simple unfired pressure vessels designed to contain air...

CEN ENx28b-4 -94 ÏË 3404.589 0086835 394

BRITISH STANDARD

Simple unfired pressure vessels designed to contain air or nitrogen Part 4. Aluminium alloy pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock

The European Standard EN 286-4 : 1995 has the status of a British Standard

UDC 621 642.02-98-034 715 629.4-5yZ 620 1 62-777

BS EN 286-4: 1995

Copyright European Committee for Standardization Provided by IHS under license with CEN

Not for ResaleNo reproduction or networking permitted without license from IHS

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BS EN 2864 : 1995

Standards Board and comes into Amd. NO. Date effect on 15 February 1995

0 BSI 1995

Cooperating organizations

R x t affected

The European Committee for Standardization, under whose supervision this European Standard was prepared, comprises the national standards organizations of the following Western European countries:

Austria Belgium Denmark Finland France Germany Greece Iceland Ireland Italy Luxembourg Netherlands Norway Portugal Spain Sweden Switzerland United Kingdom

Oesterreichisches Normungsinstitut Institut belge de normalisation Dansk Standard Suomen Standardisoimisliito, r.y. Association française de normalisation Deutsches Institut für Normung e.V. Hellenic Organization for Standardization Technological Institute of Iceland National Standards Authority of Ireland Ente Nazionale Italiano di Unificazione Inspection du Travail et des Mines Nederlands Nonnalisatie-instituut Norges Standardiseringsforbund Instituto Portuguès da Qualidade Asociación Española de Normalización y Certificación Standardiseringskommissionen i Sverige Association suisse de normalisation British Standards Institution

The following BSI references relate to the work on this standard: Committee reference PVEí17 Draft for comment 90í81699 DC

ISBN O 580 2186û 3



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C E N EN*28b-4 94 W 3404589 O086837 L b 7 m BS EN 286-4 : 1995

Contents

Page Cooperating organizations Inside front cover National foreword i Foreword 2 Text of EN 286-4 3 National annex NA (informative) Committees responsible National annex NB (informative) Cross-references

Inside back cover Inside back cover

National foreword

This British Standard has been prepared under the direction of the Pressure Vessel Standards Policy Committee and is the English language version of EN 286-4 : 1994 Simple unfired pressure vessels designed to contain air or nitrogen - Part 4: Aluminium alloy pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock, published by the European Committee for Standardization (CEN). EN 286-4 was produced as a result of international discussions in which the UK took an active part. Compliance with a British Standard does not of itself confer immunity from legal obligations.

i Copyright European Committee for Standardization Provided by IHS under license with CEN


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EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM

EN 286-4

September 1994

UDC 621.642.02-98-034.715 : 629.4-592 620.1 : 62-777

Descriptors: Railway rolling stock, brakes, pneumatic equipment, pressure vessels, tanks containers, aluminium alloys, design, computation, production control, weld defects, acceptability, assembling, certification, marking

English version

Simple unfired pressure vessels designed to contain air or nitrogen - Part 4: Aluminium alloy pressure vessels

designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock

Récipients á pression simples, non soumis à la flamme, destinés à contenir de l’air ou de l’azote - Partie 4: Récipients à pression en alliages d’aluminium destinés aux équipements pneumatiques de freinage et aux équipements pneumatiques auxiliaires du matériel roulant ferroviaire

Einfache unbefeuerte Druckbehälter für Luft oder Stickstoff - Teil 4: Druckbehälter aus Aluminiumlegierungen für Druckluftbremsanlagen und pneumatische Hilfseinrichtungen in Schienenfahrzeugen

This European Standard was approved by CEN on 1994-09-09. CEN members are bound to comply with the CENKENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any GEN member. The European Standards exist in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a GEN member into its own language and notified to the Central Secretariat has the same status as the official versions. CEN members are the national standards bodies ofAustria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

CEN European Committee for Standardization

Comité Européen de Normalisation Europäisches Komitee für Normung

Central Secretariat: rue de Stassart 36, B-1050 Brussels

@ 1994 Copyright reserved to CEN members Ref. No. EN 286-4 : 1994 E

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CEN EN*E'Bb-4 9 4 3404589 0 0 8 6 8 3 9 T 3 T = Page 2 EN 286-4 : 1994

Foreword This European Standard was prepared by CEN/TC 54, Unfired pressure vessels, of which the secretariat is held by BSI. This European Standard has been prepared under a Mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of the EC Directive(s). CEN/TC 54 decided to submit the final draft for formal vote by its resolution. The result was positive. This part is one of a series of four. The other Parts are :

Part 1: Design, manufacture and testing Part 2 : Pressure vessels for.air braking and auxiliary systems for motor vehicles and their trailers Part 3 : Steel pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock

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 March 1995, and conflicting national standards shall be withdrawn at the latest by March 1995. According to the CENKENELEC Internal Regulations, the following countries are bound to implement this European Standard: Austria, Belgium, Denmark, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain and United Kingdom

Contents

Foreword 1 Scope 2 Normative references 3 Symbols 4 Materials 5 Design

Page 2 3 3 4 4 5

6 Inspection and drainage bosses 13 7 Marking 13 8 Corrosion protection 13 9 Qualification of welding procedures 14

10 Qualification of welders and welding operators 14

11 Testing of the vessels 17 12 Certification procedures 24 13 Information to be supplied at the time of

invitation to tender and time of order 24 14 Delivery 24 15 Documentation to accompany the vessel 24 Annex A (normative) Verification 25 Annex B (normative) Declaration of conformity - Surveillance 25 Annex C (normative) Design and manufacturing schedules 27 Annex D (normative) Type examination 27 Annex E (normative) Content of the manufactured record 28 Annex F (informative) Assembly of the vehicles 28 Annex G (informative) Service surveillance of vessels 31



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CEN EN*Z86-4 74 W 3404589 0086840 7 5 1 W

1 Scope 1.1 This Part of this European Standard is applicable to simple unfired aluminium alloy pressure vessels, referred to as 'vessel' in this standard, designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock (see 1.6). 1.2 The vessels to this standard are:

a) made from a single shell; b) made from aluminium alloy; c) fabricated by welding; d) used at a maximum working pressure of 10 bar; e) the product of the maximum working pressure (in bar) and the volume (in litre):

500 bar litres < PV < 10 O00 bar litres ; f) made of a cylindrical part of circular cross- section called the shell with two outwardly dished torispherical ends, that is two dished ends with the same axis of rotation. This standard therefore does not apply to vessels with one or two flat ends or those made up of several compartments; g) calculated with a design pressure P (see 5.1.4.2) ; h) designed for a working temperature of between - 50 "C and + 100 'C [ + 65 'C for certain grades of aluminium alloy (see 4.1.111; j ) fastened to the vehicles by straps;

1.3 In normal service, a momentary overpressure of 1 bar of the maximum working pressure is permitted (10 % of E',). 1.4 This Part of this European Standard applies to the vessel proper, from the inlet connection to the outlet connection and to all other connections and fittings belonging to the vessel. 1.5 This Part of this European Standard gives the requirements to be met for the calculation, design, fabrication, inspection during fabrication and certification of the vessel, and fittings for assembly to the vehicle. These requirements cannot be written in sufficient detail to ensure good workmanship or proper construction. Each manufacturer is therefore responsible for taking every necessary step to make sure that the quality of workmanship and construction is such as to ensure compliance with good engineering practice. This Part of this standard gives:

a) in annex F, recommendations for assembly to the vehicles; b) in annex G, recommendations for the service surveillance of vessels.

Page 3 EN 286-4 : 1994

1.6 The requirements of this Part of this European Standard apply to vessels designed to be fitted to rail vehicles used on the main national networks, urban networks, underground railways, trams, private networks (regional railways, company railways, . . . 1.

