Railway applications - Infrastructure - Flash butt welding of new rails - Part 1: R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails in a fixed plant

This European Standard specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production.
It applies to new Vignole railway rails R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a flash butt welding process in a fixed plant and intended for use on railway infrastructure.
This European Standard applies to the welding of rails into welded strings.

Bahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen - Teil 1: Schweißen neuer Schienen der Stahlsorte R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT und R400HT in einer stationären Anlage

Diese Europäische Norm legt die Anforderungen an die Eignung eines Schweißprozesses in einem Schweißwerk fest, zusammen mit den Anforderungen an die Produktion von Schweißungen.
Die Norm ist anwendbar für neue Vignolschienen der Stahlsorte R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT und R400HT mit einer längenbezogenen Masse ab 46 kg/m, wie in EN 13674-1 behandelt, verschweißt durch Abbrennstumpfschweißen in einer stationären Anlage und vorgesehen für die Verwendung in der Eisenbahninfrastruktur.
Diese Europäische Norm befasst sich mit der Herstellung von Langschienen.

Applications ferroviaires - Voie - Soudage des rails neufs par étincelage - Partie 1 : R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT et R400HT dans une installation fixe

Le présent document spécifie les exigences relatives à l’approbation d’un procédé de soudage dans une installation fixe, ainsi que les exigences pour la production de soudures.
Elle s’applique aux rails Vignole neufs de nuances R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT et R400HT, de masse est supérieure ou égale à 46 kg/m, contenus dans l’EN 13674-1, soudés au moyen d’un procédé de soudage par étincelage dans une installation fixe et destinés à être utilisés dans des infrastructures ferroviaires.
Le présent document s’applique au soudage de barres longues.

Železniške naprave - Infrastruktura - Elektrouporovno varjenje novih tirnic - 1. del: Varjenje tirnic kakovosti R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT in R400HT v varilnici

Ta evropski standard določa zahteve za odobritev postopka varjenja v fiksnem obratu, skupaj z zahtevami za nadaljnjo varilno proizvodnjo.
Uporablja se za nove železniške tirnice Vignole kakovosti R220, R260, R260Mn in R350HT z nosilnostjo 46 kg/m in več, kot je določeno v standardu EN 13674-1, varjene z elektrouporovnim varjenjem v varilnici in namenjene za uporabo na železniški infrastrukturi.
Ta evropski standard se uporablja za varjenje tirnic v varjene sklope.

General Information

Status
Published
Public Enquiry End Date
24-May-2017
Publication Date
17-Dec-2018
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
12-Dec-2018
Due Date
16-Feb-2019
Completion Date
18-Dec-2018

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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Infrastruktura - Elektrouporovno varjenje novih tirnic - 1. del: Varjenje tirnic kakovosti R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT in R400HT v varilniciBahnanwendungen - Infrastruktur - Abbrennstumpfschweißen von Schienen - Teil 1: Schweißen neuer Schienen der Stahlsorte R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT und R400HT in einer stationären AnlageApplications ferroviaires - Voie - Soudage des rails neufs par étincelage - Partie 1 : R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT et R400HT dans une installation fixeRailway applications - Infrastructure - Flash butt welding of new rails - Part 1: R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails in a fixed plant93.100Gradnja železnicConstruction of railways45.080Rails and railway components25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 14587-1:2018SIST EN 14587-1:2019en,fr,de01-februar-2019SIST EN 14587-1:2019SLOVENSKI

STANDARDSIST EN 14587-1:20071DGRPHãþD
SIST EN 14587-1:2019
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 14587-1
December
t r s z ICS
t wä s x rä s râ
{ uä s r r Supersedes EN
s v w z yæ sã t r r yEnglish Version
Railway applications æ Infrastructure æ Flash butt welding of new rails æ Part

sã R t t rá R t x rá R t x rMná R u t rCrá R u w rHTá R u w rLHTá R u y rCrHT and R v r rHT grade rails in a fixed plant Applications ferroviaires æ Infrastructure æ Soudage des rails neufs par ßtincelage æ Partie

sã Rails de nuances R t t rá R t x rá R t x rMná R u t rCrá R u w rHTá R u w rLHTá R u y rCrHT et R v r rHT dans une installation fixe

