15085 requirments
TRANSCRIPT
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-EN 15085-
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Construction Surveillance
As-built & In-Service Inspections
Railcar Condition Inspection
Monitor Repair Programs
Vendor Support Services
Inspection &
Approvals
CWI, IWE, EWE
Visual Inspections (VT)
UT, Phased Array UT, UTT
Surface Flaw Detection (MT, PT)
Positive Material ID Check (PMI)
NDT ServicesASNT, AWS, API, EN, ISO,
PQR / WPS Approvals
Welder Qualifications / Training
Welding Coordinator Service
Welding Management Systems
Failure Assessments
Welding ServicesASME, AWS, API, EN, ISO,
Approval & Certification Services
AAR Rules (e.g. M-1003, ISO, ...)
European Rules (CE, EN, ISO, ...)
Product Compliance Assessments
Pre-Certification/Consulting Services
ComplianceASME, AWS, EN, ISO, GOST,
EN 15085 Welding of Rail Vehicle
ISO 3834 Quality System
CE Marking
EN 473 NDE Testing
Compliance Assessments
For EuropeEU Directives, EN, ISO,
AAR Assessments (e.g. Sect. J )
Inspections (e.g. AAR Rule 88.B.2)
Truck / Brake Assessment
Rail Car Fabrication Consultation
Quality System Implementation
For North AmericaASME, AWS, API, ISO,
1256 Remington Rd. - Schaumburg, IL 60173 - USA
+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F)
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American-European Working Group
for Welding Rail Vehicles (AEWRV)
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.
We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
ECE GlobalWe are ISO 9001:2008 CertifiedYour Global Partner in Engineering, Quality and Safety Compliance Design Fabrication Inspection Certification
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Common name Official name Accession Population Area (km) Area (miles) Capital
1 Austria Republic of Austria 1-Jan-95 8,340,924 83,871 32,383 Vienna
2 Belgium Kingdom of Belgium 25-Mar-57 10,666,866 30,528 11,787 Brussels
3 Bulgaria Republic of Bulgaria 1-Jan-07 7,640,238 110,910 42,823 Sofia
4 Cyprus Republic of Cyprus 1-May-04 778,700 9,251 3,572 Nicosia
5 Czech Republic Czech Republic 1-May-04 10,403,100 78,866 30,450 Prague
6 Denmark Kingdom of Denmark 1-Jan-73 5,511,451 43,094 16,639 Copenhagen
7 Estonia Republic of Estonia 1-May-04 1,340,935 45,226 17,462 Tallinn
8 Finland Republic of Finland 1-Jan-95 5,312,415 338,145 130,559 Helsinki
9 France French Republic 25-Mar-57 64,473,140 674,843 260,558 Paris
10 Germany Federal Republic of Germany 25-Mar-57 82,218,000 357,050 137,858 Berlin
11 Greece Hellenic Republic 1-Jan-81 11,125,179 131,990 50,962 Athens
12 Hungary Republic of Hungary 1-May-04 10,036,000 93,030 35,919 Budapest
13 Iceland Republic of Iceland --- 316,252 103,125 39,770 Reykjavk
14 Ireland Ireland 1-Jan-73 4,501,000 70,273 27,133 Dublin
15 Italy Italian Republic 25-Mar-57 59,619,290 301,318 116,340 Rome
16 Latvia Republic of Latvia 1-May-04 2,266,000 64,589 24,938 Riga
17 Lithuania Republic of Lithuania 1-May-04 3,357,873 65,303 25,214 Vilnius
18 Luxembourg Grand Duchy of Luxembourg 25-Mar-57 483,800 2,586 998 Luxembourg
19 Malta Republic of Malta 1-May-04 407,810 316 122 Valletta
20 Netherlands Kingdom of the Netherlands[t 6] 25-Mar-57 16,471,968 41,526 16,033 Amsterdam
21 Norway Reich Commissariat of Norway --- 4,954,000 385,252 148,746 Oslo
22 Poland Republic of Poland 1-May-04 38,115,641 312,683 120,728 Warsaw
23 Portugal Portuguese Republic 1-Jan-86 10,599,095 92,391 35,672 Lisbon
24 Romania Romania 1-Jan-07 21,498,616 238,391 92,043 Bucharest
25 Slovakia Slovak Republic 1-May-04 5,400,998 49,037 18,933 Bratislava
26 Slovenia Republic of Slovenia 1-May-04 2,025,866 20,273 7,827 Ljubljana