2 Normative references This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references the latest edition of the publication referred to applies. EN 287-2

EN 288-1

EN 288-2

EN 288-4

EN 10025

EN 26520

Is0 209-1

Lso 209-2

EO 2281

IS0 261

IS0 1101

Approval testing of welders - fusion welding - Part 2: Aluminium and aluminium alloys Specifications and approval of welding procedures for metallic materials - Part 1: General rules for fusion welding Specification and approval of welding procedures for metallic materials - Part 2: Welding procedure specification for arc welding Specification and approval of welding procedures for metallic materials - Part 4: Welding procedure tests for the arc welding of aluminium and its alloy Hot rolled products of non-alloy structural steels - Technical delivery conditions Classification of imperfections in metallic fusion welds, with explanations Wmughi aluminium and aluminium alloys - Chemical composition and forms of product - Part 1 Chemical composition Wmughi aluminium and aluminium &s - Chemical composition and forms of product - Part 2 : Forms of products pipe threads where pressure-tight joints are not made on the threads - Part 1 : Designation, dimensions and tolerances IS0 general purpose metric screw threads - General plan Technical drawings - Geometrical tolerancing - Tolerancing of form, orientation, location and run-out - Generalities, definitions, symbols, indications on drawings



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CEN E N x 2 8 b - 4 94 W 3404.589 OD8b84L 698 W

Page 4 EN 286-4 : 1994

IS0 2081

Is0 2107

IS0 2437

IS0 4520

Is0 6361-2

IS0 6362-2

Metallic coatings -Electroplated coating of zinc on iron or steel Aluminium, magmsium and their alloys - Temper designations Recommendation practice for the X-ray inspection of fusion welded butt joints for aluminium and its alloys and magnesium and its alloys 5 to 50 mm thick Chromate conversion coatings on electroplated zinc and cadmium coatings Wrought aluminium and aluminium alloy sheet, strip and plate. Part 2: Mechanical properties Wrought aluminium and alloy extruded rods I bars, tubes and profiles Part 2: Mechanical properties

3 Symbols For the purpose of this standard, the following symbols apply: A Afb

AfP

Afs

A, C

DO

dib

e e, ech ecs eh erb

erp

ers

f

f b

g

Elongation at rupture Cross sectional area effective as compensation, of the boss Cross sectional area effective as compensation, of the reinforcing plate Cross sectional area effective as compensation, of the shell Area of the pressurized zone Absolute value of the minus rolling tolerance for sheets as quoted in the standard Outside diameter of the shell of the vessel Internal diameter of the boss Outside diameter of the boss Nominal wall thickness Calculated thickness Calculatd thickness of the end Calculated thickness of the shell Nominal thickness of the end Wall thickness of the boss contributing to reinforcement Wall thickness of the reinforcing plate contributing to reinforcement Wall thickness of the shell contributing to reinforcement Nominal design stress at the design temperature Permitted stress of the boss Throat thickness of a weld

"All pressures are gauge pressures.

%

mm2

mm2

mm2 mm2

mm

mm mm mm mm mm mm mm mm

mm

mm

mm

N/mm2 N/mm2 mm

External height of the dished part of an end mm (see figure 3) External height of the cylindrical part of the end mm (see figure 3) Internal height of a dished part of the end (see figure 3) Design coefficient which is a function of the welding process Total length of the vessel Distance between the axis of a drainage opening and the end of the vessel Length of the boss contributing to reinforcement Length of inward projecting boss contributing to reinforcement Length of the reinforcing plate contributing to reinforcement, measured along the mid surface Length of the shell contributing to reinforcement, measured along the mid surface Design pressure'' which is a function of the maximum working pressure, the welding process and inspection used Maximum working pressure1) Internal radius of the spherical part of the end Local internal radius at the location of the opening in question Minimum tensile strength specified by the manufacturer or by the standard defining the material Minimum proof stress Internal radius of the torispherical part of the end Minimum working temperature Maximum working temperature Volume of the vessel

mm

- mm

mm

mm

mm

mm

mm

bar bar

mm

mm

N/mm2 Nímm'

mm "C "C 1

4 Materials 4.1 Pressurized parts The aluminium alloys used in the fabrication of the pressurized parts of the vessels shall hlfil the following conditions:

a) R, I 350 N/mm2 b) elongation after rupture A shall be:

-if the test piece is taken parallel to the direction of rolling 2 16%; -if the test piece is taken perpendicular to the direction of rolling 2 14%.



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CEN EN*Z&b-4 94 W 3404589 O086842 524

AlMg2Mn0,8 AlMg3 AlMg3Mn

AlMg4,5Mn0,7 1 AlMg4

4.1.1 Shell and ends The shell and ends shall be made of aluminium alloy sheet or strip of one of the grades given in table 1. 4.1.2 Inspection bosses, pipes connection branches and drainage bosses The bosses shall be made of 5083, 5086, 5454 or 5754 aluminium alloy bars or tubes in condition M in accordance with IS0 6362 : Part 2. 4.2 Non-pressurized parts The accessories to be welded t o the vessel, but which do not contribute to its strength, shall be made of aluminium alloy compatible with the aluminium alloy from which the pressurized parts of the vessel are made. The product analysis of the aluminium alloy shall meet the following requirements: - R, I 350 N/mm2; - Cu s 0,5 % and Zn I 0,25 %.

4.3 Welding materials The filler material and gas fluxes shall be suitable for the parent metals. The recommended grades of filler material to be used are 5183 and 5356. These grades are suitable for welding the grades listed in 4.1 and 4.2. Aluminium-silicon grades shall not be used. The suitability of the welding products used is verified during the qualification of the procedures described in clause 9.

5049 O 100 80 80 70 48 48 G5’ 42 5754 O 100 80 80 70 48 48 G5’ 42 5454 O 100 90 90 90 54 54 a5’54 5086 O 65 100 loo W’ 60 60 S5’ 54‘ 5083 O 65 125 1s 1204) 75 75 745) 72‘

International registration record’)

Temper designation*’

Page 5 EN 286-4 : 1994

5 Design 5.1 Shell and ends 5.1.1 General The vessels are of simple geometrical form, composed of a cylindrical body of circular cross- section and two outwardly dished torispherical ends. The design of the vessels shall take into account the installation and maintenance conditions. The installation and maintenance conditions shall be given by the manufacturer or the user (see clause 13)

NOTE. Examples of installation and maintenance requirements are given in informative annexes F and G.

5.1.2 Design of the shell Shells are generally made from a single sheet. If the shell is made of several welded parts, the number of circular welds shall be kept to a minimum. Longitudinal weld seams of parts of the shell shall : - not be located on the lower part of the vessel

defined by an angle of 30” on either side of the vertical axis (see figure 1);

- be sufficiently far apart such as to form an angle greater than 40” (see example in figure 2).

All welds, even of a temporary nature, located outside the designed seams are prohibited.

Table 1. Aluminium alloy materials IS0 designation’’ Maximum

temperature ‘C

Design temperaturea’

Temperature

Minimum proof Minimum design stress stress 1 N / m * I N/-*



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CEN EN*28b-4 74 =

eh 1 3 1 4 1 5 1 6 1 8 himin I 12 I 16 I 20 I 24 I 32

3404587 008b843 4b0

10 40

Page 6 EN 286-4 : 1994

Drainage opening

Figure 1. Position of longitudinal welds on the bottom of the shell

Drainage point or reference mark on the Lower par t

Figure 2. Position of longitudinal welds on the shell

5.1.3 Design of the ends 5.1.3.1 Shape and dimensions of the ends The torispherical ends shall be made from a single sheet.

Dishing and flanging shall be carried out by a mechanical forming procedure, for example by pressing or spinning. Hand forming is not permitted.

The torispherical end shall meet the requirements of figure 3 and table 2.

Table 2. Height of the cylindrical portion of ends

Dimensions in millimetres

I himax I 25 I 40 I 50 1 5.1.3.2 Heat treatment after forming The parameters of the heat treatment to which ends are subjected after forming cannot be

specified in this standard as they vary according to the following criteria: - the grade of aluminium alloy; - the type of oven (other than direct radiation,

- the forming process (hot or cold drawing). The heat treatment shall not affect the values of R,o,z and R, used in calculating the thickness. In addition, after heat treatment the material shall satisfy the following conditions:

convection, etc.) ;

- tensile strength R, I 350 N/mm2; - elongation after rupture A 2 16 %.

The suitability of the heat treatment parameters shall be checked by the approved inspection body when the manufacturing record is submitted for the certification procedure (see clause 12). 5.1.4 Calculation of shell and end thicknesses 5.1.4.1 General The nominal thickness e of the shells and ends shall be such that:

The value of e, shall in no case be less than 3 mm. The manufacturer shall apply a correction to allow for thinning resulting from the manufacturing process.

5.1.4.2 Calculation of the shell thickness ecs

e > e , + c

ecs = ~ K, 20f + P

The minimum design stress shall be taken from table 1.

NOTE. It has been established from the standards quoted in this part that 0,3Rm is always greater than 0,6R,,,,.

