SIST EN 14587-1:2007
(Main)Railway applications - Track - Flash butt welding of rails - Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant
Railway applications - Track - Flash butt welding of rails - Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant
This European Standard specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production.
It applies to new Vignole railway rails R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a flash butt welding process in a fixed plant and intended for use on railway infrastructure.
This European Standard applies to the welding of rails into welded strings.
Bahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen -Teil 1: Abbrennstumpfschweißen neuer Schienen der Güte R220, R260, R260Mn und R350HT in einem Schweißwerk
Diese Europäische Norm legt die Anforderungen an die Eignung eines Schweißprozesses in einem Schweißwerk fest, zusammen mit den Anforderungen an die Produktion von Schweißungen.
Die Norm ist anwendbar für neue Vignolschienen der Stahlsorte R220, R260, R260Mn und R350HT mit einer längenbezogenen Masse ab 46 kg/m, wie in EN 13674-1 behandelt, verschweißt durch Abbrennstumpf¬schweißen in einer stationären Anlage und vorgesehen für die Verwendung in der Eisenbahninfrastruktur.
Diese Europäische Norm befasst sich mit der Herstellung von Langschienen
Applications ferroviaires - Voie - Soudage des rails par étincelage - Partie 1: Rails neufs de nuances R220, R260, R260Mn et R350HT dans une installation fixe
La présente Norme européenne spécifie les exigences relatives a la qualification d’un procédé de soudage dans une installation fixe, ainsi que les exigences pour les soudures de production.
Elle s’applique aux rails Vignole neufs de nuances R220, R260, R260Mn et R350HT et dont la masse est supérieure ou égale a 46 kg/m, tels que repris dans l’EN 13674-1, soudés au moyen d’un procédé de soudage par étincelage dans une installation fixe et destinés a etre utilisés sur des infrastructures ferroviaires.
La présente Norme européenne s’applique au soudage de rails dans des longs rails soudés.
Železniške naprave - Zgornji ustroj - Elektro uporovno varjenje tirnic - 1. del: Varjenje novih tirnic kakovosti R 220, R 260, R 260 Mn in R 350 HT v varilnici
General Information
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Standards Content (Sample)
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Železniške naprave - Zgornji ustroj - Elektro uporovno varjenje tirnic - 1. del: Varjenje novih tirnic kakovosti R 220, R 260, R 260 Mn in R 350 HT v varilniciBahnanwendungen - Oberbau - Abbrennstumpfschweißen von Schienen -Teil 1: Abbrennstumpfschweißen neuer Schienen der Güte R220, R260, R260Mn und R350HT in einem SchweißwerkApplications ferroviaires - Voie - Soudage des rails par étincelage - Partie 1: Rails neufs de nuances R220, R260, R260Mn et R350HT dans une installation fixeRailway applications - Track - Flash butt welding of rails - Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant93.100Gradnja železnicConstruction of railways25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 14587-1:2007SIST EN 14587-1:2007en,fr,de01-september-2007SIST EN 14587-1:2007SLOVENSKI
STANDARD
SIST EN 14587-1:2007
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 14587-1June 2007ICS 25.160.10; 93.100 English VersionRailway applications - Track - Flash butt welding of rails - Part 1:New R220, R260, R260Mn and R350HT grade rails in a fixedplantApplications ferroviaires - Voie - Soudage des rails parétincelage - Partie 1: Rails neufs de nuances R220, R260,R260Mn et R350HT dans une installation fixeBahnanwendungen - Oberbau - Abbrennstumpfschweißenvon Schienen -Teil 1: Abbrennstumpfschweißen neuerSchienen der Güte R220, R260, R260Mn und R350HT ineinem SchweißwerkThis European Standard was approved by CEN on 3 May 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 14587-1:2007: ESIST EN 14587-1:2007
EN 14587-1:2007 (E) 2 Contents Page Foreword.4 Introduction.5 1 Scope.6 2 Normative references.6 3 Terms and definitions.6 4 Quality management system.7 5 Requirements for the welding process.8 5.1 General.8 5.2 Clamping force.8 5.3 Pre-heating.8 5.4 Flashing.8 5.5 Upsetting.8 5.6 Upset current.8 5.7 Unclamping.8 5.8 Welding parameters.8 5.9 Steps across the weld.9 5.10 Removal of excess upset.10 5.11 Post-weld heat treatment.12 5.12 Rail end preparation and horizontal alignment requirements.12 6 Procedure approval.12 6.1 General.12 6.2 Information to be supplied by the purchaser.12 6.3 Sample preparation.12 6.4 Approval tests.13 6.4.1 Visual inspection.13 6.4.2 Weld trimming.13 6.4.3 Weld straightness and flatness.13 6.4.4 Magnetic particle or dye penetrant inspection.13 6.4.5 Bend testing.13 6.4.6 Macro examination.13 6.4.7 Micro examination.14 6.4.8 Hardness testing.14 6.4.9 Fatigue testing.15 6.5 Test result report.15 7 Approval of other rail profiles or grades.15 7.1 General.15 7.2 Sample preparation.15 7.3 Approval tests.15 7.4 Test result report.15 8 Approval of the Welding Contractor.15 8.1 General.15 8.2 Welding procedure.15 8.3 Operators.15 8.4 Supervision.16 8.5 Weld Inspection.16 8.6 Equipment.16 9 Weld production following procedure approval.16 9.1 Weld production.16 9.2 Information to be supplied by the purchaser.16 SIST EN 14587-1:2007
