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Schweißmaschinen an Orten außerhalb eines SchweißwerkesApplications ferroviaires - Voie - Soudage des rails par étincelage - Partie 2 : Rails neufs de nuance R220, R260, R260Mn et R350HT par des machines de soudure mobiles dans des sites autres qu'une installation fixeRailway applications - Track - Flash butt welding of rails - Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant93.100Gradnja železnicConstruction of railways25.160.10Varilni postopki in varjenjeWelding processesICS:Ta slovenski standard je istoveten z:EN 14587-2:2009SIST EN 14587-2:2009en,fr,de01-junij-2009SIST EN 14587-2:2009SLOVENSKI
STANDARD
SIST EN 14587-2:2009
EUROPEAN STANDARDNORME EUROPÉENNEEUROPÄISCHE NORMEN 14587-2April 2009ICS 25.160.10; 93.100 English VersionRailway applications - Track - Flash butt welding of rails - Part 2:New R220, R260, R260Mn and R350HT grade rails by mobilewelding machines at sites other than a fixed plantApplications ferroviaires - Voie - Soudage des rails parétincelage - Partie 2: Rails neufs de nuance R220, R260,R260Mn et R350HT par des machines de soudure mobilesdans des sites autres qu'une installation fixeBahnanwendugen - Oberbau - Abbrennstumpfschweißenvon Schienen - Teil 2: Abbrennstumpfschweißen neuerSchienen der Stahlsorte R220, R260, R260Mn undR350HT durch mobile Schweißmaschinen an Ortenaußerhalb eines SchweißwerkesThis European Standard was approved by CEN on 28 February 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 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:
Avenue Marnix 17,
B-1000 Brussels© 2009 CENAll rights of exploitation in any form and by any means reservedworldwide for CEN national Members.Ref. No. EN 14587-2:2009: ESIST EN 14587-2:2009
EN 14587-2:2009 (E) 2 Contents Page Foreword .4 Introduction .5 1 Scope .6 2 Normative references .6 3 Terms and definitions .6 4 Requirements for the welding process .8 4.1 General .8 4.2 Clamping force .8 4.3 Pre-heating – flashing .8 4.4 Progressive flashing .8 4.5 Upsetting .8 4.6 Upset current .8 4.7 Unclamping .8 4.8 Welding program and records .8 4.9 Step across the weld .9 4.10 Weld trimming . 10 4.11 Post-weld heat treatment . 11 5 Procedure approval of a MFBW machine . 12 5.1 General . 12 5.2 Sample preparation . 12 5.3 Approval tests . 12 5.3.1 Visual inspection . 12 5.3.2 Weld trimming and upset examination . 12 5.3.3 Step across the weld . 12 5.3.4 Magnetic particle or dye penetrant inspection . 12 5.3.5 Bend testing . 13 5.3.6 Macro examination . 13 5.3.7 Micro examination . 13 5.3.8 Hardness testing . 13 5.3.9 Fatigue testing . 14 5.4 Test result report . 14 6 Approval of other rail profiles or grade . 14 6.1 General . 14 6.2 Approval tests . 14 6.2.1 General . 14 6.2.2 Grade R220 . 14 6.2.3 Grade R260Mn . 14 6.2.4 Grade R350HT . 14 7 Approval of the Welding Contractor . 15 7.1 General . 15 7.2 Requirements for initial approval . 15 7.2.1 Welding procedure . 15 7.2.2 Quality systems . 15 7.2.3 Information to be provided by the contractor . 15 7.2.4 Operators . 15 7.2.5 Supervision . 15 7.2.6 Weld Inspection . 15 7.2.7 Equipment . 16 7.3 Field approval of the welding contractor . 16 7.4 Audits . 16 SIST EN 14587-2:2009
EN 14587-2:2009 (E) 3 8 Weld production and acceptance requirements . 16 8.1 Information from the purchaser . 16 8.2 Site preparation of rail ends . 16 8.3 Rail alignment . 17 8.4 Weld parameter monitoring . 17 8.5 Weld identification . 17 8.6 Visual inspection . 17 8.7 Steps across the weld . 17 8.8 Profile finishing of the rail head . 18 8.8.1 Initial grinding . 18 8.8.2 Final grinding . 18 8.9 Geometrical acceptance criteria . 18 8.10 Weld production testing. 19 8.10.1 General. 19 8.10.2 Additional test requirements . 19 8.10.3 Bend test . 19 8.10.4 Interpretation of results . 20 8.11 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 Annex D (normative)
Macro examination and micro examination . 34 Annex E (normative)
Hardness testing . 35 Annex ZA (informative)
Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC . 36 Bibliography . 40
SIST EN 14587-2:2009
EN 14587-2:2009 (E) 4 Foreword This document (EN 14587-2:2009) 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 text 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 responsible for identifying any or all such patent rights. 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. 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 EC Directive(s). For relationship with EC Directive(s), 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, 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 the United Kingdom. SIST EN 14587-2:2009
