SIST EN 15085-5:2008
(Main)Railway applications - Welding of railway vehicles and components - Part 5: Inspection, testing and documentation
Railway applications - Welding of railway vehicles and components - Part 5: Inspection, testing and documentation
This standard applies to the welding of metallic materials during the manufacture and repair/maintenance of railway vehicles and vehicle parts. It
- defines the checks to be executed on the welds,
- describes the rules of carrying out the destructive and non-destructive tests,
- defines the necessary documentation to issue to declare the conformity of the products.
However, additional and more restrictive requirements may be applied if explicitly indicated in the order or contract.
The non-destructive and destructive inspections and testings by this part of the standard are carried out in accordance with the appropriate EN standards listed in clause 2 and in the bibliography.
Bahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 5: Überprüfung, Versuche und Dokumentation
Diese Normenreihe gilt für das Schweißen metallischer Werkstoffe bei der Herstellung und Instandsetzung von Schienenfahrzeugen und - fahrzeugteilen.
Dieser Teil der Normenreihe:
definiert die an den Schweißnähten durchzuführenden Prüfungen;
legt die Durchführung der zerstörenden und zerstörungsfreien Prüfungen fest;
definiert die notwendigen Dokumentationen zur Herausgabe der Produktkonformitätserklärung.
Applications ferroviaires - Soudage des véhicules ferroviaires et des pieces - Partie 5 : Vérification, contrôles et documentations
La présente série de normes s'applique au soudage de matériaux métalliques au cours de la construction et de la maintenance des véhicules ferroviaires et de leurs composants.
La présente partie spécifie :
les contrôles et les essais à effectuer sur les soudures ;
les contrôles destructifs et non destructifs à réaliser ;
la documentation nécessaire à la déclaration de conformité des produits.
Železniške naprave - Varjenje železniških vozil in elementov - 5. del: Nadzor, preskušanje in dokumentacija
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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Railway applications - Welding of railway vehicles and components - Part 5: Inspection, testing and documentationŽelezniške naprave - Varjenje železniških vozil in elementov - 5. del: Nadzor, preskušanje in dokumentacijaApplications ferroviaires - Soudage des véhicules ferroviaires et des pieces - Partie 5 : Vérification, contrôles et documentationsBahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 5: Überprüfung, Versuche und DokumentationTa slovenski standard je istoveten z:EN 15085-5:2007SIST EN 15085-5:2008en45.060.0125.160.01ICS:SLOVENSKI
STANDARDSIST EN 15085-5:200801-april-2008
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 15085-5October 2007ICS 25.160.10; 45.060.01 English VersionRailway applications - Welding of railway vehicles andcomponents - Part 5: Inspection, testing and documentationApplications ferroviaires - Soudage des véhiculesferroviaires et des pièces - Partie 5 : Vérification, contrôleset documentationsBahnanwendungen - Schweißen von Schienenfahrzeugenund -fahrzeugteilen - Teil 5: Prüfung und DokumentationThis European Standard was approved by CEN on 26 August 2007.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on application to the CEN 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 translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONEUROPÄISCHES KOMITEE FÜR NORMUNGManagement Centre: rue de Stassart, 36
B-1050 Brussels© 2007 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 15085-5:2007: E
EN 15085-5:2007 (E) 2 Contents Page Foreword.3 Introduction.4 1 Scope.5 2 Normative references.5 3 Terms and definitions.6 4 Inspection and testing of welded joints.6 4.1 General.6 4.2 Inspection and testing before welding.6 4.3 Inspection and testing during welding.6 4.4 Inspection and testing after welding.7 5 Test planning and test criteria.8 5.1 Test planning.8 5.2 Test criteria.9 6 Documentation.9 7 Non-conformance and corrective actions.9 7.1 General.9 7.2 Management of non-conformance.10 7.3 Additional tests.11 8 Sub-contractors.11 9 Declaration of conformity.12 10 Traceability.12 Annex A (normative)
Inspection and testing of welded joints.13
Tables Table 1 — Tests which have to be performed during production.8 Table A.1 — Relationship between essential welding related tasks and the manufacturing phases to be performed.13
EN 15085-5:2007 (E) 3 Foreword This document (EN 15085-5:2007) 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 April 2008, and conflicting national standards shall be withdrawn at the latest by April 2008. This series of European Standards EN 15085 "Railway applications — Welding of railway vehicles and components" consists of the following parts: Part 1: General Part 2: Quality requirements and certification of welding manufacturer Part 3: Design requirements Part 4: Production requirements Part 5: Inspection, testing and documentation 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. According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EN 15085-5:2007 (E) 4 Introduction Welding is a special process in the manufacture of railway vehicles and their parts. The required provisions for this process are laid down in the standards series EN ISO 3834. The basis of these provisions are the basic technical welding standards in respect of the special requirements for the construction of railway vehicles. This European Standard is aimed at defining the terms of enforcement applicable to European Standards, it is not construed as a substitute to these standards. This European Standard can also be used by internal and external parties, including certification bodies, to assess the organisation's ability to meet customer, regulatory and the organisation's own requirements.
