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RAILSAFE is a LEONARDO DA VINCI Community Vocational Training Action Programme Project

RAILSAFE/AG/PR/RI/JB/050515/1

Development of a Harmonised System forEducation, Qualification and Certification of

Railway Track Welders

RAILSAFE

Agenda RAILSAFE Workshop

Objective of the workshops is to get industry requirements as a basis for the development of: a guideline for education, qualification and certification of railway track welders a guideline for specification and approval of welding procedures for railway tracks a database of certified railway track welders and a welders passport system

Workshop participants:Rail track authorities, contractors, equipment manufacturers, consumable manufacturers,research and consultancy organisations, educators and welding institutes and welders.

Venue:

Date:

Agenda:

1 Welcome2 Introduction to the RAILSAFE project (Attachment No. 1)3 Interaction of the project with the draft standards EN 14730 (Attachment No. 2)4 Presentation and discussion on performance objectives for aluminothermic

welders (Attachment No. 3)

5 Presentation and discussion on welding procedures (Attachment No. 4)6 Inventory of requirements for a database and a passport system for certified

welders (Attachment No. 5)

7 Conclusions and actions


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Attachment No. 1 to RAILSAFE Workshop Agenda

RAILSAFE is a LEONARDO DA VINCI Community Vocational Training Action Programme ProjectRAILSAFE/PRES/PR/RI/JB/050509/1 1/2



Introduction to RAILSAFE

Background

Safety of rail traffic depends highly on the quality of the tracks, on the welds in the tracksand thus on the skills of the welder. Over the last years a number of accidents and near-accidents have happened. This resulted not only in injury to (and sometimes in death of)passengers, but also in downtime of the railway service and therefore loss of money.Some of these accidents were due to weld problems.Problems can also occur as a result of variable weld quality causing welds to be rejected andtaken out of service. This, in turn, can result in speed limits and delays.

The railway network throughout Europe is old and it is common knowledge that maintenancehas been delayed for financial reasons, especially after the privatisation of the railwaynetwork. The railways tracks need overdue maintenance and repair. In rail construction andmaintenance, reducing track possession time is a key feature of improving workforce safety.In welding terms, the same problems are experienced equally throughout Europe, like: lack ofuniformity of training and testing of welders, lack of common syllabuses and lack of mobilityof skilled welders. This is not only true between countries but also within some countries. Toset welders to work for other companies or in other countries is often hindered by differentprocedures and different qualification of welders.

The policy of the European Commission is to revitalise the railways, to promote theinteroperability between the separate national railway systems and to improve the safety.

(see EC White paper: European Transport Policy for 2010: Time to decide, 2001).Another policy of the European Commission is to stimulate, through the Leonardo da VinciCommunity Vocational Training Action Programme, education and training in a life-longlearning process to improve employability and to make work across national boundariespossible: free movement of people in the European Union.

The RAILSAFE project

Three years ago Working Group 4 of the Technical Committee 256 of the Comit Europen deNormalisation (CEN) asked the European Welding Federation (EWF) to develop and maintaina database for certified alumino-thermic railway welders in Europe.CEN Technical Committee 256 develops European standards on railways and Working Group

4 is responsible for track welding.The European Welding Federation, with national welding institutes as members, hasharmonised education, training, qualification and certification of welding personnel in Europe.The EWF has issued 50.000 diplomas over the last ten years. Railway welding is however notpart of this scheme.

To have a European database of certified welders implies the certification of welders on acommon European bases and all the necessary steps which lead to certification. Thedefinition of a certificate is in this context a document showing current competence. It haslimited validity in time and is essentially a life-long-valid diploma with a check on knowledgeand skills at regular intervals.


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RAILSAFE is a LEONARDO DA VINCI Community Vocational Training Action Programme ProjectRAILSAFE/PRES/PR/RI/JB/050509/1 2/2

The steps leading to certification include going backwards qualification of welders(diploma), harmonised (European) examination, education and training according to aharmonised curriculum guideline at approved training establishments. And above all theseactivities, quality audits on the whole system have to be performed and railway weldingparties concerned, such as railway authorities, contractors, process suppliers, trainingestablishments and welding institutes, have to be involved.

These steps actually address all the problems to some extent - as mentioned above underBackground.For the purpose of carrying out these steps a project has been formulated: Development ofa Harmonised System for Education, Qualification and Certification of Railway TrackWelders,RAILSAFE. The European Commission agreed to partially finance the project under the

Leonardo da Vinci Community Vocational Training Action Programme. The project hasstarted on 1 October 2004 and will take three years to complete. It will be carried out by 9partners from 7 different countries: a contractor building railways, a consultant on quality andharmonisation in welding, a European organisation representing welding institutes andwelding institutes themselves with expertise in education, training, qualification and

certification of welders. The project will be managed by TWI.The UK Institute of RailWelding (IoRW) has agreed to give input to the project.

