TÜV SÜD Sava d.o.o. Čakovec, 27-02-2020 By: Davor Jelačić dipl. ing. Auditor acc. to EN15085 and DIN 27201 Welding of Railway Vehicles - Quality Assurance Content: 1. 2. 3. 4. 5. 6. 7. 9.5.2024. Development and structure of EN 15085 Key Terms Welding Shop Requirements Design Requirements Production Requirements Quality Control, Testing/Inspection and Documentation Maintenance of Railway Vehicles by Welding By: Davor Jelačić, TUV SUD Sava branch office Čakovec 2TÜV SÜD Grupa www.tuv.hr Welding of Railway Vehicles - Quality Assurance 1. Key Terms 3. Design Requirements EN 15085-3 Quality Assurance 4. Production Requirements – EN 15085-4 2. Welding Shop Requirements 5. QC, Inspection/testing and Documentation 6. Maintenance by Welding –EN15085-6 NEW 7. Conclusion Prasentation Content By: Davor Jelačić, TUV SUD Sava branch office Čakovec TÜV SÜD Grupa www.tuev-sued.de Welding of Railway Vehicles - Quality Assurance Content: 1. 2. 3. 4. 5. 6. 7. 9.5.2024. Development and structure of EN 15085 Key Terms Welding Shop Requirements Design Requirements Production Requirements Quality Control, Testing/Inspection and Documentation Maintenance of Railway Vehicles by Welding By: Davor Jelačić, TUV SUD Sava branch office Čakovec 4TÜV SÜD Grupa www.tuv.hr Development and Structure of EN 15085 – until 1997 - DB-Druckschriften DS 952 01 and DS 952 02. – from 07:1997 to 12:2007 – DIN 6700 Part 1 – 6 – 2006 DVS Mb 1622 published to complete the requirements of DIN 6700 – 01:2008 –EN 15085 Part 1 to 5 published – 2014 – work on new EN 15085 edition commenced – amendment of Part 2, 3, 4 and 5 and compilation of new Part 6 – maintenance and assembly EN 15085-7 – welding shop conformity assessment – New edition: EN15085-1 2013-11 and pr.EN15085-2 2018-1 – DIN 27201-6: 2017:12 – maintenance of railway vehicles By: Davor Jelačić, TUV SUD Sava branch office Čakovec TÜV SÜD Grupa www.tuev-sued.de Welding of Railway Vehicles - Quality Assurance 2. KEY TERMS– EN 15085 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 6 www.tuv-sud.hr EN 15085-1: Key Terms Key terms: Safety category Safety relevance Stress categories Weld Class of Performance Class of Testing 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 7TÜV SÜD Grupa www.tuv.hr EN 15085-1: Key Terms • Safety category ac. to EN 15085 (consequences of default • of an individual weld) Safety relevance acc. to new DIN 6700 (consequences of default of an individual assembly) high Safety category / relevance medium low high Stress category medium low 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 8TÜV SÜD Grupa www.tuv.hr EN 15085-1: Key Terms • Class of Performance (CP) Safety category Stress categories High • Medium Low High CP A CP B, in the future CP B2 CP C2 Medium CP B in the future CP B1 CP C2 CP C3 Low CP C1 Cp C3 CP D CP Class of testing (CT) CP CT 1 CT CT 2 CT CT 3 CT 4 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 9TÜV SÜD Grupa www.tuv.hr EN 15085-3: Design Requirements • Class of testing (CT): CT Volumetric testing Surface inspection VE Certificate Documentation CT 1 (CP A) 100% 100% 100% Yes Requirement 100% 100% 100% Yes Requirement CT 3 (CP C2) - - 100% No. Internal qualif. Contract CT 4 (CP C3, CP D) - - 100% No. Qual. welder No CT 2 (CP b, CP C1) 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 10 www.tuv-sud.hr EN 15085-2: Welding Shop Requirements 3. WELDING SHOP REQUIREMENTS acc. to EN 15085-2 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 11 www.tuv-sud.hr EN 15085-2: Welding Shop Requirements • Basic requirements: – Welding shop must be certified • DIN 6700-2: Welding certificate acc. to DIN 6700-2 • EN15085-2: Welding certificate scc. To EN 15085-2 • Companies that design, buy and install, or buy and sell welded components are also WELDING SHOPS - appropriate qualification is required • Certification levels for welding shops: • DIN 6700-2: 5 component classes acc. to which certification levels for welding shops are classifies - depending on the safety relevance. • EN 15085-2 (ed. 2008): 4 certification levels – are determined according to the highest weld class of performance (CP), for some assemblies CL 1. Certification levels: CL 1 to CL 4 Acc. to highest weld CP on welded parts 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec Assemblies with highest safety category, CL1 certificate 12 www.tuv-sud.hr EN 15085-2: Welding Shop Requirements Certif. Level Welding shop can weld: CL1 CP A to CP D CL 1 includes CL 2 to CL 4 CL2 CP C2 to CP D. CP C1 can also weld when tested acc. to CT1. CL 2 includes CL3 and CL4. CL3 CP D CL includes CL 4. CL4 For shops which perform design, buy and are assemblying or which buy and are assemblying welded component of railwy vehicles. 