EN 15085-5:2007 (E) 5 1 Scope This series of standards applies to welding of metallic materials in the manufacture and maintenance of railway vehicles and their parts. This part of the series specifies: inspections and testing to be executed on the welds; destructive as well as non-destructive tests to be performed; necessary documentation to issue to declare the conformity of the products. 2 Normative references The following referenced documents are indispensable for the application 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 473, Non destructive testing — Qualification and certification of NDT personnel — General principles EN 10204, Metallic products — Types of inspection documents EN 12062, Non-destructive examination of welds — General rules for metallic materials EN 15085-1:2007, Railway applications — Welding of railway vehicles and components — Part 1: General EN 15085-2:2007, Railway applications — Welding of railway vehicles and components — Part 2: Quality requirements and certification of welding manufacturer EN 15085-3:2007, Railway applications — Welding of railway vehicles and components — Part 3: Design requirements EN 15085-4:2007, Railway applications — Welding of railway vehicles and components — Part 4: Production requirements EN ISO 3834 (all parts), Quality requirements for fusion welding of metallic materials EN ISO 5817, Welding — Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) — Quality levels for imperfections (ISO 5817:2003) EN ISO 10042, Welding — Arc-welded joints in aluminium and its alloys — Quality levels for imperfections (ISO 10042:2005) EN ISO 14731:2006, Welding coordination — Tasks and responsibilities (ISO 14731:2006) EN ISO 15609 (all parts), Specification and qualification of welding procedures for metallic materials — Welding procedure specification EN ISO/IEC 17050-1, Conformity assessment — Supplier's declaration of conformity — Part 1: General requirements (ISO/IEC 17050-1:2004) EN ISO/IEC 17050-2, Conformity assessment — Supplier's declaration of conformity — Part 2: Supporting documentation (ISO/IEC 17050-2:2004)
EN 15085-5:2007 (E) 6 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 15085-1:2007 apply. 4 Inspection and testing of welded joints 4.1 General The relationship between essential welding related tasks and the manufacturing phases to be performed by the responsible welding coordinator or his deputies are given in Table A.1. 4.2 Inspection and testing before welding Additional to Table A.1 the responsible welding coordinator is responsible for the following tasks: planning of back gouging and sealing run; provision of additional welding-related information for incorporation in the drawings. As evidence that the checks listed in Table A.1 and above have been carried out, the outcome shall be recorded. In order to carry out the above-mentioned tasks, the coordinator may seek support of other company departments. Details of responsibilities for the tasks have to be defined as applied to the organization of the welding manufacturer. The task of the welder or welding operator, before beginning any type of welding activity, is to check the following items: that the welding machine is validated and efficient; availability of the work instructions; conditions of the edges and the correct tacking of the items to be welded (conditions of cleanliness and assembly of the pieces in accordance with the design and/or the WPS); identification of the items to be welded; compliance of the welding consumables with the WPS. 4.3 Inspection and testing during welding The welders or welding operators performing the job have to check and ensure the following: adequate cleaning and shape of the joints during the intermediate passes; compliance with the prescribed values of the pre-heating and/or interpass temperatures; compliance with the WPS and/or work instructions; compliance with the sequence of operations if prescribed in specific operating instructions (e.g. the welding sequence plan).
EN 15085-5:2007 (E) 7 The process steps and phases in which it is necessary for the welding activity to be supervised by the responsible welding coordinator or his deputy shall be explained by welding planning documents (see EN 15085-4:2007, 4.1). If the welding sequence plan or test plan requires the check of a weld during production, welding shall be continued only after the weld has been checked. 4.4 Inspection and testing after welding 4.4.1 Checks by the welder or welding operator After welding, the welder or welding operator shall carry out the following checks: that the weld is complete; that the weld is cleaned; that the profile and dimensions of the weld conform to the drawing. 4.4.2 Self-inspection by the welder or welding operator If a self-inspection system is used, the personnel entrusted with the self-inspection shall be suitably trained and instructed with respect to visual examinations and the requirements of EN 15085-3:2007, Clause 5, by the responsible welding coordinator or his nominee (deputy, or personnel certified to Level 2 according to EN 473). The inspections carried out by the welder or welding operator shall then be clearly defined (acceptance criteria, dimensioning etc.) and recorded in accordance with Table 1. Recording documents shall be signed by the welder or welding operator who carries out the inspection and have to be enclosed with the other inspection documents. A copy of the personal signatures with names in clear, printed text will be held for all personnel who sign inspection documents. Alternatively, traceability can be achieved by an electronic system. 4.4.3 Conformity control of welds After welding, the NDT (Non-Destructive Testing) is carried out by certified personnel (except VT; see Table 1). Table 1 defines the type and frequency of the testing to be carried out during series production. This is based on the relationship between the weld performance class of the welded joint assigned by the design engineer and the resulting inspection class (see EN 15085-3). Testing at the beginning of production: shall be according to the inspection class, 100 % testing of all welds on each initial item of the series if testing is required in Table 1. Testing during series production: the tests described in Table 1 shall be carried out on products manufactured during series production in accordance with the frequencies indicated therein and as per the weld performance class indicated on the drawing by the design engineer. In the case of detecting unacceptable defects during the tests indicated in Table 1, the procedure for management of non-conformance shall be applied, with the extension of the testing as indicated in Clause 7.
