What is a code:

  A systematic collection of regulations and rules of procedure

IPC – Indian Penal Code - It is a comprehensive code,

intended to cover all substantive aspects of  criminal law.

IBR – Indian Boiler regulation - Regulations in respect of

materials, design and construction, inspection and testing of

boilers and boiler components for compliance by the

manufacturer's and users of boilers in the country.

ASME BPVC Section IX - Welding and Brazing Qualifications

What is a standard:  A Standard can be defined as a set of technical definitions and guidelines

that  function as instructions for designers, manufacturers, operators, or

users of  equipment. 

Different standards adopted :

• American Welding Society Standards (AWS)

• American petroleum institute standards (API)

• Australian / New zealand standards (AS/NZS)

• British Standards (BS)

• International Organisation for standardisation (ISO)

• European Union Standards (EN)

• German Standards (DIN)

• Bureau of Indian Standards (BIS)

Difference between a code and a standard

• A code is a model, a set of rules that knowledgeable people

recommend for others to follow. It is not a law, but can be

adopted into law.

• A standard tends be a more detailed elaboration, the nuts

and bolts of meeting a code.

• A standard becomes a Code when it has been adopted by

one or more  governmental bodies and is enforceable by law,

or when it has been incorporated  into a business contract.

Current Scenario

No code or standard is available / followed for welding of

railway vehicles and components.

EN 15085: 2007 (part 1 – 5) Railway applications – Welding of Railway vehicles and

components

EN 15085: 2007 consists of

Part 1 – General

Part 2 – Quality Requirements and

certification of welding manufacturer

Part 3 – Design requirements

Part 4 – Production Requirements

Part 5 – Inspection, testing and

documentation.

Railway Applications - Welding of Railway vehicles and components – part 1 -General EN 15085 -1 : 20071. Scope

Provides general recommendations

Definitions for welding railway vehicles and associated components

Applies to all assemblies, sub-assemblies or parts welded by any welding processes, (manual / partly mechanised / fully mechanised /automatic ) as per EN ISO 4063 except for specific contractual provisions.

Does not deal with product qualification

2Normative reference

EN 45020:06 – Standardization & related activities – general vocabulary

CEN/TR 14599:05 – Terms & definitions for welding purposes in relation with EN 1792

EN ISO 17659:04 – Welding – Multilingual terms for welded joints with illustrations

3. Terms & Definitions

3.1 Manufacturer certification body - a competent body that certifies the manufacturer according to EN 15082-2

3.2 Certification level (CL)- Level to classify the welded railway vehicle or the welded component depending on the weld performance class (CP)

x - Certified Certification Level√ - Included certification level A CL 1 certificate also permits design or purchase & resale or purchase & assembly for all certification levels if so indicated in the certificate A CL 2 certificates also permits design or purchase & resale or purchase & assembly for the certification levels CL 2 and CL 3 if so indicated in the certificate A CL 4 certificate permits design or purchase & resale or purchase & assembly for the certification level specified in the field of application of the certificate Note: If CL 4 for design is not included, this must be indicated in the certificate

Certified certification level Included certification level

CL 1 CL 2 CL 3 CL 4

CL 1 x √ √ √

CL 2 x √ √

CL 3 x

CL 4 x

3.3 Weld performance class - Performance requirements of the welded joint as defined by the stress category and the safety category of welded joint

3.4 Weld inspection class – defines the inspections to be carried out for a given weld with respect to weld performance class

3.5 Customer – Organisation responsible for defining the technical, quality requirement and the acceptance procedures for welded product.

3.6 Manufacturer – organisation that uses a welding facility to manufacture or maintain railway vehicle or parts of vehicle – certification level CL 1, CL 2, CL 3 ( or )

Designs welded rail vehicles or parts of vehicle/buys welded parts for assembly into railway vehicles or sells them for assembly into railway vehicles – certification level CL 4

3.7 National safety authority - National government body

responsible to set up the safety requirements

3.8 Qualification - Evidence of training, professional

knowledge, skill and experience to enable the personnal to

perform the task

3.9 Qualified – Person with evidence of training,

professional knowledge, skill and experience, proven

by an internal test.

3.10 Subcontracted welding coordinator – Welding

coordinator not employed by the welding manufacturer

3.11 Joint static dimensioning - defines the

dimensions of the weld joint to achieve the required

mechanical characteristics.