The values of P and K, to be taken into account are :

a) case no. 1: P 2 1,15P8 and K, = 1 for automatic welding and when tests are carried out in acordance with 11.1.2.1; b) case no. 2: P 2 1,3Ps and K, = 1 for automatic welding and when tests are carried out in accordance with 11.1.2.2; c) case no. 3: P 2 1,25Ps and K, = 1,15 for welding using a non-automatic process and when tests are carried out according to 11.1.1.

5.1.4.3 Calculation of the thickness of the ends ech The end thickness shall be calculated in the following manner:

a) Select the values off from table 1, and with P = P,, calculate Pllof.



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CEN ENx28b-4 94 W 3404589 0086844 3T7

Page 7 EN 286-4 : 1994

R (nominal) = 0, 0,10, < r (nominal) < 0,150,

Figure 3. Torispherical end

b) Calculate hJD, with he the smaller of the three values:

2

where :

ech = ecs ; h = eh + hz

= e h + D o - (Do - r)' - (D,/2 - e h - r)' (take eh = ecs + (3).

NOTE. 0,3 is the minus rolling tolerance for the sheet.

c) Determine ech/D0 from figure 4. d) Multiply the value found by Do to obtain the thickness ech. e) Verify the calculation with this value in place of that of ecs.

Example of calculation of thickness eeh of an end of aluminium alloy 5083 in accordance with IS0 6361-2 for a vessel of diameter Do = 400 mm and a maximum service temperature of 65 OC.

P = 1,15P, = 1,15 x 10 = 11,5 bar (case no. 1 in 5.1.4.2) for'the shell P = P, = 10 bar for the ends K, = 1 R = D o = 400 mm r = O,lDo = 40 mm T,,, = 65 "C f = 74 N/mm' from table 1

Therefore P/(lOf) = 10/(10 x 74) = 0,0135

Calculate he/D,, with he = smallest of 3 values:

a) h = eh + Do - ,+/(Do - rI2 - (D,/2 - eh - r)' = (3,38) + 400 -

J(400 - 40)' - [400/2 - 3,38 - 4012 = 79,24

= 99,23 0; b, 4íR + ech) C) 2' ech) = 92,82 when ech is taken as

equal to ecs = ~ Kc 20f + P

= 3,08 thus e h = 3,08 + 0,3 = 3,38 giving he = 79,24 and he/D, = 0,198

From figure 4: ech/Do = 0,0101 ech = 0,0101 x 400 = 4,04.

The verification of the calculation with ech = 4,04 in place of ecs = 3,08 gives:

ech = 4.

5.1.5 Weldedjoints of shells and ends

5.1.5.1 Longitudinal welds The welds shall be full penetration butt welds. Backing strips, even of a temporary nature, are not permitted.



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EN 286-4 : 1994

echlDo

1

2

0.0140" 9

8

7

6

I

4

3

ii 0,150

0,001 -

I I

0,250 0,300 0,350 0,400

e 1%

0,001

- 1 I

2 3 4 5 6 7 8 9 I O,Oì35 1 0,Ol

Figure 4. Theoretical curves for dished ends

P / ( l O f ) 3

5.1.5.2 Circular welds The shell/end joints permitted are those shown in figures 5 to 8. The welds in figures 5 to 7 Shall be of the full penetration type of the shell/end wall; and for figure 8 full penetration of the shell wall. For welding of sheets of different nominal thicknesses (shell/end weld), there shall be

alignment either of the neutral axes (figure 5) or of the walls of the internal face or external face, the Connecting Slope not exceeding 25 % (14") (see figures

misalignment of the neutral axes is greater than 1 mm, levelling shall be carried out as shown in figures 7a and 7b.

and 7, and the misaliWment Of the axes not exceeding mm- If the



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CEN E N * Z B b - 4 94 W 3404589 0086846 L7T W

Figure 5. Butt weld with centre lines aligned

11 25% rnax(t~ol- ,

Figure 6. Butt weld with centre lines offset

Figure 7a

yb 25% max [ 1 4 O )

Figure 7. Butt welds with centre lines offsel and connecting slope

Figure 8. Weld of the shell ring to end with necked edge

Page 9 EN 286-4 : 1994

5.2 Openings

5.2.1 General Inspection bosses, pipe connection branches and drainage bosses are cylindrical parts comprising an internal pipe thread complying with IS0 228-1 or an IS0 metric thread in accordance with IS0 261. The permitted shapes and welding are defined in 5.2.4.1 and 5.4.2.2. The minimum number, dimensions and location on the vessel are defined in clause 6. The wall thickness of bosses shall not be less than 2 times the thickness of the sheet to which they are welded. 5.2.2 Holes for bosses Where the diameter of the hole in the wall is greater than 75 mm, a reinforcement calculation is necessary in accordance with the method described in 5.2.3. Where holes require reinforcement, the distance that they are to be apart is defined in 5.2.3.1. The maximum distance between the centre of the dished end and the outer edge of any holes shall not be greater than 0,40, (see figure 9). Holes in shells and ends should be located as far as possible from welded seams and shall in no case cross any welded seam. The distance between any two welds measured from the extremity of the edge preparation shall not be less than 4 times the nominal thickness of the shell or end, with a minimum of 25 mm (see figures 10a and lob).

Figure 9. Position of a hole in an end



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CEN ENr28b-4 9 4 = 3404589 0086847 006 Page 10 EN 286-4 : 1994

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Ge min I

Figure 10a

be min

Figure 10. Distance between two welds measured from the end of the edge preparation

5.2.3 Calculation of the opening reinforcement 5.2.3.1 General The calculation method described in 5.2.3.2 and 5.2.3.3 is applicable to shells and dished ends in which circular holes are made in compliance with the following conditions and hypotheses. Reinforcing plates, where used, shall be made from the same material as that of the vessel to which they are welded. The distance between openings, measured from the outer face of the reinforcing plates or openings shall not be less than 2 x I,, where two openings require reinforcement, or I,, where only one of the two openings requires reinforcement.

1,s = J G G a G (1) where :

a) Ri = D,/2 - e,, for shells; b) Ri = R for ends.

Reinforcement of the openings is obtained by the use of:

a> recess welded bosses (see figures l l a and 1 lb); b) welded reinforcing plates and recess welded bosses (see figure l lc ) .

Adequate reinforcement shall be provided in all planes passing through the axis of the opening. 5.2.3.2 Reinforcement of opening Only bosses of the ‘full penetration’ type as shown in figures l l a and l l b may be used.

/ A P I I

Figure l la. Reinforcement of cylindrical shell with boss

A f b + I

I 1

Figure l lb . Reinforcement of spherical shell with boss

Figure l lc . Reinforcement of spherical shell by reinforcing plate and boss

Figure 11. Reinforcement of opening



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The length of the boss reinforcement, used in equation (3) for determining Ab shall not be greater than I,, [see equation (211:

The value of erb used for determining Aa in equation (3) shall not be more than twice ers. The following condition shall also be complied with:

contributing to the

Irh 5 ITS (2)

(3)

5.2.3.3 Reinforcement by reinforcing plate and boss One of the following two conditions shall be complied with: - the permissible stress f b is less than stress f :

Pl10 (A, + 0,5(Afs +Ab + 0,7Af,)] _< f ( & + 0,7Afp) + fh&,

- the permissible stress fb is greater than stress f :

A, & (Af, + Am + 0,7Afp where :

a) the areas A,, Ab, Af, and Af, are determined as shown in figures l l a , l l b and l l c ; b) the maximum height of the boss used in the calculation is:

to be

Irh = 0,8v?(doh - erb)e,h c) the maximum height of the part of the boss (&.hi) inside the vessel, to be used in the calculation is :

d) the dimensions of the reinforcing plate to be used in the calculation are:

hi = 0,5Irb

erp I ers and I,, 5 I,, 5.2.4 Welding of bosses 5.2.4.1 Inspection openings and pipe connection branches Welds can be either full penetration welds (see figures 12 and 13) or partial penetration welds (see figure 14). 5.2.4.2 Drainage openings The welds shall be full penetration welds of the wall of the vessel. Weld preparation of the vessel may be necessary. Examples of permitted welds are given in figures 15, 16 and 17. If the drainage opening cannot be made in the bottom of the vessel, drainage shall nevertheless be provided by one of the permitted methods shown in figures 18 to 25.