27 Spain Kingdom of Spain 1-Jan-86 46,661,950 506,030 195,379 Madrid
28 Sweden Kingdom of Sweden 1-Jan-95 9,253,675 449,964 173,732 Stockholm
29 Switzerland Swiss Confederation --- 7,785,600 41,285 15,940 Bern
30 United Kingdom United Kingdom of Great Britain 1-Jan-73 61,003,875 244,820 94,526 London
EU-27 European Union total 499,514,405 4,456,304 1,720,590
North America Canada, USA, Mexico 528,720,588 24,709,000 9,540,000 Washington
Difference 16,150,331 19,723,034 7,614,954
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Official name Population Area (km) Area (miles)
European Union total512,570,257 4,985,966 1,925,046
North America 528,720,588 24,709,000 9,540,000
16,150,331 19,723,034 7,614,954
Canada (2011) 34,482,779 9,984,670 3,855,103
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Harmonization within the European Union
The goal of harmonization:
* Freedom
* Trade: Unification and mutual requirements
* Common safety requirements; e.g.:
Product safety
Plant & facility safety
Public health and safety
Workers protection and safety
4
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Certification for Europe
certification of pressure equipment, electrical equipment, EMC,
fire protection, operating in tunnel, and more
new building and repair work of rail vehicle and components
Structural requirements of railway vehicle bodies
.
Many requirements apply when designing, fabricating and operating rail vehicles in Europe
CE Marking, etc
EN 15085
EN 12663
etc.
Derailment Safety
Operational Safety, Side wind
Stress Safety (Active and Passive)
Control Systems, Safety Technology, SoftwareBrake System
Vehicle Profile / Clearance
Fire Safety, Environmental Protection
Workers Protection
Vehicle Accessories / Equipment
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What does it take for a fabricator of
Welded Rail Vehicles and Components
to sell products in Europe?
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EN 15085 and AWS D15.1
Part 1: General
Part 2: Quality requirements and certification of welding manufacturer
Part 3: Design requirements
Part 5: Inspection, testing and documentation
Part 4: Production requirements
We will focus on EN 15085 Welding of Rail Vehicles and Components
And focus on AWS D15.1 Railroad Welding Specification for Cars and
Locomotives
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American-European WorkingGroup for Welding Rail Vehicles(AEWRV) [email protected]
Did you know:
Over 300 companies in China are certified per EN 15085 by 2012 ending
Canada roughly 5 Companies
USA roughly 15 Companies
Mexico roughly 0 Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some
approvals is an investment with an incredible ROI?
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Country company
CA Advance Manufacturing Technologies Inc. (DIN EN 15085-2)
CA Alloy Welding Centre Limited (DIN EN 15085-2)
CA China Steel Inc. (DIN EN 15085-2) open audit process
CA Phillips & Temro Industries LTD (DIN EN 15085-2)
CA Recreational & Industrial Products Corp. (DIN EN 15085-2)
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American-European WorkingGroup for Welding Rail Vehicles(AEWRV) [email protected]
The intent of the workgroup is:
To represent the interest of the North American Railroaders with focus on
exporting its products to EU countries and other global destinations (e.g. S.A.).
Our meeting outcome will provide insights, input and advice to Technical
Committees for the development of e.g. AWS D15.1 and EN 15085.
Even though these standards are addressing the same industry and same
companies, the overall scope and approach is different.