EN 15085-5:2007 (E) 8 Table 1 — Tests which have to be performed during production Inspection class Volumetric tests RT or UT Surface tests MT or PT Visual examination VT CT 1 100 % a 100 % 100 % CT 2 10 % a b 10 % b 100 % CT 3 Not required Not required 100 % CT 4 Not required Not required 100 % The percentages expressed refer to the total length to be examined for one given weld. Thus: 100 % means: request for testing of the entire length of the weld and on all the pieces built; 10 % means: testing of 10 % of the entire length of the weld on all the pieces built or 100 % testing on 1 of every 10 items built The test methods indicated in Table 1 shall be the minimum capable of ensuring compliance of the welded joints. Additional tests depending on the material, the design or customer requirements may be necessary. All NDT (RT, UT, MT or PT) shall be performed by personnel certified according to EN 473 and shall be documented. For inspection classes CT 1 and CT 2, the visual examination shall be performed by personnel certified according to EN 473 and shall be documented. For inspection class CT 3, the visual examination shall be performed as a minimum by personnel qualified by the manufacturer and should be documented. For inspection CT 4, the visual examination shall be performed as a minimum by welders who are trained in visual examination and documentation is not required. a Volumetric tests applicable only for butt welds and T-welds with full penetration. b Where volumetric testing is not feasible for welds of the weld performance class CP B in me
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2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Varjenje železniških vozil in elementov - 5. del: Nadzor, preskušanje in dokumentacijaBahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 5: Überprüfung, Versuche und DokumentationApplications ferroviaires - Soudage des véhicules ferroviaires et des pieces - Partie 5 : Vérification, contrôles et documentationsRailway applications - Welding of railway vehicles and components - Part 5: Inspection, testing and documentation45.060.01Železniška vozila na splošnoRailway rolling stock in general25.160.01Varjenje, trdo in mehko spajkanje na splošnoWelding, brazing and soldering in generalICS:Ta slovenski standard je istoveten z:EN 15085-5:2007SIST EN 15085-5:2008de01-april-2008SIST EN 15085-5:2008SLOVENSKI
STANDARD
SIST EN 15085-5:2008
EUROPÄISCHE NORMEUROPEAN STANDARDNORME EUROPÉENNEEN 15085-5Oktober 2007ICS 25.160.10; 45.060.01 Deutsche FassungBahnanwendungen - Schweißen von Schienenfahrzeugen und -fahrzeugteilen - Teil 5: Prüfung und DokumentationRailway applications - Welding of railway vehicles andcomponents - Part 5: Inspection, testing anddocumentationApplications ferroviaires - Soudage des véhicules et descomposants ferroviaires - Partie 5 : Vérification, contrôleset documentationsDiese Europäische Norm wurde vom CEN am 26.August 2007 angenommen.Die CEN-Mitglieder sind gehalten, die CEN/CENELEC-Geschäftsordnung zu erfüllen, in der die Bedingungen festgelegt sind, unter denendieser Europäischen Norm ohne jede Änderung der Status einer nationalen Norm zu geben ist. Auf dem letzen Stand befindliche Listendieser nationalen Normen mit ihren bibliographischen Angaben sind beim Management-Zentrum des CEN oder bei jedem CEN-Mitglied aufAnfrage erhältlich.Diese Europäische Norm besteht in drei offiziellen Fassungen (Deutsch, Englisch, Französisch). Eine Fassung in einer anderen Sprache,die von einem CEN-Mitglied in eigener Verantwortung durch Übersetzung in seine Landessprache gemacht und dem Zentralsekretariatmitgeteilt worden ist, hat den gleichen Status wie die offiziellen Fassungen.CEN-Mitglieder sind die nationalen Normungsinstitute von Belgien, Bulgarien, Dänemark, Deutschland, Estland, Finnland, Frankreich,Griechenland, Irland, Island, Italien, Lettland, Litauen, Luxemburg, Malta, den Niederlanden, Norwegen, Österreich, Polen, Portugal,Rumänien, Schweden, der Schweiz, der Slowakei, Slowenien, Spanien, der Tschechischen Republik, Ungarn, dem Vereinigten Königreichund Zypern.EUROPÄISCHES KOMITEE FÜR NORMUNGEUROPEAN COMMITTEE FOR STANDARDIZATIONCOMITÉ EUROPÉEN DE NORMALISATIONManagement-Zentrum: rue de Stassart, 36
B-1050 Brüssel© 2007 CENAlle Rechte der Verwertung, gleich in welcher Form und in welchemVerfahren, sind weltweit den nationalen Mitgliedern von CEN vorbehalten.Ref. Nr. EN 15085-5:2007 DSIST EN 15085-5:2008
EN 15085-5:2007 (D) 2 Inhalt Seite Vorwort.3 Einleitung.4 1 Anwendungsbereich.5 2 Normative Verweisungen.5 3 Begriffe.6 4 Prüfungen von Schweißverbindungen.6 4.1 Allgemeines.6 4.2 Prüfungen vor dem Schweißen.6 4.3 Prüfungen während des Schweißens.6 4.4 Prüfungen nach dem Schweißen.7 5 Prüfplan und Prüfkriterien.9 5.1 Prüfplanung.9 5.2 Prüfkriterien.9 6 Dokumentation.9 7 Nichtkonformitäten und Korrekturmaßnahmen.10 7.1 Allgemeines.10 7.2 Behandlung der Nichtkonformitäten.10 7.3 Zusätzliche Prüfungen.11 8 Untervergabe.12 9 Konformitätserklärung.12 10 Rückverfolgbarkeit.12 Anhang A (normativ)
Prüfungen von Schweißverbindungen.13
Tabellen Tabelle 1 — Prüfungen, die während der Produktion zu dokumentieren sind.8 Tabelle A.1 — Beziehung der wesentlichen auf das Schweißen bezogenen Aufgaben, die bei der Herstellung schrittweise durchgeführt werden müssen.13 SIST EN 15085-5:2008
