1、BS EN 15594:2009ICS 25.160.10; 93.100NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBRITISH STANDARDRailway applications Track Restorationof rails by electric arcweldingThis British Standardwas published under theauthority of the StandardsPolicy and StrategyCommittee on 30 Apr
2、il2009 BSI 2009ISBN 978 0 580 57760 4Amendments/corrigenda issued since publicationDate CommentsBS EN 15594:2009National forewordThis British Standard is the UK implementation of EN 15594:2009.The UK participation in its preparation was entrusted to TechnicalCommittee RAE/2, Railway track components
3、.A list of organizations represented on this committee can be obtained onrequest to its secretary.This publication does not purport to include all the necessary provisionsof a contract. Users are responsible for its correct application.Compliance with a British Standard cannot confer immunityfrom le
4、gal obligations.BS EN 15594:2009EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 15594April 2009ICS 25.160.10; 93.100English VersionRailway applications - Track - Restoration of rails by electric arcweldingApplications ferroviaires - Voie - Rparation des rails parsoudure larc lectriqueBahnanwendung
5、en - Oberbau - Aufarbeiten von Schienendurch elektrisches LichtbogenauftragschweienThis European Standard was approved by CEN on 5 March 2009.CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a nati
6、onal 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 an
7、y 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, Eston
8、ia, 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 STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHE
9、S KOMITEE FR NORMUNGManagement Centre: Avenue Marnix 17, B-1000 Brussels 2009 CEN All rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 15594:2009: EBS EN 15594:2009EN 15594:2009 (E) 2 Contents Page Foreword 4Introduction .41 Scope 52 Normativ
10、e references 53 Terms and definitions .64 Consumable and WPS approval tests for MMA electrodes and FCAW wires .64.1 General 64.2 Consumable and WPS approval model .64.3 Information supplied by the manufacturer to the certifying body 74.4 Batch testing by the manufacturer 84.5 Test requirements of th
11、is standard under the supervision of certifying body .84.5.1 List of tests .84.5.2 Information to be confirmed by the certifying body 94.5.3 Statement on the general weldability 94.6 Laboratory tests .94.6.1 Purpose .94.6.2 General requirements for laboratory tests 94.6.3 Description of the sample f
12、or laboratory test 104.6.4 Single bead on rail tests 114.6.5 Single layer deposit on rail tests . 124.6.6 Multi-layer deposit on rail tests . 124.6.7 Welders report from trials . 124.6.8 Preparation, examination and testing of samples . 134.6.9 Acceptance criteria . 144.7 Track trial tests . 154.7.1
13、 General . 154.7.2 Excavation detail for track trials . 154.7.3 Track trial test categories 164.7.4 Test methods . 164.7.5 Requirements for in-track test samples . 164.7.6 Acceptance criteria for track trial restoration 164.7.7 Inspection frequency 164.8 Evaluation, reporting and decision following
14、track trials. 174.8.1 General . 174.8.2 List of general information 174.8.3 Track trial tests inspection records 174.8.4 Decision by approving RA on consumable and WPS . 174.9 Validation of consumables 175 Approval of contractors . 185.1 Quality management systems . 185.2 Inspection and testing 185.
15、3 Subcontracting 185.4 Equipment . 185.5 Welding activities 185.6 Storage and handling of welding consumables 185.7 Care of the infrastructure . 185.8 Welding procedure specifications 195.9 Pre-heating of rails . 195.10 Welders 19BS EN 15594:2009EN 15594:2009 (E) 3 5.11 Welder records 195.12 Supervi
16、sion 195.13 Traceability . 195.14 Audits 205.15 Training. 205.16 Documentation 206 Personnel and qualification requirements 206.1 Training and qualification requirements . 206.2 Diploma in electric arc welding of rails . 206.3 Permit to restore rails by electric arc welding . 217 Repair applications
17、 . 22Annex A (informative) Track trials supplementary information . 25Annex B (informative) Welding Procedure Specification (WPS) 26Annex C (informative) Diploma in electric arc restoration welding of rails 28Annex D (normative) Permit to restore rail by electric arc welding. 29Annex E (informative)
18、 Track components 30Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC 31WARNING Other requirements and other EC Directives may be applicable to the product(s) falling within the scope of this standard. . 33Bibliography 34BS E
19、N 15594:2009EN 15594:2009 (E) 4 Foreword This document (EN 15594:2009) 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 t
20、ext or by endorsement, at the latest by October 2009, and conflicting national standards shall be withdrawn at the latest by October 2009. 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 respon
21、sible for identifying any or all such patent rights. The purpose of this standard is to unify the restoration of rail electric arc welding across Europe. The standard provides control systems for the approval and qualification of welding processes, welding procedures, welding consumables, contractor
22、s and welders for the successful delivery of welds into track. 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 the EU Directive 2008/57/EC. For relationship with the EU Directive 2
23、008/57/EC, see informative Annex ZA, which is an integral part of this document. 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, Denma
24、rk, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. Introduction Restoration of rails by electric arc welding is a
25、 special process requiring the co-ordination of welding and grinding activities to establish confidence and reliability of the weld deposit and safety of the line. Controls must be in place from the design phase through to inspection. Incorrect selection of materials, consumables or procedure may re
26、sult in serious track welding failure. The correct application of the approved processes and the types of repairs permitted to be carried out on various rail components will be strictly adhered to. Only consumables approved by the method described in this standard are to be used. The tasks and respo
