SIST EN 16910:2018
(Main)Railway applications - Rolling stock - Requirements for non-destructive testing on running gear in railway maintenance - Part 1: Wheelsets
Railway applications - Rolling stock - Requirements for non-destructive testing on running gear in railway maintenance - Part 1: Wheelsets
This standard provides the specific requirements for non-destructive testing (NDT) of wheelsets for:
— in-service inspection,
— off-vehicle inspection,
— NDT Personnel Certification (incl. training, qualification, renewal),
— NDT Procedure and Instruction,
— introduction of new NDT Techniques,
For this standard, the following NDT methods considered are:
— ultrasound testing (UT),
— magnetic particle testing (MT),
— eddy current testing (ET),
For application of these methods, a catalogue of common defects is given as guidance.
Other methods considered in ISO 9712 are outside the scope of this standard.
For application of this standard the definition of the “Wheelset Class” is given and attached to the Railway Maintenance Sector as named in ISO 9712.
Specific NDT requirements for infrastructure or requirements relating to the quality of new products delivered by manufacturers are not within the scope of this standard.
Bahnanwendungen - Schienenfahrzeuge - Anforderungen an die zerstörungsfreie Prüfung an Fahrwerken in der Instandhaltung - Teil 1: Radsätze
Diese Europäische Norm legt die spezifischen Anforderungen der ZfP von Radsätzen fest, für:
- Instandhaltung im Betrieb;
- Instandhaltung im ausgebauten Zustand;
- ZfP-Personal;
- ZfP-Dokumentation (Verfahren und Anweisung);
- Rückverfolgbarkeit der ZfP-Ergebnisse in der Instandhaltung.
Sie gibt Anleitungen für die Einführung neuer ZfP-Techniken.
In dieser Norm werden folgende ZfP-Verfahren berücksichtigt:
- Ultraschallprüfung (UT);
- Magnetpulverprüfung (MT);
- Wirbelstromprüfung (ET).
Beispiele üblicher ZfP-Anzeigen sind im informativen Anhang zu finden.
Andere in EN ISO 9712:2012 genannte Verfahren liegen außerhalb des Anwendungsbereichs dieser Norm.
Zu diesem Zweck ist ein Katalog der häufigsten Fehler als Orientierungshilfe gegeben.
Spezifische ZfP-Anforderungen an die Qualität neuer Produkte, die durch die Hersteller geliefert werden, liegen außerhalb des Anwendungsbereichs dieser Norm.
Applications ferroviaires - Matériel roulant - Exigences pour les essais non destructifs sur les organes de roulement lors de la maintenance ferroviaire - Partie 1: Essieux
La présente Norme européenne définit les exigences spécifiques relatives aux END des essieux pour :
- la maintenance des essieux posés sous véhicule ;
- la maintenance des essieux déposés ;
- le personnel END ;
- la documentation END (Procédures et Instructions) ;
- la traçabilité des résultats des END de maintenance.
Elle donne les lignes directrices pour la mise en place de nouvelles techniques END.
Pour les besoins de la présente norme, les méthodes END suivantes sont prises en compte :
- Ultrasons (UT) ;
- Magnétoscopie (MT) ;
- Courants de Foucault (ET).
Des exemples des indications communes d’END sont donnés dans une annexe informative.
Les autres méthodes traitées dans l'EN ISO 9712:2012 sont en dehors du domaine d'application de la présente norme.
À cet effet, un catalogue des défauts communs est fourni à titre de ligne directrice.
Les exigences END spécifiques concernant la qualité des produits neufs fournis par les fabricants sont en dehors du domaine d'application de la présente Norme européenne.
Železniške naprave - Vozna sredstva - Zahteve za neporušitveno preskušanje na tekalnih sestavih pri vzdrževanju železnice - 1. del: Kolesne dvojice
Ta standard določa posebne zahteve za neporušitveno preskušanje (NDT) kolesnih dvojic za: – pregled med obratovanjem,
– pregled kolesnih dvojic, ki niso nameščene na vozilu,
– certifikacijo osebja za NDT (vklj. z usposabljanjem, kvalifikacijami, obnovitvijo),
– postopke in navodila za NDT,
– uvedbo novih tehnik za NDT.
Ta standard se nanaša na naslednje metode za NDT: – ultrazvočno preskušanje (UT),
– preskušanje z magnetnimi delci (MT),
– preskušanje z metodo vrtinčnih tokov (ET).
Za uporabo teh metod je naveden katalog pogostih napak, ki služi kot smernice. Druge metode, obravnavane v standardu ISO 9712, niso zajete v področje uporabe tega standarda. Za uporabo tega standarda je navedena opredelitev »razreda kolesnih dvojic« in priložena razdelku o vzdrževanju železnice, kot je imenovan v standardu ISO 9712. Posebne zahteve glede NDT za infrastrukturo ali zahteve v zvezi s kakovostjo novih izdelkov, ki jih dobavijo proizvajalci, niso zajete v področje uporabe tega standarda.
