SIST EN 14587-3:2012
(Main)Railway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction
Railway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction
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 rails welded by flash butt welding to crossing components in a fixed plant, and intended for use on railway infrastructures.
Bahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen - Teil 3: Schweißen im Zusammenhang mit Weichenkonstruktionen
Diese Europäische Norm legt die Anforderungen für die Zulassung eines Schweißverfahrens in einem Schweißwerk fest, gemeinsam mit den Anforderungen für die spätere Schweißung.
Diese Europäische Norm ist anwendbar für neue Vignol-Schienen mit in einer stationären Anlage abbrennstumpfgeschweißten Herstückkomponenten, die für den Einsatz in der Eisenbahn-Infrastruktur vorgesehen sind.
Applications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3 : Soudure associée à la fabrication des appareils de voie
La présente norme européenne spécifie les exigences pour l'homologation d'un procédé de soudage dans une installation fixe, ainsi que les exigences pour les soudures de production.
La présente norme européenne s’applique aux rails Vignole neufs soudés par étincelage à des composants d’appareil de voie dans une installation fixe et destinés à des infrastructures ferroviaires.
Železniške naprave - Zgornji ustroj - Elektro uporovno varjenje tirnic - 3. del: Varjenje pri izdelavi kretnic
Ta evropski standard določa zahteve za odobritev postopka varjenja v fiksnem obratu, skupaj z zahtevami za nadaljnjo varilno proizvodnjo. Uporablja se za nove tirnice Vignole, ki se varijo z elektrouporovnim varjenjem prečnih komponent v fiksnem obratu in so namenjene za uporabo v železniških infrastrukturah.
General Information
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Zgornji ustroj - Elektro uporovno varjenje tirnic - 3. del: Varjenje pri izdelavi kretnicBahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen - Teil 3: Schweißen im Zusammenhang mit WeichenkonstruktionenApplications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3 : Soudure associée à la fabrication des appareils de voieRailway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction93.100Gradnja železnicConstruction of railways25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 14587-3:2012SIST EN 14587-3:2012en,fr01-november-2012SIST EN 14587-3:2012SLOVENSKI
STANDARD
SIST EN 14587-3:2012
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 14587-3
September 2012 ICS 25.160.10; 93.100 English Version
Railway applications - Track - Flash butt welding of rails - Part 3: Welding in association with crossing construction
Applications ferroviaires - Voie - Soudage des rails par étincelage - Partie 3: Soudure associée à la fabrication des coeurs de voie
Bahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen - Teil 3: Schweißen im Zusammenhang mit Herzstückkonstruktionen This European Standard was approved by CEN on 6 July 2012.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions.
CEN members are the national standards bodies of 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, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2012 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 14587-3:2012: ESIST EN 14587-3:2012
EN 14587-3:2012 (E) 2 Contents Page Foreword .4Introduction .51 Scope .62 Normative references .63 Terms and definitions .64 Information to be supplied for approval of procedure.84.1 By the purchaser.84.2 By the manufacturer .85 Approval of the manufacturer .85.1 General .85.2 Welding procedure .85.3 Operators .95.4 Supervision .95.5 Weld Inspection .95.6 Equipment .95.7 Quality assurance .96 Requirements for the welding process .96.1 General .96.2 Workpiece preparation .96.3 Clamping force . 106.4 Initial burn-off . 106.5 Preheating . 106.6 Final flashing . 106.7 Upsetting . 106.8 Post-weld treatment. 116.8.1 Before unclamping . 116.8.2 After removal from machine . 116.9 Welding parameters . 116.10 Removal of upset and correction of weld alignment . 117 Profile finishing of the weld . 118 Weld geometry and dimensions . 128.1 General . 128.2 Alignment and flatness across the weld . 128.3 Foot dimensions . 139 Weld identification . 1310 Procedure approval . 1310.1 General . 1310.2 Test weld specimen preparation . 1410.3 Number of specimens . 1410.4 Approval tests . 1410.4.1 General . 1410.4.2 Weld geometry and dimensions . 1410.4.3 Visual inspection . 1410.4.4 Surface finish . 1410.4.5 Liquid penetrant testing and magnetic particle testing . 1410.4.6 Internal soundness . 1510.4.7 Bend testing . 1510.4.8 Fatigue testing . 1510.4.9 Macro-examination . 15SIST EN 14587-3:2012
EN 14587-3:2012 (E) 3 10.4.10 Micro-examination . 1610.4.11 Hardness testing . 1610.5 Test result report . 1710.6 Validity of approval . 1711 Approval of other rail profiles or grades . 1711.1 General. 1711.2 Sample preparation . 1711.3 Approval tests . 1711.4 Test result report . 1812 Track trials . 1812.1 General. 1812.2 Track trial test result report . 1813 Weld production following procedure approval . 1813.1 Weld production . 1813.2 Weld parameter monitoring . 1813.3 Visual inspections . 1813.4 Weld geometry and dimensions . 1913.5 Liquid penetrant testing and magnetic particle testing . 1913.6 Internal soundness . 1913.7 Bend Testing . 1913.7.1 General. 1913.7.2 Additional test requirements . 1913.7.3 Bend test procedure . 1913.7.4 Interpretation of results . 2013.7.5 Retesting . 2013.7.6 Documentation . 20Annex A (informative)
Example of Flat spot and Bright spot . 21Annex B (normative)
Bend test requirements . 22Annex C (normative)
