EN 14587-2-2009 en Railway applications - Track - Flash butt welding of rails - Part 2 New R220 R260 R260Mn and R350HT grade rails by mobile welding machines at sites other than a .pdf

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1、BS EN14587-2:2009ICS 25.160.10; 93.100NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAWBRITISH STANDARDRailway applications Track Flash buttwelding of railsPart 2: New R220, R260, R260Mn andR350HT grade rails by mobile weldingmachines at sites other than a fixedplantThis British

2、 Standardwas published under theauthority of the StandardsPolicy and StrategyCommittee on 30 April2009 BSI 2009ISBN 978 0 580 57761 1Amendments/corrigenda issued since publicationDate CommentsBS EN 14587-2:2009National forewordThis British Standard is the UK implementation of EN 14587-2:2009.The UK

3、participation in its preparation was entrusted to TechnicalCommittee RAE/2, Railway track components.A list of organizations represented on this committee can be obtained onrequest to its secretary.This publication does not purport to include all the necessary provisionsof a contract. Users are resp

4、onsible for its correct application.Compliance with a British Standard cannot confer immunityfrom legal obligations.BS EN 14587-2:2009EUROPEAN STANDARDNORME EUROPENNEEUROPISCHE NORMEN 14587-2April 2009ICS 25.160.10; 93.100English VersionRailway applications - Track - Flash butt welding of rails - Pa

5、rt 2:New R220, R260, R260Mn and R350HT grade rails by mobilewelding machines at sites other than a fixed plantApplications ferroviaires - Voie - Soudage des rails partincelage - Partie 2: Rails neufs de nuance R220, R260,R260Mn et R350HT par des machines de soudure mobilesdans des sites autres quune

6、 installation fixeBahnanwendugen - Oberbau - Abbrennstumpfschweienvon Schienen - Teil 2: Abbrennstumpfschweien neuerSchienen der Stahlsorte R220, R260, R260Mn undR350HT durch mobile Schweimaschinen an Ortenauerhalb eines SchweiwerkesThis European Standard was approved by CEN on 28 February 2009.CEN

7、members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this EuropeanStandard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such nationalstandards may be obtained on applica

8、tion to the CEN 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 translationunder the responsibility of a CEN member into its own language and notified to the CEN Management Centre has t

9、he same status as theofficial versions.CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland,France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal

10、,Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.EUROPEAN COMMITTEE FOR STANDARDIZATIONCOMIT EUROPEN DE NORMALISATIONEUROPISCHES KOMITEE FR NORMUNGManagement Centre: Avenue Marnix 17, B-1000 Brussels 2009 CEN All rights of exploitation in any form and by any means reserved

11、worldwide for CEN national Members.Ref. No. EN 14587-2:2009: EBS EN 14587-2:2009EN 14587-2:2009 (E) 2 Contents Page Foreword 4 Introduction .5 1 Scope 6 2 Normative references 6 3 Terms and definitions .6 4 Requirements for the welding process .8 4.1 General 8 4.2 Clamping force .8 4.3 Pre-heating f

12、lashing .8 4.4 Progressive flashing .8 4.5 Upsetting 8 4.6 Upset current 8 4.7 Unclamping 8 4.8 Welding program and records 8 4.9 Step across the weld .9 4.10 Weld trimming . 10 4.11 Post-weld heat treatment . 11 5 Procedure approval of a MFBW machine . 12 5.1 General . 12 5.2 Sample preparation 12

13、5.3 Approval tests . 12 5.3.1 Visual inspection 12 5.3.2 Weld trimming and upset examination . 12 5.3.3 Step across the weld 12 5.3.4 Magnetic particle or dye penetrant inspection 12 5.3.5 Bend testing 13 5.3.6 Macro examination . 13 5.3.7 Micro examination 13 5.3.8 Hardness testing . 13 5.3.9 Fatig

14、ue testing 14 5.4 Test result report 14 6 Approval of other rail profiles or grade 14 6.1 General . 14 6.2 Approval tests . 14 6.2.1 General . 14 6.2.2 Grade R220 14 6.2.3 Grade R260Mn . 14 6.2.4 Grade R350HT . 14 7 Approval of the Welding Contractor . 15 7.1 General . 15 7.2 Requirements for initia