General Information
Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Vozna sredstva - Zahteve za neporušitveno preskušanje na tekalnih sestavih pri vzdrževanju železnice - 1. del: Kolesne dvojiceBahnanwendungen - Schienenfahrzeuge - Anforderungen an die zerstörungsfreie Prüfung an Fahrwerken in der Instandhaltung - Teil 1: RadsätzeApplications ferroviaires - Matériel roulant - Exigences pour les essais non destructifs sur les organes de roulement lors de la maintenance ferroviaire - Partie 1: EssieuxRailway applications - Rolling stock - Requirements for non-destructive testing on running gear in railway maintenance - Part 1: Wheelsets45.120åLþQLFEquipment for railway/cableway construction and maintenance45.060.01Železniška vozila na splošnoRailway rolling stock in generalICS:Ta slovenski standard je istoveten z:EN 16910-1:2018SIST EN 16910:2018en01-julij-2018SIST EN 16910:2018SLOVENSKI
STANDARD
SIST EN 16910:2018
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 16910-1
April
t r s z ICS
v wä r v r English Version
Railway applications æ Rolling stock æ Requirements for nonædestructive testing on running gear in railway maintenance æ Part
sã Wheelsets Applications ferroviaires æ Matériel roulant æ Exigences pour les essais non destructifs sur les organes de roulement lors de la maintenance ferroviaire æ Partie
sã Essieux
Bahnanwendungen æ Schienenfahrzeuge æ Anforderungen an die zerstörungsfreie Prüfung an Fahrwerken in der Instandhaltung æ Teil
sã Radsätze This European Standard was approved by CEN on
t t January
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
9
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 x { s ræ sã t r s z ESIST EN 16910:2018
EN 16910-1:2018 (E) 2 Contents
Page European foreword . 4 Introduction . 5 1 Scope . 6 2 Normative references . 6 3 Terms and definitions . 7 4 Requirements for NDT personnel . 8 4.1 General . 8 4.2 Training . 9 4.2.1 Training contents for Wheelsets . 9 4.2.2 Industrial experience . 9 4.3 Examination for levels 1 and 2 . 10 4.3.1 General examination . 10 4.3.2 Specific examination in wheelsets . 10 4.3.3 Practical examination in wheelsets . 11 4.3.4 Grading of the level 1 and level 2 competencies . 11 4.4 Specific requirements to operate as a Level 3 wheelsets . 12 4.5 Validation of competences . 12 4.6 Requirements for the training centre . 13 4.7 Requirements for the trainer . 13 4.8 Authorization to operate . 13 4.8.1 General principle . 13 4.8.2 Validity of authorization . 13 4.8.3 Maintenance of authorization . 14 5 In-service and off-vehicle NDT requirements for maintenance . 14 5.1 General principles . 14 5.2 Detection of defects by NDT . 15 5.2.1 General . 15 5.2.2 Defects . 16 5.3 Traceability of maintenance results . 17 5.3.1 General . 17 5.3.2 Traceability requirement for the examination report . 17 5.3.3 Traceability storage time . 18 6 Requirements for NDT procedures and instructions for wheelsets . 18 6.1 NDT procedures . 18 6.2 NDT instructions . 19 6.3 Validation and approval of NDT documents . 19 6.3.1 Validation of NDT instructions . 19 6.3.2 Approval of NDT procedures . 20 7 Requirements for NDT equipment. 20 7.1 Authorization of use of NDT equipment . 20 7.1.1 Scope . 20 7.1.2 Recommendations . 20 7.1.3 Requirements . 21 7.1.4 Authorisation of use document . 21 SIST EN 16910:2018
EN 16910-1:2018 (E) 3 7.1.5 Maintenance of equipment . 21 8 Introduction of new NDT techniques . 21 9 Requirements for the NDT facilities . 22 10 Visual acuity . 22 Annex A (informative)
Processes to acquire competencies for levels 1, 2 and 3 in wheelsets . 23 Annex B (normative)
Training content for specific knowledge of wheelsets for Levels 1 and 2 in MT, ET and UT . 24 Annex C (informative)
NDT equipment verification management plan . 27 Annex D (informative)
Examples for common indications . 28 D.1 Wheels . 28 D.2 Axles . 29 Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC aimed to be covered. 34 Bibliography . 36
SIST EN 16910:2018
EN 16910-1:2018 (E) 4 European foreword This document (EN 16910-1:2018) 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 October 2018, and conflicting national standards shall be withdrawn at the latest by October 2018. 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 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 2008/57/EC. For relationship with EU Directive 2008/57/EC, see informative Annex ZA, which is an integral part of this document. 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 16910:2018
EN 16910-1:2018 (E) 5 Introduction For many years, non-destructive testing (NDT) has been used as a part of the maintenance system on European networks to control the influence of in-service condition on safety-relevant assembly groups, components and parts in order to ensure that the inspected entity treated will be used in-service in a safe condition. The maintenance standard (EN 15313 wheelsets maintenance) requires appropriately trained and capable personnel undertaking these NDT maintenance tasks (see EN ISO 9712:2012). The purpose of this document is to describe the necessary requirements on NDT additional to the existing standards to promote safety, interoperability and cross acceptance. The maintenance plan for wheelsets should ensure safe operation of railway vehicles at the right cost. It deals with wear, unexpected damages, and takes into account the vehicles usage and the track conditions. In this context, NDT is used to search for defects and failures on wheelsets. SIST EN 16910:2018
