1、BS EN 16725:2016Railway applications Track Restoration and repair ofmanganese crossingsBSI Standards PublicationWB11885_BSI_StandardCovs_2013_AW.indd 1 15/05/2013 15:06BS EN 16725:2016 BRITISH STANDARDNational forewordThis British Standard is the UK implementation of EN 16725:2016. The UK participat
2、ion in its preparation was entrusted to TechnicalCommittee RAE/2, Railway Applications - Track.A list of organizations represented on this committee can be obtained on request to its secretary.This publication does not purport to include all the necessary provisions of a contract. Users are responsi
3、ble for its correct application. The British Standards Institution 2016.Published by BSI Standards Limited 2016ISBN 978 0 580 77865 0 ICS 93.100 Compliance with a British Standard cannot confer immunity from legal obligations.This British Standard was published under the authority of the Standards P
4、olicy and Strategy Committee on 30 November 2016.Amendments/corrigenda issued since publicationDate T e x t a f f e c t e dBS EN 16725:2016EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16725 November 2016 ICS 93.100 English Version Railway applications - Track - Restoration and repair of mang
5、anese crossings Applications ferroviaires - Voie - Rparation des curs en acier au manganse Bahnanwendungen - Oberbau - Instandsetzung und Reparatur von Herzstcken aus ManganhartstahlgussThis European Standard was approved by CEN on 22 July 2016. CEN members are bound to comply with the CEN/CENELEC I
6、nternal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to
7、any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official
8、 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, Nor
9、way, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels 2016 CEN All rights of expl
10、oitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 16725:2016 EBS EN 16725:2016EN 16725:2016 (E) 2 Contents Page European foreword . 4 Introduction 5 1 Scope 6 2 Normative references 6 3 Terms and definitions . 7 4 Consumable and WPS approval tests for MMA
11、 electrodes and FCAW wires . 8 4.1 General 8 4.2 Consumable and WPS approval model 8 4.2.1 Flow chart 8 4.2.2 Minimum information to be included in the pWPS 9 4.3 Information supplied by the manufacturer of the welding consumable to the certifying body 10 4.4 Laboratory examinations of weld samples
12、. 11 4.5 Description of the samples for laboratory test for resurfacing work . 11 4.5.1 General requirements for laboratory tests 11 4.5.2 Single bead on AMS 11 4.5.3 Multi-layer on AMS 12 4.5.4 Single bead on tri-metal zone 13 4.5.5 Single layer on tri-metal zone 13 4.5.6 Multi-layer on tri-metal z
13、one . 14 4.5.7 Preparation and examination of AMS samples . 15 4.5.8 Preparation and examination of the tri-metal zone samples 16 4.6 Assessment of general weldability 18 4.7 Acceptance criteria 18 4.7.1 Visual inspection 18 4.7.2 PT examination . 18 4.7.3 Hardness 18 4.7.4 Macro and micro examinati
14、on of single and multi-layer sections . 19 4.8 Track trial tests . 19 4.8.1 General . 19 4.8.2 Excavation detail for track trials 19 4.8.3 Track trial test categories . 20 4.8.4 Test methods . 20 4.8.5 Number of in-track test samples 20 4.8.6 Welders report from track trials . 20 4.8.7 Acceptance cr
15、iteria for track trial tests . 20 4.9 Evaluation, reporting and decision following track trials 21 4.9.1 General . 21 4.9.2 List of general information . 21 4.9.3 Track trial tests inspection records 21 4.9.4 Decision by approving RA on consumable and WPS . 21 4.10 Validation of consumables 21 5 App
16、roval of contractors . 22 5.1 Quality management systems 22 5.2 Inspection and testing 22 BS EN 16725:2016EN 16725:2016 (E) 3 5.3 Subcontracting . 22 5.4 Equipment . 22 5.5 Welding activities . 22 5.6 Storage and handling of welding consumables 22 5.7 Care of the infrastructure 22 5.8 Welding proced
17、ure specifications 23 5.9 Pre-heating of rails when welding in tri-metal zone . 23 5.10 Welders 23 5.11 Welder records 23 5.12 Supervision . 23 5.13 Traceability . 23 5.14 Audits 23 5.15 Training 23 5.16 Documentation 24 6 Personnel and qualification requirements . 24 6.1 Training and qualification
18、requirements 24 6.2 Diploma in electric arc welding of cast manganese track components 24 6.3 Permit to weld cast manganese components in track . 24 7 Repair applications 25 Annex A (informative) Welding Procedure Specification (WPS) . 26 Annex B (informative) Permit to weld cast manganese track com
19、ponents by electric arc welding . 28 BS EN 16725:2016EN 16725:2016 (E) 4 European foreword This document (EN 16725:2016) 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
20、 standard, either by publication of an identical text or by endorsement, at the latest by May 2017, and conflicting national standards shall be withdrawn at the latest by May 2017. Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. C
21、EN 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. According to the CEN-CENELEC Internal Regulations, the national standards organisations of
22、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, Nethe
23、rlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. BS EN 16725:2016EN 16725:2016 (E) 5 Introduction Restoration of cast manganese crossings by electric arc welding is a special process requiring the co-ordination of welding and g
24、rinding activities to establish confidence and reliability of the weld deposit and safety of the line. Incorrect selection of materials, consumables or procedure may result in serious track welding failure. The correct application of the approved processes and the types of repairs permitted to be ca
25、rried out on various rail components need to be strictly adhered to. Only consumables approved by the method described in this standard are to be used. The tasks and responsibilities of personnel involved in restoration e.g. planning, executing, supervising and inspection need to be clearly defined.