EN 15085-5:2007 (D) 3 Vorwort Dieses Dokument (EN 15085-5:2007) wurde vom Technischen Komitee CEN/TC 256 „Eisenbahnwesen“ erarbeitet, dessen Sekretariat vom DIN gehalten wird. Diese Europäische Norm muss den Status einer nationalen Norm erhalten, entweder durch Veröffentlichung eines identischen Textes oder durch Anerkennung bis April 2008, und etwaige entgegenstehende nationale Normen müssen bis April 2008 zurückgezogen werden. Die Europäische Normenreihe EN 15085 „Bahnanwendungen — Schweißen von Schienenfahrzeugen und -fahrzeugteilen“ besteht aus den folgenden Teilen: ⎯ Teil 1: Allgemeines ⎯ Teil 2: Qualitätsanforderungen und Zertifizierung von Schweißbetrieben ⎯ Teil 3: Konstruktionsvorgaben ⎯ Teil 4: Fertigungsanforderungen ⎯ Teil 5: Prüfung und Dokumentation Es wird auf die Möglichkeit hingewiesen, dass einige Texte dieses Dokuments Patentrechte berühren können. CEN [und/oder CENELEC] sind nicht dafür verantwortlich, einige oder alle diesbezüglichen Patentrechte zu identifizieren. Entsprechend der CEN/CENELEC-Geschäftsordnung sind die nationalen Normungsinstitute der folgenden Länder gehalten, diese Europäische Norm zu übernehmen: Belgien, Bulgarien, Dänemark, Deutschland, Estland, Finnland, Frankreich, Griechenland, Irland, Island, Italien, Lettland, Litauen, Luxemburg, Malta, Niederlande, Norwegen, Österreich, Polen, Portugal, Rumänien, Schweden, Schweiz, Slowakei, Slowenien, Spanien, Tschechische Republik, Ungarn, Vereinigtes Königreich und Zypern. SIST EN 15085-5:2008
EN 15085-5:2007 (D) 4 Einleitung Schweißen ist ein spezieller Prozess zur Herstellung von Schienenfahrzeugen und -fahrzeugteilen. Die erforderlichen Festlegungen für diesen Prozess sind in der Normenreihe EN ISO 3834 getroffen. Die Basis dieser Festlegungen sind die grundlegenden schweißtechnischen Normen unter Berücksichtigung der besonderen Anforderungen an den Schienenfahrzeugbau. Diese Europäische Norm bezweckt, die Anwendung der Begriffe der entsprechenden Europäischen Normen zu definieren, sie ersetzt diese Normen nicht. Diese Europäische Norm kann auch von internen und externen Stellen, einschließlich der Zertifizierungs-stellen, angewendet werden, um abzuschätzen, ob die Fähigkeiten der Organisation den Anforderungen des Kunden, der Aufsichtsbehörde und der eigenen Organisation genügen. SIST EN 15085-5:2008
EN 15085-5:2007 (D) 5 1 Anwendungsbereich Diese Normenreihe gilt für das Schweißen metallischer Werkstoffe bei der Herstellung und Instandsetzung von Schienenfahrzeugen und -fahrzeugteilen. Dieser Teil der Normenreihe: ⎯ definiert die an den Schweißnähten durchzuführenden Prüfungen; ⎯ legt die Durchführung der zerstörenden und zerstörungsfreien Prüfungen fest; ⎯ definiert die notwendigen Dokumentationen zur Herausgabe der Produktkonformitätserklärung. 2 Normative Verweisungen Die folgenden zitierten Dokumente sind für die Anwendung dieses Dokuments erforderlich. Bei datierten Verweisungen gilt nur die in Bezug genommene Ausgabe. Bei undatierten Verweisungen gilt die letzte Ausgabe des in Bezug genommenen Dokuments (einschließlich aller Änderungen). EN 473, Zerstörungsfreie Prüfung — Qualifizierung und Zertifizierung von Personal der zerstörungsfreien Prüfung — Allgemeine Grundlagen EN 10204, Metallische Erzeugnisse — Arten von Prüfbescheinigungen EN 12062, Zerstörungsfreie Prüfung von Schweißverbindungen — Allgemeine Regeln für metallische Werkstoffe EN 15085-1:2007, Bahnanwendungen — Schweißen von Schienenfahrzeugen und -fahrzeugteilen — Teil 1: Allgemeines EN 15085-2:2007, Bahnanwendungen — Schweißen von Schienenfahrzeugen und -fahrzeugteilen — Teil 2: Qualitätsanforderungen und Zertifizierung von Schweißbetrieben EN 15085-3:2007, Bahnanwendungen — Schweißen von Schienenfahrzeugen und -fahrzeugteilen — Teil 3: Konstruktionsvorgaben EN 15085-4:2007, Bahnanwendungen — Schweißen von Schienenfahrzeugen und -fahrzeugteilen — Teil 4: Fertigungsanforderungen EN ISO 3834 (alle Teile), Qualitätsanforderungen für das Schmelzschweißen von metallischen Werkstoffen EN ISO 5817, Schweißen — Schmelzschweißverbindungen an Stahl, Nickel, Titan und deren Legierungen (ohne Strahlschweißen) — Bewertungsgruppen von Unregelmäßigkeiten (ISO 5817:2003) EN ISO 10042, Schweißen — Lichtbogenschweißverbindungen an Aluminium und seinen Legierungen — Bewertungsgruppen von Unregelmäßigkeiten (ISO 10042:2005) EN ISO 14731:2006, Schweißaufsicht — Aufgaben und Verantwortung (ISO 14731:2006) EN ISO 15609 (alle Teile), Anforderung und Qualifizierung von Schweißverfahren für metallische Werkstoffe — Schweißanweisung EN ISO/IEC 17050-1, Konformitätsbewertung — Konformitätserklärung von Anbietern — Teil 1: Allgemeine Anforderungen (ISO/IEC 17050-1:2004) EN ISO/IEC 17050-2, Konformitätsbewertung — Konformitätserklärung von Anbietern — Teil 2: Unterstützende Dokumentation (ISO/IEC 17050-2:2004) SIST EN 15085-5:2008
EN 15085-5:2007 (D) 6 3 Begriffe Für die Anwendung dieses Dokuments gelten die Begriffe nach EN 15085-1:2007. 4 Prüfungen von Schweißverbindungen 4.1 Allgemeines Die Beziehung zwischen den wesentlichen, auf das Schweißen bezogenen Aufgaben der verantwortlichen Schweißaufsicht oder seiner beauftragten Stellvertreter in der Fertigungsphase ist in Tabelle A.1 angegeben. 4.2 Prüfungen vor dem Schweißen Zusätzlich zu Tabelle A.1 ist die verantwortliche Schweißaufsicht für folgende Aufgaben verantwortlich: ⎯ Planung der Ausarbeitung der Wurzel- und der Gegenlage; ⎯ zusätzliche schweißtechnische Angaben in den Zeichnungen. Die Durchführung der Konstruktionsprüfung nach Tabelle A.1 und den o. g. Prüfungen ist zu dokumentieren. Um die oben genannten Aufgaben zu erfüllen, darf die Schweißaufsicht die Unterstützung anderer Abteilungen/Bereiche des Unternehmens in Anspruch nehmen. Einzelheiten über die Zuständigkeiten der Aufgaben sind, wie angewandt, von den Schweißbetrieben festzulegen. Der Schweißer/Bediener hat vor Beginn jeder Art von Schweißarbeiten folgende Punkte zu prüfen: ⎯ dass die Schweißgeräte in einsatzbereitem Zustand sind; ⎯ Verfügbarkeit der Arbeitsanweisungen; ⎯ den Zustand der Schweißnahtvorbereitungen und die korrekten Heftnähte der zu schweißenden Werk-stücke (Reinheit und Montagezustand der Werkstücke nach Angaben in der Zeichnung und/oder der WPS); ⎯ Identifizierung der zu schweißenden Werkstücke; ⎯ dass die Schweißzusätze mit der WPS übereinstimmen. 4.3 Prüfungen während des Schweißens Der Schweißer oder Bediener hat während der Schweißarbeiten folgende Punkte zu überprüfen und sicherzustellen: ⎯ die angemessene Reinigung und die Form der Verbindungen während der Zwischenlagenschweißung; ⎯ die Einhaltung der vorgegebenen Vorwärm- und/oder Zwischenlagentemperaturen; ⎯ die Einhaltung der WPS und/oder Arbeitsanweisungen; ⎯ die Einhaltung der Reihenfolge der Arbeitsgänge, wenn dies in der spezifischen Arbeitsanweisung vorgeschrieben ist (z. B. Schweißfolgeplan). Die Prozessschritte und -phasen, bei denen eine Überwachung durch die verantwortliche Schweißaufsicht oder deren Vertreter für die Schweißarbeiten notwendig ist, sind in den schweißtechnischen Planungsunter-lagen anzugeben (siehe EN 15085-4:2007, 4.1). Falls im Fertigungs- oder Prüfplan eine Prüfung der Schweißnaht während der Fertigung vorgesehen ist, dürfen die Schweißarbeiten erst nach Durchführung dieser Prüfung fortgesetzt werden. SIST EN 15085-5:2008