27、nsibilities of personnel involved in restoration e.g. planning, executing, supervising and inspection will be clearly defined. BS EN 15594:2009EN 15594:2009 (E) 5 1 Scope This European Standard specifies restoration by electric arc welding and is limited to the head of the rails only. This European
28、Standard describes the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit rail repair welding. The standard includes the quality-related tasks and responsibilities of personnel involved in the electric arc repair welding of rails. The standard appli
29、es to plain rail and switches and crossings manufactured from new vignole railway rails R200, R220, R260, R260Mn, R260Cr and R350HT grade rails of 46 kg/m and above as contained in EN 13674-1 and EN 13674-2. The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4
30、063 and are by description Process No 111: MMA (Manual Metal Arc) and Process No 114: FCAW (Flux Cored Arc Welding). This European Standard may be applied in situ, at line side or at out of track locations. The flash welded leg ends of austenitic manganese steel crossings are included in this standa
31、rd, except when located within 500 mm of manganese crossings. 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
32、(including any amendments) applies. EN 287-1, Qualification test of welders Fusion welding Part 1: Steels 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 applicatio
33、ns Track Rail Part 1: Vignole railway rails 46 kg/m and above EN 13674-2, Railway applications - Track - Rail - Part 2: Switch and crossing rails used in conjunction with Vignole railway rails 46 kg/m and above EN ISO 544, Welding consumables Technical delivery conditions for welding filler material
34、s Type of product, dimensions, tolerances and markings (ISO 544:2003) EN ISO 3580, Welding consumables Covered electrodes for manual metal arc welding of creep-resisting steels Classification (ISO 3580:2004) EN ISO 4063, Welding and allied processes Nomenclature of processes and reference numbers (I
35、SO 4063:1998) EN ISO 6506-1, Metallic materials Brinell hardness test Part 1: Test method (ISO 6506-1:2005) EN ISO 6507-1, Metallic materials Vickers hardness test Part 1: Test method (ISO 6507-1:2005) EN ISO 14341, Welding consumables Wire electrodes and deposits for gas shielded metal arc welding
36、of non alloy and fine grain steels Classification (ISO 14341:2002) EN ISO 15613, Specification and qualification of welding procedures for metallic materials Qualification based on pre-production welding test (ISO 15613:2004) UIC 714, Classification of lines for the purpose of track maintenance BS E
37、N 15594:2009EN 15594:2009 (E) 6 3 Terms and definitions For the purposes of this European Standard, the following terms and definitions apply. 3.1 Railway Authority (RA) either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railw
38、ay infrastructure 3.2 contractor and sub-contractor company approved by a railway authority to carry out the restoration of rails by electric arc welding on that particular infrastructure NOTE This may include staff from within the RA. 3.3 preliminary welding procedure specification (pWPS) tentative
39、 welding procedure specification, which is assumed to be adequate by the manufacturer, but which has not been approved. Welding of test pieces needed for approval of a welding procedure specification has to be carried out on the basis of a preliminary welding procedure specification 3.4 weld procedu
40、re specification (WPS) procedure approved to European standards and agreed by the RA for use on the railway infrastructure 3.5 training establishment welder training organisation or centre approved by the railway authority or alternatively a welder training organisation or centre approved by and bel
41、onging to a railway authority 4 Consumable and WPS approval tests for MMA electrodes and FCAW wires 4.1 General The approval of consumables and the related WPS is broadly in line with the requirements of EN ISO 15613, but owing to the special nature of the repair weld in terms of rail steel grade an
42、d use, e.g. rolling contact fatigue, the approval process shall follow this standard. 4.2 Consumable and WPS approval model The following flow chart describes how a consumable and its related WPS shall be approved. WPS approval shall follow the principle of EN ISO 15613 approval by a pre-production
43、test. BS EN 15594:2009EN 15594:2009 (E) 7 Consumable Certification body Classification according to EN ISO 3580/EN ISO 14341 EN 15594 pWPS (checked by the approving RA) pWPS becomes WPS Track trials (see note 1) Decision (see note 2) Other RAs (see note 3) Results Preliminary acceptance by the appro
44、ving RA Trial terminated No Yes NOTE 1 These track trials are undertaken by the approving RA. NOTE 2 The approving RA shall issue an approval certificate upon successful outcome of track trial. NOTE 3 Other RAs may require further tests to verify suitability for special service/operational condition
45、s or deposition techniques. 4.3 Information supplied by the manufacturer to the certifying body Toxicity threshold levels; BS EN 15594:2009EN 15594:2009 (E) 8 Rail steel grades in accordance with EN 13674-1; MMA electrode classification in accordance with EN ISO 3580; Wire electrodes classification
46、in accordance with EN ISO 14341; Chemical analysis and batch analysis; Storage requirements with manufacturers recommendations; Current range/voltage range/polarity; Availability of vacuum sealed MMA electrodes; Dimensions, length and diameter; FCAW spool size/weight availability; Drying requirement
47、s; Description of marking system; Optimum deposition technique. 4.4 Batch testing by the manufacturer The batch testing criteria are: concentricity and dimensions; chemical composition; consumable performance e.g. wire behaviour. 4.5 Test requirements of this standard under the supervision of certif
48、ying body 4.5.1 List of tests The following tests shall be supervised by the certifying body: Mechanical tests; Chemical analysis of undiluted weld metal with batch verification; Hardness; Weld integrity (lab conditions); Crack free; Defect level; Porosity; Craters; BS EN 15594:2009EN 15594:2009 (E) 9 Open Circuit Voltage (OCV) requirements; Welding parameters. 4.5.2 Information to be confirmed by the certifying body The certifying body shall confirm the following: marking/branding before and after drying; compliance with th
