comply with any of the requirements in 7.2 to 7.6, a further complete test piece shall be welded and subjected to the same examinations. If this additional test piece does not comply with the relevant requirements, the procedure shall be regarded as not capable of complying with this standard without modification.The test pieces shall be sectioned as shown in Figure 1 to Figure 4 and subjected to the specified tests.NOTE It may be useful and advantageous, or even necessary for compliance with other standards, to carry out more comprehensive testing than is required by this clause (e.g. magnetic particle inspection, ultrasonic examination, micro-examination) in order to gain more information and to avoid having to repeat the Welding procedure test at a later date just to obtain additional test data.

7.2 Visual examination

After any post-weld heat treatment and appropriate cleaning, and prior to the cutting of test specimens, the test piece shall be examined visually.The welds shall show uniform contour without excessive reinforcement, with the bores of the tubes free from any spatter or burn through. Weld spillage into the bore shall be assessed in accordance with Table 3.

7.3 Liquid penetrant examination

The external surfaces of all welds shall be subjected to liquid penetrant examination in accordance with BS 4416.The internal surfaces of bore welds shall be examined after sectioning for macro-examination.

7.4 Radiographic examination

All test welds, except those for push-out tests, shall be radiographed.For front face welds, the tube-plate shall be reduced in thickness to not less than the maximum weld depth into the tube-plate plus 2.5 mm, but in any case the resultant thickness shall be not less than 6.5 mm. Sensitivity shall be 2 % or better when using a wire type image quality indicator in accordance with BS 3971. General requirements for the method of examination shall be in accordance with BS 2600-1.NOTE 1 It is recommended that technique 2 in BS 2600-1:1983 should be used.

For back face welds, sensitivity shall be 5 % or better when using a wire type image quality indicator in accordance with BS 3971. General requirements for the method of examination shall be in accordance with BS 2910.NOTE 2 It is recommended that technique 11 in BS 2910:1973 should be used.

7.5 Macro-examination

After visual and non-destructive examination the test piece shall be sectioned as shown in Figure 1 to Figure 4, by sawing or machining. The macro-examination specimens (see Figure 5) shall be prepared and examined in accordance with BS 709.NOTE Where radiography reveals defects other than gas pores, it may be necessary to carry out macro-examination of additional sections to assess compliance with the acceptance levels in Table 3.

The minimum throat thickness or potential leak path of each weld shall be assessed in accordance with Table 3.A hardness traverse shall be carried out across two macro-examination specimens in accordance with BS 709. The hardness shall be recorded for the weld metal, both parent metals and the heat-affected zones.

7.6 Push-out tests

When, by agreement between the contracting parties, push-out tests are required, they shall be carried out as shown in Figure 2, Figure 4 and Figure 6.Unless otherwise agreed between the contracting parties, the push-out load shall provide a stress in the tube above the minimum tensile strength specified for the tube material.

8 Statement of resultsA statement of the results of assessing each test piece, including repeat tests, shall be made for each welding procedure. The items listed in clause 3 shall be included, together with details of any features that would be rejectable by the requirements of clause 7.If no rejectable features or test results are found, a statement that the test piece made according to the particular welding procedure satisfied the requirements of this standard in respect of that type of test piece shall be signed by the person conducting the test.NOTE 1 It is recommended that welding procedure tests carried out in accordance with this standard and witnessed by an independent inspecting authority should be accepted by other inspecting authorities, provided that all the provisions have been fulfilled.NOTE 2 Attention is drawn to Appendix B of BS 4870-1:1981 which should be used as a basis for a form to record details of welding procedure approval testing carried out in accordance with this Part of the standard.

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Figure 1 — Test piece for tube ends on triangular pitch

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Figure 2 — Test piece for tube ends on triangular pitch when push-out tests are required

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Figure 3 — Test piece for tube ends on square pitch

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Figure 4 — Test piece for tube ends on square pitch when push-out tests are required

Figure 5 — Typical examples of macro-examination specimens

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Figure 6 — General arrangement of push-out test pieces for front face and back face welds

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Table 3 — Acceptance levels

Defects and parameters Acceptance levels

Planar defects a) Cracks and lamellar tears Not permitted

b) Lack of side fusionLack of inter-run fusion

Not permitted

Throat thickness or barrier to leakage Minimum throat thickness:

a) 0.7t for single run weldb) t for multi-run welds

Burn through of tube wall Not permitted

Weld spillage Not to exceed 0.5 mm for tubes up to and including 25 mm diameter and 1 mm for tubes over 25 mm

Slag inclusions or other solid inclusions(e.g. tungsten)

Individual inclusions

length < twidth < 0.25t

The through thickness dimension of the inclusion shall not reduce the minimum throat thickness or barrier to leakage below that specified

Cavities a) Isolated pores Diameter < 0.25tThe through thickness dimension of the pores shall not reduce the minimum throat thickness or barrier to leakage below that specified

b) Wormhole and pipe Length < 0.5tThe through thickness dimension of the wormhole or pipe shall not reduce the minimum throat thickness or barrier to leakage below that specified

c) Linear porosity For back face welds this may indicate lack of fusion and is therefore not permittedNOTE For front face welds lack of fusion is usually inherent because of the joint design

d) Uniformly distributed or localized porosity

The sum of all the pores at one section shall not reduce the minimum throat thickness or barrier to leakage below that specified

Burn down of tube end Not permitted where it reduces the weld below its required dimensions

NOTE 1 t is the nominal thickness of the tube.NOTE 2 For definitions of defect types, see BS 499-1.NOTE 3 It should be appreciated that the details given in Table 3 are being used for the approval testing of welding procedures and as such may be different from those specified for a particular application.

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Publications referred to

BS 499, Welding terms and symbols. BS 499-1, Welding, brazing and thermal cutting glossary. BS 709, Methods of destructive testing fusion welded joints and weld metal in steel. BS 2600, Radiographic examination of fusion welded butt joints in steel. BS 2600-1, Methods for steel 2 mm up to and including 50 mm thick. BS 2910, Methods for radiographic examination of fusion welded circumferential butt-joints in steel pipes. BS 3971, Specification for image quality indicators for industrial radiography (including guidance on their use). BS 4360, Specification for weldable structural steels. BS 4416, Method for penetrant testing of welded or brazed joints in metals. BS 4870, Specification for approval testing of welding procedures. BS 4870-1, Fusion welding of steel. BS 4871, Specification for approval testing of welders working to approved welding procedures. BS 4871-3, Arc welding of tube to tube-plate joints in metallic materials. BS 4677, Specification for arc welding of austenitic stainless steel pipework for carrying fluids.

BS 4870-3:1985

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