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 13TÜV SÜD Grupa www.tuv.hr EN 15085-2: Welding Shop Requirements EN – components and sub-assemblies – manufacturers with CL 1, see annex A DE – Komponenten und Bauteile – Betriebe mit CL 1, siehe Anhang A Bogie frames and bolsters Drehgestellrahmen und Drehgestellwiege Body shell components (e.g. under frames, structures) Fahrzeugrohbauten (z.B. Untergestell,Seitenwand, Aufbauten) Buffers and draw gear Zug und Stoßeinrichtungen Wheel set components (e.g. Wheel set mountings, axle boxes, spring supports) Bauteile für Radsatzführung (z.B. Radsatzhalterungen, Radsatzlagergehäuse, Federböcke) Brake equipment (e.g. Magnetic track brake, brake rods, brake triangles, brake cylinders, brake cross beams) Bremsausrüstung (z.B. Magnet-schienebremse, Zugstangen, Bremsdreiecke, Bremszylinder, Bremstraversen) Supporting frames for heavy components (e.g. Traction units, pantographs) Tragrahmen für schwere Komponenten (z.B. Antriebsaggregate, Stromabnehmer) Welded components for drag transmission from bogie to vehicle Anschweißteile für Zugkraftübertragung vom Drehgestell zum Fahrzeug Vibration dampers and their link between bogie and vehicle or between vehicles Schwingungsdämpfer und deren Anbindung zwischen Drehgestell und Fahrzeug bzw. Zwischen den Fahrzeugen, Finishing welding of castings within components indicated above Fertigungsschweißen von Gusstücken and vorgenannten Bauteilen External fuel tanks Äußere Kraftstofftanks 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 14TÜV SÜD Grupa www.tuv.hr EN 15085-2: Welding Shop Requirements 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 15TÜV SÜD Grupa www.tuv.hr NEW prEN 15085-2 11:2018 Welding Shop Requirements • • • • prEN 15085-2, ed. 11:2018: „Certification level becomes Classification level (CL) Component classification levels depend on safety relevance of the component in question. List of components classified in Classification Class CL 1 Only welding shops with CL 1 can weld components with high safety relevance. 9.5.2024. Classification level CL Welding shop can weld the following: CL 1 Welded component with high safety relevance CL 2 Welded component with medium safety relevance CL 3 Welded component with low safety relevance By: Davor Jelačić, TUV SUD Sava branch office Čakovec 16 www.tuv-sud.hr NEW prEN 15085-2 11:2018 Welding Shop Requirements • pr EN 15085-2 (2018): marking on the certificate is amended by adding the term Scope of the Welding Shop D: design P: Production Scope M; Maintenance S: Purchase and Supply 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 17 www.tuv-sud.hr NEW prEN 15085-2 11:2018 Welding Shop Requirements • Quality assurance system for welding shops – acc. to EN ISO 3834 • Link between classification levels and EN ISO 3834 • Certificate acc. to EN ISO 3834 not a condition! Classification levels CL Quality assurance requirements acc. to EN ISO 3834 CL 1 ISO 3834-2 CL 2 ISO 3834-3 CL 3 ISO 3834-4 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 18 www.tuv-sud.hr NEW prEN 15085-2 11:2018 Welding Shop Requirements • Requirements for welding supervisor: – – – – – – 3 welding supervisor levels, level A, B and C Prove that they possess technical knowledge for classification class CL Work experience of min. 3 years, Duties and responsibilities acc. to ISO 14731 and EN 15085 Annex B In EN 15085-2: Annex with special technical requirements for welding supervisor Certification acc. to IIW guidelines not required Welding superviosr level Level A Extended technical knowledge acc. to ISO 14731 Level B Specific technical knowledge acc. to ISO 14731 Level C General technical knowledge acc. to ISO 14731 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 19 www.tuv-sud.hr EN 15085-3: Zahtjevi za konstruiranje 4. DESIGN REQUIREMENTS acc. to 15085-3 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 22 www.tuv-sud.hr EN 15085-3: Design Requirements • EN 15085-3 defines: Weld Class of Performance (CP) Design rules Drwing data. • This standard does not define sizing parameters for railway components, see e.g. EN 12663 and EN 13749 • Alternatively, the allowed stresses obtained as a result of dynamic strength tests on representative samples may be used in the design. 