EN 14587-1:2007 (E) 3 9.3 Rail end preparation and horizontal rail alignment requirements.17 9.4 Weld parameter monitoring.17 9.5 Weld identification.17 9.6 Visual inspections.17 9.7 Steps across the weld.17 9.8 Finishing.17 9.8.1 Correction of vertical and horizontal weld alignment.17 9.8.2 Profile finishing of the rail head.17 9.9 Weld straightness and flatness.18 9.10 Bend testing.19 9.10.1 General.19 9.10.2 Additional bend test.19 9.10.3 Bend test procedure.19 9.10.4 Interpretation of results.19 9.10.5 Retesting.20 9.11 Documentation.20 Annex A (normative)
Bend test requirements.21 Annex B (normative)
Test weld fracture faces – Recording of defects.23 Annex C (normative)
Fatigue test method for flash butt welds.25 C.1 Scope.25 C.2 Test equipment.25 C.3 Calibration procedure.27 C.3.1 General.27 C.3.2 Test piece.27 C.3.3 Test piece preparation.27 C.3.4 Instrumentation.27 C.3.5 Procedure.27 C.4 Fatigue test method.31 C.4.1 General.31 C.4.2 Staircase testing method.31 C.4.3 Example of the data analysis of a fatigue strength determination by the staircase method.33 C.4.4 Past-the-post testing method.34 Annex D (normative)
Macro examination and micro examination.36 D.1 Macro examination.36 D.2 Micro examination.36 Annex E (normative)
Hardness testing.37 Bibliography.38
SIST EN 14587-1:2007
EN 14587-1:2007 (E) 4 Foreword This document (EN 14587-1:2007) 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 December 2007, and conflicting national standards shall be withdrawn at the latest by December 2007. This document is one of a series of three parts of the EN 14587 Railway applications – Track – Flash butt welding of rails. The list of parts is as follows: Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant Part 3: Welding in association with crossing construction 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. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 5 Introduction This part of EN 14587 has five main topics: a) requirements of a welding process; b) procedure approval for a fixed plant; c) approval of other rail profiles or grade; d) approval of the welding contractor; e) weld production following approval. This part of EN 14587 has been occasioned by a European Directive that will permit the freedom of an open European market. To enable this perception to become a reality, it is essential a standard is in place that satisfies the needs of the infrastructure owners or custodians and reflects the production capabilities of the manufacturers in technical and quality terms. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 6 1 Scope This European Standard specifies requirements for the approval of a welding process in a fixed plant, together with the requirements for subsequent welding production. It applies to new Vignole railway rails R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by flash butt welding in a fixed plant and intended for use on railway infrastructure. This European Standard applies to the welding of rails into welded strings. 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 571-1, Non destructive testing — Penetrant testing — Part 1: General principles EN 1290, Non-destructive examination of welds — Magnetic particle examination of welds EN 13674-1, Railway applications — Track — Rail — Part 1: Vignole railway rails 46 kg/m and above EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1:2004, Metallic materials — Verification of static uniaxial testing machines — Part 1: Tension/compression testing machines — Verification and calibration of the force-measuring system (ISO 7500-1:2004) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 as welded condition rails that have been welded and trimmed only 3.2 contractor company approved by a railway authority to provide staff and machinery to execute the production of FB weld in a fixed plant NOTE This may include staff and machinery from within the railway authority 3.3 die burn damage caused by localised overheating on the surface of the rail caused by poor contact between the rail and the electrode during welding 3.4 dressing removing trimmed upset by grinding or other similar process 3.5 finished condition welded, trimmed, dressed and profile finished SIST EN 14587-1:2007