EN 15085-5:2007 (D) 7 4.4 Prüfungen nach dem Schweißen 4.4.1 Prüfungen durch den Schweißer oder Bediener Nach dem Schweißen muss der Schweißer oder Bediener prüfen ob: ⎯ die Schweißnaht vollständig ist; ⎯ die Schweißnaht gereinigt ist; ⎯ die Form und Abmessungen der Schweißnaht der Zeichnung entsprechen. 4.4.2 Werkerselbstprüfung durch den Schweißer oder Bediener Wenn ein Werkerselbstprüfungssystem eingesetzt wird, muss das Personal, das mit der Werkerselbstprüfung betraut wurde, in geeigneter Weise im Hinblick auf die Durchführung der Sichtkontrolle und die Anforderungen der EN 15085-3:2007, Abschnitt 5, durch die verantwortliche Schweißaufsicht oder einen Beauftragten (Vertreter der verantwortlichen Schweißaufsicht oder VT 2-Prüfer nach EN 473) ausgebildet und eingewiesen werden. Die Prüfungen, die von dem Schweißer oder Bediener durchgeführt werden, müssen in Übereinstimmung mit Tabelle 1 klar definiert (Abnahmekriterien, Abmessungen usw.) und aufgezeichnet werden. Diese Aufzeich-nungen sind von dem Schweißer oder Bediener, der die Prüfung durchgeführt hat, zu unterschreiben und den weiteren Prüfungsunterlagen beizufügen. Eine Kopie der persönlichen Unterschriften mit Namen in Druckschrift ist für das Personal, das Prüfdokumente unterschreibt, zu hinterlegen. Alternativ können auch elektronische Systeme verwendet werden. 4.4.3 Prüfung der Konformität der Schweißnähte Nach dem Schweißen werden die zerstörungsfreien Prüfungen durch dafür qualifiziertes Personal ausgeführt (außer VT; siehe Tabelle 1). Tabelle 1 definiert die Art und den Umfang der Prüfungen, die während der Serienfertigung durchzuführen sind. Dieses basiert auf der durch den Konstrukteur festgelegten Schweißnahtgüteklasse und der sich daraus ergebenden Schweißnahtprüfklasse (siehe EN 15085-3). In Übereinstimmung mit der Schweißnahtprüfklasse bei Fertigungsbeginn: 100 % Prüfung an allen zu prüfenden Nähten des ersten Bauteils der Serie, wenn dies in Tabelle 1 gefordert wird. Prüfung während der Serienfertigung: Die Prüfungen, die in Tabelle 1 beschrieben werden, müssen an in Serienfertigung hergestellten Produkten in Übereinstimmung mit dem darin angegebenen Umfang und entsprechend der vom Konstrukteur auf der Zeichnung angegebenen Schweißnahtgüteklasse ausgeführt werden. Wenn während der in Tabelle 1 angegebenen Prüfungen eine nicht zulässige Unregelmäßigkeit entdeckt wird, ist das Verfahren zur Behandlung von Unregelmäßigkeiten anzuwenden, gleichzeitig erfolgt die Ausweitung der Prüfungen, wie in Abschnitt 7 beschrieben. SIST EN 15085-5:2008
EN 15085-5:2007 (D) 8 Tabelle 1 — Prüfungen, die während der Produktion zu dokumentieren sind Schweißnahtprüfklasse Volumetrische PrüfungRT oder UT Oberflächenprüfung MT oder PT Sichtprüfung VT CT 1 100 %a
100 % 100 % CT 2 10 %a
b 10 %b 100 % CT 3 Nicht erforderlich Nicht erforderlich 100 % CT 4 Nicht erforderlich Nicht erforderlich 100 % Die angegebenen Prozentsätze beziehen sich auf die totale Länge aller Schweißnähte. Damit gilt: ⎯ 100 % bedeutet: Prüfung aller Schweißnähte aller Bauteile; ⎯ 10 % bedeutet: Prüfung von 10 % der Schweißnähte aller Bauteile, oder 100 % Prüfung eines Bauteils von jeweils 10 Bauteilen. Die in Tabelle 1 angezeigten Prüfverfahren sind Mindestprüfanforderungen an Schweißverbindungen. Zusatzprüfungen können je nach dem Material, Konstruktion oder Kundenanforderungen notwendig sein. Jedes ZfP-Verfahren (RT, UT, MT oder PT) ist von Prüfpersonal, das nach EN 473 zertifiziert ist, auszuführen und zu dokumentieren. Für die Prüfklassen CT 1 und CT 2 ist die Sichtprüfung von Prüfpersonal, das nach EN 473 zertifiziert ist, auszuführen und zu dokumentieren. Für die Prüfklasse CT 3 ist mindestens die Sichtprüfung von Prüfpersonal auszuführen, das vom Hersteller qualifiziert ist, und sollte dokumentiert werden. Für die Prüfklasse CT 4 ist mindestens die Sichtp
...
SLOVENSKI oSIST prEN 15085-5:2005
PREDSTANDARD
januar 2005
Železniške naprave – Varjenje železniških vozil in elementov - 5. del: Nadzor,
preskušanje in dokumentacija
(istoveten prEN 15085-5:2004)
Railway applications - Welding of railway vehicles and components - Part 5:
Inspection, testing and documentation
ICS 25.160.01; 45.060.01 Referenčna številka
oSIST prEN 15085-5:2005(en)
© Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno
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EUROPEAN STANDARD
DRAFT
prEN 15085-5
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2004
ICS
English version
Railway applications - Welding of railway vehicles and
components - Part 5: Inspection, testing and documentation
Applications ferroviaires - Soudage des véhicules Bahnanwendungen - Schweißen von Schienenfahrzeugen
ferroviaires et des pièces - Partie 5 : Vérification, essais et und -fahrzeugteilen - Teil 5: Überprüfung, Versuche und
documentation Dokumentation
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 256.
If this draft becomes a European Standard, 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.
This draft European Standard was established by CEN 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 Management Centre has the same
status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,
Slovenia, Spain, Sweden, Switzerland and United Kingdom.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36 B-1050 Brussels
© 2004 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 15085-5:2004: E
worldwide for CEN national Members.
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prEN 15085-5:2004 (E)
Contents Page
Foreword.3
Introduction .4
1 Scope .5
2 Normative references .5
3 Terms and definitions .6
4 Inspection and testing of welded joints .6
5 Status of the inspections and testing.10
6 Non-destructive and destructive tests .11
7 Non conformities and corrective actions.15
8 Management of the sub-suppliers .17
9 Supplier’s declaration of conformity .17
Bibliography .19
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prEN 15085-5:2004 (E)
Foreword
This document (prEN 15085-5:2004) has been prepared by Technical Committee CEN/TC 256 “Railway
Applications”, the secretariat of which is held by DIN.