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 23 www.tuv-sud.hr EN 15085-3: Design Requirements Weld Class of Performance CP Safety category (failure risk assessment) 9.5.2024. Stress category Access for inspection By: Davor Jelačić, TUV SUD Sava branch office Čakovec Full penetration weld 24 www.tuv-sud.hr EN 15085-3: Design Requirements • Class of testing (CT): CT Volumetric testing Surface inspection VE Certificate Documentation CT 1 (CP A) 100% 100% 100% Yes Requirement 100% 100% 100% Yes Requirement CT 3 (CP C2) - - 100% No. Internal qualif. Contract CT 4 (CP C3, CP D) - - 100% No. Qual. welder No CT 2 (CP b, CP C1) • 9.5.2024. Additionally for CT 2: if for BW with CP B2 or CP C1 volumetric examination due to partial penetration is not possible – mock-up + surface tests 100% for first 5 parts, then 25%. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 25 www.tuv-sud.hr EN 15085-3: Design Requirements • • „Without the possibility for a volumetric test” make no sense for fillet welds and other welds without full penetration (e.g. for Y / HY) Joints with weld performance class CP A, CP B and CP C1, which can be inspected during production but cannot be inspected and repaired in maintenance, shall be allocated to the NEXT HIGHER INSPECTION CLASS acc. to the table or the stress level shall be reduced 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 26 www.tuv-sud.hr EN 15085-3: Design Requirements • • Design of welded joints: Following shall be avoided: – sudden changes in cross section, – local accumulation of welds – Welding in cold formed areas 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 27TÜV SÜD Grupa www.tuv.hr EN 15085-3: Design Requirements • Rules for design of welded joints: – Welded joints in high stress areas – accessibility for welding and testing 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 28 www.tuv-sud.hr EN 15085-3: Design Requirements • Rules for design of welded joints : 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 29 www.tuv-sud.hr EN 15085-3: Design Requirements • Rules for design of welded joints : 9.5.2024. Pripremio: Davor Jelačić, TUV SUD Sava Podružnica Čakovec 30 www.tuv-sud.hr EN 15085-3: Design Requirements • Rules for design of welded joints : 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 31 www.tuv-sud.hr EN 15085-3: Design Requirements • Rules for design of welded joints : – Edge distance for FW – Minimum overlapping distance for overlapping welds – 9.5.2024. run-on and run-off plates for BW for CP A and CP B By: Davor Jelačić, TUV SUD Sava branch office Čakovec 32 www.tuv-sud.hr EN 15085-3: Design Requirements – Solutions to be avoided because residual stress can cause cracks: • welding round bars or pipes on thick plates – because the weld has no possibility of free shrinking • Welding of thin parts on thick plates • Welding of ribs on thick-walled pipes 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 33 www.tuv-sud.hr EN 15085-3: Design Requirements • Measures to improve the dynamic properties of welds (extension of service life or increase of dynamic bearing capacity) • Reducing residual stress: processes for generating compressive stresses, eg shot blasting with metal shot or heat treatment – Reduction of stress concentrations in the transition area between welds and base material e.g. by grinding the transition area to a depth k≤0.3mm and radius r≥3mm 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 34 www.tuv-sud.hr EN 15085-3: Design Requirements • Welded assembly drawings shall include: 1. Welded joints on drawings shall be marked with item No. 2. Weld shape + weld dimension + weld length 3. Weld Class of Performance (CP), electric resistance spot welding additionally surface quality; 4. Dana on Class of Testing (CT) is required only when the same deviates from the one stated in EN 15085-3 Table 3 acc. to the corresponding CP 5. Certification level (CL) 6. Materials according to appropriate material standards 7. Filler metals for welding according to appropriate standards 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 