Page 11 EN 286-4 : 1994

Figure 12. Fixing of a boss by an external I weld I

Figure 13. Fixing of a boss by internal and external welds

Figure 14. Fixing of a boss by internal and external fillet welds

Figure 15. Fixing of a drainage boss by an external weld



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CEN EN*2ôb-4 9 4 3404589 008bô49 989

I I /// 'f.L/ A I

Page 12 EN 286-4 : 1994

Figure 16. Fixing of a drainage boss by internal and external welds

Figure 17. Fixing of a drainage boss with drainage groove

Figure 18. Dip tube k e d to an end

Figure 19. Dip tube fixed to the shell of a horizontal vessel

Figure 20. Dip tube fixed to the shell of a vertical vessel

Figure 21. Dip tube fixed to a top end of a vertical vessel

Figure 22. Dip tube fixed to the upper part of the shell of a horizontal vessel

SW figures x 12, 13 and 14 Figure 23. Fixing of a dip tube



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CEN ENY28b-4 94 3404589 O086850 bTO m

d i b l

d i b i

'igures and 14

Minimum diameter: 30 mm A diameter of 30 mm corresponds approximately to internal threads G1 and M33

Minimum diameter: 18 mm A diameter of 18 mm corresponds approximately to internal threads and M20

Figure 24. Fixing of a dip tube to a boss

figures 13 and 14

Figure 25. Recessed fixing of a dip tube to a boss

6 Inspection and drainage bosses The vessels shall have a t least the inspection and drainage bosses of the dimensions given in table 3 However, vessels with a PV less than or equal to 1000 bar litres (with L < 1500) may have only onc boss for pipe connection, inspection and drainage. In this case, the minimum diameter is 30 mm. Other bosses intended particularly for pipe connections may be provided, as long as they are located well away from welded joints or seams subject to deformation, and in particular away from the knuckle ends.

Page 13 EN 286-4 : 1994

The locations of the bosses shown in figure 26 are recommended. Other locations may be specified as long as they permit access for internal inspection and drainage of the vessel.

7 Marking 7.1 General Vessels complying with this Part of this European Standard shall bear the identification and service marks given in 7.4. These marks are stamped either in the metal of the vessel itself or on a plate welded to the vessel wall. These marks shall be located on the vessel at one of the positions shown in figure 27.

7.2 Marking stamped in the metal of the vessel Stamping of marks shall only be carried out on vessel walls of thickness e 2 5 mm. The stamps shall not have any sharp edges and the depth of the stamping shall not exceed one tenth of the wall thickness. When the marking is on an end, the mark shall be stamped as far as possible away from the theoretical line of intersection of the knuckle radius and the spherical radius and shall be close to the end base, without interfering with the weld of the pipe connection branch. Marking shall be carried out before the ends are welded onto the shell. The only marks that shall be stamped onto the finished vessel are those given in items 6 ) and 10) of 7.4. 7.3 Marking stamped on a plate The dimensions of the marking plate are given in figure 28. 7.4 Identity and service marks This marking shall follow the general arrangement shown in figure 29 or, if necessary, shall be in three zones (see figure 27). These marks shall have a minimum height of 5 mm. The dimensions in figure 29 are given for guidance.

8 Corrosion protection 8.1 General An aluminium alloy vessel is particularly sensitive to electrochemical corrosion. It should therefore be insulated electrically from the chassis of the vehicle. NOTE. Examples of installation conditions are given in the informative annex F.



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C E N EN*28h-Y 9Y 3404589 OOBb85L 537

Page 14 EN 286-4 : 1994

fi ¡b2 Le 1 5 0 0 mm

-I D II I nl c

L ‘1 L Z 1500 rnm

NOTE. The drainage opening may be located other than in the bottom of the vessel provided that the vessel has a system for ensuring its complete drainage (see 5.2.4.2)

Figure 26. Location of openings

If corrosion protection is necessary (see 8.3) it shall be the subject of an agreement between the railway customer and the supplier and meet the service surveillance requirements given in annex G.

8.2 Protection of internal walls No protection is required.

8.3 Protection of external walls The outer walls of vessels not protected against impact of ballast or particles from the braking of the vehicle shall be given a protective surface coating.

9 Qualification of welding procedures Welding procedures shall be specified in accordance with EN 288 : Parts 1, 2 and 4. The qualification shall be witnessed by an approved inspection body.

10 ualification of welders and we1 3 ing operators Welders and welding operators shall be qualified in accordance with EN 287 : Part 2. The qualification shall be witnessed by an approved inspection body.



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CEN ENw28b-4 9 4 W 3404589 0086852 473

Page 15 EN 286-4 : 1994

O I



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C E N ENr28b-4 9 4 3404589 0086853 30T = Page 16 EN 286-4 : 1994

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CEN EN*ZBb-4 94 = 3404589 OOôbô5Y 246 Page 17

EN 286-4 : 1994

1) Name or trademark of the manufacturer and place of fabrication. (The arrangement and height of the characters are left to the discretion of the manufacturer).

2) Year of fabrication. 3) Vessel pattern number and batch identification. 4) Internal volume (in litres). 5 ) Maximum working pressure (in bars). 6) Mark of compliance with this European Standard : EN 286-4, and the last 2 digits of the year in which the mark is affixed.

The CE mark and the distinguishing number of the approved inspection body. 7) Minimum service temperature T,,, (in C). 8) Maximum service temperature T,,, (in C) 9) Name or trademark of the user. Order number allocated by the user. 10) Provision for date (last 2 digits of the year) and inspectors stamp corresponding to the detailed inspections and tests given

in G.6.

NOTE. If the vessel is re-tested, the corresponding marks (data and stamp) should be located next to the existing obligatory marks. In the case of a plate, it should have a free space for this purpose.

Figure 29. Identity and service marks

11 Testing of the vessels

11.1 Testing of welds by the manufacturer Welds shall be tested in accordance with the requirements of tables 4 to 6. The acceptance criteria are specified in 11.1.5. 11.1.1 Welds made by non-automatic welding In this case: P 2 1,25Ps and Kc = 1,15 (see 5.1.4.2 case no. 3). 11.1.2 Welds made by an automatic process 11.1.2.1 With P 2 1,15Ps and Kc = 1 (see 5.1.4.2 case no. 1) 11.1.2.2 With P 2 1,3Ps and Kc = 1 (see 5.1.4.2 case no. 2). 11.1.3 Destructive testing of welds on coupon plates The following tests shall be carried out by the manufacturer on coupon plates:

a) one face bend test around a mandrel of

diameter 2e, through an angle of 180"; b) one reverse bend test around a mandrel of diameter 2e, through an angle of 180"; c) one macro test.

11.1.4 Quality of the films The quality class of the films shall be determined in accordance with the requirements of IS0 2437.

11.1.5 Acceptance criteria for welds The results of all the tests shall be recorded. If a test gives an unsatisfactory result, the reason shall be sought and a further two samples shall be prepared and verified. If it can be shown that the failure is a result of a local or accidental defect and that the re-tests are satisfactory, the re-test results shall be accepted. If a new sample gives unsatisfactory results all the welds of all the vessels produced since the start of production or since the last unsatisfactory non- destructive test shall undergo a non-destructive test.



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CEN ENx28b-4 94 3404589 0086855 1 8 2 W

Nondestructive test (NDT) i00 yo visual inspection

Page 18 EN 286-4 : 1994

Destructive test @T)

Tables 7 and 8 show the acceptance levels. If any part of a weld has been repaired the whole of the repaired weld seam shall be verified by means of a non-destructive test. Following the bending tests, the sample shall not have any defects greater than 3 mm in any direction. In the macrographic examination, the affected surface of the sample shall show, through the microscope, a welded point image with an adequate penetration and with no defects other than those permitted in table 8.

11.1.6 Finish of longitudinal and circular joints All welds shall have a smooth finish without valleys and shall merge into the plates without undercutting or abrupt irregularity (see table 7). To ensure that the weld is fully penetrated and thus that the surface of the weld metal does not fall below the surface of the adjoining plate, weld metal may be built up as reinforcement on each side of the plate. This reinforcement shall not exceed the values given in table 9. The reinforcement need not be removed except to the extent that it exceeds the permissible thickness.

Table 4. Amount of testing reauired for welds made by a non-automatic process ~

Testing by the manufacturer

Test Each vessel

Each welding machine and each welding procedure

1 i00 yo X-ray of or 1 coupon plate the weld, including junctions, on the same vessel

Circumferential weld

If the welding process or the designation of the filler metal is identical to that used for the longitudinal weld, then the circumferential weld needs no further testing.