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EN 15085 Scope
certification and quality requirements
new building and repair work of rail vehicle and components.
applies to manufacturers of welded rail vehicles and components
outlines
covers
steel and aluminum (principles apply to other materials equally)covers
EN1
5085
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94 95 9680 83 85 89 90
Non regulated /
voluntary /
market oriented
initiatives
regulated /
mandatory /
initiatives
Old Approach
New Approach
Global Approach
Quality Policy System/Personnel
00 01 02
Europe changed ..
From a Country by Country Approval Schemeto the New European Approach!
Product Liability;
Declaration
of Conformity,
EU Representation
Business Excellence &
European Competitiveness
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EN 15085-2: Definition of certification levels
Annex A (informative)
Possible allocation of parts and subassemblies of rail vehicles to the certification levels
Certification
level
Parts classification
Level CL 1 New build, conversion and repair of rail vehicles and their components Examples for components: bogies (headstocks, solebars, cross bearers,
bogie frames) under-frames (extensions, solebars, cross bearers, assembly) vehicle body (front walls, side walls, roof) draw and buffing gear
supporting frames for external equipment parts (e. g. tanks, electrical, air-conditioning and compressed air containers ) wheel set mountings, axle
boxes, spring supports, shock absorbers, vibration dampers brake equipment (magnetic track brake, brake rods, brake triangles, brake cylinders,
brake cross beams) supporting frames for heavy duty vehicles including road/rail vehicles welded components for drag transmission from bogie
to vehicle (bolster) fuel tanks of vehicles finishing welding of castings within components indicated above pressure gas tanks, tanks and tankcontainers of rail vehicles with test pressure a containers for dangerous materials a.
Level CL 1
or
Level CL 2
New build, conversion and repair of rail vehicles and their components, depending on the weld performance class (CL 1 only for CP A, CP B or CP C1),
e.g.: entrance doors, end doors self-supporting equipment boxes and underfloor containers (fresh water and waste-water containers) external
machine equipment parts (transformer, engine, transmission suspension) roof construction (pantograph, paneling) machine room equipment
(transformer casing, transformer suspension, engine suspension, transmission suspension, attachment for traction motor, instrument racks)
power transmission parts (traction coupling, cardan shafts) traverses (i.e. car wagon) turning and tipping equipment obstacle deflectors
stanchions and lashing rings compressed-air reservoirs for rail vehicles a pressurized pipes.
Level CL 2 New build, conversion and repair of non-pressurized containers without special test pressure, e.g.: payload container for non-dangerous materials
other transport containers. New build, conversion and repair of structural parts for rail vehicles, e.g.: internal parts of passenger coaches
(partitions, walls, doors, paneling) supporting frame for internal parts (electrical, air-conditioning and compressed air installations) driving cab
equipment lavatory parts and water containers with installations sliding doors in vehicles including runways fastenings for brake pipes non-self-supporting equipment boxes underneath the base frame (without supporting frame) gearboxes and consoles for hand brake operation
steps, hand rails (including handrails in entry areas) and railings external to the vehicle.
Level CL 3 New build, conversion and repair production of simple attached parts for rail vehicles, e.g: cranks and levers for various operations striking plates
equipment boxes and switch cabinets in rail vehicles (including gearboxes and consoles for hand brake operation, without supporting frame )
holders for index plates wheel scotches covers for freight wagons (heat protection on tank wagons) steps, handrails, railings on rail vehicles.
New build, conversion and repair of parts or trade supply parts for rail vehicles, for instance: seating frames window frames ventilation grilles.
Level CL 4 This certification level is valid for manufacturers that do not carry out their own welding fabrication if welded components and parts are: designed
bought and assembled.
a The requirements of this standard will be superseded by specific product standards, e.g. EN 286, air reservoirs.
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CL 2: New build, conversion and
repair of non-pressurized
containers without special test
pressure, e.g.:
payload container for non-
dangerous materials
other transport containers.