Bahnanwendungen æ Infrastruktur æ Abbrennstumpfschweißen von Schienen æ Teil

sã Schweißen neuer Schienen der Stahlsorte R t t rá R t x rá R t x rMná R u t rCrá R u w rHTá R u w rLHTá R u y rCrHT und R v r rHT in einer stationären Anlage This European Standard was approved by CEN on

s y September
t r s zä

egulations which stipulate the conditions for giving this European Standard the status of a national standard without any alterationä Upætoædate lists and bibliographical references concerning such national standards may be obtained on application to the CENæCENELEC Management Centre or to any CEN memberä

translation under the responsibility of a CEN member into its own language and notified to the CENæCENELEC Management Centre has the same status as the official versionsä

CEN members are the national standards bodies of Austriaá Belgiumá Bulgariaá Croatiaá Cyprusá Czech Republicá Denmarká Estoniaá Finlandá Former Yugoslav Republic of Macedoniaá Franceá Germanyá Greeceá Hungaryá Icelandá Irelandá Italyá Latviaá Lithuaniaá Luxembourgá Maltaá Netherlandsá Norwayá Polandá Portugalá Romaniaá Serbiaá Slovakiaá Sloveniaá Spainá Swedená Switzerlandá Turkey and United Kingdomä

EUROPEAN COMMITTEE FOR STANDARDIZATION COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre:
Rue de la Science 23,
B-1040 Brussels

t r s z CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Membersä Refä Noä EN

s v w z yæ sã t r s z ESIST EN 14587-1:2019

EN 14587-1:2018 (E) 2 Contents Page European foreword ....................................................................................................................................................... 4 Introduction .................................................................................................................................................................... 5 1 Scope .................................................................................................................................................................... 6 2 Normative references .................................................................................................................................... 6 3 Terms and definitions ................................................................................................................................... 6 4 Requirements for the welding process ................................................................................................... 8 4.1 General ................................................................................................................................................................ 8 4.2 Rail end preparation and horizontal alignment requirements ..................................................... 8 4.3 Clamping force ................................................................................................................................................. 8 4.4 Pre-heating ........................................................................................................................................................ 8 4.5 Final flashing ..................................................................................................................................................... 8 4.6 Upsetting ............................................................................................................................................................ 8 4.7 Unclamping........................................................................................................................................................ 8 4.8 Slippage............................................................................................................................................................... 9 4.9 Welding parameters ...................................................................................................................................... 9 4.10 Steps across the weld ..................................................................................................................................... 9 4.11 Removal of excess upset ............................................................................................................................ 11 4.12 Post-weld thermal treatment .................................................................................................................. 13 5 Procedure approval..................................................................................................................................... 13 5.1 General ............................................................................................................................................................. 13 5.2 Information to be supplied by the purchaser .................................................................................... 13 5.3 Sample preparation ..................................................................................................................................... 14 5.4 Approval tests ................................................................................................................................................ 14 5.4.1 Visual examination ...................................................................................................................................... 14 5.4.2 Weld trimming .............................................................................................................................................. 14 5.4.3 Weld straightness and flatness ............................................................................................................... 14 5.4.4 Magnetic particle or dye penetrant testing ........................................................................................ 14 5.4.5 Bend test .......................................................................................................................................................... 14 5.4.6 Macro examination ...................................................................................................................................... 15 5.4.7 Micro examination ....................................................................................................................................... 16 5.4.8 Hardness test ................................................................................................................................................. 16 5.4.9 Fatigue test ..................................................................................................................................................... 16 5.5 Test report ...................................................................................................................................................... 17 6 Approval of other rail profiles and grades .......................................................................................... 17 6.1 General ............................................................................................................................................................. 17 6.2 Sample preparation ..................................................................................................................................... 17 6.3 Approval tests ................................................................................................................................................ 17 6.4 Test report ...................................................................................................................................................... 17 7 Approval of the contractor........................................................................................................................ 17 7.1 General ............................................................................................................................................................. 17 7.2 Welding procedure ...................................................................................................................................... 18 7.3 Operators ........................................................................................................................................................ 18 7.4 Supervision ..................................................................................................................................................... 18 7.5 Weld testing ................................................................................................................................................... 18 SIST EN 14587-1:2019