15、l approval 15 7.2.1 Welding procedure . 15 7.2.2 Quality systems 15 7.2.3 Information to be provided by the contractor 15 7.2.4 Operators . 15 7.2.5 Supervision . 15 7.2.6 Weld Inspection 15 7.2.7 Equipment . 16 7.3 Field approval of the welding contractor . 16 7.4 Audits . 16 BS EN 14587-2:2009EN 1

16、4587-2:2009 (E) 3 8 Weld production and acceptance requirements 16 8.1 Information from the purchaser . 16 8.2 Site preparation of rail ends . 16 8.3 Rail alignment 17 8.4 Weld parameter monitoring 17 8.5 Weld identification . 17 8.6 Visual inspection . 17 8.7 Steps across the weld . 17 8.8 Profile

17、finishing of the rail head . 18 8.8.1 Initial grinding 18 8.8.2 Final grinding . 18 8.9 Geometrical acceptance criteria 18 8.10 Weld production testing 19 8.10.1 General 19 8.10.2 Additional test requirements 19 8.10.3 Bend test 19 8.10.4 Interpretation of results 20 8.11 Documentation . 20 Annex A

18、(normative) Bend test requirements 21 Annex B (normative) Test weld fracture faces Recording of defects . 23 Annex C (normative) Fatigue test method for flash butt welds 25 Annex D (normative) Macro examination and micro examination . 34 Annex E (normative) Hardness testing . 35 Annex ZA (informativ

19、e) Relationship between this European Standard and the Essential Requirements of EU Directive 2008/57/EC 36 Bibliography 40 BS EN 14587-2:2009EN 14587-2:2009 (E) 4 Foreword This document (EN 14587-2:2009) has been prepared by Technical Committee CEN/TC 256 “Railway applications”, the secretariat of

20、which is held by DIN. 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 October 2009, and conflicting national standards shall be withdrawn at the latest by October 2009. Attention is drawn to the p

21、ossibility that some of the elements of this document may be the subject of patent rights. CEN and/or CENELEC shall not be held responsible for identifying any or all such patent rights. This document is one of a series of three parts of the EN 14587 “Railway applications Track Flash butt welding of

22、 rails”. The list of parts is as follows: Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant; Part 2: New R220, R260, R260Mn and R350HT grade rails by mobile welding machines at sites other than a fixed plant; Part 3: Welding in association with crossing construction. This docume

23、nt has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association, and supports essential requirements of EC Directive(s). For relationship with EC Directive(s), see informative Annex ZA, which is an integral part of this document. According to the

24、CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania

25、, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. BS EN 14587-2:2009EN 14587-2:2009 (E) 5 Introduction This part of EN 14587 has three main topics: a) approval procedure for a mobile flash butt welding (MFBW) m

26、achine; b) approval of the welding contractor; c) weld production. This part of EN 14587 has been occasioned by a European Directive that will permit the freedom of an open European market. To enable this perception to become a reality, it is essential a standard is in place that satisfies the needs

27、 of the infrastructure owners or custodians and reflects the production capabilities of the manufacturers in technical and quality terms. This part of EN 14587 differs from Part 1 significantly due to the peculiarities of a MFBW machine: they are used at different places and for different purchasers

28、 within a short time; they work in various conditions such as weather, rail, track, worksites, power supply, legal regulations; they are operated by contractors, but personnel from different companies (including the purchaser) may be on site for the production of the continuous welded track; there a

29、re technical differences of the equipment used in order to guarantee the required mobility. Due to the above mentioned special operating conditions of a MFBW machine, the following requirements have been relaxed as a result: minimum bend test requirements for production bend tests only; maximum perm

30、itted trimmed upset. This part of EN 14587 does not identify any approval of a MFBW machine in terms of electromagnetic compatibility, vehicle braking systems or any requirements regarding load gauge, environment and its attendant issues or infrastructure access pertaining to any railway authority.

31、BS EN 14587-2:2009EN 14587-2:2009 (E) 6 1 Scope This European Standard specifies requirements for the approval of a welding process by a MFBW machine at sites other than fixed plant, as well as the welding contractor together with the requirements for subsequent welding production. Where a MFBW mach

32、ine is to be used in a static but temporary situation, the requirements of this part of the standard shall apply. It applies to new Vignole R220, R260, R260Mn and R350HT grade rails of 46 kg/m and above, as contained in EN 13674-1, welded by a MFBW machine at sites other than a fixed plant and inten

33、ded for use on railway infrastructures. This European Standard applies to the welding of rails into welded strings. 2 Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated refe