EN 16910-1:2018 (E) 6 1 Scope This European Standard provides the specific requirements for NDT of wheelsets for: — in-service maintenance; — off-vehicle maintenance; — NDT personnel; — NDT documentation (Procedure and Instruction); — traceability of the maintenance NDT results. It gives guidance for the introduction of new NDT techniques. For this standard, the following NDT methods are considered: — Ultrasonic testing (UT); — Magnetic particle testing (MT); — Eddy Current testing (ET). Other methods considered in EN ISO 9712:2012 are outside the scope of this standard. For this purpose, a catalogue of the common defects is given as guidance. Examples of common NDT indications are given in an informative annex. Specific NDT requirements relating to the quality of new products delivered by manufacturers are not within the scope of this European Standard. 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 15313, Railway applications - In-service wheelset operation requirements - In-service and off-vehicle wheelset maintenance EN ISO 9712:2012, Non-destructive testing - Qualification and certification of NDT personnel (ISO 9712:2012) CEN ISO/TR 25107:2006, Non-destructive testing — Guidelines for NDT training syllabuses (ISO/TR 25107:2006) SIST EN 16910:2018
EN 16910-1:2018 (E) 7 3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 15313 and the following apply. 3.1 non-destructive tests NDT process of examining a component to assess its integrity by a means which does not compromise the components properties and characteristics 3.2 indication representation or signal from a discontinuity in the format typical for the NDT method used [SOURCE: EN 1330-2:1998, 2.12] 3.3 defect discontinuity defect discontinuity or inhomogeneity which creates an indication which can prevent the component from fulfilling its designed purpose 3.4 acceptance or rejection criteria criteria against which the specimen is examined in order to determine its acceptability / rejectability 3.5 cracks local separation of material mostly of 2 dimensions direction resulting from thermal, chemical or mechanical exposure 3.6 NDT instruction written description of the precise steps to be followed in testing to an established standard, code, specification or NDT procedure [SOURCE: EN ISO 9712:2012, 3.16] 3.7 NDT method discipline applying a physical principle in non-destructive testing [SOURCE: EN ISO 9712:2012, 3.17] 3.8 NDT procedure written description of all essential parameters and precautions to be applied when non-destructively testing products in accordance with standard(s), code(s) or specification(s) [SOURCE: EN ISO 9712:2012, 3.18] 3.9 NDT technique specific way of utilizing an NDT method SIST EN 16910:2018
EN 16910-1:2018 (E) 8 [SOURCE: EN ISO 9712:2012, 3.19] 3.10 NDT training process of instruction in theory and practice in the NDT method 3.11 semi-automated test equipment mechanical equipment with automated mechanical movement of the test object or test equipment but evaluation is left to the NDT personnel 3.12 detection threshold defect size at which defects can be reliably detected by the chosen method 4 Requirements for NDT personnel 4.1 General NDT personnel shall have knowledge and skills relevant to the component to which they are inspecting. An example of a typical process is shown in the Informative Annex A. The organization offering the training, examination and acceptance of experience shall provide evidence of fulfilling the relevant requirements of this standard. NOTE In practice the evidence is provided by an independent body to the organization. These processes are organized with three levels of competence: — level 1 personnel: persons with competencies in a specific NDT method that allows to perform the following in accordance with NDT instructions: set up NDT equipment, perform the tests, record and classify the results of the tests according to written criteria, report the results; — level 2 personnel: persons with competencies in a specific NDT method that allows to deal with the following points:
choose NDT techniques, tests, equipment, specification and procedures;
select the NDT technique for the testing method to be used;
define the limitations of application of the testing method;
translate NDT codes, standards, specifications and procedures into NDT instructions adapted to the actual working conditions;
set up and verify equipment settings;
perform and supervise tests;
interpret and evaluate results according to applicable standards, codes specifications or procedures;
carry out and supervise all tasks at or below Level 2;
provide guidance for personnel at or below level 2; SIST EN 16910:2018
EN 16910-1:2018 (E) 9
report the results; — level 3 personnel: persons with competencies that allow to perform and direct NDT operations and validate documents. In order to work as NDT personnel the person has to follow training and pass an examination. In addition the employer shall authorize the person to operate in accordance with the conditions of paragraph 4.8. 4.2 Training 4.2.1 Training contents for Wheelsets The training required for each different NDT method shall include both wheelset-specific theoretical and practical training. The minimum length of training required for each different NDT method shall be in accordance with Table 1. Table 1 — Minimum training requirements (hours) NDT methods Level 1 Level 2 from level 1 wheelset Direct access level 2
Basics Wheelsets Basics Wheelsets Basics Wheelsets Ultrasonic Testing (UT) 40 40 80 0 120 40 Magnetic particle Testing (MT) 16 8 24 0 40 8 Eddy Current Testing (ET) 40 8 48 0 88 8 The complete training content is defined in the Normative Annex B. 4.2.2 Industrial experience Table 2 gives the minimum days of experience of NDT on wheelsets prior to examination. Table 2 — Minimum period of experience prior to examination (in days) NDT methods level 1 level 2 From level 1 in wheelset direct Magnetic particle Testing (MT) 3 7 10 Ultrasonic Testing (UT) Eddy Current Testing (ET) 7 19 26 SIST EN 16910:2018
