Questionnaire for EN 15085

Clause
Numbe
r
Description
4 Certification of welding manufacturers
Are design engineers aware about four certification levels for rail
coach manufacture?
Ie
Certification level-(CL -1,CL-2,CL-3,CL-4)
Yes/no
Some briefing is
given for easy
understanding.
Certification level-CL-1:
This level applies to welding manufacturers which manufacture
welded railway vehicles or their welded parts with
weldedjoints classified in weld performance classes CP A
to CP D.
Certification level CL 2 to CL 4 is included.


Reproduced from standard for Information.
Ex. CL-1 is for manufacturers of the following items.
Because of their safety relevance the following components
and sub-assemblies shall be welded by welding
manufacturers with a certification level CL 1.

bogie frames and bolsters;
body shell components (e.g. under frames, structures);
buffers and draw gear;
wheel set components (e.g. wheel set mountings, axle
boxes, spring supports);
brake equipment (e.g. magnetic track brake, brake
rods, brake triangles, brake cylinders, brake cross beams);
supporting frames for heavy components (e.g. traction
units, pantographs);
welded components for drag transmission from bogie to
vehicle;
vibration dampers and their link between bogie and
vehicle or between vehicles;
finishing welding of castings within components indicated
above;
external fuel tanks.

Are design engineers aware that certification level depends on
weld performance class? Abbreviation for the same is CP
Ie: CPA,CPB etc

5 Quality requirements for the welding manufacturer.
5.1 Staff requirements
5.1.1 Welders and welding operators Same as ISO 3834
5.1.2 Welding coordination

Same as ISO 3834
5.1.3 Sub contracted welding coorinator Not applicable to
ICF
5.1.4 Inspection Personnel

EN 15085 -Part 3: Design requirements

4 Design Requirements


4.1
4.2 Joint static dimensioning
Are Calculation performed on local areas to ensure that the
cross section of the weld is sufficient to withstand static
stresses?

Are weld bead static dimensioning followed as per
annexure B&C of EN 15085- part-3(design requirements)
Annex B&C enclosed for reference.

4.3 Joint fatigue dimensioning
Are weld Joints designed according to stress and safety
categories?

4.4 Stress categories and stress factors.
Are we calculating stress factor according to the
following formula?

The stress factor is the ratio of the calculated fatigue
stress to the admissible fatigue stress of the joint type,
adjusted by the appropriate safety factor.

What is the standard or source of data for the
admissible stress used while designing rail coach?

Are we following the following standards for guidelines for
design purposes?
EN 12663 -(Railway applications - Structural requirements of
railway vehicle bodies - Part 1: Locomotives and passenger
rolling stock (and alternative method for freight wagons) .
EN 13749 (Railway applications. Wheelsets and bogies. Method
of specifying the structural requirements of bogie frames (British
Standard)


4.5 Safety categories
The safety category defines the consequences of failure of the
single welded joint in respect to the effects on persons,
facilities and the environment.

Are classifying welded joints as high, medium, or low
safety? Ref: annex G of EN 15085-3
Low: Failure of the welded joint does not lead to any
direct impairment of the overall function. Consequential
events with personal injuries are unlikely.
Example for low safety category: welded joints for damper
connection support for brake pipes and electric panels.
Medium: Failure of the welded joint leads to an
impairment of the overall function or can lead to
consequential events with personal injuries.
Example for medium safety category: welded joints of box
girder of bogie frame, car body structure frame

High: Failure of the welded joint leads to consequential events
with personal injuries and breakdown of the overall function.

Example for high safety category: welded connection between
car body and bogie frame.


4.6 Weld performance classes(CP)
Weld performance classes shall be defined in the design
phase depending on the safety category and the stress
category
Example: for high stress and high safety category it is indicated
as CP-A
Weld performance class CP A is a special class which applies
only for welds with full penetration and full accessibility for
inspection in production and maintenance

Are performance classes indicated in ICF drawings?



Are design engineers aware that certification level depends on
weld performance class? Abbreviation for the same is CP
Ie: CPA,CPB etc



4.7 Weld inspection classes(CT)
The inspection class applicable to each welded joint is defined
depending on the weld performance class defined formerly, see
Table 3of EN 15085-Part-3

These inspection classes are used to identify the various types
and minimum levels of inspections on the welded joints.


Are inspection classes indicated in ICF drawings?


5 Quality levels for imperfections
5.2.1 Quality levels for imperfections for fusion welded joints
(beam welding excluded)



5.2.1.1 Steel
Quality levels for imperfections according to EN ISO 5817
B- Stringent level
C-intermediate level
D-Moderate level

Are accepted quality level for imperfection as per EN ISO 5817
is given in the drawing?



5.2.2
Are quality levels for imperfections for laser beam
welding related to the weld performance class is
defined in the drawing?

The applicable standard is Quality levels for imperfections shall

be according to EN ISO 13919-1(Welding - Electron and laser-
beam welded joints - Guidance on quality levels for
imperfections - Part 1: Steel)
5.2.4 Quality requirements for resistance spot welding, and
resistance seam welding related to the weld performance
class
Spot spacing, distance from edge -) Table F.1
Are spot spacing between two spot welds are designed as
standards?
Ex. It is mentioned in table F-1 as 40 mm as distance between two
spots for 2 mm thick sheet.


5.2.4 Table F.2 defines the quality requirements for resistance
spot welded joints, resistance seam welded joints for
production welds

Are we defining weld performance class in drawings?


5.2.4
Table F.3 defines the surface quality for resistance spot welded
joints, and resistance seam welded joints.

Table F.3 Surface quality
The standard defines spot welding surface quality into four
levels. Viz. level-1, level-2, level-3,level-4.

For example it defines level 2 for sidewall, end wall, roof of
passenger coaches the requirement as given below.
Surfaces where welding marks (electrode impressions, ring
shaped reinforcement-formation, imperfections, through heat
distortion etc.) do not amount to more than 10 % of the
particular single sheet metal thickness.

Note: If required the indentation can be filled in.

Are we specifying one such requirement for surface quality in
sidewall, roof drawings involving spot welding?