If the welding process or standard designation of the filler metal differs from those used for making the longitudinal weld:

1 coupon plate at the start of fabrication

Then every 300 m of we-3 with a minimum on any one vessel of the batch of

1 100 % X-ray of or 1 coupon plate the weld I

Verification by the approved inspection body where required

Visual inspection of coupon plates and films held by the manufacturer.

Inspection of the results of the various tests carried out in application of this standard.



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CEN EN*28b-4 9 4 I 3404589 0086856 019

Non-destructive test (NDT)

100% visual inspection

Page 19 EN 286-4 : 1994

Destructive test (DT)

Table 5. Amount of testing required for welds made by an automatic Testing by the manufacturer

F Each vessel 1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

During manufacture

Every 100 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change of standard designation of the filler metal:

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

Circumferen tia1 weld

If the welding process or the designation of the filler metal is identical to that used for the longitudinal weld, then the circumferential weld needs no further testing.

If the welding process or standard designation of the filler metal is different from those used for making the longitudinal weld :

After adjustment


During manufacture

Every 300 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change in the standard designation of the filler metal:


rocedure with P 2 1,15P Verification by the approved inspection body where required

Visual inspection of coupon plates and films held by the manufacturei

Inspection of the results of the various tests carried out in applicatioi of this standard.



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CEN EN*K286-4 7 4 w 3 4 0 4 5 8 9 0086857 T55

Non-destrucüve test 0 100% visual inspection

Page 20 EN 286-4 : 1994

Destructive test (DT)

Table 5. Amount of testing required for welds made by an automatic procedure with P 2 1,15Ps (concluded) Testing by the manufacturer Verification by the approved

inspection body where reauired

Test I Non-destructive test ("ï) I Destructive test (DT) I

With a minimum per batch of vessels or per month:

2 X-rays per film of length greater than 200 mm including at least one junction NOTE. The coupon plates or X-rays shall be from different vessels in the batch

or 2 coupon plates

Table 6. Amount of testing required for welds made by an automatic procedure with P 2 1,15P, Testing by the manufáctwer

Test Each vessel

Each welding machine and each welding ProCedure

Longitudinal weld ARer adjustment .

1 X-ray per film of length greater than 200 mm including at least one junction

or 1 coupon plate

During manufacture

Every 200 m of weld or at each change of adjustment outside the tolerances fixsed in the description of the welding procedure or at each change of standard designation of the mer metal:

1 X-ray per film of length greater than 200 mm including at least one junction

or 1 coupon plate

circumferential weld

If the welding process or the designation of the mer metal is identical to that used for the longitudid weld, then the circumferential weld needs no further testing:

Verification by the approved inspedion body where rw-

Viiual inspechon of coupon plates and films held by the manufacturer.

Inspection of the various tests carried out in application of this standard.



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CEN EN*2ôb-4 94 3 4 0 4 5 8 9 O086858 7’71

Page 21 EN 286-4 : 1994

Table 6. Amount of testing required for welds made by an automatic procedure with P 2 1,3P, (concluded) Testing by the manufacturer

Non-destructive test (NDT)

If the welding process or standard designation of the filler metal is different from those used for making the longitudinal weld :

I Destructive test (DT)

After adjustment


During manufacture

Every 500 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change of standard designation of the filler metal:


Within a minimum per batch of vessels or per month:


NOTE. The coupon plates or X-rays shall be from any vessels in the batch

Verification by the approved inspection body where required



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EN 286-4 1994

5011 5012 5013

Table 7. Acceptance levels of defects in butt-welds, detected by visual examination

Slight and intermittent, permitted provided not sharp and does not exceed 0,5 mm depth As undercut

Defect

502 See 11.1.6 514 509 511 513 517 506 Not permitted 507 See 5.1.5.2

Reinforcement to be of continuous and regular shape with complete filling of groove

b

TEN 26520 reference I Acceptance level

100 2011 2013 2017

Lack of penetration I 402 I Not permitted

Not permitted Individual diameter e/4 but not more than 2 mm for a 2 % projected area max.”

Undercut

2012

2014

Shrinkage groove

Individual diameter e/4 but not more than 2 mm for a 2 % projected area max.” Check for lack of fusion before accepting. Otherwise as 2011,2012,2013

2024 3011 302 1 2015

I I I I

Root concavity I515 I Asundercut I

Not permitted Individual length max. e/3

Summation of length = e max. in 12e length if

Excessive penetration I 504 I See 11.1.6 I

3012

Excess weld metal

separation < 6 x longest defect Individual length max. e/3

Irregular surface

Overlap Linear misalignment Arc strike Spatter Torn surface Grinding mark Chipping mark

60 1 602 603 604 605

Grind smooth Acceptance subject to thickness verification and crack detection test

Table 8. Acceptance levels of Defect

Cracks Porosity (isolated and grouped)

Porosity (uniformly distributed)

Porosity (linear)

Crater pipes Slag and flux inclusions and elongated cavities (individual and parallel to weld axis) Slag and flux inclusions and wormholes (random not parallel to weld axis)

Copper inclusions Lack of fusion (side, root or inter-run)

lefects in butt-welds, detected by X-ray examination EN 26520 reference I Acceptance level

3013 3022 3023 2016 3042 I Not permitted

I Not pe-itted 40 1 ’’ Area = maximum length of weld affected x local width of weld.



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CEN EN*K28b-4 9 4 = 3404589 0086860 5LlT

Table 9. Maximum permissible reinforcemenl for longitudinal and circular welds

Dimensions in millimetres Maximum reinforcement

or r2 (see figure 30)

Thickness of the thicker plate thickness r l

5 < e 1 1 2

500 mm) c) circularity of the cylindrical body d) straightness of any generating line of the cylindrical body * 0,O1Do;2’ d) straightness of any generating line of the cylindrical body f o,01L;2’ e) volume of the vessel in the as-delivered state f 3,5 %.

In addition, the wall of the vessels shall be free of localized defects such as sudden local irregularities, bumps, flats, cavities, folds, tool marks or visible symmetry defects. Cavities or bumps are permitted provided that they connect with the surrounding surface with gentle slopes

f 7 mm; f 3 mm;

0,6 %; 0,01D,;2’

Page 23 EN 286-4 : 1994

not exceeding 25% (14”) and with rounding of radius greater than 50 mm. Their dimensions shall not exceed :

f) radially - + 3 mm; g) longitudinally 0,25 L ; h) transversely 71DJ20.

In addition, surface scratches are permitted as long as they are less than 0,l mm deep. Acceptance of a concentration of scratches shall be the subject of agreement between the manufacturer and the client.

11.3 Pressure test Each vessel with all its fittings (bosses, brackets, etc.) shall be subjected to a hydrostatic test, prior to the application of the protective coating, equivalent to a pressure of 1,5 times the design pressure, i.e.:

a) 17,25 bar when the design pressure is taken as 11,5 bar (case no. 1 - 5.1.4.2); b) 19,5 bar when the design pressure is taken as 13 bar (case no. 2 - 5.1.4.2); c) 18,75 bar when the design pressure is taken as 12,5 bar (case no. 3 - 5.1.4.2).

in the presence of a person of recognized competence (see clause 12). This pressure shall be maintained for a sufficient length of time to permit a visual examination of all the surfaces and all the welded joints. The vessel shall show no sign of plastic deformation or leakage. Subject to agreement, a pneumatic test may be carried out on each vessel, at the pressure defined above.

WARNING. The pneumatic test is potentially a much more dangerous operation than the hydraulic test in that, irrespective of the size of the vessel, any failure during testing may result in an explosion. It should therefore only be carried out after consultation with the inspection body and having ensured that the safety measures taken comply with current legislation of the country in which the test is carried out. All vessels which fail the pressure test shall be rejected. Repairs may be permitted, with the agreement of the client network, but in this case the pressure test shall be repeated.

2’The tolerances of shape and position are set out in IS0 1101.



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CEN ENx28b-4 9 4 3404589 0086861 486

Verification

Verification’’ or declaration of conformity” and surveillance (and special documents)

Page 24 EN 286-4 : 1994

I

See annex A

See annex A

See annex B

12 Certification procedures This standard specifies three classes of vessel to which the certification procedure set out in table 10 applies.

