DIN EN 16725-2017 Railway applications - Track - Restoration and repair of manganese crossings German version EN 16725 2016《轨道交通 轨道 锰交叉口的修复和修理 德文版本EN 16725-2016》.pdf

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1、January 2017 English price group 15No part of this translation may be reproduced without prior permission ofDIN Deutsches Institut fr Normung e. V., Berlin. Beuth Verlag GmbH, 10772 Berlin, Germany,has the exclusive right of sale for German Standards (DIN-Normen).ICS 93.100!%_*“2605907www.din.deDIN

2、EN 16725Railway applications Track Restoration and repair of manganese crossings;English version EN 16725:2016,English translation of DIN EN 16725:2017-01Bahnanwendungen Oberbau Instandsetzung und Reparatur von Herzstcken aus Manganhartstahlguss;Englische Fassung EN 16725:2016,Englische bersetzung v

3、on DIN EN 16725:2017-01Applications ferroviaires Voie Rparation des coeurs en acier au manganse;Version anglaise EN 16725:2016,Traduction anglaise de DIN EN 16725:2017-01www.beuth.deDTranslation by DIN-Sprachendienst.In case of doubt, the German-language original shall be considered authoritative.Do

4、cument comprises 31 pages 01.17 2 A comma is used as the decimal marker. National foreword This standard (EN 16725:2016) has been prepared by Technical Committee CEN/TC 256 “Railway applications” (Secretariat: DIN, Germany). The responsible German body involved in its preparation was DIN-Normenaussc

5、huss Fahrweg und Schienenfahrzeuge (DIN Standards Committee Railway), Subcommittee NA 087-00-01-01 UA Schienen-schweien. This standard is based on the English reference version. DIN EN 16725:2017-01 EUROPEAN STANDARD NORME EUROPENNE EUROPISCHE NORM EN 16725 November 2016 ICS 93.100 English Version R

6、ailway applications - Track - Restoration and repair of manganese crossings Applications ferroviaires - Voie - Rparation des curs en acier au manganse Bahnanwendungen - Oberbau - Instandsetzung und Reparatur von Herzstcken aus ManganhartstahlgussThis European Standard was approved by CEN on 22 July

7、2016. CEN members are bound to comply with the CEN/CENELEC 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 obtaine

8、d on application to the CEN-CENELEC Management Centre or to any CEN member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-C

9、ENELEC Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, I

10、taly, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom. EUROPEAN COMMITTEE FOR STANDARDIZATION COMIT EUROPEN DE NORMALISATION EUROPISCHES KOMITEE FR NORMUNG CEN-CENELEC Management Centre: A

11、venue Marnix 17, B-1000 Brussels 2016 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 16725:2016 EEN 16725:2016 (E) 2 Contents Page European foreword . 4 Introduction 5 1 Scope 6 2 Normative references 6 3 Terms and definitions . 7

12、 4 Consumable and WPS approval tests for MMA electrodes and FCAW wires . 8 4.1 General 8 4.2 Consumable and WPS approval model 8 4.2.1 Flow chart 8 4.2.2 Minimum information to be included in the pWPS 9 4.3 Information supplied by the manufacturer of the welding consumable to the certifying body 10

13、4.4 Laboratory examinations of weld samples . 11 4.5 Description of the samples for laboratory test for resurfacing work . 11 4.5.1 General requirements for laboratory tests 11 4.5.2 Single bead on AMS 11 4.5.3 Multi-layer on AMS 12 4.5.4 Single bead on tri-metal zone 13 4.5.5 Single layer on tri-me

14、tal zone 13 4.5.6 Multi-layer on tri-metal zone . 14 4.5.7 Preparation and examination of AMS samples . 15 4.5.8 Preparation and examination of the tri-metal zone samples 16 4.6 Assessment of general weldability 18 4.7 Acceptance criteria 18 4.7.1 Visual inspection 18 4.7.2 PT examination . 18 4.7.3

15、 Hardness 18 4.7.4 Macro and micro examination of single and multi-layer sections . 19 4.8 Track trial tests . 19 4.8.1 General . 19 4.8.2 Excavation detail for track trials 19 4.8.3 Track trial test categories . 20 4.8.4 Test methods . 20 4.8.5 Number of in-track test samples 20 4.8.6 Welders repor