New build, conversion and
repair of structural parts for
rail vehicles, e.g.:
internal parts of passenger
coaches (partitions, walls,
doors, paneling)
supporting frame for internal
parts (electrical, air-conditioning and compressed
air installations)
driving cab equipment
lavatory parts and water
containers with installations
CL 1 / 2: New build, conversion
and repair of rail vehicles and
their components, depending
on the weld performance class(CL 1 only for CP A, CP B or CP
C1), e.g.:
entrance doors, end doors
self-supporting equipment
boxes and underfloor
containers (fresh water andwaste-water containers)
external machine equipment
parts (transformer, engine,
transmission suspension)
roof construction
(pantograph, paneling) machine room equipment
(transformer casing,
transformer suspension,
engine suspension,
transmission suspension,
attachment for tractionmotor, instrument racks)
15
CL 1: New build, conversion and
repair of rail vehicles and their
components Examples for
components:
bogies (headstocks, solebars,
cross bearers, bogie frames)
underframes (extensions,
solebars, cross bearers,assembly)
vehicle body (front walls, side
walls, roof)
draw and buffing gear
supporting frames for
external equipment parts (e.g. tanks, electrical, air-
conditioning and compressed
air containers)
wheel-set mountings, axle
boxes, spring supports, shock
absorbers, vibration dampers
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EN 15085 Essential
performance requirements during design (e.g. static / dynamic safety)
achieving appropriate weld quality during production or repair
provides an essential link
between
and
inspection requirements during production and in-service maintenanceand
Knowing engineering / fabrication / inspection /and certification principles is key
for fabrication supervisory
The same applies to CE Marking
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How can the cost for doing business with Europe be estimated?
Internal sales experience? Calls to service providers?
Negotiation of customer requirements to what is standard practice?
Other .
Would you believe me, if I would state that:
defining cost saving questions for a customer is tough!
negotiating standard practice processes costs more time and money
than complying with EU requirements!
calling service providers may end up with a surprise!
Other .
Let me try to plant a suggestion ..
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A pound of Canadian feathers
cradles as much as
A pound of European feathers
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Stress category Safety categories
High Medium Low
High CP A a CP B c CP C2
Medium CP B b CP C2 CP C3
Low CP C1 d CP C3 CP D
Stress categories and Safety categories
Weld performance class CP A through CP D set the rules for
Quality System Requirements
Personnel Qualification Requirements
Process Approval Requirements
Cost for Certification!
Assessing and defining Weld Performance Requirements is a fundamental need,
regardless if the products operates in Europe or Canada or North America or
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Back to the roots! definitions breakdown ..
certification level CL weld performance class CP
safety categorystress category
weld inspection class CT
The safety categories are differentiated as follows:
low Failure of the welded joint does not lead to any direct impairment of
the overall function. Consequential events with personal injuries
are unlikely.
Failure of the welded joint leads to an impairment of the overall
function or can lead to consequential events with personal injuries.
medium
Failure of the welded joint leads to consequential events withpersonal injuries and breakdown of the overall function.
high
stress factor
EN 15085-3 Table 1
some default CL EN 15085-2, Annex A
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Rely on what you know .
Adopt what is global practice .
Build bridges, do not reinvent the wheel
Slid f 45
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Stresscategory Safetycategory Weldperformanc
e class
Quality levelsfor
imperfections
EN ISO 5817
EN ISO 10042
Inspectionclass Volumetrictests
RT or UT
Surface testsMT or PT Visualexamination
VT
High High CP Asee Table 5 or
Table 6CT 1 100% 100% 100%
High Medium CP B B CT 2 10% 10% 100%
Medium High CP B B CT 2 10% 10% 100%
Low High CP C1 C CT 2 10% 10% 100%
High Low CP C2 C CT 3 Not required Not required 100%
Medium Medium CP C2 C CT 3 Not required Not required 100%
Medium Low CP C3 C CT 4 Not required Not required 100%
Low Medium CP C3 C CT 4 Not required Not required 100%
Low Low CP D D CT4 Not required Not required 100%
EN 15085-3: Design Requirements
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EN 15085-3: Design Requirements
Imperfections
according to
Weld performance classes
EN ISO 5817 (Steel)
EN 15085-3 (Table 5)
Weld performance classes
CP A CP B CP C1 / CP C2 / CP C3 CP D
1.1 to 1.6, 1.13, 1.15,
1.18, 1.19, 1.22, 2.1,
2.7, 2.8, 2.11 to 2.13,
B B C D
1,7, 1.8, 1.9, 1.11,
1.14, 1.17, 1.23, 2.2,
2.3 to 2.6, 2.9, 2.10,
3.1
Not permitted B C D
1.10, 1.16, 1.20,
1.21, 3.2Not applicable B C D
1.12 a, 4.1, 4.2 These imperfections are not assessed
a For CPA, see also 7.3.15.