The project aims for well-trained and qualified welders. In the project the cause for weldfailures and rejects will be analysed. An education, training, qualification and certificationsystem for railway track welders will be developed, using the best of existing nationalmaterial, but with a fresh look at rejects and failure prevention and thus on quality andsafety. As far as welding processes are concerned, RAILSAFEs main attention will go toaluminothermic welding.The objectives of the project are: to harmonise education, qualification and certification to make exchange of welders for

national railway authorities and companies in the European Union possible and to assure the quality of and access to continuing vocational education and certification for

life-long competences and better employability of railway welders across national

borders.The harmonisation will comprise the performance objectives and curriculum for education andtraining (not the training material), examination, qualification (European diploma) andcertification (European certificate, database of certified welders).

Getting RAILSAFE started

During the preparation of the RAILSAFE project proposal, CEN TC 256 WG 4 has beendeveloping standards on railway track welding procedures and on training of welders foraluminothermic welding. These standards are for comments and are not in force yet.These emerging standards prove to be a basis for the RAILSAFE activities, especially thestandard on procedures. The draft standard on training of welders has however featureswhich are different from the originally proposed ideas of RAILSAFE.While the project activities has begun, RAILSAFEs project management has starteddiscussions with major process suppliers and railway network authorities to determine how toget to the most effective way of cooperation.


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Attac

RAILSAFE is a LEONARDO DA VINCI Community Vocational Training Action Programme ProjectRAILSAFE/LTR/CO/RI/JB/050427/3



Comparison between the original RAILSAFE plan and the CEN standard prE

aluminothermic railway welders and a proposal for a revised RAILSAFE pla

Original RAILSAFE plan CEN standard prEN 14730-2 Revised RAILSAFE plrequirements

1 Overall structure

Authorised National Body (ANB) in eachcountry authorised by EWF to approvetraining schools, conduct examination ofwelders, issue diplomas and certificates,

following EWF rules, developed by experts

Not defined EWF produces special rulerail welder training, qualificsupplement those that alrerules require the ANB to es

committee for this activity industry sector. The represbut not be limited to: rail authorities rail welding contractor the rail welding proces

concerned rail welder training orgThis rail welding specialistimplementation of the schegoverning board of the AN

A specialist group is establproduce and maintain harm

representation on this grou rail authorities rail welding contractor rail welding process su rail welding training or ANBs


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Attac



2 Responsibility for training

Education and training by training schools,

approved by the EWF ANB

Initial training by: process supplier or process suppliers appointed agency or railway authorityin training establishment approved by: process supplier and railway authority or railway authority and belonging to a railway

authority

Education and training by

through the ANB's rail weld

3 Scope/content of training

Education and training according to acurriculum guideline of EWF, specifyingperformance objectives, education andtraining subjects and qualification and

certification rules, developed by experts

Initial training, according to process manual ofprocess supplier, who also determines duration oftraining and number of welds to be made

Education and training accincorporating those of and

4 Responsibility for testing

Examination of welders by the EWF ANB,through an Examination Committee,consisting of experts

Testing of welders after initial training by: process supplier or process suppliers appointed agency or railway authorityin training establishment approved by: process supplier or railway authority and belonging to a railway

authority

Examination of welders byof members of the rail wel

5 Responsibility for issuingqualification

Qualification (Diploma) by the EWF ANB Diploma by training establishment European Qualification (Di

6 Responsibility for re-training

Not defined Re-training for a Permit to weld by the employer Re-training for a Certificate


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Attac



7Scope/content of re-training

Not defined Re-training for a permit to weld according to railway

authority requirements

Re-training for a Certificate

authority requirements

8 Responsibility for re-testing

Examination for certification by theExamination Committee of the EWF ANB

Re-testing for a Permit to weld by the employer Examination for a CertificaCommittee, consisting of mcommittee

9 Responsibility for certification

Certification by the EWF ANB Permit to weld by the railway authority through theemployer

European certification by tauthority; in some countriepermit to weld

10 Administration of database ofcertified welders

Certified welders in EWF database Not defined Certified welders in EWF d

Observations

1. EWF has installed a harmonised European system (now taken over as an international system by IIW) for the qualifiThis has operated successfully since 1990 and over 100,000 EWF/IIW diplomas have been awarded. The higher level p

referenced in EN 719/ISO 14731 on Welding Co-ordination.Companies and individuals throughout the world have benefited enormously from the enhanced mobility and recognitioharmonised system. It is believed that no other profession has been able to install such a comprehensive and successfu

One of the outcomes of the RAILSAFE project will be to extend the scope of the harmonised system to include welders


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Attac


This will use exactly the same, successful, system as is used currently in EWF for approving training organisations, condiplomas; but EWF will ensure that appropriate rail welding expertise is present in the decision-making mechanisms bo

2. It is believed that many countries in Europe do not have a nationally harmonised system for rail welder training. Thein the competence of welders within, as well as across, national boundaries. By using the tried and tested EWF model,

bring about national and European harmonisation.