16、t from track trials . 20 4.8.7 Acceptance criteria for track trial tests . 20 4.9 Evaluation, reporting and decision following track trials 21 4.9.1 General . 21 4.9.2 List of general information . 21 4.9.3 Track trial tests inspection records 21 4.9.4 Decision by approving RA on consumable and WPS

17、. 21 4.10 Validation of consumables 21 5 Approval of contractors . 22 5.1 Quality management systems 22 5.2 Inspection and testing 22 DIN EN 16725:2017-01 EN 16725:2016 (E) 3 5.3 Subcontracting . 22 5.4 Equipment . 22 5.5 Welding activities . 22 5.6 Storage and handling of welding consumables 22 5.7

18、 Care of the infrastructure 22 5.8 Welding procedure specifications 23 5.9 Pre-heating of rails when welding in tri-metal zone . 23 5.10 Welders 23 5.11 Welder records 23 5.12 Supervision . 23 5.13 Traceability . 23 5.14 Audits 23 5.15 Training 23 5.16 Documentation 24 6 Personnel and qualification

19、requirements . 24 6.1 Training and qualification requirements 24 6.2 Diploma in electric arc welding of cast manganese track components 24 6.3 Permit to weld cast manganese components in track . 24 7 Repair applications 25 Annex A (informative) Welding Procedure Specification (WPS) . 26 Annex B (inf

20、ormative) Permit to weld cast manganese track components by electric arc welding . 28 DIN EN 16725:2017-01 EN 16725:2016 (E) 4 European foreword This document (EN 16725:2016) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of which is held by DIN. This Eur

21、opean Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by May 2017, and conflicting national standards shall be withdrawn at the latest by May 2017. Attention is drawn to the possibility that some of the elements o

22、f this document may be the subject of patent rights. CEN shall not be held responsible for identifying any or all such patent rights. This document has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association. According to the CEN-CENELEC Internal

23、 Regulations, the national standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Irela

24、nd, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom. DIN EN 16725:2017-01 EN 16725:2016 (E) 5 Introduction Restoration of cast manganese crossings by electric arc welding is a s

25、pecial process requiring the co-ordination of welding and grinding activities to establish confidence and reliability of the weld deposit and safety of the line. Incorrect selection of materials, consumables or procedure may result in serious track welding failure. The correct application of the app

26、roved processes and the types of repairs permitted to be carried out on various rail components need to be strictly adhered to. Only consumables approved by the method described in this standard are to be used. The tasks and responsibilities of personnel involved in restoration e.g. planning, execut

27、ing, supervising and inspection need to be clearly defined. DIN EN 16725:2017-01 EN 16725:2016 (E) 6 1 Scope This European Standard specifies restoration of cast austenitic manganese steel for fixed crossings and cradles for crossings with movable parts, designed to be flash butt welded or bolted to

28、 adjoining rails manufactured according to EN 15689. The standard also applies to flash welded leg ends of austenitic manganese steel crossings and the associated tri-metal zone. The standard specifies the approval systems for consumables and procedures used in manual metal arc and flux cored metal

29、deposit repair welding. The standard includes the quality-related tasks and responsibilities and qualifications of personnel involved in the electric arc repair welding of cast crossings. The permitted welding processes are limited to Electric Arc (EA) in accordance with EN ISO 4063, specifically Pr

30、ocess No 111: MMA (Manual Metal Arc) and Process No 114: FCAW (Flux Cored Arc Welding). Their applications are described. This standard may be applied for procedures in situ, at line side or at out of track locations. The purpose of this standard is to unify restoration of cast manganese crossings b

31、y electric arc welding across Europe. The standard provides control systems for the approval and qualification of welding processes, WPS, welding consumables, contractors and welders for the successful delivery of welds on crossings in service. 2 Normative references The following documents, in whol

32、e or in part, are normatively referenced in this document and are indispensable for its application. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. EN 1371-1, Founding - Liquid penetrant

33、testing- Part 1: Sand, gravity die and low pressure die castings EN 13674-1, Railway applications - Track - Rail - Part 1: Vignole railway rails 46 kg/m and above EN 15689, Railway applications - Track - Switches and crossings - Crossing components made of cast austenitic manganese steel EN ISO 544,

34、 Welding consumables - Technical delivery conditions for filler materials and fluxes - Type of product, dimensions, tolerances and markings (ISO 544) EN ISO 2560, Welding consumables Covered electrodes for manual metal arc welding of non-alloy and fine grain steels Classification (ISO 2560) EN ISO 3