This document is currently submitted to the CEN Enquiry.
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive:
Council Directive 93/38/EEC of 14 June 1993 coordinating the procurement procedures of entities
1
operating in the water, energy, transport and telecommunications sectors )
This series of European Standards prEN 15085 "Railway applications – Welding of railway vehicles and
components" consists of the following parts:
Part 1: General
Part 2: Quality requirements and certification of welding manufacturer
Part 3: Design requirements
Part 4: Production requirements
Part 5: Inspection, testing and documentation
1
) Official Journal of the European Communities No L 199 of 9.8.93
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prEN 15085-5:2004 (E)
Introduction
Welding is an essential process in the manufacture of railway vehicles and their parts. The required provisions
for the special process “welding” are laid down in the standards EN ISO 9001 (see [1]) and EN 729. The basis
of these provisions is the basic technical welding standards in respect of the special requirements for the
construction of railway vehicles.
This standard is aimed at defining the terms of enforcement applicable to European Standards, it shall not be
construed as a substitute to these standards.
This standard can also be used by internal and external parties, including certification bodies, to assess the
organisation's ability to meet customer, regulatory and the organisation's own requirements.
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prEN 15085-5:2004 (E)
1 Scope
This standard applies to the welding of metallic materials during the manufacture and repair/maintenance of
railway vehicles and vehicle parts. It
defines the checks to be executed on the welds,
describes the rules of carrying out the destructive and non-destructive tests,
defines the necessary documentation to issue to declare the conformity of the products.
However, additional and more restrictive requirements may be applied if explicitly indicated in the order or
contract.
The non-destructive and destructive inspections and testings by this part of the standard are carried out in
accordance with the appropriate EN standards listed in clause 2 and in the bibliography.
2 Normative references
The following referenced documents are indispensable for the application 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 288-2, Specification and approval of welding procedures for metallic materials − Part 2: Welding procedure
specification for arc welding / Note: To be replaced by prEN ISO 15609-1 (2003-10).
EN 473, Non destructive testing − Qualification and certification of NDT personnel − General principles.
EN 729-1, Quality requirements for welding − Fusion welding of metallic materials − Part 1: Guidelines for
selection and use / Note: To be replaced by prEN ISO 3834-1 (2004-02).
EN 729-2, Quality requirements for welding − Fusion welding of metallic materials − Part 2: Comprehensive
quality requirements / Note: To be replaced by prEN ISO 3834-2 (2004-02).
EN 729-3, Quality requirements for welding − Fusion welding of metallic materials − Part 3: Standard quality
requirements / Note: To be replaced by prEN ISO 3834-3 (2004-02).
EN 729-4, Quality requirements for welding − Fusion welding of metallic materials − Part 4: Elementary quality
requirements / Note: To be replaced by prEN ISO 3834-4 (2004-02).
EN 1321, Destructive tests on welds in metallic materials − Macroscopic and microscopic examination of
welds.
EN 10204:1991, Metallic products; types of inspection documents.
EN 12062, Non-destructive examination of welds − General rules for metallic materials.
EN 30042, Arc-welded joints in aluminium and its weldable alloys − Guidance on quality levels for
imperfections (ISO 10042:1992.)
EN 45014, General criteria for supplier's declaration of conformity (ISO/IEC Guide 22:1996) / Note: To be
replaced by prEN ISO/IEC 17050-1 (2003-05), prEN ISO/IEC 17050-2 (2003-05).
EN ISO 5817, Welding − Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding
excluded) − Quality levels for imperfections (ISO 5817:2003).
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prEN 15085-5:2004 (E)
EN ISO/IEC 17025, General requirements for the competence of testing and calibration laboratories (ISO/IEC
17025:1999) / Note: To be amended by EN ISO/IEC 17025/prA1 (2003-11).
EN ISO/IEC 17025/prA1, General requirements for the competence of testing and calibration laboratories
(ISO/IEC 17025:1999/DAM 1:2003); Amendment A1 / Note: Intended as an amendment to EN ISO/IEC 17025
(2000-05).
prEN 15085-1:2004, Railway applications – Welding of railway vehicles and components – Part 1: General.
prEN 15085-2:2004, Railway applications – Welding of railway vehicles and components – Part 2: Quality
requirements and certification of welding manufacturer.
prEN 15085-3:2004, Railway applications – Welding of railway vehicles and components – Part 3: Design
requirements.
prEN 15085-4:2004, Railway applications – Welding of railway vehicles and components – Part 4: Production
requirements.
3 Terms and definitions
For the purposes of this European Standard, the terms and definitions given in prEN 15085-1:2004 apply.
4 Inspection and testing of welded joints
4.1 Inspection and testing prior to welding
a) During the phase of the design review it shall be the responsibility of the authorized welding coordinator to
check the following:
accessibility and positioning of the welds;
preparation of the edges of the welded joints;
welding techniques (fixed or mobile supporting plate, back rewelding, etc.);
specifications of base materials;
specifications of filler materials;
testability of the welds and the types of non-destructive tests that can be carried out;
quality requirements and defect levels accepted for each welded joint;
finishing and dimensions of the welded joints.
As evidence that the checks listed above have been carried out, the outcome shall be recorded in the minutes
of the design review meetings.
In order to carry out the above-mentioned tasks the coordinator may make use of, or request whenever
necessary and at his own discretion, the specialised backup of other company departments or offices.
The welding coordinator shall also check the following items:
the validity of the qualifications of the welders/welding operators;
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prEN 15085-5:2004 (E)
the existence of appropriate and applicable WPAR and WPS.
b) The tasks of the head of the production department, prior to the beginning of any type of welding activity,
in connection with the RWC, include the following:
to check that the safety and environmental conditions of the work stations are suitable;
to check the status of the fastening equipment of the parts to be welded;
to check the calibration status of the welding machines;
to establish the work sequences in accordance with the WPS and/or applicable work instructions,
ascertaining that these are all available at each work station;
to check that the pieces to be welded have been identified;
to provide the suitable equipment necessary for cleaning the pieces to be welded;
to ensure the availability of all the weld materials in compliance with the indications in the WPS;
to pre-arrange the materials and/or calibrated equipment for checking the pre-heating and/or interpass
temperatures.
c) The task of the welder/welding operator, before beginning any type of welding activity, is to check the
following items:
that the welding machine is calibrated and efficient;
the existence of the work sequences with the applicable WPS/work instructions;
the conditions of the edges and the correct tacking of the items to be welded (conditions of cleanliness
and assemblage of the pieces in accordance with the design and/or the WPS);
the identification of the items to be welded;
the compliance of the welding materials with the WPS.