3. It has taken a considerable amount of work within CEN to reach a consensus on the qualification requirements for Even so, the current draft standards do not specify in detail the level of training or competence of welders, they mainlywhat. The outcomes of RAILSAFE will include unified performance objectives for welders, and guidelines on education Because of differences from country to country, this will not be an easy task. However, the value of success is consideimplementation of the new standards when they are published.

4. The same points apply to certification, and it is expected that the EWF certificate of competence, envisaged by the Rcredibility and status to be widely accepted by employers and rail authorities as the 'permit to work' required by the drathe potential for RAILSAFE to underpin the standard in an a very efficient and cost effective way, obviating the need focertification of welders who move from employer to employer.

5. The 'passport' concept of RAILSAFE is novel. Not only would it enable employers to keep track of their welders' qualimechanism for instantaneous, reliable verification of a welder's qualifications by rail authorities, etc, on a European-wid


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RAILSAFE/GUIDE/PR/IIS/CR/050517/3 1/6

PERFORMANCE OBJECTIVES

FOR

RAILWAY TRACK WELDING PERSONNEL

Aluminothermic Welding - Assistant (RTW - A)Aluminothermic Welding - Welder (RTW - W)


________

The scope of this guide is to document the performance objectives for personnel involved inrailway track welding operations and by means of these to prepare, as the next step, a guidelinefor the education and training of such personnel


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1 Qualification levels

This guide has been prepared considering two different levels of qualification, as follows:

Aluminothermic Welding - Assistant (RTW - A), a person without practical experience, who achieves,

through the training course, theoretical and practical knowledge to assist railway track welders and tounderstand the application of the process in its variants;

Aluminothermic Welding - Welder (RTW - W), a person with practical experience in the field of railwaytrack welding, already having the basic knowledge of the relevant processes, who achieves, through thetraining course, theoretical and practical knowledge to perform railway track welding

2 Education and training

2.1 Training establishment

Training shall be conducted in . and its execution must comply with the rules established in the

documents . (CEN standards and others)Training establishment shall possess sufficient facilities and equipment for all the attending personnel, asfollows:- Welding equipment- Rails- Oxy-fuel heaters- Grinding equipment- Oxy-fuel cutting torches- Disc cutters

Moreover, the training school shall fulfil requirements given in prEN 14730-2.

2.2 Course content

The training course is divided in several parts, as shown in table 1.

An applicant must satisfy the access conditions given in paragraph . If these conditions are adequatelymet, the applicant is then required to attend a training course giving, as a minimum, the hours of theoreticalinstruction detailed as recommended teaching hours for module I.

Recommended teachinghoursModule Sub Module

RTW - A RTW - W

1. Materials and their behaviour during welding 4 8

2. Welding Processes and Equipment 16 24

3. Fabrication, Applications Engineering 4 8

I. Theoreticaleducation

Total Module I 24 40

1. Aluminotermic welding 12 64

2. Ancillary activities 16 16II. Practical training

Total Module II 28 80

Total course 56 120

Table 1 - Parts composing the training course


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The recommended periods of time given in table 1 referenced as module II (practical training) represent theaverage time required to attain the expected level of skill, and can be changed depending on applicants skilland/or attitude, subject to evaluation of the trainers and/or qualification body.

A teaching hour shall contain at least 50 minutes of direct teaching time. Free choice in the arrangement ofthe syllabus is permitted.

2.3 Minimum requirements for the education and training

In the following paragraphs the minimum requirements for education and training courses are given, with theindication of teaching hours, making particular reference to the expected results (welder performanceobjectives).The scope and the objectives of each item will be added later when the expected results have been agreed.