35、452-1, Non-destructive testing - Penetrant testing - Part 1: General principles (ISO 3452-1) EN ISO 4063, Welding and allied processes - Nomenclature of processes and reference numbers (ISO 4063) EN ISO 5817, Welding - Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding ex

36、cluded) - Quality levels for imperfections (ISO 5817) EN ISO 6507-1, Metallic materials - Vickers hardness test - Part 1: Test method (ISO 6507-1) EN ISO 15607, Specification and qualification of welding procedures for metallic materials - General rules (ISO 15607) EN ISO 15609-1, Specification and

37、qualification of welding procedures for metallic materials - Welding procedure specification - Part 1: Arc welding (ISO 15609-1) DIN EN 16725:2017-01 EN 16725:2016 (E) 7 EN ISO 15613, Specification and qualification of welding procedures for metallic materials - Qualification based on pre-production

38、 welding test (ISO 15613) EN ISO 17632, Welding consumables - Tubular cored electrodes for gas shielded and non-gas shielded metal arc welding of non-alloy and fine grain steels - Classification (ISO 17632) 3 Terms and definitions For the purposes of this document, the following terms and definition

39、s apply. 3.1 Railway Authority RA either the railway regulator or the owner of a railway infrastructure or the custodian with a delegated responsibility for a railway infrastructure 3.2 contractor and sub-contractor company approved by a railway authority to carry out the restoration of cast mangane

40、se track components by electric arc welding on that particular infrastructure Note 1 to entry: This may include staff from within the RA 3.3 preliminary welding procedure specification pWPS tentative welding procedure specification, which is assumed to be adequate by the consumable manufacturer, but

41、 which has not been approved by the RA Note 1 to entry: Welding of test pieces needed for approval of a welding procedure specification has to be carried out on the basis of a preliminary welding procedure specification. 3.4 welding procedure specification WPS procedure approved to European standard

42、s and agreed by the RA for use on the railway infrastructure 3.5 training establishment welder training organisation or centre approved by the railway authority or alternatively a welder training organisation or centre approved by and belonging to a railway authority 3.6 manual metal-arc welding MMA

43、 manually operated metal-arc welding using a covered electrode 3.7 flux-cored arc welding FCAW semi-automatic or automatic arc welding process Note 1 to entry: FCAW requires a continuously fed consumable tubular electrode containing a flux and a constant-voltage or a constant-current welding power s

44、upply. DIN EN 16725:2017-01 EN 16725:2016 (E) 8 3.8 certification body body for the purpose of witnessing and reporting the welding and testing of test pieces 3.9 AMS austenitic manganese steel, in accordance with EN 15689 3.10 penetrant testing PT method of crack detection employing capillary actio

45、n. A low surface tension liquid is applied to a test area, after a given soak time a powder developer is applied, the developer draws the liquid from any cracks present giving a clear indication of any surface breaking defect 3.11 tri-metal zone flash butt welded area of the casting containing AMS,

46、rail steel and the stainless steel insert 3.12 million gross tonnes (MGT) Equivalent Million Gross Tonnes Per Annum (EMGTPA) annual traffic load (metric for assigning track category) 4 Consumable and WPS approval tests for MMA electrodes and FCAW wires 4.1 General The approval of consumables and the

47、 related WPS is broadly in line with the requirements of EN ISO 15613, but owing to the special nature of the repair weld in terms of steel grades, the approval process shall follow this standard. 4.2 Consumable and WPS approval model 4.2.1 Flow chart The following flow chart describes how a consuma

48、ble and its related WPS shall be approved. WPS approval shall follow the principle of EN ISO 15613 approval by a pre-production test. DIN EN 16725:2017-01 EN 16725:2016 (E) 9 NOTE 1 The approving RA has to issue an approval certificate upon successful outcome of track trial. NOTE 2 Other RAs may req

49、uire further tests to verify suitability for special service/operational conditions or deposition techniques. Figure 1 WPS approval 4.2.2 Minimum information to be included in the pWPS The pWPS shall contain as a minimum the following: Parent material; Consumable classification type and size; DIN EN 16725:2017-01 EN 16725:2016 (E) 10 Welding process; Methods of preparation and cleaning; Current (A); Arc Voltage (V); Type of Current (AC/DC); Polarity; Travel Speed (