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How should the inspection class be introduced to fabrication?
Inspection shall be very well
trained and familiar withinspection / validation
requirements!
Imperfections
according to
Weld performanceclasses
EN ISO 5817 (Steel)
EN 15085-3 (Table 5)
Weld performance classes
CP A CP BCP C1 / CP C2 /
CP C3CP D
1.1 to 1.6, 1.13, 1.15,
1.18, 1.19, 1.22, 2.1,
2.7, 2.8, 2.11 to 2.13,
B B C D
cost control: fabrication, inspection, repair, estimation, parts
Engineering must be very familiar
with the codes and requirements!
Engineering must produce sound and
informative drawings!
Welder / Operator
must perform onhighest acceptance
level.
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CL determined by weld performance class CP
CP
stress category approved calculations & drawings
safety category risk assessment / engineering
engineering welding coordinator inspection
sales / purchasing
Fabrication
PQR / welder / welding operator
inspector
CT
CL mandates inspection scope
technology can demand deviation from rules
lets summarize!
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AWS D15.1: Brief Background on AWS Welding of Railroad Components
- A single comprehensive document of welding data,
applicable throughout the railroad industry
- Contribution to improvements in welding quality and
performance
Purpose of Standard
Experts from all segments of the industry
- Users
- Suppliers
- General Public
- Representatives of the Association of American Railroads (AAR)
Committee Members
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General Scope Information
Material Thickness 1/8 in [3 mm]
Clauses 1 through 17: General requirements for welded construction for metal
components 1/8 in [3 mm] or greater, in thickness
Material Thickness Less 1/8 in [3 mm]
Clauses 18 through 23: Welding of base metals less than 1/8 in [3 mm] in thickness 11
gauge (0.1196 in [3.04 mm]) material may be considered 1/8 in [3 mm] plate or sheet
steel
This document includes data from
- AWS D1.1/D1.1M, Structural Welding CodeSteel
- AWS D1.2/D1.2M, Structural Welding Code Aluminum
- AWS D1.3/D1.3M, Structural Welding CodeSheet Steel
- AWS D1.6/D1.6M, Structural Welding CodeStainless Steel
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General Scope Information
AWS D15.1: - Pragmatic
- Based on experience
- Focused on essential tasks and disciplines related to welding
- Details requirements for welding process qualifications
- Addresses welding personnel qualification
- Partially addresses inspection personnel qualification
- Defines acceptance criteria for weld quality
- Highlights requirements certain product
Not included:
Product
Classification
and Quality
System
Requirements
No reference to
i.e. M-1003
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General Scope Information
Welding
Requirements
Technique andWorkmanship
PrequalifiedWPS
GeneralQualification
Requirements
ProcedureQualification
WeldingPersonnel
Qualification
Inspection /
AcceptanceAWS D15.1 - Content:
AWS D15.1
Does not include
information / requirements
concerning
PRODUCT CERTIFICATION
QUALITY SYSTEMS
Only a limited comparison between AWS D15.1 and EN 15085 is currently possible!
However, similarities in PHILOSOPHIES can be recognized!