EN 14587-1:2018 (E) 3 7.6 Equipment ....................................................................................................................................................... 18 8 Weld production following procedure approval .............................................................................. 18 8.1 Weld production ........................................................................................................................................... 18 8.2 Information supplied by the purchaser ............................................................................................... 18 8.3 Rail end preparation and horizontal rail alignment requirements ........................................... 19 8.4 Weld parameter monitoring ..................................................................................................................... 19 8.5 Weld identification ....................................................................................................................................... 19 8.6 Visual examination ...................................................................................................................................... 19 8.7 Steps across the weld .................................................................................................................................. 19 8.8 Finishing .......................................................................................................................................................... 19 8.8.1 Correction of vertical and horizontal weld alignment .................................................................... 19 8.8.2 Profile finishing of the rail head .............................................................................................................. 19 8.9 Weld straightness and flatness ................................................................................................................ 20 8.9.1 Alignment requirements ............................................................................................................................ 20 8.9.2 Straightness and flatness measurement .............................................................................................. 20 8.10 Bend test .......................................................................................................................................................... 21 8.10.1 General ............................................................................................................................................................. 21 8.10.2 Additional test requirements ................................................................................................................... 21 8.10.3 Bend test procedure .................................................................................................................................... 21 8.10.4 Interpretation of results ............................................................................................................................ 22 8.10.5 Retesting .......................................................................................................................................................... 22 8.11 Documentation .............................................................................................................................................. 22 Annex A (normative)

Bend test requirements ................................................................................................ 23 Annex B (normative)

Test weld fracture faces – Recording of defects ................................................... 25 Annex C (normative)

Fatigue test method for flash butt welds ................................................................ 27 C.1 General ............................................................................................................................................................. 27 C.2 Test equipment .............................................................................................................................................. 27 C.3 Calibration ....................................................................................................................................................... 29 C.3.1 General ............................................................................................................................................................. 29 C.3.2 Test piece ......................................................................................................................................................... 29 C.4 Fatigue test method ..................................................................................................................................... 29 C.4.1 General ............................................................................................................................................................. 29 C.4.2 Staircase test method .................................................................................................................................. 29 C.4.3 Example of the data analysis of a fatigue strength determination by the staircase method .............................................................................................................................................................. 32 C.4.4 Past-the-post test method ......................................................................................................................... 32 Annex D (normative)

Macro examination and micro examination ......................................................... 34 D.1 Macro examination ...................................................................................................................................... 34 D.2 Micro examination ....................................................................................................................................... 34 Annex E (normative)

Hardness testing .............................................................................................................. 36 Bibliography ................................................................................................................................................................. 37

SIST EN 14587-1:2019

EN 14587-1:2018 (E) 4 European foreword This document (EN 14587-1:2018) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by June 2019, and conflicting national standards shall be withdrawn at the latest by June 2019. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN shall not be held responsible for identifying any or all such patent rights. This document supersedes EN 14587-1:2007. This document is one of a series of three parts of the EN 14587 series: — Railway applications – Infrastructure - Flash butt welding of new rails – Part 1: R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails in a fixed plant; — Railway applications – Track - Flash butt welding of rails – Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant; — Railway applications – Track - Flash butt welding of rails – Part 3: Welding in association with crossing construction. According to the CEN-CENELEC Internal Regulations, the national standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. SIST EN 14587-1:2019

EN 14587-1:2018 (E) 5 Introduction This part of EN 14587 has five main topics: a) requirements of a welding process; b) procedure approval for a fixed plant; c) approval of other rail profiles or grades; d) approval of welding contractor; e) weld production following approval. SIST EN 14587-1:2019