EN 14587-1:2007 (E) 7 3.6 fixed plant stationary production line for flash butt welding of rails 3.7 flat spot process driven discontinuity showing as a small lens like shape in vertical longitudinal section, or a generally circular/elliptical shape having a localised smooth texture when viewed in a vertical transverse section 3.8 lack of bond area of incomplete fusion between the rails in the joint. This may appear as crack like or line discontinuity at the interface either on the surface after removal of the upset or in a weld section 3.9 profile finishing operation by which the rail head or relevant part of the rail head at the weld is returned to rail profile NOTE The operation can be by grinding, milling, planing or any other suitable means. 3.10 purchaser purchaser of the welds 3.11 railway authority either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.12 trimmed upset metal remaining around the rail profile following trimming 3.13 trimming removal of upset 3.14 upset metal extruded around the rail profile as a result of forging 3.15 welded string long rail comprising a number of shorter rails flashbutt welded together 3.16 welding process part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 4 Quality management system The contractor shall operate an independently approved and audited quality management system. A quality management system conforming to EN ISO 9001 will be deemed to satisfy the requirements. Additionally, a product quality plan shall be validated by the purchaser. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 8 5 Requirements for the welding process 5.1 General All welding shall be carried out on a flash butt welding machine (FBWM) using an automatic, programmed welding sequence. 5.2 Clamping force Rails shall be secured in the FBWM by clamps of such a surface shape or contour, that when a clamping force is exerted on the rails, it shall not damage the rail in such a way that subsequent cracking in the rail in operation is generated, see 6.4.1. 5.3 Pre-heating The fronts of the heating area shall progress uniformly perpendicularly to the running surface during the whole cycle. There shall be no evidence of local melting on the ends of the rails during pre-heating. 5.4 Flashing Once initiated, flashing shall be continuous. 5.5 Upsetting Upsetting shall immediately follow flashing. Sufficient forging pressure shall be applied to ensure that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The weld interface shall extend into the upset. 5.6 Upset current The upset welding current shall be maintained until the rapid forge has finished and the progressive forging commences. 5.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. 5.8 Welding parameters 5.8.1 The welding machine and/or management system equipment shall be capable of displaying the following; a) programme identification and setting details; b) welding current; c) upset force or pressure; d) displacement; e) welding time. 5.8.2 The welding parameters shall be determined during procedural trials. Once approval has been granted, the welding parameters shall not be changed, with the exception of changes concerning the environments in 5.8.4. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 9 5.8.3 The welding parameters shall be monitored and recorded. These records shall be referenced to the appropriate welds. 5.8.4 The welding parameters shall permit the production of welds without any alteration to the program, at rail temperatures of – 10 ºC and above. Alterations of preheating parameters due to various rail temperatures are not considered as alterations to the welding program. A bending test according to 6.4.5 shall be carried out in this case. NOTE Owing to extreme variations in seasonal temperatures, the manufacturer may request the use of alternative welding programs. 5.9 Steps across the weld 5.9.1 Any step between the rails across the weld in the trimmed but not dressed condition shall not exceed those dimensions shown in Table 1. 5.9.2 Checks shall be made at a position 20 mm on each side of the weld upset centreline using a 1 m nibbed straight edge and feeler shims as shown in Figure 1. Table 1 — Maximum permitted steps Position of step on the rail Maximum permitted step (in mm) Vertically on the longitudinal centreline of the running surface 0,5 Horizontally on the aligned face or edge 14 mm below the running surface 0,5 Horizontally on the edge of the rail foot 2,0
NOTE Where the step arises from the rail dimensions the rail foot tips may be dressed locally to achieve this requirement. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 10 Dimensions in millimetres
Detail Z Key A running surface B nibbed straight edge C weld upset centre line NOTE Step = |x-y| mm. Figure 1 — Measurement of the step 5.10 Removal of excess upset
