15085 requirments

8/10/2019 15085 Requirments

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ECE Global

Your Global Partner in Engineering, Quality and Safety Compliance

DesignFabricationInspectionCertification

Business in Europe

-EN 15085-

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Thomas Schmidt

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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)

[email protected]

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?
mailto:[email protected]:[email protected]


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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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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

ECE Gl b l Slid f 4523


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EN 15085-3: Design Requirements

Imperfections

according to

Weld performance classes

EN ISO 5817 (Steel)

EN 15085-3 (Table 5)


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.

ECE Gl b l Slid f 4524


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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)


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!

ECE Global B i i E Slide: of 4526


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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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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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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!

ECE Global Business in Europe Slide: of 45


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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.

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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

ECE Global Business in Europe Slide:20 2 di i

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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

ECE Global

Gl b l Q l d S f C lBusiness in Europe Slide:

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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

ECE Global

Y Gl b l P i E i i Q li d S f C liBusiness in Europe Slide:

D t 2012 Editi

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Thomas Schmidt

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?

ECE Global

Y Gl b l P t i E i i Q lit d S f t C liBusiness in Europe Slide:

Date 2012 Edition

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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?

ECE Global

Your Global Partner in Engineering Quality and Safety ComplianceBusiness in Europe Slide:

Date: 2012 Edition

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Thomas Schmidt

Please stay on track!

Thank you for you attention!

ECE Global


Date: 2012 Edition

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Thomas Schmidt

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)

[email protected]

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

ECE Global


Date: 2012 Edition

of 4547
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DesignFabricationInspectionCertification -EN 15085-Date: 2012 Edition

Thomas Schmidt