EN 14587-2:2009 (E) 5 Introduction This part of EN 14587 has three main topics: a) approval procedure for a mobile flash butt welding (MFBW) machine; b) approval of the welding contractor; c) weld production. 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. This part of EN 14587 differs from Part 1 significantly due to the peculiarities of a MFBW machine: they are used at different places and for different purchasers within a short time; they work in various conditions such as weather, rail, track, worksites, power supply, legal regulations; they are operated by contractors, but personnel from different companies (including the purchaser) may be on site for the production of the continuous welded track; there are technical differences of the equipment used in order to guarantee the required mobility. Due to the above mentioned special operating conditions of a MFBW machine, the following requirements have been relaxed as a result: minimum bend test requirements for production bend tests only; maximum permitted trimmed upset. This part of EN 14587 does not identify any approval of a MFBW machine in terms of electromagnetic compatibility, vehicle braking systems or any requirements regarding load gauge, environment and its attendant issues or infrastructure access pertaining to any railway authority. SIST EN 14587-2:2009
EN 14587-2:2009 (E) 6 1 Scope This European Standard specifies requirements for the approval of a welding process by a MFBW machine at sites other than fixed plant, as well as the welding contractor together with the requirements for subsequent welding production. Where a MFBW machine is to be used in a static but temporary situation, the requirements of this part of the standard shall apply. It applies to new Vignole R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a MFBW machine at sites other than a fixed plant and intended for use on railway infrastructures. 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 14587-1, Railway applications – Track – Flash butt welding of rails – Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant EN ISO 6507-1, Metallic materials – Vickers hardness test – Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1, 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 fixed plant stationary production line for flash butt welding of rails, as specified by EN 14587-1 3.2 welding process any part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 3.3 upset metal extruded around the rail profile as a result of forging 3.4 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 SIST EN 14587-2:2009
EN 14587-2:2009 (E) 7 3.5 trimming removal of upset 3.6 trimmed upset metal remaining around the rail profile following trimming 3.7 dressing removing trimmed upset by grinding or other similar process 3.8 as welded condition rails that have been welded and trimmed only 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 finished condition welded, trimmed, dressed and profile finished 3.11 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 3.12 lack of bond area of incomplete fusion between the rails in the joint
NOTE 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. 3.13 welded string long rail comprising a number of shorter rails flash butt welded together 3.14 MFBW machine abbreviation for a mobile flash butt welding machine 3.15 purchaser purchaser of the welds 3.16 railway authority (RA) either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.17 contractor company approved by a RA to provide staff and machinery to execute the production of mobile flash butt welds on that particular infrastructure NOTE This may include staff and machinery from within the RA. SIST EN 14587-2:2009
EN 14587-2:2009 (E) 8 3.18 manufacturer manufacturer of the welding machine 4 Requirements for the welding process 4.1 General All welding shall be carried out on a MFBW machine using an automatic, programmed welding sequence. 4.2 Clamping force Rails shall be secured in the MFBW machine 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. 4.3 Pre-heating – flashing The fronts of the heated area shall progress uniformly perpendicularly to the running surface during the whole cycle. There shall be no evidence of overheating on the ends of the rails during pre-heating – flashing. Once initiated, the flashing process shall not be interrupted. 4.4 Progressive flashing Once initiated, progressive flashing shall be continuous. 4.5 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. 4.6 Upset current The upset welding current shall be maintained until the rapid forge has finished and the progressive forging commences. 4.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. 4.8 Welding program and records The welding program (settings) shall be determined during procedural trials and, once approval has been granted, shall not be changed. The welding machine and/or management system equipment shall be capable of displaying the following: a) welding program identification and setting details; b) welding current; c) upset force or pressure; SIST EN 14587-2:2009