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94 95 9680 83 85 89 90
Non regulated /
voluntary /
market oriented
initiatives
regulated /
mandatory /
initiatives
Old Approach
New Approach
Global Approach
Quality Policy System/Personnel
00 01 02
Business Excellence &
European Competitiveness
Quality Assurance / Control System
Certification Tool to Compliance
Product Liability;
Declaration
of Conformity,EU Representation
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EN 15085-2: Quality requirements and certification of welding manufacturer
Definition of requirements for welding manufacturer
Certification levels
Level CL 1 Level CL 2 Level CL 3 Level CL 4
Manufacturer Certification Required Required Not required Required
Weld performance class CP A to CP D (CP C1) a , CP C2 to CP D CP D CP A to CP D
Quality requirements b EN ISO 3834-2 EN ISO 3834-3 EN ISO 3834-4 EN ISO 3834-3
Welding coordinator Level A Level B or C No requirement
For:
level 1 welding work: Level A
level 2 welding work: Level B or C
Deputy of the welding coordinatorDeputy: Level A c Further
deputies: Level B or C d
Deputy: Level C No requirement No requirement
Welders and operators
Depending on the welding process and material group, qualified welders or welding operators
are required according to EN 287-1 (for steels), EN ISO 9606-2 (for aluminum) or EN 1418 (for
welding operators).
Not relevant
Testing personnel
- Testing personnel for welding quality tests
- Testing supervisors for welding quality tests: responsible welding coordinator (not for CL 3)
- Non-destructive testing personnel: level 1 according to EN 473
- Testing evaluator for non-destructive testing: level 2 according to EN 473.
Not relevant
Welding instruction WPS according to the relevant parts of EN ISO 15609 or EN ISO 14555 or EN ISO 15620 Not relevant
Welding instruction
WPS qualified by WPQR the relevant parts of EN ISO 15610,
EN ISO 15611, EN ISO 15612, EN ISO 15613, EN ISO 15614 e
or EN ISO 14555 or EN ISO 15620 (for details see EN 15085-4)
For CP D, only if specified in the contract.
WPS qualified by WPQR only if
specified in the contractNot relevant
a CL 1 when CT 1
b The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN ISO 3834 is required.
c Level A deputy is not required for small welding manufacturers with a single welding shop.
d For welding manufacturers with several welding shops an additional deputy, Level C, is required for each welding shop.
e For railway applications, only EN ISO 15614-1, EN ISO 15614-2, prEN ISO 15614-3, EN ISO 15614-4, EN ISO 15614-7, EN ISO 15614-11, EN ISO 15614-12 and
EN ISO 15614-13 are relevant.
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ISO 3834 Similar to ISO 9000EN 15085-2: Quality Assurance / Control
Recourse
ManagementAudits
Continuous
Improvement
Customer
Satisfaction
Sales & Projects
Custom
er
CustomerReq
uirements
Engineering /
Product
Development
Product
Realization /
Fabrication
CustomerService
Procurement
Development
Material
Management
Maintenan
ce
Test
Equipment
ControlofNon-
Conformin
g
Product/Proc
ess
Communication
CommunicationControl od Documents & Records
Communication
BUT SPECIFIC for Welding Shops
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Level CL 1 Level CL 2 Level CL 3
Manufacturer Certification Required Required Not required
Weld performance class CP A to CP D (CP C1) a) , CP C2 to CP D CP D
Quality requirements b) EN ISO 3834-2 EN ISO 3834-3 EN ISO 3834-4
Welding coordinator Level A Level B or C No requirement
Deputy of the welding
coordinator
Deputy: Level A c)
additional deputies:
Level B or C d)
Deputy: Level C No requirement
Welding Coordination A Key Function within the System
a) CL 1 when CT 1
b) The requirements of the relevant part of EN ISO 3834 shall be met, but no certification according to EN
ISO 3834 is required.
c) Level A deputy is not required for small welding manufacturers with a single welding shop.
d) For welding manufacturers with several welding shops an additional deputy, Level C, is required for each
welding shop.