EN 16910-1:2018 (E) 10 Table 3 gives the minimum duration of supervised experience after examination. Table 3 — Minimum period of experience after examination (in months) NDT methods Experience a Level 1 Level 2 Magnetic particle Testing (MT) 1 3 Ultrasonic Testing (UT) Eddy Current Testing (ET) 3 9 a Work experience is based on a nominal 40 h/week or the legal week of work. When an individual works in excess of 40 h/week, they may be credited with experience based on the total hours, but they shall be required to produce evidence of their experience. 4.3 Examination for levels 1 and 2 4.3.1 General examination The general examination shall include only randomly selected questions from a collection of general examination questions valid at the date of examination. The candidate shall give answers to the minimum number of multiple choice questions shown in Table 4. The collection of questions shall be validated by an independent body. Table 4 — Minimum required number of questions - general examination NDT method Number of questions UT 40 ET 40 MT 30 4.3.2 Specific examination in wheelsets The specific examination shall include only questions selected from a collection of questions related to wheelsets. During the specific examination, the candidate shall be required to give answers to at least 20 multiple choice questions, including questions involving calculations, NDT procedures and questions on codes, standards and specifications. The following topics shall be addressed in the questions: 1) terms and definitions; 2) purpose of NDT; 3) typical equipment and techniques; 4) typical defects for wheelsets for manufacturing as well as in service; 5) typical procedures. The collection of questions shall be validated by an independent body. SIST EN 16910:2018
EN 16910-1:2018 (E) 11 4.3.3 Practical examination in wheelsets The practical examination shall involve applying the test to prescribed wheelset specimens, recording (and, for level 2 candidates, interpreting) the resulting information to the degree required, and reporting the results in the required format. The training specimen shall not be used during practical examination. Each specimen shall be uniquely identified and have a master report which includes all of the equipment settings used to detect specified discontinuities contained within the specimen, which shall be uniquely identified by an appropriate permanent marking to ensure that it is completely traceable. Such marking shall not interfere with the practical testing or inspection of the specimen and shall, wherever practicable, be concealed from the candidate while the specimen is being used for examination. The master report shall be compiled based upon at least two independent tests, and shall be validated by level 3 wheelset NDT personnel, for use in grading examinations. The independent test reports from which the master report is compiled shall be retained as records. The practical examination shall be performed with: — tests and procedures typical for the candidates working site; — defects typical to those detected during maintenance. They should be natural or artificially created. The candidate is required to demonstrate their ability to: — set up the test equipment; — check and calibrate the said equipment; — perform tests on specified specimen; — complete test reports. The level 1 candidate shall follow the NDT instruction(s) provided by the examiner. The level 2 candidate shall select the NDT technique and determine the operating conditions related to a given code, standard and specification. The time allowed for the examination depends on the number of specimens and on their complexity. The average time allowed shall be defined by an independent body. The recommended maximum time allowed for each area or volume tested: — for level 1: 2 h; — for level 2: 3 h. Level 2 candidates shall draft one written instruction for Level 1 NDT personnel. This instruction shall be applicable to a wheelset component. The collection of specimens and practical questions shall be validated by an independent body. The candidate shall be evaluated on a minimum of 2 wheelset specimens for the practical examination of levels 1 and 2. 4.3.4 Grading of the level 1 and level 2 competencies The general, specific and practical examinations shall be graded separately. An examiner shall be responsible for the grading of the examinations by comparing with model answers. The grading of the practical examination shall be based on items 1 to 4 in Table 5. SIST EN 16910:2018
EN 16910-1:2018 (E) 12 Table 5 — Subjects and weighting factors for grading - practical examination Item Subject Weighting factor level 1 (%) Weighting factor level 2 (%) 1 Knowledge of the NDT equipment, including the function and verification of the setting of the apparatus 20 10 2 The application of NDT to the specimen. This consists of the following parts: For level 2, selection of the techniques and determination of the operating conditions; The preparation (surface condition) and visual examination of the specimen; The setting up of the equipment; The performance of the test; The operations after the test. 35 20 3 The detection and reporting of the discontinuities and, for level 2, their characterization (position, orientation, dimensions and type) and evaluation. 