35 www.tuv-sud.hr EN 15085-3: Design Requirements • Welded assembly drawings shall include the following data: 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 36 www.tuv-sud.hr EN 15085-3: Design Requirements 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 37 www.tuv-sud.hr NEW prEN 15085-3 Design Requirements • Amendments in the new EN 15085-3 edition: – Weld symbols on drawings according to ISO 2553 – Recommendations for handling 3D models are likely to be given as they replace classic drawings 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 38TÜV SÜD Grupa www.tuv.hr Welding of Railway Vehicles - Quality Assurance 5. PRODUCTION REQUIREMENTS acc. to EN 15085-4 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 39 www.tuv-sud.hr EN 15085-4: Production Requirements • practical rules for welding as well as rules for qualification of welding procedures (WPS) - taken from DIN 6700 • New in EN 15085 – Production weld tests • Key elements of EN 15085-4: – Documentation – WPSs – Production weld tests – Welding requirements (preparation, implementation, testing/inspection) – Choice of filler metals – Additional requirements for welding of some types of base materials (e.g. cast steel see EN 1011-8) 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 40TÜV SÜD Grupa www.tuv.hr EN 15085-4: Production Requirements • Welding documentation: • – Working plans – Welding sequence plans – Testing plans – Welding procedure specifications (WPS) Working plan is required for bogies, body shell components and structures • • 9.5.2024. For more complicated assemblies, Welding Sequence Plans are required Additional welding documentation: Acceptance welding plans, Repair instructions, Drawings of devices or tools, operating instructions, etc. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 41TÜV SÜD Grupa www.tuv.hr EN 15085-4: Production Requirements • Production weld tests (PWT) can be welded as: – testing plate, – mock-up or – zajedno sa dijelom/sklopom, npr. u produžetku dotičnog zavara / together with the part / assembly, e.g. in an extension of the weld in question. • Purpose of PWT: 1. In the design phase to check welding possibilities (e.g. due to limited access) 2. To control the welding process (for welds with partial penetration), 3. PWT to test the qualification (skill) of welders - for joints that require special skills of welders 4. PWT as proof of weld quality (e.g. when for CT 2 welds there is no possibility of RE (radiographic) or UE (ultrasound examination) due to incomplete welding) 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 42TÜV SÜD Grupa www.tuv.hr EN 15085-4: Production Requirements • CP defines methods and requirements for the qualification of WPS: • For CP A: – Qualification according to ISO 15614-1; according to ISO 15613 only if WPQR according to ISO 15614-1 already exists. For materials with ReH> 500 MPa or mechanized welding: ISO 15614-1. – WPQR should meet the acceptance criteria for CP A • For CP B, CP C1, CP C2: – Qualifications acc. to ISO 15613, ISO 14555. Due to builtin material or welding process – acc. to ISO 15614-1 • For CP C3: – Qualifications acc. to ISO 15610, ISO 15611, ISO 15612, ISO 15613 or ISO 14555. Due to built-in material or welding process – acc. to ISO 15614-1. • CP D: acc. to customer requirements 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 43TÜV SÜD Grupa www.tuv.hr EN 15085-4: Production Requirements • • • • • • • 9.5.2024. Selection of filler metals and proof of compliance: For non-alloy and low-alloy steels: the criteria are the properties of the weld metal. Weld properties should meet the requirements for basic materials and the classification of filler metals from the appropriate standard For stainless steels: mechanical/technological properties of filler metal correspond to the basic material. When welding Al and AL alloys: EN 1011-4. Filler metals meet the requirements according to EN 13479 and the corresponding EN ISO standards for the classification of filler metals. present a valid Certificate with information on the planned welding process, materials, welding positions and type of current. