European_Welding_Standards_for_Railroad_Georg_Wackerbauer.pdf

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EN 15085

Welding of Railway vehicles and components

European Quality Requirements of EN 15085

Abstract

Welding in railway vehicle manufacturing is an

important process regarding to safety in public

transport.In this case the EN 15085-2 is an established element of

quality assurance. [1]

Gesellschaft fr Schweitechnik International mbH - Niederlassung SLV Mnchen 2


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From German Regulations to EN 15085

History of Regulations in Germany [1]

DV 952 Regulations for state railways (Deutsche Reichsbahn) DR

and later on (Deutsche Bundesbahn) DB

DS 952 Regulations for state railways DB

later

DS 951 01 Regulations for state railways DB and later on

(Deutsche Bahn AG) DB AG

and

DS 952 02 Welding outside DB

DIN 6700 German liberalised system

EN 15085 European liberalised system



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EN 15085

Standards and Guidelines

Obligatory Standards and Guidelines

EN 15085 Railway applications Welding of railway vehiclesand components

Part 1: General (Jan. 2008)

Part 2: Quality requirements and certification of

welding manufacturer (Jan. 2008)Part 3: Design requirements (Jan. 2010)

Part 4: Production requirements (Jan. 2008)

Part 5: Inspection, testing and

documentation (Jan. 2008)

Guideline of the Railway Vehicles Coordination Committee (KoA)

(Nov. 2011)



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EN 15085


Obligatory Guidelines

(link: www.en15085.net )



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Additional rules and regulations for welding repair of

railway vehicles:



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Additional regulations for welding repair of railway

vehicles:



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Certif icate according EN 15085-2 [2]

Starting April 2008, the series of standards EN 15085 parts 1 to 5

( issued October 2007 ) has been introduced by the German NationalSafety Authority, the Eisenbahn-Bundesamt (EBA) as generally accepted

rules of technology for the area of competence of the EBA.

Workshops intending to carry out welding works in new building, conversion

and repair including finishing welding of rail vehicles must have proved theircompetence according to EN 15085 Part 2 and - for repair - DIN 27201-6.

The evidence is taken as granted if the certificate has been issued by the

manufacturer certification body (HZS for example SLV Munich branch of

GSI mbH).These HZS bodies in Germany are authorised by EBA and in near future

by DAkkS (Deutsche Akkreditierungsstelle GmbH).



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EN 15085

Contents

Contents1. Classification of the certificates (CL)

1.1 Class of Performance (CP)

1.2 Class of Testing (CT)

2. Requirements

2.1 Quality requirements

2.2 Staff requirements2.2.1 Welding coordinators

2.2.2 Welders/welding operators

2.2.3 Inspection personnel

3. Welding procedure specifications (WPS)4. Welding procedure test (WPQR)



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Contents

Contents

5. Certification procedure and verification

5.1 Application for certification5.2 Audit

5.3 Documentation of result

5.4 Issuance of the certificate

5.5 Online Register Railway Vehicles

5.5.1 European Committee for Welding on Railway Vehicles

5.6 Period of validity of the certificate



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EN 15085

Classification of the certificates

1. Classification of the certificates

The certificates are classified based on the certification levels (CL) .According to EN 15085-2, section 4, these certification levels

depend on the weld performance class (CP) of the welded joints

and the safety relevance of the components and subassemblies.

The certification levels should be specified in the relevant drawing(see EN 15085-3).



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EN 15085

Classification of the certificates

Certif ication Level and examples of parts acc. EN 15085-2:

CL 1 (highest level)

Bogies, underframes, supporting frames for external

equipment parts

CL 2 supporting frame forinternal parts, steps, hand rails

CL 3 seating frames, window frames, ventilation grilles

CL 4 (only for companies without an own welding-workshop but

design railway vehicles or buy and assemble them or buy

and sell spare parts)



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EN 15085

Class of Performance

1.1 Class of Performance (CP)CP A Applies only to welds with full penetration and full accessibility

for inspection (NDT) in production and maintenance.

CP B For safety category "high": Requirements see CP A

For safety category "medium" : Applies to welds without full

accessibility for NDT. Testing for surface cracks in

production and maintenance must be possible.

CP C1 Welds without full penetration and without volumetric test

Only testing for surface cracks.

CP C2; CP C3 and CP D

Welds without special requirements for NDT; only visual

inspection is sufficient.

B, C and D Quality level for imperfections acc. EN ISO 5817



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Class of Testing

1.2 Class of Testing (CT)Tests which have to be performed during production


[3]


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Correspondence CP with CT

Correspondence between CP and

inspection classes CT


[3]


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Requirements

2. Requirements

2.1 Quality requirements

With regard to the EN 15085 series of standards, the welding

manufacturer must demonstrate his compliance with the

requirements of EN ISO 3834 (Quality requirements for fusionwelding of metallic materials) to the manufacturer certification body.

EN ISO 3834-2 Comprehensive quality requirements for level CL1

EN ISO 3834-3 Standad q. r. for level CL2 and CL4EN ISO 3834-4 Elementary q. r. for level CL3

No certificate acc. EN 3834 is required!



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Staff requirements

2.2 Staff requirements

2.2.1 Welding coordinators

The welding manufacturer must demonstrate its compliance with

the requirements of section 5.1.2 of EN 15085-2.

EN 15085-2 contains the minimum requirements on the availabilityof welding coordinators (responsible coordinators and depuites).

The independence of the welding coordinators must be clearly

shown in an organisation chart.