EN 14587-2:2009 (E) 9 d) displacement; e) welding time. The welding parameters shall be monitored and recorded. These records shall be referenced to the appropriate welds. 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 8.10.3 shall be carried out in this case. NOTE Due to extreme variations in seasonal temperatures, the contractor may request the use of alternative welding programs. 4.9 Step across the weld Any step between the rails across the weld in the as welded condition (see 3.8) shall not exceed those dimensions shown in Table 1. Checks shall be made using the gauge as shown in Figure 1. Table 1 — Maximum permitted steps Position of step on the rail Maximum permitted step 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 both edges of the rail foot 2,0 Dimensions in millimetres
Key 1 Tip 2 Strip recess 3 Stock Figure 1 — Gauge for measuring the step SIST EN 14587-2:2009
EN 14587-2:2009 (E) 10 4.10 Weld trimming Weld trimming shall conform to the following requirements: a) excess upset shall be automatically trimmed; b) the weld shall be in compression during the removal of excess upset. One side may be released for the shearing operation; c) removal of the excess upset shall not cause any mechanical or thermal damage to the rails; d) the surface of the trimmed area shall be free from visible cracking; e) 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; f) attention shall be given to the quality of trimming on the underside of the rail foot; g) the upset shall be free from tearing, notches from the extrusion, cracks, undercut or damage to the adjacent rails; h) the maximum thickness of the trimmed upset shall be as set out in Table 2 and shown in Figure 2. 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. Table 2 — Maximum permitted trimmed upset Zone Position of trimmed upset about the weld Maximum permitted upset mm 1 Full head profile from the lower corner on the gauge face to the lower corner on the opposite face 2,5 1+ The fishing surface on the underside of the head 3,0 2 The web, from the end of the top fillet radius and extending down to the start of the bottom fillet radius 2,5 3 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 2,0
SIST EN 14587-2:2009
EN 14587-2:2009 (E) 11 Dimensions in millimetres
Key 1 Zone 1 – rail head 1+ Zone 1+ – on the underside of the rail head 2 Zone 2 – web of the rail 3 Zone 3 – foot of the rail Figure 2 — Maximum permitted trimmed upset 4.11 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. SIST EN 14587-2:2009
EN 14587-2:2009 (E) 12 5 Procedure approval of a MFBW machine 5.1 General Procedure approval shall be carried out for each individual machine (no type approval) by testing weld samples produced in accordance with this European Standard. Procedure approval testing shall be carried out on the rail profile 60E1 or 60E2 and grade R260. All test results and weld fracture faces shall be made available for inspection. 5.2 Sample preparation The rail ends shall always be sawn or disc cut to the tolerances as specified in 8.2. The rail brand marks shall be removed from any electrical contact area. 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 rails shall not be damaged by the cleaning operation or through poor electrical contact. Rails 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. Five welds in the as welded condition (see 3.8) shall be manufactured for bend testing (see 5.3.5). No pressing is permitted to correct the geometry of these test welds. NOTE The contact surface with the stamp of the test press can be prepared by grinding, if necessary. Depending on the type of fatigue test specified by the purchaser, ten welds in the finished condition (see 3.10) shall be taken for the staircase test method, or three welds in the finished condition (see 3.10) shall be taken for the past the post test method. 5.3 Approval tests 5.3.1 Visual inspection All of the welds and rails shall be inspected visually for welding, trimming, clamping or profile finishing imperfections, such as tears, cavities, cracks, damage and thermal damage, in particular, in the electrode contact areas. 5.3.2 Weld trimming and upset examination The upset shall be in accordance with 4.10. 5.3.3 Step across the weld All the welds submitted in the as welded condition shall be measured to determine the step across the weld, which shall conform to 4.9. 5.3.4 Magnetic particle or dye penetrant inspection Following visual inspection, all of the welds in the finished condition (see 3.10) shall undergo magnetic particle inspection in accordance with EN 1290 or dye penetrant inspection in accordance with EN 571-1. The profile finished area and the area of the electrode contacts shall be checked.
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