26、 BS EN 16725:2016EN 16725:2016 (E) 6 1 Scope This European Standard specifies restoration of cast austenitic manganese steel for fixed crossings and cradles for crossings with movable parts, designed to be flash butt welded or bolted to adjoining rails manufactured according to EN 15689. The standar
27、d also applies to flash welded leg ends of austenitic manganese steel crossings and the associated tri-metal zone. The standard specifies the approval systems for consumables and procedures used in manual metal arc and flux cored metal deposit repair welding. The standard includes the quality-relate
28、d tasks and responsibilities and qualifications of personnel involved in the electric arc repair welding of cast crossings. The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063, specifically Process No 111: MMA (Manual Metal Arc) and Process No 114: FCAW (F
29、lux Cored Arc Welding). Their applications are described. This standard may be applied for procedures in situ, at line side or at out of track locations. The purpose of this standard is to unify restoration of cast manganese crossings by electric arc welding across Europe. The standard provides cont
30、rol systems for the approval and qualification of welding processes, WPS, welding consumables, contractors and welders for the successful delivery of welds on crossings in service. 2 Normative references The following documents, in whole or in part, are normatively referenced in this document and ar
31、e 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 1371-1, Founding - Liquid penetrant testing- Part 1: Sand, gravity die and low pressure die castings
32、 EN 13674-1, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above EN 15689, Railway applications - Track - Switches and crossings - Crossing components made of cast austenitic manganese steel EN ISO 544, Welding consumables - Technical delivery conditions for filler
33、materials and fluxes - Type of product, dimensions, tolerances and markings (ISO 544) EN ISO 2560, Welding consumables Covered electrodes for manual metal arc welding of non-alloy and fine grain steels Classification (ISO 2560) EN ISO 3452-1, Non-destructive testing - Penetrant testing - Part 1: Gen
34、eral principles (ISO 3452-1) EN ISO 4063, Welding and allied processes - Nomenclature of processes and reference numbers (ISO 4063) EN ISO 5817, Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) - Quality levels for imperfections (ISO 5817) EN ISO 650
35、7-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1) EN ISO 15607, Specification and qualification of welding procedures for metallic materials - General rules (ISO 15607) EN ISO 15609-1, Specification and qualification of welding procedures for metallic materials - Wel
36、ding procedure specification - Part 1: Arc welding (ISO 15609-1) BS EN 16725:2016EN 16725:2016 (E) 7 EN ISO 15613, Specification and qualification of welding procedures for metallic materials - Qualification based on pre-production welding test (ISO 15613) EN ISO 17632, Welding consumables - Tubular
37、 cored electrodes for gas shielded and non-gas shielded metal arc welding of non-alloy and fine grain steels - Classification (ISO 17632) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 Railway Authority RA either the railway regulator or the
38、 owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.2 contractor and sub-contractor company approved by a railway authority to carry out the restoration of cast manganese track components by electric arc welding on that particular infras
39、tructure Note 1 to entry: This may include staff from within the RA 3.3 preliminary welding procedure specification pWPS tentative welding procedure specification, which is assumed to be adequate by the consumable manufacturer, but which has not been approved by the RA Note 1 to entry: Welding of te
40、st 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 welding procedure specification WPS procedure approved to European standards and agreed by the RA for use on the railway infrastructure 3.5 trai
41、ning establishment welder training organisation or centre approved by the railway authority or alternatively a welder training organisation or centre approved by and belonging to a railway authority 3.6 manual metal-arc welding MMA manually operated metal-arc welding using a covered electrode 3.7 fl
42、ux-cored arc welding FCAW semi-automatic or automatic arc welding process Note 1 to entry: FCAW requires a continuously fed consumable tubular electrode containing a flux and a constant-voltage or a constant-current welding power supply. BS EN 16725:2016EN 16725:2016 (E) 8 3.8 certification body bod
43、y for the purpose of witnessing and reporting the welding and testing of test pieces 3.9 AMS austenitic manganese steel, in accordance with EN 15689 3.10 penetrant testing PT method of crack detection employing capillary action. A low surface tension liquid is applied to a test area, after a given s
44、oak time a powder developer is applied, the developer draws the liquid from any cracks present giving a clear indication of any surface breaking defect 3.11 tri-metal zone flash butt welded area of the casting containing AMS, rail steel and the stainless steel insert 3.12 million gross tonnes (MGT)
45、Equivalent Million Gross Tonnes Per Annum (EMGTPA) annual traffic load (metric for assigning track category) 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
46、 owing to the special nature of the repair weld in terms of steel grades, the approval process shall follow this standard. 4.2 Consumable and WPS approval model 4.2.1 Flow chart The following flow chart describes how a consumable and its related WPS shall be approved. WPS approval shall follow the p
47、rinciple of EN ISO 15613 approval by a pre-production test. BS EN 16725:2016EN 16725:2016 (E) 9 NOTE 1 The approving RA has to issue an approval certificate upon successful outcome of track trial. NOTE 2 Other RAs may require further tests to verify suitability for special service/operational condit
48、ions or deposition techniques. Figure 1 WPS approval 4.2.2 Minimum information to be included in the pWPS The pWPS shall contain as a minimum the following: Parent material; Consumable classification type and size; BS EN 16725:2016EN 16725:2016 (E) 10 Welding process; Methods of preparation and clea
49、ning; Current (A); Arc Voltage (V); Type of Current (AC/DC); Polarity; Travel Speed (mm/min); Deposition sequence direction of welding; Heat input (kJ/mm); Welding position; Excavation details (sketch); Temperature measurement points (sketch); Maximum or minimum temperature values at measurement points; Interpass temperature at measurement points; Peening details. 4.3 Information supplied by the manufacturer of the welding consumable to the certifying body Toxicity threshold levels; Applicable steel grades in accordance with EN 1