Verification” or declaration of conformity’’ (and special documents)

13 Information to be sup lied at the

time of order The invitation to tender and order, to which is attached the final drawing of the vessel, shall indicate the number of this standard and specify the following, if they have not already been specified in the drawing or the documents attached to it:

time of invitation to ten 8 er and the

a) the dimensions and volume of the vessel; b) the aluminium alloy or alloys, together with the number of the reference standard, from which the shell and ends are to be made (see clause 4);

c ) the type of shell/end joints (see 5.1.5.2); d) the shape of the openings and their welding to the vessel (see 5.2.4);

e) the location of the openings (see clause 6);

f) whether the marking is stamped in the metal or on a plate (see clause 7 ) ; g) the marks which the vessel shall have and their location on it (see 7.4);

h) corrosion protection measures (see clause 8) ; j) a drawing showing how the vessel is assembled on the vehicle (see annex F); k) the requirements for service surveillance (see informative annex G).

See annex A

See annex B

14 Delivery After complete drying of the inside walls, the vessel in the delivery condition shall have all its openings plugged with plastic stoppers or some other means to ensure that the inside of the vessel is free from dust, water or any other foreign bodies.

Prior to despatch, the vessel shall be suitably protected to avoid any damage (impact, deformation . . . ) during transport. The packing shall be determined by the railway customer and the manufacturer.

15 Documentation to accompany the vessel The documentation to accompany the vessel shall include :

a) particulars given on the vessel nameplate, including the serial identification; b) the use for which the vessel has been designed; c) the installation and maintenance requirements where they differ from those given in annexes F and G respectively; d) a declaration that the vessel is in accordance with the requirements of this European Standard (see annex BI; e) for information to the customer, a statement on the test certificate that there shall be no welding operations carried out on pressurized parts of the vessel.

The documentation shall be in the language, or languages, of the country of destination.

Table 10. Classification of vessels

Class 1 Greater than 3000 bar litres and not more than 10000 bar litres

Class 2 _ _ _ _ _ ~

Greater than 200 bar litres and not more than 3000 bar litres

Class 3 Greater than 50 bar litres and not more than 200 bar litres

Certification Drocedure2’ I Comment Type examination” (see annex D) or approval of design and construction dossier” (see annex C, clause 2)

”At manufacturer’s choice. ‘)The mark of the inspection body shall be affixed to the vessels subjected to verification.



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Annex A (normative) Verification A.1 General Verification shall be performed by an approved inspection body on batches of vessels submitted by their manufacturer or by his authorized representative. Batches shall be accompanied by the type-examination certificate (see annex D) or by the certificate of approval of the design and manufacturing schedule (certificate of adequacy) (see annex C). When a batch is examined, the inspection body shall ensure that the vessels have been manufactured and checked in accordance with the design and manufacturing schedule and shall perform a hydrostatic test or, subject to the agreement of the Member State, a pneumatic test on each vessel in the batch at at a pressure equal to 1,5 times the design pressure. Moreover, the inspection body shall carry out tests on test pieces taken from a representative production coupon plate or from a vessel, as the manufacturer chooses, in order to examine weld quality. The tests shall be carried out on lonstudinal welds. However, where differing welding techniques are used for longitudinal and circumferential welds, the tests shall be repeated on representative test pieces of circumferential welds. A.2 Construction verification The approved inspection body shall perform the following checks and examinations. A.2.1 Check of the manufacturing record

The manufacturing record shall be checked (see annex E). A.2.2 External and internal inspection, dimensional check

The inspection body shall check the identification of the vessel, e.g. the data-plate, and shall inspect the vessels visually, externally and internally, for defects, especially the seams. The inspection shall be performed before any permanent covering coatings are applied. The inspection body shall check dimensions of shells, ends, openings and other parts, that are of importance to the safety of the vessel, for conformity with the drawings. Distances important for safety (e.g. distance between openings) shall be checked if considered necessary. NOTE. Normally it is adequate if 10% of vessels are checked and inspected, these to be selected by the approved inspection body. A.2.3 Destructive testing Destructive testing as required by 11.1.3 shall be witnessed by the approved inspection body who will certify the results.

Page 25 EN 286-4 : 1994

A.2.4 Non-destructive testing Non-destructive testing of butt weld seams as required by clause 11 shall be checked by the approved inspection body. This includes spot checks of films. If the films are not available, spot NDT shall be performed according to tables 4 to 6.

Annex B (normative) Declaration of conformity - Surveillance B.l General B.l.l Declaration of conformity

Vessels in accordance with the European Standard whose product Ps and V exceeds 50 bar litres but which does not exceed 3000 bar litres are, at the choice of the manufacturer, either subject to verification (see annex A) or subject to the declaration of conformity. B.1.2 Surveillance By the declaration of conformity the manufacturer becomes subject to surveillance for vessels for which the product of Pc and V exceeds 200 bar litres and does not exceed 3000 bar litres. The purpose of surveillance is to ensure that the manufacturer duly fulfils the obligations required by this European Standard. In the case of vessels manufactured in accordance with an approved specimen, for which a type examination certificate exists, surveillance shall be the responsibility of the approved inspection body which issued this type of examination certificate. In the case of vessels not manufactured in accordance with an approved specimen, surveillance shall be the responsibility of the approved inspection body which issued the certificate of approval of the design and manufacturing schedule (certificate of adequacy) (see C.2).

B.2 Procedure required before commencement of manufacture of vessels of classes 2 and 3 (see clause 12) subject to a declaration of conformity B.2.1 Responsibilities of the manufacturer Before commencing manufacture, the manufacturer shall submit to the approved inspection body which issued the type examination certificate or the certificate of adequacy (see annex C), a document describing the manufacturing processes and all of the predetermined, systematic measures taken to ensure conformity of the vessels with this European Standard. This document shall include the design and manufacturing schedule and the documents referred to in B.2.1.1 to B.2.1.5.



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CEN EN*Z8b-4 9 4 m 3404589 008b8b3 259 Page 26 EN 286-4 : 1994

The manufacturer shall appoint a management representative who, irrespective of other responsibilities, shall have independent authority and responsibility for ensuring that the requirements of this European Standard are implemented and maintained. B.2.1.1 A description of the means of manufacture and inspection appropriate to the construction of the vessels. B.2.1.2 An inspection document describing the appropriate examinations and test to be carried out during manufacture together with the procedures thereof and the frequency with which they are to be performed. B.2.1.3 An undertaking to carry out the examinations and tests in accordance with the inspection document referred to above and to have a hydrostatic test carried out on each vessel in accordance with this European Standard. B.2.1.4 The addresses of the places of manufacture and storage and the date on which manufacture is to commence. B.2.1.5 In addition, when the product of Ps and V exceeds 200 bar litres, the manufacturer shall authorize access to the said places of manufacture or storage by the body responsible for the surveillance, for inspection purposes, and allow that body to select sample vessels and provide it with all necessary information and in particular:

a) the design and manufacturing schedule; b) the inspection report; c ) the type examination certificate or certificate of adequacy, where appropriate; d) a report on the examinations and test carried

out. B.2.2 Responsibilities of the approved inspection bodies The inspection body responsible for the surveillance shall examine the documents referred to in B.2.1.1 and B.2.1.3 in order to check their conformity with the requirements of this European Standard and with:

a) the conditions stated in the certificate of adequacy; or b) the design and manufacturing record and the conditions stated in the type examination certificate.

Manufacturing cannot commence before the approved inspection body has issued written approval of this document.

B.3 Procedures required during manufacture of vessels of classes 2 and 3 (see clause 12) subject to a declaration of conformity B.3.1 Responsibilities of the manufacturer The manufacturer shall ensure that the inspections and testing are carried out in accordance with the documented procedures to complete the evidence of full conformance of the vessel to this European Standard. The inspection and test status of vessels shall be identified by using markings, authorized stamps, tags, labels, inspection records, physical location or other suitable means which indicate conformance or non-conformance of vessels with regard to inspection and tests performed. Records shall identify the inspection authority responsible for the release of conforming vessels. The manufacturer shall maintain control of vessels that do not conform to the requirements of this European Standard. All nonconforming vessels shall be clearly identified and segregated to prevent unauthorized use, delivery or mixing with conforming vessels. Repaired or re-worked vessels shall be re-inspected in accordance with documented procedures. B.3.2 Responsibilities of approved inspection bodies For vessels whose product of Ps and V exceeds 200 bar litres, the inspection body responsible for surveillance shall, during fabrication:

a) ensure that the manufacturer manufactures and checks the vessels in accordance with the documents described in B.2.1; b) take random samples - two at each visit (see B.3.4.2) - at the place of manufacture or storage of vessels for inspection purposes as given in B.3.3 and B.3.4.