4.2 Inspection and testing during welding
The personnel involved in this activity are the welders/welding operators whose task is to check and ensure
the following:
adequate cleaning and shape of the joints during the intermediate passes;
the prescribed values of the pre-heating and/or interpass temperatures;
the correct application of the parameters indicated in the WPS/operating instructions;
the correct sequence of the operations if prescribed in specific operating instructions (for example, the
sequence of assembling operations and/or the sequence of welds for limiting distortions).
When a manufacturing and control plan is required (see 4.2), this document will explain the process steps and
phases in which it is necessary for the welding activity to be supervised by the RWC or his deputy.
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prEN 15085-5:2004 (E)
4.3 Inspection and testing after welding
4.3.1 Checks/self-inspection carried out by the welders/welding operators
4.3.1.1 Checks carried out by the welders/welding operators
Within the framework of their job, checks after welding are carried out by welders/welding operators in
accordance with the technical knowledge required in series of standards EN 287 (see [2] and [3]) and in
EN 1418 (see [4]):
check the correct cleaning of the seam of the weld;
check the shape and dimensions of the weld;
remove any superficial imperfections;
check for any distortions.
Although they are mentioned in the control plan, these checks made by welders/welding operators will not
officially be recorded.
Without documented visual checks made by welders/welding operators this work has to be documented by a
qualified inspector.
4.3.1.2 Self-inspection carried out by the welders/welding operators
If a self-inspection system is installed the personnel entrusted with the self-inspection phase shall be suitable
nd
trained and instructed with regards to the visual inspection techniques by the welding coordinator or a 2 level
EN 473 personnel certified for visual method.
The inspections carried out by welders/welding operators shall be clearly defined (acceptance criteria,
dimensioning, etc.) and recorded. The signature of the welders/welding operators who carried out the
inspection will be appended on the recording document mentioned in the control plan and enclosed with the
other control documents.
4.3.2 Control of the conformity of the welds
After welding, the NDT (Non-Destructive Testing) is carried out by qualified personnel (see clause 6).
Table 1 defines the type and frequency of the testing to be carried out during series production. This is based
on the relationship between the classification (quality class) of the welded joint assigned by the design
engineer and the inspection class (see prEN 15085-3:2004).
Testing at the beginning of production: 100 % testing on each initial item produced if testing is demanded in
table 1.
Testing during series production: The tests prescribed in table 1 shall be carried out on products
manufactured during series production in accordance with the frequencies indicated therein and as per the
classification indicated on the drawing by the design engineer.
In the case of detecting unacceptable defects during the tests indicated in table 1, the procedure for
management of non-conformities shall be applied, with the extension of the testing as indicated in clause 7.
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prEN 15085-5:2004 (E)
Table 1 — Tests which have to be documented during production
Inspection class Volumetric tests Surface tests Visual inspection
RT or UT a b MT or PT VT
I 100 % 100 % 100 %
II 10 % 10 % c 50 % c
III NR d NR d 10 %
IV NR d NR d NR d
a
Volumetric tests only for butt welds and T-welds full penetration. Not applicable for T-welds partial penetration and for fillet welds
(see also EN 12062).
b
Work piece tests prior to manufacture are required in cases where NDT is not feasible. In addition to work piece tests, mock-ups
during the production are required if agreed between customer and manufacturer.
For the methods pertaining to the construction, preparation and destructive testing on the work pieces and on mock-ups refer to
TC 256 WI 180 and to clause 5.
c
For fillet welds and T-welds partial penetration in inspection class II and classified C1 on the drawings it is required to extend the
percentage of surface test and of visual examination to 100% (see prEN 15085-3:2004, 4.7).
d
NR = Not required
Additional notes to table 1:
a) The percentages expressed in table 1 refer to the total length to be examined for one given weld. Thus:
100 %: request for testing of the entire length of the weld and on all the pieces built;
10 % (or 50 %): testing of the entire length of the weld on 1 of every 10 (or 2) items built; or as the
equivalent (at the manufacturer’s discretion):
testing on 10 % (or 50 %) of the total length of the welding of all the products built.
However, the minimum length of the weld to be inspected should be not less than 30 mm.
b) The testing methods indicated in the table above shall be the minimums capable of guaranteeing the
compliance of the welded joints. These may be varied according to the contractual requirements,
agreements with the customer, or on the basis of indications from the design engineer.
c) Additional tests shall be performed dependent on possible problems connected to the material or the
design.
4.3.3 Final tests on the welded structures
After the testing of the welds as indicated in 4.3.1 and 4.3.2, further testing shall be carried out on the welded
structures in order to certify the final conformity.
Examples of these tests (assigned to the quality control personnel) are as follows:
testing of the post-welding heat treatment or the post-welding ageing process;
dimensional and geometric test of the welded structure;
testing of the welded product after final grinding operations;
inspection of the identification of the product, its components and parts.
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prEN 15085-5:2004 (E)
5 Status of the inspections and testing
5.1 General
For each welded assembly and subassembly the current status of the inspections and testing required shall
always be identifiable.
The latter refers to all those tests aimed at ascertaining the effective execution of the quality requirements and
the operating methods, previously established during the planning of the production activities and necessary
for guaranteeing the requested quality level of the welded product.
A list of these tests (testing prior to, during, and after the welding) is outlined in clause 4.
5.2 Inspection and testing status: applicable methods
The inspection and testing status should be identifiable via the use of appropriate methods that will depend on
the complexity or importance of the welded structure.
If sufficiently explicit, the method of marking on the item itself may be acceptable.
The importance of a welded structure is indicated by its classification which will depend on the safety
requirements (see, for example, levels 1 and 2 indicated in annex A of prEN 15085-2:2004).
Complex welded structures having different operations and checks require the process to be pre-planned and
documented.
For particularly complex or important structures it is recommended that a specific document (manufacturing
and test plan or a work cycle) describes explicitly all the various phases relating to the above-mentioned tests.
For minor components (e.g. those welded individually outside the main assembly, small sub-units,
geometrically simple structures, etc.) which do have a demonstrated importance, their management may be
by means of suitable “control sheets“, in which all the essential tests from those listed in clause 4 are included.