34、rences, the latest edition of the referenced document (including any amendments) applies. EN 571-1, Non destructive testing Penetrant testing Part 1: General principles EN 1290, Non-destructive examination of welds Magnetic particle examination of welds EN 13674-1, Railway applications Track Rail Pa

35、rt 1: Vignole railway rails 46 kg/m and above EN 14587-1, Railway applications Track Flash butt welding of rails Part 1: New R220, R260, R260Mn and R350HT grade rails in a fixed plant EN ISO 6507-1, Metallic materials Vickers hardness test Part 1: Test method (ISO 6507-1:2005) EN ISO 7500-1, Metalli

36、c materials Verification of static uniaxial testing machines Part 1: Tension/compression testing machines Verification and calibration of the force-measuring system (ISO 7500-1:2004) 3 Terms and definitions For the purposes of this document, the following terms and definitions apply. 3.1 fixed plant

37、 stationary production line for flash butt welding of rails, as specified by EN 14587-1 3.2 welding process any part of the sequence from the selection of the rail prior to welding through to the finishing of the welded string 3.3 upset metal extruded around the rail profile as a result of forging 3

38、.4 die burn damage caused by localised overheating on the surface of the rail caused by poor contact between the rail and the electrode during welding BS EN 14587-2:2009EN 14587-2:2009 (E) 7 3.5 trimming removal of upset 3.6 trimmed upset metal remaining around the rail profile following trimming 3.

39、7 dressing removing trimmed upset by grinding or other similar process 3.8 as welded condition rails that have been welded and trimmed only 3.9 profile finishing operation by which the rail head or relevant part of the rail head at the weld is returned to rail profile NOTE The operation can be by gr

40、inding, milling, planing or any other suitable means. 3.10 finished condition welded, trimmed, dressed and profile finished 3.11 flat spot process driven discontinuity showing as a small lens-like shape in vertical longitudinal section, or a generally circular/elliptical shape having a localised smo

41、oth texture when viewed in a vertical transverse section 3.12 lack of bond area of incomplete fusion between the rails in the joint NOTE This may appear as crack like or line discontinuity at the interface either on the surface after removal of the upset or in a weld section. 3.13 welded string long

42、 rail comprising a number of shorter rails flash butt welded together 3.14 MFBW machine abbreviation for a mobile flash butt welding machine 3.15 purchaser purchaser of the welds 3.16 railway authority (RA) either the railway regulator or the owner of a railway infrastructure or the custodian with a

43、 delegated responsibility for a railway infrastructure 3.17 contractor company approved by a RA to provide staff and machinery to execute the production of mobile flash butt welds on that particular infrastructure NOTE This may include staff and machinery from within the RA. BS EN 14587-2:2009EN 145

44、87-2:2009 (E) 8 3.18 manufacturer manufacturer of the welding machine 4 Requirements for the welding process 4.1 General All welding shall be carried out on a MFBW machine using an automatic, programmed welding sequence. 4.2 Clamping force Rails shall be secured in the MFBW machine by clamps of such

45、 a surface shape or contour, that when a clamping force is exerted on the rails, it shall not damage the rail in such a way that subsequent cracking in the rail in operation is generated. 4.3 Pre-heating flashing The fronts of the heated area shall progress uniformly perpendicularly to the running s

46、urface during the whole cycle. There shall be no evidence of overheating on the ends of the rails during pre-heating flashing. Once initiated, the flashing process shall not be interrupted. 4.4 Progressive flashing Once initiated, progressive flashing shall be continuous. 4.5 Upsetting Upsetting sha

47、ll immediately follow flashing. Sufficient forging pressure shall be applied to ensure that voids are closed and oxides are expelled such that they are kept to a minimum at the weld interface. The weld interface shall extend into the upset. 4.6 Upset current The upset welding current shall be mainta

48、ined until the rapid forge has finished and the progressive forging commences. 4.7 Unclamping In order to maintain the alignment, the time between completion of forging and unclamping shall be a minimum of 4 s. 4.8 Welding program and records The welding program (settings) shall be determined during

49、 procedural trials and, once approval has been granted, shall not be changed. The welding machine and/or management system equipment shall be capable of displaying the following: a) welding program identification and setting details; b) welding current; c) upset force or pressure; BS EN 14587-2:2009EN 14587-2:2009 (E) 9 d) displacement; e) welding time. The welding parameters shall be monitored and recorded. These records shall be referenced to the appropriate welds. The welding parameters shall permit the production