3.9 Qualified – Person with evidence of training,

professional knowledge, skill and experience, proven by an

internal test.

3.10 Subcontracted welding coordinator – Welding

coordinator not employed by the welding manufacturer

3.11 Joint static dimensioning - defines the dimensions

of the weld joint to achieve the required mechanical

characteristics.

3.12 Acceptance authority - organisation responsible for

acceptance of the product.

3.13 Effect cross section – cross section of a welded joint

considered for dimensional calculations.

3.14 Joint fatigue dimensioning - the dimension of a weld to

achieve the required fatigue characteristics.

3.15 Stress category –

calculated fatigue stress / admissible fatigue stress

3.19 Production weld test -

Mock up sample welded joint to prove the skill of

operator or to demonstrate acceptable production of

welded joint

3.16 Stress factor - calculated fatigue stress / admissible fatigue stress

3.17 Admissible fatigue stress maximum stress applicable to materials to which a specific coefficient to the assembly to be welded is applied

3.18 Safety category consequences of failure of the welded joint with respect to persons, facilities and environment

EN 15085 – 2 Quality requirements and certification of welding manufacturer

Scope: Defines the certification levels as well as the requirements for welding manufacturers and describes the procedure for the recognition of welding manufacturers.

•Four certification levels (CL) are laid down for the certification of welding manufacturers (Level 1 to level 4)

•Level 1 to Level 3 depends on the weld performance classes CP A to CP D of the welded joints specified in EN 15085-3:2007, Table 2

Certification Level Description Certification Level

(CL)

Applies to manufacturer of welded railway vehicles/parts with welded joints classified in weld performance classes CP A to CL 4 is included

CL 1

Manufacturers of welded parts of railway vehicles with welded joints classified in weld performance classes CP C2 to CP D.

Welded joints classified in weld performance class CP C1 are included if these welds are checked according to weld inspection class CT 1 according to EN 15085-5:2007, table 1. Certification level CL 4 is only included according to welded joints of certification level CL 2 to CL 3

CL 2

Description Certification level

For manufacturers of welded parts of railway vehicles with welded joints classified in weld performance class CP D

CL 3

For manufacturers who do not weld but design railway vehicles and parts of rail vehicles or buy and assemble or sell them. Certification not required for welding works of certification level CL 3

CL 4

Items to be welded by welding manufacturers with a certification level CL 1

Bogie frames and bolstersBody shell components (e.g., under frames, structures)Buffers and draw gearWheel set components ( wheel set mountings, axle boxes, spring supports)Brake equipment (e.g., magnetic track brake, brake rods, brake triangles, brake cylinders, brake cross beams)Supporting frames for heavy components (e.g., traction units, pantographs)

welded components for drag transmission from bogie to vehicle

Vibration dampers and their link between bogie and vehicle or

between vehicles

Finishing welding of castings within components indicated above

External fuel tanks.

As per EN 15085-3:2007, certification level CL1 to CL3 shall be

clearly indicated in the drawings.

5 Quality requirements for the welding manufacturer

5.1 Staff requirements

5.1.1. Welders and welding operators

o Welders with qualification in accordance with EN 287-1 / EN ISO

9606-2 or EN 1418

o Such qualification shall be carried out by either

-- accredited examining body

-- responsible welding co ordinator of the manufacturer,

recognised by the manufacturer certification body

-- if fillet welds are done, then a fillet weld test piece is

necessary

5.1.2 Welding coordination -- The manufacturer shall have suitable experienced welding

coordinators with relevant technical knowledge according to EN

ISO 14731

-- The manufacturer shall clearly prove to the manufacturer

certification that the technical knowledge of the welding

coordinator is at the required level.

• Welding coordinators with comprehensive technical knowledge (level A)

-- Personnel with qualification according to Doc. IAB-002-2000/EWF-

409 – International Welding Engineer (IWE) or European Welding

Engineer (EWE)

-- Personnel with qualification according to Doc IAB-003-2000 /EWF –

410 – International Welding Technologist (IWT) or European Welding

Technologist (EWT) with suitable experience in welding supervision

. Welding coordinators with specific technical

knowledge (Level B)

Personnel with atleast three years and proof of specific technical

knowledge with

-- Personnel with qualification according to Doc. IAB-003-2000/EWF-

410 – International Welding Technologist (IWT) or European

Welding Technologist (EWT)

-- Personnel with qualification according too Doc. IAB-004-

2000/EWF-411 – International Welding Specialist (IWS) or

European Welding Specialist (EWS) with suitable experience and

proof of technical knowledge

Welding coordinators with basic technical

knowledge (Level C)

Personnel with atleast three years of experience and proof of basic

technical knowledge.