Test weld fracture faces – Recording of defects . 24Annex D (normative)
Fatigue test method for flash butt welds . 26D.1 Scope . 26D.2 Test equipment . 26D.3 Calibration procedure . 28D.3.1 General. 28D.3.2 Test piece . 28D.3.3 Test piece preparation . 28D.3.4 Instrumentation . 28D.3.5 Procedure . 28D.4 Fatigue test method . 32D.4.1 General. 32D.4.2 Staircase testing method . 32D.4.3 Example of the data analysis of a fatigue strength determination by the staircase method . 35D.4.4 Past-the-post testing method . 35Annex E (normative)
Macro-examination and micro-examination. 37E.1 Macro examination . 37E.2 Micro examination . 37Annex F (normative)
Hardness testing . 39Annex G (normative)
Ultrasonic testing non-austenitic materials . 40G.1 Reference line (DAC) generation – Reference block . 40G.2 Reference line (DAC) generation and acceptance criteria . 40Bibliography . 42 SIST EN 14587-3:2012
EN 14587-3:2012 (E) 4 Foreword This document (EN 14587-3:2012) 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 March 2013, and conflicting national standards shall be withdrawn at the latest by March 2013. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association. This document is one of a series of three parts of the EN 14587 “Railway applications – Track – Flash butt welding of rails”. The list of parts is as follows: Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant Part 3: Welding in association with crossing construction (the present standard) 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, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. SIST EN 14587-3:2012
EN 14587-3:2012 (E) 5 Introduction This part of EN 14587 has four main topics: requirements of a welding process; procedure approval for a fixed plant; approval of other rail profiles or grades; weld production following approval. This European Standard satisfies the needs of the railway authority. The manufacturer should achieve the specified requirements of this European Standard. SIST EN 14587-3:2012
EN 14587-3:2012 (E) 6 1 Scope This European Standard specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production. This European Standard applies to new Vignole rails welded by flash butt welding to crossing components in a fixed plant, and intended for use on railway infrastructures. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 571-1, Non-destructive testing — Penetrant testing — Part 1: General principles EN 1371-1, Founding — Liquid penetrant testing — Part 1: Sand, gravity die and low pressure die castings EN 13674-1, Railway applications — Track — Rail — Part 1: Vignole railway rails 46 kg/m and above EN 13674-2, Railway applications — Track — Rail — Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above EN 13674-4, Railway applications — Track — Rail — Part 4: Vignole railway rails from 27 kg/m to, but excluding 46 kg/m EN 14587-1:2007, Railway applications — Track — Flash butt welding of rails — Part 1: New R220, R260, R260Mn and 350HT grade rails in a fixed plant EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method (ISO 6507-1) EN ISO 11666, Non-destructive testing of welds — Ultrasonic testing — Acceptance levels (ISO 11666) EN ISO 17638, Non-destructive testing of welds — Magnetic particle testing (ISO 17638) EN ISO 17640, Non-destructive testing of welds — Ultrasonic testing — Techniques, testing levels, and assessment (ISO 17640) EN ISO 23279, Non-destructive testing of welds — Ultrasonic testing — Characterization of indications in welds (ISO 23279) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 manufacturer company that joins rails to rails, rails to crossings and rails to crossing components by flash butt welding in a fixed plant 3.2 purchaser buyer of the flashbutt welded crossings working in accordance with the requirements of the railway authority 3.3 railway infrastructure permanent way of national or private railways SIST EN 14587-3:2012
EN 14587-3:2012 (E) 7 3.4 fixed plant stationary machine for flash butt welding of rails to rails, rails to crossings and rails to crossing components 3.5 die burn damage caused by localised overheating on the electrode contact surfaces 3.6 upset metal extruded around the rail profile as a result of forging 3.7 specimen portion detached from a welded component or a welded joint and prepared as required for testing 3.8 profile finishing operation by which the rail or relevant part of the component at the weld is returned to original profile, by removal of upset material Note 1 to entry: This operation can be achieved by grinding, milling, planing or any other suitable means. 3.9 finished condition welded and profile finished 3.10 flat spot feature having a localised smooth texture when viewed in a vertical transverse section (see Annex A) Note 1 to entry: When viewed longitudinally in macro this may appear as a lens-shaped feature. 3.11 bright spot localised bright area occurring at the stainless insert/rail interface indicative of a possible martensitic area (see Annex A) 3.12 lack of bond area within the weld where there is no metal to metal contact (excluding flat spots and bright spots) Note 1 to entry: This may appear as a linear discontinuity at the interfaces when examined in the finished condition or after sectioning. 3.13 welded zone areas of 50 mm on either side of the weld centreline 3.14 throat flare wing entry flare (front) machining or setting of wings to give an entry flare into the throat 3.15 foundry method system to produce casting compliant with the requirements of EN 15689 3.16 workpiece crossing component, insert rail or rail leg-end extension SIST EN 14587-3:2012