45 55 4 For level 2, drafting the written instruction for level 1. - 15 The candidate shall obtain a minimum grade of 70 % in each part of the examination (general, specific, and practical). In addition, for the practical examination, a minimum grade of 70 % shall be obtained for each specimen tested, and for the NDT instruction, as applicable. The grading system shall be validated by an independent body. 4.4 Specific requirements to operate as a Level 3 wheelsets A level 3 qualification shall include forging products in the relevant NDT methods according to EN ISO 9712. A documented file shall be established to demonstrate that the candidate has manufacturing knowledge and experience in wheelsets maintenance, including wheelset, usage, and failure modes. NOTE Knowledge of EN 15313 is a possible way to demonstrate knowledge in wheelset maintenance. 4.5 Validation of competences Competencies of the candidate shall be documented. The document (like a wallet card) shall refer to “Wheelset Maintenance”. NOTE Wallet card as defined in EN ISO 9712. SIST EN 16910:2018
EN 16910-1:2018 (E) 13 4.6 Requirements for the training centre The training centre shall: — apply a documented quality procedure; — have the resources needed to administer training, including the calibration and control of equipment; — have adequate staff, premises and equipment to ensure a satisfactory training program as defined in this clause for the applicable levels and methods; — use specimen with defects and equipment as used in the field; NOTE CEN ISO/TR 25108 can be used as guidance. 4.7 Requirements for the trainer The operative trainer shall be level 2 or higher and shall have at least one year of experience in the method and in wheelset maintenance. The theory trainer shall either be: — level 3 or — level 2 that shall have at least one year experience in the method and in wheelset maintenance. 4.8 Authorization to operate 4.8.1 General principle The NDT personnel shall be authorized to perform non-destructive tests on designated components and assemblies, within a given context. Basic requirements for NDT personnel to be authorized are: — Successfully passed a training programme according 4.2; — Successfully passed an examination according 4.3; — Documented internal on the job training and documented specific instruction by the employer; — Valid (yearly) visual acuity according to § 10; — Yearly documentary evidence of satisfactory work activity in the method. NOTE The authorization is usually provided by the organization responsible for the workshop or its subcontracting entity. 4.8.2 Validity of authorization The duration of authorization shall not exceed one year except the authorization of level 3 personnel. SIST EN 16910:2018
EN 16910-1:2018 (E) 14 4.8.3 Maintenance of authorization Option 1 The following points are required to maintain the authorization during a one year period: a) level 1: 1) shall undertake a documented technical evaluation by a level 2 or higher; 2) this evaluation shall be performed in the workshop or by a training centre and shall last a minimum of 2 h per NDT method; b) level 2: 1) shall undertake a documented technical evaluation by a Level 2 or a Level 3 person; 2) shall participate or organize a 4 h minimum meeting per NDT method where the following areas should be addressed: — return of experience (review of events, findings, evaluations); — new developments in the method. Option 2 The following points are required to maintain the authorization, during a five year period: Yearly documentary evidence of skills by satisfactory work activity in the NDT method, and; a) level 1: 1) shall undertake yearly a documented technical evaluation by a level 2 or higher; 2) shall undertake a review of adequate technical knowledge of NDT methods every five years by a training centre that shall last a minimum of 10 h per NDT method; b) level 2: 1) shall undertake yearly a documented technical evaluation by a level 2 or a Level 3 person; 2) shall undertake a review of adequate technical knowledge of NDT methods every five year
...
SLOVENSKI STANDARD
oSIST prEN 16910:2015
01-september-2015
Železniške naprave - Vozna sredstva - Zahteve za neporušitveno preskušanje na
tekalnih sestavah pri vzdrževanju železnice
Railway applications - Rolling stock - Requirements for non-destructive testing on
running gear in railway maintenance
Bahnanwendungen - Schienenfahrzeuge - Anforderungen an die zerstörungsfreie
Prüfung an Fahrwerken in der Instandhaltung
Applications ferroviaires - Matériel roulant - Exigences pour les essais non destructifs sur
les organes de roulement lors de la maintenance ferroviaire
Ta slovenski standard je istoveten z: prEN 16910
ICS:
45.060.01 Železniška vozila na splošno Railway rolling stock in
general
45.120 2SUHPD]DJUDGQMRLQ Equipment for
Y]GUåHYDQMHåHOH]QLFR] railway/cableway
åLþQLF construction and
maintenance
oSIST prEN 16910:2015 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.
---------------------- Page: 1 ----------------------
oSIST prEN 16910:2015
---------------------- Page: 2 ----------------------
oSIST prEN 16910:2015
EUROPEAN STANDARD
DRAFT
prEN 16910
NORME EUROPÉENNE
EUROPÄISCHE NORM
August 2015
ICS
English Version
Railway applications - Rolling stock - Requirements for non-
destructive testing on running gear in railway maintenance
Applications ferroviaires - Matériel roulant - Exigences pour Bahnanwendungen - Schienenfahrzeuge - Anforderungen
les essais non destructifs sur les organes de roulement lors an die zerstörungsfreie Prüfung an Fahrwerken in der
de la maintenance ferroviaire Instandhaltung
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 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.
Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to
provide supporting documentation.