--- Personnel with qualification according to Doc. IAB-004-

2000/EWF-411 – International Welding Specialist (IWS) or

European Welding Specialist (EWS)

--- Personnel with qualification according too Doc. IAB-005-

2001-451 – International Welding Practitioner (IWP) or European

Welding Practitioner (EWP) with suitable experience in welding

supervision and proof specific technical knowledge.

5.1.3 Subcontracted welding coordinator

1. Only one welding coordinator per location site shall be subcontracted.

2. At least one deputy who is employed by the manufacturer is available

in the location site and recognized.

3. The welding coordinator shall be contractually tied to the welding

manufacturer.

4. The minimal hours of work depends on the extent of the welding

production and shall contractually be regulated & shall be recorded

in a production log.

5. The sub contracted welding coordinator may work for more than one

manufacturer. If he works for more than two welding manufacturers,

agreement with all customers is required. Further subcontracted

welding coordination shall be accepted by the customer.

5.1.4 Inspection personnel

The welding manufacturer shall have sufficient qualified inspection

personnel for

-- quality testing within the welding production facility.

-- Inspection required either by design or by the performance

class of the weld.

--This inspection shall be carried out as per EN 473. The

inspection personnel for PT, MT, ET, UT, RT shall have a

procedure based qualification of at least level 1.

The testing evaluator shall be certified atleast to level 2 of EN

473. Non destructive tests may be done by external inspection

personnel certified according to EN 473.

5.2 Technical requirements

The technical requirements shall be as per EN ISO 3834 and

roofed, dry, ventilated and sufficiently lit workshops and working places.

Dry store rooms for welding fillers and ancillary supplies

If different materials are welded, separate tools, machines and

equipments shall be used for each materials, and cleaned before use.

Suitable power supply

If no suitable testing equipment is available, an external inspection body

can be contracted.

Lifting gear for transporting and turning parts

Work platforms

Turning devices or manipulators to facilitate welding in the flat position.

Clamping devices for welding assemblies

Devices for straightening

Protection when working with aluminium or stainless steel to keep away

dust, spatter, gases and fumes which might reduce the corrosion

resistance of the parent metal or the quality of weld.

5.3 Welding coordination organisation

a welding coordinator can be recognised only if he is involved in the

welding manufacturer organisation in such a way that they can accept

their tasks and responsibility without rreservation as per EN ISO 14731

and according welding coordination (5.1.2 of EN 15085-2)

The responsibilities , competencies and should be documented. The

following items, in particular should be specified and described.

-- tasks of the welding coordinators

-- rules for who deputises for the welding coordinator

-- activities which require the attendance of the responsible welding

coordinators

-- measures which are required if the welding coordinator is absent

-- involvement of the responsible welding coordinator in the internal

process.

5.4 Welding procedure specification

For welds which are classified in the weld performance

classes CP A to CP C3, a welding procedure specification is

necessary according to EN ISO 15607 and depending on the

welding process, according to series of standards EN ISO 15609,

EN ISO 14555 or EN 15620.

For welds which are classified in the weld performance class

CP D, a welding procedure specification is necessary only if it is

demanded by the customer.

6 Certification procedure

6.1 Audit for certification the manufacturer certification body undertakes verification of

compliance with the requirements of this standard, particularly -- welding personnel (welding coordinators, welders, welding operators ) requirements -- welding coordinators shall be interviews to demonstrate that they have the necessary knowledge on welding as per EN ISO 14731 and this series of standards -- welding procedure specifications based on WPQR -- Qualification test of welders according to EN 287-1 or EN ISO 9606-2 -- Qualification test for operators according to EN 1418 -- Additional test specimens (mock-up) -- technical requirements and welding production -- welding quality requirements according to the relevant parts of EN ISO 3834

6.2 Certificate

The certificate shall indicate

-- name and address of certified welding manufacturer

-- certification level at which welding manufacturer is entitled

to weld

-- field of application

-- range of certification(welding procedures, materials, sheet

thickness, remarks)

-- welding coordinators (first name, name, date of birth &

qualification)

-- remarks and extension of application

-- validity

-- date of issue

7 Validity

The validity is limited to a maximum of 3 years