B.3.3 Frequency of inspection body operation Initial operation a) and b) of B.3.2 shall be carried out within two months of the commencement of manufacture and, afterwards, random checks will be made at the normal rate of one visit per year if the rate of production of vessels of the same type is up to 3000/year and twice if production is more than 6000/year. For production quantities between these, the rate of visit will be adjusted accordingly.

B.3.4 Surveillance checks and tests To ensure that the manufacturer produces and checks vessels subject to the declaration of conformity in accordance with this European Standard, the inspection body responsible for the surveillance shall perform the following checks, inspections, examinations and tests.



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CEN EN*28b-4 94 3404589 0086864 19.5

B.3.4.1 Check of the design and manufacturing record, the inspection report and the report on the examinations and tests carried out, in particular with respect to completeness, consistency, validity of certificates, qualification of personnel, etc. B.3.4.2 The inspection body shall select at random at least two vessels in such a manner that at least one vessel per family is selected per year. On these vessels, it shall perform an external and internal inspection, a dimensional check, a non-destructive test of all butt welds (radiographic examination) and a hydrostatic test (see A.l). B.3.4.3 The inspection body shall make available to the manufacturer a copy of the surveillance report that has been prepared.

Annex C (normative)

Design and manufacturing schedules C. l Content The design and manufacturing schedules shall contain the name of the manufacturer and the place of manufacture and shall give the following information: - a detailed manufacturing drawing of the

- a set of instructions comprising: vessel type;

a) the maximum working pressure, Ps ......... bar; b) the maximum working temperature,

c) the minimum working temperature,

d) the volume of the vessel, V .......... litre; e) the name or mark of the manufacturer; f ) a drawing showing assembly of the vessel to the rolling stock approved by the client network indicating in particular the method of attachment (see annex F); g) the service surveillance requirements approved by the client network (see annex GI;

a) the materials selected; b) the welding processes used; c) the checks to be carried out; dj any pertinent details as to the vessel design including the design pressure; e) the certificates relating to the suitable qualification of the welding procedures and of the welders or operators;

T,,, ...... "C;

T,,, ...... 'C;

- a document describing:

Page 27 EN 286-4 : 1994

f ) if the certificates for the welding procedures, welders or operators are not available, this shall not prevent the approved body from evaluating the other documents. However, they shall be submitted before approval is given or manufacturing commences ; g) the inspection slips for the materials used for the manufacture of parts and assemblies contributing to the strength of the pressure vessel or a specimen of these inspection slips; h) a specimen of the proposed report on examination and tests.

C.2 Approval of design and manufacturing schedule (certificate of adequacy)

If vessels are not manufactured on the basis of a type-examination certificate, the manufacturer or his authorized representative shall submit to an approved inspection body an application for design approval and enclose three copies of this design and manufacturing schedule (see C.1). Various vessels or vessel families can be included in one design and manufacturing schedule, but all vessel details (including branches, bosses and attachments) of the production envisaged shall be included. The approved inspection body shall examine these documents in order to check the conformity of the design, of the required tests, and of the qualifications with the requirements of this standard. If they are in agreement with the requirements of this standard the approved inspection body shall issue a certificate of adequacy which shall be forwarded to the applicant.

Annex D (normative) Type examination Type examination is the procedure by which an approved inspection body ascertains and certifies that a prototype vessel satisfies the provisions of this part of this European Standard. The manufacturer or his authorized representative shall submit to an approved inspection body an application for type examination. The application shall include three copies of the design and manufacturing schedule (see annex C) and a prototype vessel which is representative of the production envisaged. If the application is lodged for various vessels, a prototype vessel is required for each vessel type. Various vessels or vessel types can be included in one design and manufacturing schedule, but all vessel details (including branches, bosses and attachments) of the production envisaged shall be included.



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C E N EN*:28b-4 94 3404589 0086865 021

Page 28 EN 286-4 : 1994

The approved inspection body shall examine the documents in order to check the conformity of design, qualifications and the proposed tests with the requirements of this European Standard.

The approved inspection body shall also verify that the vessel has been manufactured in conformity with the design and manufacturing schedule and is representative of the type and shall perform appropriate examinations and tests (including 100 % NDT of main seams and a hydrostatic test). If the design and manufacture schedule and the prototype(s) comply with the provisions of this part of this European Standard, the approved inspection body shall draw up a type-examination certificate (per vessel type) which shall be forwarded to the applicant. The certificate shall state the conclusions of the examination, indicate any conditions to which its issue may be subject and be accompanied by the descriptions and drawings necessary for identification of the approved prototype.

Annex E (normative)

Content of the manufacturing record The manufacturing record of the vessels shall contain (at least) the following information. E.l General information

a) the name or mark of the manufacturer; b) the place of manufacture; c) the qualification certificates for the welding procedures and the welders or welding operators ; d) the reports of the tests and inspections performed, or description of the proposed verifications.

E.2 Specific information a) the identification codes of the vessels specific to the manufacturer (example No. . . . to . . . 1; b) the type approval number or the certificate of adequacy; c ) the diameter of the vessels; d) the volume of the vessels; e) the maximum working pressure; f) the maximum working temperature; g) the minimum working temperature, if below - 10 OC; h) the test pressure; j) the drawing number(s); k) the date of manufacture; 1) the size of the batch;

m) the inspection document for the materials used in the manufacture of main pressurized parts;

For parts, other than shells and ends with diameters not exceeding 250 mm, a declaration by the manufacturer stating that only materials complying with the required documents have been used, is acceptable.

n) the date of the hydrostatic test, signed by the manufacturer’s inspector and, in the case of verification, by the inspector from the approved inspection body.

E.3 Records Records shall contain information required by E.1 and E.2 in such a way as to allow traceability. For the purpose of traceability, records shall be maintained of the vessel numberícustomer. Records shall be kept for at least 40 years.

Annex F (informative) Assembly to the vehicles F.l General Particular attention should be paid to the materials from which surrounding components are made (straps, cradle, pipes etc.). The difference between materials in the vessel and the surrounding unit affects the corrosion resistance of the aluminium alloy of the vessel. This corrosion is generally the result of the difference in the electrical potentials of the materials present, the presence of stray electric current and the electrolyte resulting from a moist environmen t. Particular attention should be paid to the assembly of the vessel on the vehicle in order to avoid the effects of electrochemical corrosion. F.2 Fixing The vessels should be fked by means of straps with properties as indicated in F.3 and inserts of corrosion protection tape as defined in F.4. The vessel is generally fixed by means of two straps (see figures F.l and F.2 for typical examples). However, for small vessels, a single strap may be used as long as it does not obstruct reading of the identity and service marks. The straps are fastened to the vehicles by one of the approved methods shown in figures F.3 to F.6. Other methods may be used provided that all safety requirements are complied with. The means of fixing to the vehicle should be electrically insulated (see the assembly examples shown in figures F.7 and F.8). The cradle should, as far as possible, be part of the vehicle chassis.



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EN 286-4 : 1994

,Cradle rWersd vessel

Insulating tapes I

Figure F.l Fixing by straps of a vessel in the horizontal position

- Welded vessel jo ints Insulating tapes

‘L- Welded vessel j o in ts Cradle-

-

Insulating tapes

Strap

Figure F.2 Fixing by straps of a vessel in thc vertical position

F.3 Fixing straps

I Figure F.3 End of straps with angle brackets Straps made of circular rod are not permitted.

F.3.1 Fixing by two straps The dimensions of the straps are given in table F.1. F.3.2 Fixing by a single strap The strap section should be approved by the customer for each particular case. F.4 Insulating tapes The insulating tapes should meet the following requirements :

a) remain elastic within the limits of the service temperatures specified by this standard; b) not be susceptible to creep;

The fixing straps should be made of flat galvanized steel of minimum tensile strength R, 5 580 N/mm2 as specified in EN 10025 or steel with equivalent mechanical properties and dimensions specified in F.3.1.

C) retain their insulating Properties on ageing and in the presence of moisture. The value of the insulating resistance should, under no circumstances, be less than 700 ka.