EN 14587-1:2018 (E) 6 1 Scope This document specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production. It applies to new Vignole railway rails R220, R260, R260Mn, R320Cr, R350HT, R350LHT, R370CrHT and R400HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a flash butt welding process in a fixed plant and intended for use on railway infrastructure. This document applies to the welding of rails into welded strings. 2 Normative references The following documents are referred to in the text in such a way that some or all of their content constitutes requirements of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 13674-1, Railway applications — Track — Rail — Part 1: Vignole railway rails 46 kg/m and above EN ISO 3452-1, Non-destructive testing — Penetrant testing — Part 1: General principles (ISO 3452-1) EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method (ISO 6507-1) EN ISO 7500-1:2018, Metallic materials — Calibration and verification of static uniaxial testing machines — Part 1: Tension/compression testing machines — Calibration and verification of the force-measuring system (ISO 7500-1:2018) EN ISO 17638, Non-destructive testing of welds — Magnetic particle testing (ISO 17638) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. ISO and IEC maintain terminological databases for use in standardization at the following addresses:

IEC Electropedia: available at http://www.electropedia.org/
ISO Online browsing platform: available at http://www.iso.org/obp

3.1 as-welded condition rails that have been welded and trimmed only 3.2 contractor company approved by a railway authority to provide staff and machinery to execute the production of flash butt welds in a fixed plant, which may include staff and machinery from within the railway authority 3.3 die burn damage caused by localized overheating (arcing) on the surface of the rail due to poor contact between the rail and electrode during welding SIST EN 14587-1:2019

EN 14587-1:2018 (E) 7 3.4 dressing removing trimmed upset by grinding or other similar process 3.5 finished condition welded, trimmed and rail head profile finished 3.6 fixed plant stationary production line for flash butt welding of rails 3.7 flat spot process driven discontinuity shown after the slow bend test on the weld fracture face, which has a small lens like shape Note 1 to entry: In a vertical longitudinal section (macro) it appears elliptical in shape. 3.8 lack of bond area of incomplete fusion between the rails at the fusion line Note 1 to entry: This may appear crack like or as a line discontinuity at the interface either on the surface after removal of the upset or in a weld macro section. 3.9 profile finishing operation by which the rail head or relevant part of the rail head at the weld is restored to rail profile Note 1 to entry: The operation can be by grinding, milling, planing or any other suitable means. 3.10 purchaser purchaser of the welds 3.11 railway authority either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.12 trimmed upset metal remaining around the rail profile following the shearing process 3.13 trimming removal of upset 3.14 upset metal extruded around the rail profile as a result of forging SIST EN 14587-1:2019

EN 14587-1:2018 (E) 8 3.15 welded string long rail comprising of a number of shorter rails welded together 3.16 welding process part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 4 Requirements for the welding process 4.1 General All welding shall be carried out on a flash butt welding machine using an automatic, programmed welding sequence. 4.2 Rail end preparation and horizontal alignment requirements The rail ends shall always be sawn or disc cut to the tolerances specified by the purchaser. Areas of electrical contact on the rails and the machine shall be cleaned to bright metal to give a consistent and good electrical contact at the interface. The rail shall not be damaged by the cleaning operation or through poor electrical contact. Rails of the same profile shall be positioned in the welding machine such that the welding interface is central to the contact electrodes as assessed by visual or mechanical means. Before welding, rails shall be aligned laterally to the required rail face or edge, i.e. left, or right, or to the rail centreline. For reasons of asymmetry rails may be welded with the brand marks on the same side throughout the welded string. 4.3 Clamping force Rails shall be secured in the flash butt welding machine by a clamping arrangement. The clamping force that is exerted on the rails shall not damage in such a way that subsequent cracking in the rail is generated, see 5.4.1. 4.4 Pre-heating For the pre-heating, the rail ends shall progress uniformly in a reversible or a continuous process, and perpendicular to the running surface during the whole welding cycle. 4.5 Final flashing Once initiated the final flashing shall be continuous. 4.6 Upsetting Upsetting shall immediately follow final flashing. Sufficient forging pressure shall be applied to ensure that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The weld interface shall extend into the upset. 4.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. SIST EN 14587-1:2019