The welding manufacturer should have suitably experiencedwelding coordinators with the relevant technical knowledge

according to EN ISO 14731 (welding coordination)



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EN 15085-2

Welding Coordinators

Level AWelding coordinators with comprehensive technical knowledge

1. Personnel with experience of welding supervision for the production of

railway vehicles for at least three years

and proof of comprehensive technical knowledge

2. EWE or IWE

3. EWT or IWT only with comprehensive technical knowledge

Level BWelding coordinators with specific technical knowledge

1. Personnel with experience of welding supervision for railway vehicles for

at least three years and proof of specific technical knowledge

2. EWT or IWT

3. EWS or IWS only with specific technical knowledge



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EN 15085-2

Welding Coordinators

Level CWelding coordinators with basic technical knowledge

1. Personnel with experience of welding supervision for railway vehicles for

at least three years and proof of basic technical knowledge

2. EWS or IWS

3. EWP or IWP

Subcontracted welding coordinatoris possible.

The Guideline of the Railway Vehicles Coordination Committee (KoA)

is limiting the job as welding coordinator in more than 1 or 2 companies .



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Welders and Operators

2.2.2 Welders/welding operators


For each

-welding process acc. ISO 4063-material group acc. ISO/TR 15608

-joint type BW and/or FW

-dimension e.g. t=3-25mm

in the Certificate at least two welders/welding operators with valid

qualification pursuant to the applicable standards

(EN 287-1; EN ISO 9606-2 or EN 1418) must be available.


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Inspection personnel

2.2.3 Inspection personnel

The existence of certified inspection personnel acc. toISO 9712

(VT, PT, MT, UT and RT)

must be demonstrated if inspections in the inspection

classes CT 1 and CT 2 according to EN 15085-3 arerequired.

Subcontracting is possible.

Qualification acc. ISO 9712 for Visual Test in CT 3 and

CT 4 is not necessary.Gesellschaft fr Schweitechnik International mbH - Niederlassung SLV Mnchen 21


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EN 15085

WPS and WPQR

3. Welding procedure specifications (WPS)

WPS in line with EN ISO 15607 (EN ISO 15609ff, EN ISO 14555

stud welding, EN ISO 15620 friction welding) are required for welds

of weld performance classes CP A to CP C3.

4. Welding Procedure test (WPQR)A procedure qualification test with WPQR according to

ISO 15614-1 (steel) or ISO 15614-2 (aluminium) is necessary for

butt weld and fillet weld.

Qualification acc. ISO 15613 (pre-production welding test)

is possible in accordance with KoA-Guideline.



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EN 15085-2

Requirements for the welding manufacturer[3]



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Certification procedure and verification

5. Certification procedure and verification

5.1 Application for certification for welding of

railway vehicles and components according to EN

15085-2

The application for the initial or renewed certification must beaddressed by the welding manufacturer to one of the manufacturer

certification bodies recognized by the national safety authority



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5.2 Audit5.2.1 Site inspection

with welding test to demonstrate practical knowledge of the

welding coordinators

5.2.2 Checking the

- Qualification of welding coordinators

- Qualification of welders

- NDT personnel

- Documentation of the welding planning

- WPS- WPQR

- Compliacse with EN ISO 3834

5.2.3 Interview with welding coordinators



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5.3 Documentation of the results

Audit Report

An official copy of this report is given to the welding manufacturer

and a copy is posting into the Online-Register Railway Vehicles

5.4 Issuance of the certificateUpon a successful audit, the manufacturer certification body issues

the certificate which states that the welding manufacturer is

qualified to perform welding work in line with the requirements of

the standardand the manufacturer certification body posts the certificate in the

Online Register Railway Vehicles

Only certificates posted in this Register are valid.



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5.6 Period of validity of the certificate

The certificate has a maximum validity of 3 years with

annual verifications.



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5.5 Online Register Railway Vehicles -

Online Database EN 15085

(link: www.en15085.net )

The database provides transparency regarding the

validity of certificates as well as technical information

like-Welding process

-Material group

-Dimensions

-Welding coordinators

It is possible for everybody to have a look at all

certificates in the database and also load them down.


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At the moment national certification bodies from

- Germany (GSI mbH / 9 SLVs) and 4 other bodies

- Italy 1 body

- France 1 body- Czech Republic 1 body

- Switzerland 1 body

- Slovakia 1 body

- Sweden 1 body- Austria 2 bodies

are posting certificates in the register.


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Online Register Railway Vehicles (01.10.2012)

2101 companies1. Germany 868

2. China 298

3. Switzerland 115

4. France 99

5. Poland 94

6. Czech Rep. 937. Austria 92

8. Italy 61

9. Turkey 58

10. Hungary 50

11. Slovakia 39

12. Romania 26

and 28 other contries [USA 14]


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Online Register Railway Vehicles (01.10.2012)

2101 Companies

CL1 1415

CL2 364

CL3 34

CL4 288

EN 15085


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ECWRV


5.5.1 ECWRV European Committee for

Welding on Railway Vehicles

Manufacturers, operators, national safety authorities aswell as manufacturer certification bodies from more

than 10 countries are members of the ECWRV.

ECWRV was established in 2010.

In May 2012 the 2nd Internatonal Conference

JOIN TRANS 2012 has take in place at SLV Halle

(Saale) with a meeting of ECWRV.

Next International Conference: 2014 at SLV Halle

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Reference

[1] S. Keitel - European Quality Requirements of EN 15085

Welding in Railway Vehicle Construction

(Congress Okt. 2011 in Antalya, Turkey)

[2] Guideline of the Railway Vehicles Coordination Committee (KoA)

(link: www.en15085.net/docs/KoA Richtlinie

Ausgabe 2011-11 english.pdf)

[3] DIN EN 15085-2 Railway applications Welding of railway vehicles

and components Part 2: Quality requirements and

certification of welding manufacturer (Jan. 2008)


European_Welding_Standards_for_Railroad_Georg_Wackerbauer.pdf

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