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CEN EN*k2ôb-4 9 4 3404589 0086867 9 T 4

Page 30 EN 286-4 : 1994

Figure F.4 Ends with straps folded and reinforced

Figure F.5 Ends of straps with welded bolt

Figure F.6 Ends of straps with grooved welded bolt

YI W

Figure F.7 Fixing to the vehicle with a bolt

r $,;suia t ing washer n:&:

L Straps as shown in figures F5 I- and F6 Figure F.8 Fixing to the vehicle with a nut

Table F.l Dimensions of straps Dimensions in miliimetres

60 x 6

F.5 Mounting

F.5.1 General The drawing showing assembly of the vessel on the vehicle should ensure that the identity and service marks can be read under all possible conditions. Contact between the vessel and the vehicle should always be via cradles, with insulating tape (see F.4) inserted between the vessel and the cradle.

*



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~~~~ . ~~

CEN E N * Z 8 6 - 4 9 4 3404589 0086868 830 =

mm

< 450 450 < Do < 600 > 600

The fixing straps and their insulating tape should always be placed around the shell (see figures F. l and F.2). All necessary steps should be taken to avoid movement of the insulating tape relative to the straps and the vessel. The cradle should:

a) be placed transversely in relation to the vessel; b) be adapted to the shape of the vessel; c) have a width at least equal to that of the fixing straps; d) have a span equal to or greater than 0,6D,.

The tension on the straps required to prevent movement of the vessel is applied via fasteners (see figures F.7 and F.8). NOTE. The nuts should have locking devices.

Excessive tightening causes plastic deformation of the vessel wall at the position of the straps, resulting in rapid fatigue fracture of the vessel. The assembly drawing should therefore state the maximum torque to be applied to the fasteners. Table F.2 gives the permitted tightening torque values which have been calculated for a Shore hardness of the insulating tape of 50, and with a coefficient of friction in the fasteners of 0,2. F.5.2 Fixing by two straps They should be located as close as possible to the circular welds without, however, obscuring them as they should remain visible once the vessel has been fixed.

M10 M12 M16 M20

0,3 0,35 0,5 0,65

035 1.2

I Table F.2 Tightening torques I Diameter of vessel Maximum tightening torque 1 daN.m I

Fastener diameter

Page 31 EN 286-4 1994

F.5.3 Fixing by a single strap It should be located so as not to obscure the circular welds. F.6 Pipe connections Connections between the non-alloy steel pipes and the vessels should be of passivated and galvanized steel FeíZn 12 c 2C or Fe/Zn 12 c 2D in accordance with IS0 2081 and ISO. 4520. F.7 Protection of the drainage mechanism Where an automatic drainage mechanism is mounted directly on to the vessel opening, it should be protected against accidental damage by a cap. NOTE. In the case of vehicles fitted with an air dryer, the drainage opening may be closed by a passivated and galvanized (see F.6) steel threaded plug with a pressure relief hole and gasket.

Annex G (informative)

Service surveillance of vessels G.l General The maintenance recommendations in this annex meet the minimum safety requirements during normal service of aluminium alloy vessels which comply with the requirements of this European Standard. The vessels are used throughout the whole service life of the vehicle or device to which they are fitted, to a maximum of 40 years. At the end of this period, they are dispensed with under the conditions specified in G.10 However, under special circumstances (a series of vehicles being replaced or vehicles destined for a museum), the service life of the vessels may be prolonged subject to suitable surveillance specified in G.9. The service surveillance of the vessels complying with this European Standard is carried out during periodic inspections or revisions to the vehicle or the device fitted with it, under the following conditions.



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EN 286-4 : 1994

~

Maximum interval between 2 operations Operation Removal Method and

In a scheduled examination before External visual inspection and No G.4 600000 km" or 6 years

sanction

drainage

6 . 2 Vessels used at: Ps 5 6 bar

I Table G.l Service surveillance of vessels used at P, I 6 bar I

-24 years on the occasion of a revision I Internal and external inspection I No I G.4 and G.5 "This period may be extended to a maximum of 6 years if the vessel is protected against external attacks, for example if it is installed in an enclosure or is an integral part of the apparatus.

Maximum interval between 2 operations

In a scheduled examination before 2 years and 8 weeks''

Operation Removal Method and sanction

External visual inspection and No 6 .4 drainage

6 . 3 Vessels used at: 6 bar < P, < 10 bar

Population of vessels concerned Sample

Vessels of the same type, from whole vehicle fleet or from items they are fitted to, more than 20 years old

1 % rounded to the nearest whole number

m G . 2 Service surveillance of vessels used at 6 bar < P , I 10 bar I

Removal Method and

Yes G.6 and 6.7 sanction

24 years on the occasion of a revision I Internal and external inspection "This period may be extended to a maximum of 6 years if the vessel is protected against external attacks, for example if it is installed in an enclosure or is an integral part of the apparatus.

I No I 6.4 and 6 .5

In addition, the satisfactory performance of these vessels is ensured by an annual sampling examination under the following conditions.

G.4 External inspection 6.4.1 Cleaning Vessels that are particularly dirty should be cleaned so as to permit examination of the walls under acceptable conditions. Cleaning by air blast should be carried out until all dirt is completely removed. If a cleaning agent is used, it should not be aggressive to aluminium alloys. 6.4.2 Examination of marking If the marks specified in clause 7 are illegible, the vessel should be rejected.

If a data plate is deformed as a result of impact or oxidation, but the marks are still visible, it may be replaced. Conformity to the original marking should be certified by the affixing of the expert's stamp.

If a new plate is welded on to the vessel, the vessel should undergo a pressure test in accordance with 11.3. G.4.3 Inspection of the walk G.4.3.1 Deformation and irregularities If the walls of the vessel show localized deformations or irregularities resulting mainly from impacts, the vessel should be rejected if these deformations or irregularities exceed the tolerances given in G.4.3.1.1 and G.4.3.1.2.



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CEN ENx28b-4 9 4 3404587 008b870 499

G.4.3.1.1 Dished ends Deformations and irregularities should not:

a) have any sharp angles (radius less than half the knuckle radius); b) be located on the welds or at a tangent to them; c) be located more than 0,4D, from the centre of the end; dj have a depth greater than U100 of the vessel diameter.

G.4.3.1.2 Shell wall Deformation and irregularities should not:

a) connect with the surrounding surface with slopes greater than 25% (14 ) or with roundings or radius less than half the knuckle radius ; b) be deeper than: - 1/50 of the vessel diameter and width less

- 1/25 of the vessel diameter for other cases. than 4 times the depth;

G.4.3.2 Corrosion The process of electrochemical corrosion of the walls of the vessels can only start as a result of a defect in the electrical insulation of the h ing . This type of corrosion always starts from the outside of the vessel. The vessel should therefore be visually examined to check:

a) that the external surface of the vessel will be protected until the next scheduled inspection at the intervals stated in G.2 and G.3 and if not, the protection should be re-applied; b) for presence of corrosion. If any corrosion is of a depth equal to or greater than 1/10 of the wall thickness, the vessel should be rejected.

If the vessel is not rejected, the surface protection and, if necessary, the electrical insulation of the fastening described in G.4.4 should be re-applied. G.4.3.3 Other cases leading to rejection of the vessel If there is doubt about the seriousness of the defects listed above, or if the vessel has other discontinuities which may adversely affect its strength, it should be rejected. G.4.4 Inspection of the fixings If it is observed that a strap is broken or cracked it should be replaced. Welded repairs are not permitted. Check the value of the electrical insulation resistance between the straps and the vessels greater than 700 kR. If not, replace the defective insulation. Inspect for traces of corrosion on the vessel walls, particularly at the strap points, in accordance with G.4.3.2.

Page 33 EN 286-4 : 1994

G.5 Internal examination Internal inspection of the vessel walls is carried out with suitable apparatus, such as an endoscope for example. If traces of corrosion are detected, their extent should be assessed. Any pitting of depth equal to or greater than 1/10 of the wall thickness should lead to rejection of the vessel. If there is doubt about the assessment of the depth of the corrosion, suitable apparatus for measuring the wall thickness should be used, for example ultrasonic apparatus. If the extent of the corrosion does not lead to rejection of the vessel but is located in an area corresponding to an external area where traces of corrosion have already been detected, but without leading to rejection of the vessel, this vessel should be rejected.

G.6 Detailed inspection and hydrostatic test G.6.1 General These operations should be carried out by competent approved personnel.

G.6.2 Detailed inspection Detailed inspection of a vessel entails its removal. Before carrying out the various phases of the inspection, the vessel should be examined to see if there are any defects which might lead to its rejection.

G.6.2.1 Preparation Internal and external walls of the vessel should be exposed by careful cleaning, if

simple unfired pressure vessels designed to contain air...

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