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
CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2015 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 16910:2015 E
worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Contents Page
Foreword .4
Introduction .5
1 Scope .6
2 Normative references .6
3 Terms and definitions .7
4 Railway Maintenance Sector .8
5 Requirements for NDT personnel .8
5.1 General .8
5.2 Training .9
5.2.1 Training contents for class “Wheelsets” .9
6 In-service and off-vehicle NDT requirements for maintenance .9
6.1 General Principles .9
6.2 Requirements for the NDT Plan .9
6.3 The NDT Plan Design Justification File (NDT-PDJF).9
6.3.1 Scope .9
6.3.2 Requirements . 10
6.4 Definitions and defects catalogue and associated NDT methods . 10
6.4.1 General . 10
6.4.2 Definitions . 11
6.4.3 Wheelset defects. 12
6.5 Defects catalogue, appearance under MT . 13
6.5.1 General . 13
6.5.2 Wheel . 14
6.5.3 Axles . 14
6.6 Threshold . 18
6.7 Traceability of maintenance results. 18
6.7.1 General . 18
6.7.2 Traceability requirement for the Examination Report. 18
6.7.3 Traceability storage time . 19
7 NDT procedures and instructions for Railway Sector, Class Wheelset . 19
8 Authorization of NDT equipment and new NDT techniques . 19
9 Requirements for the NDT facilities . 19
Annex A (informative) Possible processes to acquire competencies for Levels 1, 2 and 3 in
Railway Maintenance, Wheelsets class . 20
A.1 Requirements to operate as a Level 1 and 2 in Railway Maintenance Sector . 20
A.2 Requirements to operate as a Level 3 in Railway Maintenance Sector . 20
A.2.1 Product sectors . 20
A.2.2 Training . 20
Annex B (informative) Minimum specific railway knowledge for class “Wheelsets” for Levels 1
and 2 in MT, ET and UT . 22
B.1 Training contents for class “Wheelsets” for levels 1 and 2 . 22
B.2 Requirements for the Trainer . 22
2
---------------------- Page: 4 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
B.3 Requirement for the Training Centre . 22
B.4 Industrial Experience for the “Wheelset” class . 25
B.5 Examination for levels 1 and 2 . 26
B.5.1 General examination . 26
B.5.2 Specific examination . 26
B.5.3 Practical examination in Railway Maintenance Sector, Wheelset Class . 26
B.6 Requirements to operate as a Level 3 in Railway Maintenance Sector . 26
B.7 Activities . 27
B.8 Certification . 27
B.9 Authorization to operate . 27
B.9.1 General principle . 27
B.9.2 Validity of operating authorization . 27
B.9.3 Maintenance of Authorization . 28
Annex C (informative) Recommended requirements for NDT procedures and Instructions . 29
C.1 Requirements for NDT procedures and instruction . 29
C.2 Qualification of author . 30
C.3 Validation and Approval of NDT documents . 30
C.3.1 Validation of NDT Instructions . 30
C.3.2 Approval of NDT procedures. 30
C.3.3 NDT Instructions . 30
Annex D (informative) Recommended procedures for Authorization of NDT equipment and new
NDT techniques . 32
D.1 Authorization of use of NDT equipment . 32
D.1.1 Scope . 32
D.1.2 Recommendations . 32
D.1.3 Requirements . 32
D.1.4 Authorization of use document . 33
D.1.5 Maintenance of equipment . 33
D.2 Introduction of new NDT techniques . 33
D.2.1 Scope . 33
Annex E (informative) Calibration management plan . 35
Bibliography . 36
3
---------------------- Page: 5 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Foreword
This document (prEN 16910:2015) 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(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.
4
---------------------- Page: 6 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Introduction
For many years, Non Destructive Testing (NDT) has been used on European networks to control the in
service condition of running gears through maintenance processes in order to guarantee the safety during
trainset operations.
The two maintenance standards (EN 15313 Wheelsets Maintenance and EN 15827 Bogies) require
appropriately trained and capable personnel undertaking these NDT maintenance tasks (see EN ISO 9712).
The purpose of this document is to describe the necessary requirements additional to the existing standards
to promote safety, interoperability and cross acceptance.
A sound Maintenance Plan for Rolling Stock helps guarantee safe operation of railway vehicles at the right
cost. It deals with wear, unintended damage or malfunction, and takes into account the vehicles usage and
the track conditions. In this context, NDT are used to search for running gear faults and failures.
For running gear, the defects are most often, fatigue cracks located either at surface when it is free or at seat
surface, or in sub-surface where pressure contact load applies.
NDT surface methods like MT or ET are preferred in proof of defects on free surfaces if the area examined is
accessible.
For volume defects or non-visible non-accessible surfaces for example seats in mounted wheel sets the only
usable method is UT.
5
---------------------- Page: 7 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
1 Scope
This European Standard provides the specific requirements for NDT of Wheelset for:
— in-service inspection;
— off-vehicle inspection;
and guidance for the introduction of new NDT Techniques.
NOTE In addition examples are given in informative annexes for:
- NDT Personnel Certification (incl. training, qualification, renewal),
- NDT Procedure and Instruction
For this standard, the following NDT methods considered are:
— ultrasound testing (UT);
— magnetic particle testing (MT);
— eddy current testing (ET).
Other methods considered in EN ISO 9712 are outside the scope of this standard.
For this purpose, a catalogue of the common defects is given as guidance.
For application of this standard, the definition of the “Wheelset Class” is given and attached to the Railway
Maintenance Sector as named in EN ISO 9712.
Specific NDT requirements for infrastructure or requirements relating to the quality of new products delivered
by manufacturers are not within the scope of this standard.