95
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engineering
quality
fabricationwelding
sales
purchasing
Welding Coordination A Key Function within the System
welding
coordinator
- design requirements
(e.g. static / dynamic safety)
- weld quality
(production or repair)
welding coordinators are an essential link
- inspection requirements
(production / maintenance)
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Material
Suitability for
Welding/Fab.
Weldability
Of
Components
Design
Requirements
-Design
-Production-In-Service
Inspection
Testing
Validation
The European Standard Focus on
design requirements
infrastructure conditions
weld performance
material suitability
e.g. low temperature
Attention SALES !
inspectability
- new construction
- in-service
- maintenance
certification level CL based on a weld! Later: CL definition acc to EN 15085-2
Attention PURCHASING !
This is not new
This is now part of an approval/certificationprocess .
The pragmatic approach is going to be replaced
with a new approach
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A216 WCC A588
Sectioned close to center stiffener
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ASTM A588 Chemical Composition
GradeThe Element Max (%)
C Mn P S Si Cu Ni Cr Mo V N Nb
A 0.19 0.80-1.25 0.04 0.05 0.30-0.65 0.25-0.40 0.40 0.40-0.65 0.02-0.10 0.01 ..
Carbon Equivalent:CEV [max]: 0.60
CET [max]:0.38
(CET: acc. Uwer and Hoehne)CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
ASTM A216 Chemical Composition
GradeThe Element Max (%)
C [max] Mn [max] P [max] S [max] Si [max] Cu [max] Ni [max] Cr [max] Mo [max] V [max] Rest
WCC 0.25 1.20 0.04 0.045 0.60 0.30 0.50 0.50 0.20 0.03 1.00
Carbon Equivalent:CEV [max]: 0.55
CET [max]:0.44
(CET: acc. Uwer and Hoehne)CET = C +((Mn+Mo)/10)+((Cr+Cu)/20)+Ni/40
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Tp = 697 X CET + 160 X tanh (d/35) + 62 X HD 0 35 +(53 X CET- 32) X Q - 328 (C) i ii iii
Weldment: ASTM A588-A Plate with ASTM A216-WCC Casting
Material: ASTM A588-A
WPS BT002-1 (with Backing)
HD: 1/Q: Root HD: 1/Q: Intermediate HD: 5/Q: Root HD: 5/Q: Intermediate
1.i Determination of the lowest preheat temperature for cold cracking I sate welding of steels. Authors Uwer D, Hoehne H, IIW. Do c IX-1631 - 91.
2.ii Comparison of methods for determining weld proceduresfor the avoidance of hydrogen cracking infabrication.Authors HartP.H.M, Pargetter R.J, Wright M.D, IIW. DocIX- 1602-90
3. iii Industry standards
Tp 58.22863
Factor 1 697
CET 0.38
Factor 2 160
d 14
35tanh(d/35 0.379949
Factor 3 62
HD 1
HD0.35
1
Factor 4 53
CET 0.38
Factor 5 32
Q 0.12
Factor 6 328
Tp 56.09383
Factor 1 697
CET 0.38
Factor 2 160
d 14
35tanh(d/35 0.379949
Factor 3 62
HD 1
HD0.35
1
Factor 4 53
CET 0.38
Factor 5 32
Q 0.30
Factor 6 328
Tp 105.1295
Factor 1 697
CET 0.38
Factor 2 160
d 14
35tanh(d/35 0.379949
Factor 3 62
HD 5
HD0.35
1.756465
Factor 4 53
CET 0.38
Factor 5 32
Q 0.12
Factor 6 328
Tp 102.9947
Factor 1 697
CET 0.38
Factor 2 160
d 14
35tanh(d/35 0.379949
Factor 3 62
HD 5
HD0.35
1.756465
Factor 4 53
CET 0.38
Factor 5 32
Q 0.30
Factor 6 328
AWS D15.1 does not require pre-heating per default.
If the weld is in a high stressed area, pre-heating requirements should be reviewed!