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 44TÜV SÜD Grupa www.tuv.hr NEW prEN 15085-4 Production Requirements • • • 9.5.2024. Some customers (e.g. DB) require for filler metals a certificate of conformity according to EN 14532-1 issued by a Notified Body. These certificates are available online under www.en15085.net The new edition of EN 15085-4 is likely to revise the chapter on filler metals by adding recommendations for the selection of filler metals. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 45TÜV SÜD Grupa www.tuv.hr ASME Sec. IX – Development and Qualification of WPS 6. QC, TESTING/INSPECTION AND DOCUMENTATION acc. to EN 15085-5 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 46 www.tuv-sud.hr EN 15085-5: Testing/Inspection and documentation requirements • • • • 9.5.2024. Testing/Inspection before, during and after welding Requirements for the scope of testing of performed welds and required documentation EN 15085-3 defines acceptance criteria for VE of welds. CP B, C and D are identical to the acceptance criteria for welds B, C and D according to EN ISO 5817 (for steel) or EN ISO 10043 for aluminum alloys. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 47TÜV SÜD Grupa www.tuv.hr EN 15085-3: Design requirements • Class of testing (CT) /Schweißnahtprüfklassen: CT Volumetric testing Surface inspection VE Certificate Documentation CT 1 (CP A) 100% 100% 100% Yes Requirement 100% 100% 100% Yes Requirement CT 3 (CP C2) - - 100% No. Internal qualif. Contract CT 4 (CP C3, CP D) - - 100% No. Qual. welder No CT 2 (CP b, CP C1) • Additionally for CT 2: when volumetric testing is not possible with CP B with medium safety category (CP B2) or with CP C1 – production weld test + 100% surface test share for the first 5 parts and then 25%. 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 48 www.tuv-sud.hr EN 15085-5: Testing/Inepsction and documentation requirements • Requirements for the subcontracted manufacture of welded assemblies: – The subcontractor should meet the requirements of this standard – Subcontractor certificate – Audit of the potential subcontractor for CL 1 and CL 2 components – Inform the end customer (user) about the manufacturing of CL 1bein subcontracted – With the new edition of EN 15085-5, it is likely that only editorial changes will be made and the cited standards will be updated. 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 49TÜV SÜD Grupa www.tuv.hr EN 15085-6 Maintenance of Railway Vehicles by Welding Requirements 7. MAINTENANCE OF RAILWAY VEHICLES BY WELDING acc. to EN 15085-6 and DIN 27201 9.5.2024. Pripremio: Davor Jelačić, TUV SUD Sava Podružnica Čakovec 50 www.tuv-sud.hr EN 15085-6 Maintenance by Welding - Requirements • New EN 15085-6 is planned„Requirements for Maintenance by Welding” • Content taken from DIN 27201-6 • Railway vehicle operator is in charge of maintaining his railway vehicle • Each railway vehicle is assigned to ECM (Entity in Charge of Maintenance) which defines regulations • The components of railway vehicles are divided into 3 classes for maintenance purposes: – CL 1- welded components with high safety category, CL 2- medium safety category (see 5.1.2) and – CL 3 – with low safety category 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec • 51TÜV SÜD Grupa www.tuv.hr EN 15085-6 Maintenance by Welding - Requirements • Important topics in the new EN 15085-6: – Components on which maintenance by welding is not allowed - list – Welding shop qualification acc. to EN 15085 for CL of the certain component required. – Additional requirements for welding supervisor (min. 2 years experience in maintenance of railway vehicles or appropriate internal qualification) – Minimum requirement for the number and qualification of welding supervision in the maintenance shop – Maintenance documentation requirements (drawings, instructions for use, data from the manufacturer as well as regulations are the basis for maintenance) – Handling of drawings that do not comply with EN 15085 – old railway vehicles – CP and range of testing and documentation depending on CL of the certain component – see Chart 1 in DIN 27201-6 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 52TÜV SÜD Grupa www.tuv.hr 8. CONCLUSION 9.5.2024. By: Davor Jelačić, TUV SUD Sava branch office Čakovec 53 www.tuv-sud.hr TÜV SÜD Sava branch office Čakovec Davor JELAČIĆ e-mail: davor.jelacic@tuvsud.com TÜV SÜD Sava Branch office Čakovec Ivana Mažuranića 2 40000 Čakovec Mobitel:++385(0)98 344 536 www.tuv-sud.hr www.tuev-sued.de