EN 14587-1:2018 (E) 9 4.8 Slippage Clamping force shall be maintained to avoid any movement between the contact dies and rails. 4.9 Welding parameters 1) The welding machine and/or management system equipment shall be capable of displaying the following: a) programme identification and setting details; b) welding current; c) upset force or pressure; d) displacement; e) welding time; f) limits/range of the main welding parameters. 2) The welding parameters shall be determined during procedural trials and, once approval has been granted, shall not be changed, with the exception of changes concerning the environments in 4.9, 4). 3) The welding parameters shall be monitored and recorded. These records shall be referenced to the appropriate welds. 4) Due to extreme variations in seasonal temperatures, the contractor may request from the railway authority the use of an alternative welding program. A bending test according to 5.4.5 shall be carried out in this case. 4.10 Steps across the weld — Any step between the rails across the weld in the trimmed but not dressed condition shall not exceed those dimensions shown in Table 1. — Checks shall be made at a position 20 mm on each side of the weld upset centreline using a 1 m nibbed straight edge and feeler shims as shown in Figure 1. An alternative step measurement gauge may be used as shown in Figure 2. Table 1 — Maximum permitted steps Position of step on the rail Maximum permitted step (in millimetres) Vertically on the longitudinal centreline of the running surface 0,5 Horizontally on the aligned face or edge (14 ± 1) mm below the running surface 0,5 Horizontally on the edge of the rail foot 2,0

Where the step arises from the rail dimensions the rail foot tips may be dressed locally to achieve this requirement. SIST EN 14587-1:2019

EN 14587-1:2018 (E) 10 Dimensions in millimetres

b) Key A running surface B nibbed straight edge C weld upset centreline Z detail view of the step NOTE Step = [x-y] mm. Figure 1 — Measurement of the step with nibbed straight edge SIST EN 14587-1:2019

EN 14587-1:2018 (E) 11 Dimensions in millimetres

Figure 2 — Gauge for measuring the step 4.11 Removal of excess upset a) Excess upset should be automatically trimmed. If not possible, the upset shall be removed by grinding. b) Removal of the excess upset shall not cause any mechanical or thermal damage to the rails. c) The surface of the trimmed area shall be free from visible transverse cracking. d) Removal of the excess upset shall be completed in such a manner to keep the joint in compression. e) Any dressing of the weld following the removal of upset shall not cause damage to the rail or weld nor reduce either to a dimension below the original rail profile. f) The maximum thickness of the trimmed upset shall be as set out in Table 2 below and shown in Figure 3. A suggested measurement gauge is shown in Figure 4. Table 2 — Maximum permitted trimmed upset Zone Position of trimmed upset about the weld Maximum permitted upset (in millimetres) A Full head profile from the lower corner on the gauge face to the lower corner on the opposite face 2,5 B The fishing surface on the underside of the head 3,0 C The web, including the top fillet radius and extending down to the start of the bottom fillet radius 2,5 D The foot, including the start of the bottom fillet radii in the web and extending to the foot tips and completely across the underside of the rail foot 2,0 SIST EN 14587-1:2019

EN 14587-1:2018 (E) 12 Where there is a difference in the rail dimensions, the trimmed upset shall be measured in relation to the rail giving the maximum protruding surface. If the values of the trimmed upset are above the maximum values, the trimmed upset shall be dressed locally to the required values without damaging the parent rails. Dimensions in millimetres

Key A zone A – rail head B zone B – on the underside of the rail head C zone C – web of the rail D zone D – foot of the rail Figure 3 — Maximum permitted trimmed upset SIST EN 14587-1:2019

EN 14587-1:2018 (E) 13 Dimensions in millimetres

Key A zone A – rail head B zone B – on the underside of the rail head C zone C – web of the rail D zone D – foot of the rail Figure 4 — Gauge for measuring upset 4.12 Post-weld thermal treatment With the exception of R220 and R260 rail grades it may be necessary to conduct a post-weld thermal treatment. This may involve either an accelerated (forced) cooling process or additional heat input. 5 Procedure approval 5.1 General Procedure approval shall be carried out by testing weld samples produced in accordance with this European Standard. Procedure approval testing shall be carried out on the rail profile and grade specified by the purchaser, see 5.2. All test results and weld fracture faces shall be made available for inspection. 5.2 Information to be supplied by the purchaser The following information shall be supplied by the purchaser: a) the rail profile; b) the rail grade; c) the straightness class as in EN 13674-1; d) running edge requirements and identification – left, right or centre alignment; e) alignment class/classes, according to Table 4; f) the type of fatigue test.

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