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 13261, Railway applications – Wheelset and Bogies — Axles product requirements
EN 15313, Railway applications — In-service wheelset operation requirements — In-service and off-vehicle
wheelset maintenance
EN ISO 9712:2012, Non-destructive testing — Qualification and certification of NDT personnel
(ISO 9712:2012)
ISO/TR 25107, Non-destructive testing — Guidelines for NDT training syllabuses
6
---------------------- Page: 8 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
3 Terms and definitions
3.1
non-destructive tests
NDT
non-destructive testing is the process of examination of a component to enable its integrity to be assessed by
a means which does not compromise the service life or design life of the component
3.2
indication
representation or signal from a discontinuity in the format allowed by the NDT method used
[SOURCE: EN 1330-2:1998, definition 2.12]
3.3
defect
indication which may prevent the component from fulfilling its designed purpose
3.4
acceptance or rejection criteria
criteria against which the specimen is examined in order to determine its acceptability / rejectability
[SOURCE: EN 1330-2:1998, definition 2.1]
3.5
cracks
2-D discontinuity of the material resulting from thermal, chemical or mechanical action
3.6
NDT instruction
written description of the precise steps to be followed in testing to an established standard, code, specification
or NDT procedure
[SOURCE: EN ISO 9712:2012, definition 19]
3.7
NDT method
discipline applying a physical principle in non-destructive testing
[SOURCE: EN ISO 9712:2012, definition 20]
3.8
NDT procedure
written description of all essential parameters and precautions to be apllied when non destructively testing
prducts in accordance with standard(s), code(s) or specification(s)
[SOURCE: EN ISO 9712:2012, definition 21]
3.9
NDT technique
specific way of utilizing an NDT method
[SOURCE: EN ISO 9712:2012, definition 22]
7
---------------------- Page: 9 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
3.10
NDT training
process of instruction in theory and practise in the NDT method in which certification is sought, which takes
the form of training courses to a syllabus approved by the certification body, but which does not include the
use of the specimens used in qualification examinations
[SOURCE: EN ISO 9712:2012, definition 23]
3.11
semi-automated equipment
equipment where part of the testing is supported by a machine
Note 1 to entry: Scan reading and interpretation remains with the operator
4 Railway Maintenance Sector
For the purposes of application of this standard the two following classes may be defined:
— wheelsets (wheels, solid or hollow axles, bearings);
— bogies and connecting components (bogie frames, equalising beams, rods, suspension gear, buffing and
draw gear).
These two classes are part of the Rolling Stock sub-sector as shown in Figure 1.
Sector RAILWAY MAINTENANCE
(EN ISO 9712 – Annex A)
Sub- Infrastructure Rolling Stock
sectors
Classes
Wheelsets Bogie and
connecting
components
Figure 1 — Sector, sub-sector and classes
5 Requirements for NDT personnel
5.1 General
For the Class “Wheelsets” and for NDT personnel shall have relevant knowledge and skills acquired through
an appropriate process. An example of such a process is given in the Informative Annex A.
Any organization offering the training, examination and acceptance of experience should be checked against
the conformity with the requirements of this standard by a body independent of the company.
8
---------------------- Page: 10 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
5.2 Training
5.2.1 Training contents for class “Wheelsets”
The training required for each different NDT methods shall include both specific railway theoretical and
practical training.
EN ISO 9712 and ISO/TR 25107 apply. An example of the minimum length of training required and
information on experience and additional requirements is given in the Informative Annex B.
6 In-service and off-vehicle NDT requirements for maintenance
6.1 General Principles
The NDT Plan Design Justification File (PDJF) is part of the Maintenance Design Justification File, set out in
compliance with EN 15313.
An NDT plan is defined taking into account other planned maintenance activities, return of experience,
component design and maintenance documentation in order to ensure that the component will be used in-
service in a safe condition.
The activities in the NDT Plan are defined through a process that shall be documented in a NDT Plan Design
Justification File (NDT-PDJF).
Establishing a PDJF file is a collaborative process.
A level 3 should be part of this process (see Annex B).
6.2 Requirements for the NDT Plan
NDT-Plan file shall include:
— the frequency of examinations;
— the NDT Method and procedures;
— the definition of the areas to be tested;
— the examination technique and the instructions used to perform the NDT;
— the resources needed (equipment and NDT personnel) to perform the NDT activities, and
— the decision criteria.
In order to minimize the out-of-service time of the rolling stock material, the frequency of examination should
correspond with other maintenance activities planned intervals.
6.3 The NDT Plan Design Justification File (NDT-PDJF)
6.3.1 Scope
Scope of the NDT PDJF is:
— to describe criteria and methods used to design the NDT Plan for the component;
— to motivate the necessity (or not, in comparison to similar components) to perform periodic or condition
based or linked to another maintenance operation, NDT examination on the component;
9
---------------------- Page: 11 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
— to document the input elements and relevant data used to design the NDT Plan such as statistics from
return of experience, tests, investigations, calculations.
6.3.2 Requirements
The following areas shall be addressed:
— material characteristics;
— stresses and fatigue limits on the component in service;
— environmental conditions on the component;
— risk of surface degradation of the component in service;
— particular service conditions;
— return of experience from similar applications.
6.4 Definitions and defects catalogue and associated NDT methods
6.4.1 General
In this document, the NDT-plan is designed to search for cracks and defects.