5.10.1 Excess upset shall be automatically trimmed. 5.10.2 Removal of the excess upset shall not cause any mechanical or thermal damage to the rails. 5.10.3 The surface of the trimmed area shall be free from visible cracking. 5.10.4 The weld shall be in compression during the removal of excess upset. 5.10.5 Any dressing of the weld following the removal of upset shall not cause damage to the rail or weld nor reduce either to a dimension below the original rail profile. 5.10.6 The maximum thickness of the trimmed upset shall be as set out in Table 2 below and shown in Figure 2. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 11 Table 2 — Maximum permitted trimmed upset Zone Position of trimmed upset about the weld Maximum permitted upset (in mm)
Full head profile from the lower corner on the gauge face to the lower corner on the opposite face 2
The fishing surface on the underside of the head 2,5
The web, including the top fillet radius and extending down to the start of the bottom fillet radius 2
The foot, including the start of the bottom fillet radii in the web and extending to the foot tips and completely across the underside of the rail foot 1,5
Where there is a difference in the rail dimensions, the trimmed upset shall be measured in relation to the rail giving the maximum protruding surface. If the values of the trimmed upset are above the maximum values, the trimmed upset shall be dressed locally to the required values without damaging the parent rails. Dimensions in millimetres
Key
Zone
– rail head
Zone
- on the underside of the rail head
Zone
– web of the rail
Zone
– foot of the rail Figure 2 — Maximum permitted trimmed upset SIST EN 14587-1:2007
EN 14587-1:2007 (E) 12 5.11 Post-weld heat treatment For the grade R260Mn, a post-weld heat treatment could be required. For the grade R350HT, a post-weld controlled accelerated cooling could be required. NOTE The post-weld controlled accelerated cooling is carried out after the removal of excess upset. 5.12 Rail end preparation and horizontal alignment requirements The rail ends shall be sawn or disc cut. Areas of electrical contact on the rails and the machine shall be cleaned to bright metal to give a consistent and good electrical contact at the interface. The rail shall not be damaged by the cleaning operation or through poor electrical contact. Rails of the same profile shall be positioned in the welding machine such that the welding interface is central to the contact electrodes as assessed by visual or mechanical means. Before welding, rails shall be aligned laterally to the required rail face or edge, i.e. left, or right, or to the rail centreline. For reasons of asymmetry all rails should be welded with the brand marks on the same side throughout the welded string. 6 Procedure approval 6.1 General Procedure approval shall be carried out by testing weld samples produced in accordance with this European Standard. Procedure approval testing shall be carried out on the rail profile and grade specified by the purchaser, see 6.2. All test results and weld fracture faces shall be made available for inspection. 6.2 Information to be supplied by the purchaser The following information shall be supplied by the purchaser: a) rail profile; b) rail grade; c) straightness class as in EN 13674-1; d) running edge requirements and identification – left, right or centre alignment; e) alignment class/classes, according to 9.9.1, Table 3; f) type of fatigue test;
6.3 Sample preparation For the specified rail profile and grade, five welds in the as-welded conditions (see 3.1) shall be manufactured. SIST EN 14587-1:2007
EN 14587-1:2007 (E) 13 Depending on the type of fatigue test specified by the purchaser, fourteen additional welds in the finished condition (see 3.5) for the staircase test method, or seven additional welds in the finished condition (see 3.5) for the past-the-post test method shall be manufactured to meet the test program. 6.4 Approval tests 6.4.1 Visual inspection All of the welds and rails shall be inspected visually for welding, trimming, pressing, clamping or profile finishing imperfections, such as tears, cavities, cracks, damage, geometrical non-conformities, thermal damage in particular in the electrode contact areas. 6.4.2 Weld trimming The weld upset on all the welds in the as welded condition shall be measured and shall conform to 5.10.7. In addition, there shall be no evidence in the upset of tearing, notches from the extrusion, cracks, undercut or damage to the adjacent rails. Attention shall be given to the quality of trimming on the underside of the rail foot. 6.4.3 Weld straightness and flatness All the welds submitted in the as welded condition shall be measured to determine the step across the weld, which shall not exceed the limits specified in 5.9.1. All the welds submitted in the finished condition shall be measured, using the procedures in 9.9, to determine the horizontal and vertical straightness, which s
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