EN 14587-3:2012 (E) 8 3.17 railway authority (RA) either the railway regulator or the owner of the railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.18 as welded condition rails that have been welded and trimmed only 4 Information to be supplied for approval of procedure 4.1 By the purchaser The following information shall be supplied by the purchaser, agreed upon by the manufacturer, and shall be fully documented: a) the rail profile and crossing geometrical details; b) the rail and crossing grades/materials; c) the profile class of the rail leg-end extension as specified in EN 13674-1, EN 13674-2 or EN 13674-4; d) alignment class/classes of the flash butt welds (see Table 1); e) the type of fatigue tests (if applicable) for approval; f) tolerances at rail ends on the delivered crossing; g) minimum length of rail leg-end extension; h) rail profile, number and frequency of production bend tests (see 13.7); i) requirements of any track trials. 4.2 By the manufacturer The following information shall be supplied by the manufacturer, agreed upon by the purchaser, and shall be fully documented: a) a qualified weld procedure; b) traceability system of the welds; c) type and identification number of machine being used. 5 Approval of the manufacturer 5.1 General The manufacturer shall meet the approval requirements as defined in 5.2 to 5.7. The purchaser reserves the right to audit the manufacturer at any time. 5.2 Welding procedure The manufacturer shall use welding procedures and flash butt welding machines that are approved by the RA. SIST EN 14587-3:2012
EN 14587-3:2012 (E) 9 5.3 Operators The manufacturer shall maintain a system that ensures the competence of their welding operators by appropriate training and assessment. 5.4 Supervision The manufacturer shall maintain a management and supervision system of flash butt welding that complies with the requirements of the purchaser. 5.5 Weld Inspection The manufacturer shall maintain a system of weld inspection according to the purchaser requirements. Instances of non-conformity found during these inspections shall be recorded in the traceability system. 5.6 Equipment Equipment shall comply with the operating manual. Inspection and calibration equipment shall comply with those requirements as agreed between the manufacturer and the purchaser. 5.7 Quality assurance The manufacturer shall operate an independently approved and audited quality assurance system, e.g. conforming to the requirements of EN ISO 9001 or other approval accepted by the purchaser. 6 Requirements for the welding process 6.1 General All welding shall be carried out on a flash butt welding machine using an automatic, programmed welding sequence using RA approved procedures. 6.2 Workpiece preparation The crossing/insert/rail faces to be welded shall always be sawn, disc cut or machined prior to welding and shall conform to the tolerances given in Figure 1. Areas of electrical contact on the workpieces and the machine shall be clean and free of any deleterious materials that could affect current flow. The workpieces shall not be damaged by the cleaning operation. The total mismatch of the two workpieces shall not exceed 2 mm and shall be corrected by grinding or machining prior to welding. SIST EN 14587-3:2012
EN 14587-3:2012 (E) 10
Key 1 elevation 2 plan Figure 1 — Tolerances for rail end squareness 6.3 Clamping force Workpieces shall be secured in the flash butt welding machine by clamps of such a surface shape or contour, that when a clamping force is exerted on the workpieces, it shall not damage the workpiece. The clamping force shall be sufficient such that slippage does not occur. 6.4 Initial burn-off The workpieces should undergo initial flashing to ensure full rail end contact during the subsequent preheating cycles. 6.5 Preheating The fronts of the heating area shall progress such that at completion of preheating an even heat band is present in both workpieces. On completion of welding there shall be no evidence of localised melting on the ends of the workpieces. 6.6 Final flashing Once initiated, final flashing shall be continuous. 6.7 Upsetting Upsetting shall immediately follow 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. The time between completion of upsetting and unclamping shall be sufficient to ensure required weld integrity. During this time, sufficient longitudinal force shall remain present to prevent damage to the weld. SIST EN 14587-3:2012
EN 14587-3:2012 (E) 11 6.8 Post-weld treatment 6.8.1 Before unclamping Post-weld heating could be required for certain rail grades and alloyed steels. 6.8.2 After removal from machine A post-weld controlled cooling could be required. Additional post-weld heat treatment may be required after removal from the welding machine for certain steel grades. 6.9 Welding parameters The welding machine and/or management system equipment shall be capable of recording the following: a) welding current; b) upset force or pressure; c) displacement; d) welding time; e) programme identification and setting details; f) weld identification; g) post-weld heat treatment (if applicable). The welding programmes and any post-weld heat treatment shall be determined during procedural trials and once approval has been granted they shall not be changed without prior purchaser approval. The welding parameters shall be monitored, checked against approval limits and recorded. These records shall be referenced to the appropriate welds.
The post-weld heat treatment parameters shall be monitored, checked against approval limits and recorded. These recor
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