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AWS D15.1, Clause 4.7:
Fabricator Engineer is responsible for interpretations related to approval needs
If so agreed, same responsibility applies to Owners Engineer
When both engineers are assigned, the references assigned to only one entityshall apply to both entities
Note: Engineers are often degreed mechanical or civil engineers
Welding Coordination
EN 15085-2, Annex B: Competence of Welding Coordinator
Welding coordinator a comparable educational program as outlined in EN
15085-2, Sect 512 and EN ISO 14731 is not available in AWS D15.1
AWS D15.1 requires the company to employ suitably educated employees
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EN 15085-2 and AWS D15.1
sales
purchasing
engineering
fabrication
inspection
customer
national safety authority
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Summary
1) Manufacturers of welded products will have to be certified according to theCertification Level (CL) and Weld Performance Class (CP)
2) Front End Loading standard knowledge and engineering / fabrication
requirements safes time, cost and increases confidence
3) Quality System approval per EN 15085-2 with compliance to ISO 3834 is a
FUNDAMENTAL MILESTONE
4) Personnel with suitable qualifications are essential
a. Welding Coordinator Technology and Standards
b. NDE Personnel Qualification per EN 473/ISO 9712 depends on CP Class5) Approved welding procedure per EN / ISO
6) Welder / Welding Operator approval per EN / ISO
7) Contractual agreements shall include technology requirements
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Summary --- Estimated Time Frames for Companies with QA Systems
Assess the Weldment forClassification X days, depending oncomplexity
Quality System an
Fabrication Performance1 to 2 days, Gap Audit
Welding Procedure and
Welder Approvals
X days, plus Time for
Testing Lab
Personnel Training for
Welding CoordinationX days, including Test
Personnel Training for
Inspection / NDE
X days, depending on
current status
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Implementation Support and Duration, as well as
Certification Audit and Cost need to be added!
What does it take to become AAR Section J, M-1003
Certified?
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American-European WorkingGroup for Welding Rail Vehicles(AEWRV) [email protected]
Maybe in the near future, the score card looks like this?
Over 300 companies in China that are certified per EN 15085 by 2012 ending
Canada roughly 55+ Companies
USA roughly 55+ Companies
Mexico roughly 55+ Companies are certified per EN 15085!
That Quality Assurance / Quality Control Programs combined with some
approvals is an investment with an incredible ROI?
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Please stay on track!
Thank you for you attention!
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Construction Surveillance
As-built & In-Service Inspections
Railcar Condition Inspection
Monitor Repair Programs
Vendor Support Services
Inspection &
Approvals
CWI, IWE, EWE
Visual Inspections (VT)
UT, Phased Array UT, UTT
Surface Flaw Detection (MT, PT)
Positive Material ID Check (PMI)
NDT ServicesASNT, AWS, API, EN, ISO,
PQR / WPS Approvals
Welder Qualifications / Training
Welding Coordinator Service
Welding Management Systems
Failure Assessments
Welding ServicesASME, AWS, API, EN, ISO,
Approval & Certification Services
AAR Rules (e.g. M-1003, ISO, ...)
European Rules (CE, EN, ISO, ...)
Product Compliance Assessments
Pre-Certification/Consulting Services
ComplianceASME, AWS, EN, ISO, GOST,
EN 15085 Welding of Rail Vehicle
ISO 3834 Quality System
CE Marking
EN 473 NDE Testing
Compliance Assessments
For EuropeEU Directives, EN, ISO,
AAR Assessments (e.g. Sect. J )
Inspections (e.g. AAR Rule 88.B.2)
Truck / Brake Assessment
Rail Car Fabrication Consultation
Quality System Implementation
For North AmericaASME, AWS, API, ISO,
1256 Remington Rd. - Schaumburg, IL 60173 - USA
+1 (847) 250-5240 (P) - +1 (847) 713-4860 (F)
[email protected] - www.eceglobal.com
American-European Working Group
for Welding Rail Vehicles (AEWRV)
Helping with clientele success, nationally / globally, with cost-effective pricing, excellent service and a quick turnaround is our policy.
We deliver engineering verification services, new and in-service equipment assessments and inspections, compliance assessments
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