The above documents shall contain the following data as a minimum:
d) a complete description of the inspection/testing phases, including all suitable references (e.g. acceptability
criteria, operating methods and procedures to be followed, etc.);
e) data referring to the operator assigned to the test. Obligatory and recommended requirements in clause 4
and 6 are necessary for the personnel assigned to testing and inspection;
f) indications for each phase of the requirement levels necessary to progress to the subsequent phases;
g) frequency of the inspections and testing in percentages during the series production;
h) criteria and methods of identifying the parts, if necessary for guaranteeing their traceability;
i) indications of any binding points contractually agreed or established (e.g. obligation of notifying the
customer of his presence during the specified testing phases – hold point, witness point);
j) the need to issue test reports for the test phase.
5.3 Documents for recording the inspections and testing
In order to be related to the individual products the appropriate documents (manufacturing and test plans,
work cycles, control sheets, etc.), shall be marked with the product identification data (type, job order, drawing
and its revision, serial number or progressive manufacturing number).
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Wherever and whenever requested, these shall also be filled out/signed in every part by the personnel
carrying out the phases.
In this way this documentation shall be capable of demonstrating and documenting the progress of the
construction activities during the manufacturing of the individual products.
These shall therefore be considered as “documents for recording the quality” and as such, they shall be filled
and retained by the manufacturer according to the methods indicated in the appropriate clause of the series of
standards EN 729, together with any other documentation referred to therein.
6 Non-destructive and destructive tests
6.1 General
The status of the non-destructive, and if necessary the destructive (indirect) tests, on the welded joints of the
sub-units, units or assemblies shall be appropriately identifiable by means of suitable documentation capable
of objectively outlining the conformity or non-conformity of the welds with respect to the tests carried out.
6.2 Non-destructive tests
6.2.1 General criteria
The methods of the non-destructive tests (NDT) have to be done in accordance to EN 12062. Other tests may
be agreed.
Feasibility and reliability of the non-destructive tests:
The verification of the feasibility and reliability of the non-destructive volumetric tests (UT, RT) on the welded
joints, required by this standard, should be carried out before the beginning of production for the preparation
of the following specific operating procedures.
In the case in which the above mentioned verifications reveal limitations in the validity of the non-destructive
tests to be carried out (e. g. inaccessibility for conducting the test), alternative tests of a non-destructive type
may be carried out in accordance with the methods indicated in prEN 15085-4:2004.
Materials:
The test methods foreseen by this standard refer to welded joints the base materials of either steel or
aluminium alloys.
6.2.2 Personnel assigned to the testing
It shall be the manufacturer’s responsibility to:
plan the non-destructive tests for the single sub-units, units or assemblies produced;
identify the phases of the production process during which the tests shall be carried out;
apply the test methods and procedures in accordance with the specific prescriptions contained in this
clause;
approve and record the results of the tests carried out;
act as guarantor for the non-destructive tests carried out on welded parts produced by his own sub-
suppliers.
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6.2.2.1 Qualifications of the personnel assigned to the non-destructive tests
The personnel assigned to the preparation of the procedures, plus those assigned to the assessing of the
results, as well as the persons in charge of the carrying out of the tests shall all be in possession of the
qualification obtained for the inspections and testing in compliance with EN 473, according to the appropriate
qualification levels (3, 2 and 1, respectively).
In the event of the testing organization belonging to the company, it shall be arranged in such a way as to be
independent from the production, and its activities shall be monitored and managed according to a quality
assurance system (e. g. quality control).
If the testing organization is external to the manufacturing company, it shall be qualified and operate in
compliance with EN ISO/IEC 17025.
6.2.3 Documentation and procedures
Before beginning the production and testing, the manufacturer shall be in possession of the suitable technical
documents (test procedures) including the following:
rd
general NDT procedures, countersigned by 3 level personnel qualified according to EN 473, for each
non-destructive method used;
nd
operating procedures foreseen by the test plan, prepared and signed by 2 level personnel according to
EN 473.
Furthermore, the company shall also have on hand an updated list of the qualified personnel in accordance
with EN 473.
6.2.3.1 Test methods and techniques
For every non-destructive test method used, the following operating procedure shall be required for the testing
technique used:
st
step-by-step if the test is carried out by 1 level NDT personnel;
nd
with the essential characteristics of the specific test if carried out by 2 level NDT personnel and on the
basis of the reference EN standard.
If the test technique is not governed by a reference EN standard or if supplementary references are used, the
rd
operating procedure shall be drawn up or validated by 3 level personnel, and if requested, agreed upon
between the parties.
6.2.3.2 Test certification
For all the non-destructive test methods, a test report shall be drawn up at the end of each test. This test
report shall contain a minimum of data requested by the relative EN standard method.
In the case in which the test carried out is only partial, meaning if only carried out on a fraction of the total
length of the weld, the test report shall be accompanied by a detailed diagram (mapping of the area
examined) for the purpose of traceability of the area tested.
6.2.3.3 Quality level of the joints
In relation to the corresponding quality class of each welded joint indicated in the drawing, the imperfections
shall not exceed the maximum acceptability criteria indicated in EN ISO 5817 or EN 30042 respectively for
steel and aluminium and its alloys.
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For the correlation between the quality classes B, C and D of the above mentioned standards and the
classification indicated in the drawing, refer to prEN 15085-3:2004.
For the quality class A, it is necessary to take into account further restrictions with regard to level B, that are
prescribed for several types of imperfections (as indicated in prEN 15085-3:2004).
6.2.3.4 Test levels and acceptability levels
EN 12062 refers to the test levels and acceptability levels corresponding to the quality levels required in
accordance with the non-destructive test method used.
In specific cases in which a more precise assessment of the extent and type of imperfection is required in
order to determine, for example, its operating compatibility, it may be necessary to establish and make use of
non-destructive methods that are not contained in the above-mentioned standard.
For this purpose specific procedures agreed upon between the parties shall be applied.
6.3 Indirect destructive tests
This clause deals with the indirect destructive tests relating to welded joints that are not testable.
6.3.1 General
During the design review phases, the design engineer, with the co-operation of the welding coordinator, shall
ascertain the actual testability of the joints according to the NDT methods prescribed in table 1.
In the cases in which this cannot be guaranteed (for example due to inaccessibility, partial accessibility or lack
of test reliability), or whenever it is not possible for valid reasons to oversize the joint in order to reclassify it at
a lower level, suitable alternative tests shall be defined which give evidence of achieving the required welding
quality.
Alternative tests, of the macrographic destructive type, shall be performed on facsimile welds (work pieces or
mock-ups), to be produced prior or during the production.
The admissibility of the
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