For Axles, Wheels and Bearing that comply with EN standards (EN 13103, EN 13104, EN 13260, EN 13261,
EN 13262), the manufacturing defects are not considered.
For the other Axles and Wheels manufacturing defects may be considered
10
---------------------- Page: 12 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
6.4.2 Definitions
Key
Area 1: Rim
Area 2: Web
Area 3: Hub
Figure 2 — Monobloc Wheel
11
---------------------- Page: 13 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Key
1 axle body
2 abutment, Fillets, Transition area
3 wheel seat, break disc, final drive or traction motor seats, journal
4 part of axle body hidden by component
5 journal
6 wheel seat
7 seat
8 abutment/collar
9 body
10 transition area
Figure 3 — Wheelset Axle
6.4.3 Wheelset defects
The following Tables 1 and 2 give recommendations for a manual NDT method to detect defects of the
Wheelset components.
With the exception of the Wheel Rim, in general, in service defects for the wheel and the axles starts at the
surface of the component.
During heavy maintenance, where the surface access allows it, the surface based NDT methods such as MT
or ET are preferred over volume NDT methods such as UT.
12
---------------------- Page: 14 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Table 1 — Axle defects
Possible NDT Method
Axle Surface Defect
ET MT UT
a
yes yes yes
Longitudinal
Circumferential yes yes yes
b
Pitting and Impact yes no
no
a
longitudinal defects could come from Damage or Manufacturing (only for Axles that do not comply to Design and
Product EN standard (starting from EN 13260, EN 13261 and EN 13262). The search for longitudinal defect is
submitted to agreement between parties.
b
MT can be used to verify that the Pitting or Impact has not developed a fatigue defect, like a circumferential crack.
Table 2 — Wheel defects
Possible NDT Method
Wheel Defect Area
MT/ET UT
Surface Defects Hub yes yes
Surface Defects Web yes yes
Surface Defects (except tread) Rim yes yes
Deep Sub-Surface tread defects Rim no yes
Surface tread defects Rim yes yes
6.5 Defects catalogue, appearance under MT
6.5.1 General
The definitions and reference images of the defects are given in EN 15313
For the specific purposes of this document, some pictures and explanations are given hereafter for common
axle defects, in addition to the defects detailed in EN 15313. Pictures are examples of how defect appears
through MT with UV light illumination or Black and White contrast.
13
---------------------- Page: 15 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
6.5.2 Wheel
Key
1 start
2 web
3 fatigue
4 opened
Figure 4 — Wheel Web Crack - MT with Ultra Violet source appearance - Paint removed.
Left: circumferential Crack on a wheel centre started on a machining groove; right: circumferential
crack on a monobloc wheel initiated by forged defects; upper left: same crack after opening
Figure 5 — deep sub crack found by UT – Visual appearance after radial cut of the rim
6.5.3 Axles
If an axle is not compliant with EN 13261, longitudinal defects shall be included.
14
---------------------- Page: 16 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Key
1 axle body
2 transition area
3 wheel seat
Figure 6 — Abutment/Collar or Transition Area MT indications – Transverse - Typical corrosion - MT
with Ultra Violet source appearance
Figure 7 — Transverse crack in axle shaft; left: MT appearance with Ultra Violet source; right: same
crack, fractography
15
---------------------- Page: 17 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Figure 8 — right: longitudinal axle shaft crack, MT with Ultra Violet source appearance; same defect
under UT, left C-scan (upper) and A-scan (lower)
Key
2 transition area
Figure 9 — Abutment/Collar or Transition Area MT indications – Transverse - Typical corrosion - MT
with Ultra Violet light appearance – Enlargement (left) and crack depth fractography (right)
16
---------------------- Page: 18 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Key
1 axle body
2 transition area
3 wheel seat
Figure 10 — Abutment/Collar or Transition Area MT indications – Transverse - Typical corrosion –
black and white MT
Key
1 axle body
2 transition area
3 wheel seat
Figure 11 — Abutment/Collar or Transition Area MT indications – Transverse then at 45° - Typical of a
torsion stress - MT with Ultra Violet light appearance
17
---------------------- Page: 19 ----------------------
oSIST prEN 16910:2015
prEN 16910:2015 (E)
Figure 12 — Crack at an Axle Abutment/Collar or Transition Area. Micrograph
6.6 Threshold
Threshold values depend on the method, the equipment, and the tested component, for example, material,
geometry and surface preparation.
6.7 Traceability of maintenance results
6.7.1 General
NDT examination is a key element to decide whether a wheelset can be put back into service or not. In the
unlikely event of a problem, it is of importance to be able to trace back the NDT parameters.
6.7.2 Traceability requirement for the Examination Report
The Examination Report shall contain the following information:
— examination date;
— examination Part identification (for example, serial number and registered name);
— examination Equipment identification;
— NDT personnel identification (name, qualification type and level);
— procedure or NDT instruction reference;
— NDT parameters;
— inspected Area identification;
...
Questions, Comments and Discussion
Ask us and Technical Secretary will try to provide an answer. You can facilitate discussion about the standard in here.