RTW-A RTW-W

Module I Theoretical education 24 40

I.1 Materials and their behaviour during welding 4 8

I.1.1 Basics of metallurgy 2 4

Expected results1. Describe properties of steel X X2. Evaluate the effects of cooling rate X3. Interpret mechanical properties X

I.1.2 Welding metallurgy and structure of welded joints 1 2

Expected results1. Understand the effect of the heat supply on the weld metallurgy X X2. Describe the different regions constituting a weld X X3. Identify the effects of the welding parameters on the thermal cycle X

I.1.3 Rails 1 2

Expected results

1. Compare different types of rail steels X2. Appraise the susceptibility to cracking by reference to chemical

composition of steelsX X

3. Establish welding procedures depending on different factors affectingweldability X

4. Identify rail sections X X

I.2 Welding processes and equipment 16 24

I.2.1 Principles of Aluminothermic welding 1 2

Expected results1. Understand the base materials, equipment, plant and consumables used in

aluminothermic weldingX X

2. Understand given standards for consumables X X

2 4


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I.2.2 Aluminothermic welding process application

Expected results1. Select correct parameters and establish procedures for the execution of welds X X2. Appraise the susceptibility to welding defects and the influence of operative and

metallurgical factors X X3. Know how to use and care for the equipment and accessories X4. Outline differences in Railtech (PLA) and Thermit welding X5. Care for the equipment and accessories X X

I.2.3 Arc welding application for repair and building up of rail 1 2

Expected results1. Evaluate correct parameters and establish procedures for the execution of

weldsX X

2. Appraise the susceptibility to welding defects and the influence of operative andmetallurgical factors

X

3. Care for the equipment and accessories X X

I.2.4 Cutting processes for rails 4 4

Expected results1. Recognise gas equipment and explain the principle of oxy-fuel cutting X2. Know how to use (including assembly, testing, lighting up and closing down),

and care for, the equipment and accessoriesX X

3. Limitations of oxy-fuel cutting X4. Compare mechanical and oxy- fuel cutting X X

5. To cut rails freehand using a gas-cutting torch using two types of fuel gas. X X

6. To be competent to select, inspect and mount abrasive wheels safely andcorrectly.

7. To be able to operate the abrasive wheel cutting machine safely.

X

X

X

X

I.2.5 Other joining processes 2 2

Expected results1. Explain principle and field of application for each process X2. Compare different processes in use for rail track welding X X

I.2.6 Practice and application of aluminothermic welding processes 6 10

Expected results1. Identify components and equipment for all the welding and related processes X X2. Identify good practices in welding X X

I.3 Fabrication, Appl ications engineering 4 8

I.3.1 Health and safety 2 4

Expected results1. describe the risks associated with welding processes and equipment X X2. interpret Health and Safety regulations with respect to the above hazards. X X

3. Name from measurements the risk associated with welding operations. X X4. describe safe working procedures to ensure the requirements are met. X X


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5. correctly use the protection devices X6. Recognise and have an understanding of the relevant safety documentation X X

I.3.2 Fabrication of rail tracks 2 4

Expected results

1. Describe the phases of rail track construction X X2. Know and interpret the relevant rail fabrication standards, specifications and

documents.X X

3. Correctly describe measures of thermal deformation control in welding X X

4. Identify the difference in duties and responsibilities between an assistant welderand a welder

X

Module II Practical education1

28 80

II.1.1 Aluminothermic welding 12 64

Expected results1. Competent and full execution of welds for Thermit SkV-E, SkV-E between

tensors, SkV-L, Railtech PLA and PLA Gap 68 (?Plotz and KLK?) ; including:X X

- Prepare and dry the crucible X X- Select the correct portion X- Ensure correct rail end preparation and align the rails X X- Understand alignment requirements. X- Understand the need for, and correctly apply, datum marks X X- Select and attach the support equipment and align the preheater X X- Select and modify moulds X X- Fit and lute moulds X X- Align and charge the crucible and attach remaining equipment X X

- Set pressures and flame conditions X X- Eliminate moisture from support equipment prior to welding X X- Preheat rail ends X X- Ignite portion, cast the weld, remove support equipment, trim weld, note

timingsX X

- Produce a weld between rails of dissimilar wear X- Produce a 3 piece weld X- Produce a composite weld X- Identify pour irregularities and take appropriate remedial action X- Identify correct procedure for removal of waste material and hot material X- Reinstate track fastenings, remove runners and risers, clean the weld, clear

and tidy the site, store equipment correcltyX X

2. Interpret good practice in the execution of welds X X

3. Correct use of ancillary equipment. X X

II.1.2 Ancillary activities 16 16

Expected results1. Execution of ancillary activities, including: X X

- Clean rails ends, prior to producing the weld gap, remove ballast/fastenings X X- Prepare a welding gap using disc cutters X X- Prepare a welding gap using a cutting torch X- Correctly assemble a set of tensors around the weld joint.

1In the following paragraphs the items to be covered in the practical training are given. The typical training

time is reported, assumed as average teaching hours to be spent on every item, however subject toevaluation by the trainers, taking into consideration applicants skill and experience


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- Carry out all pre-start checks on the rail grinding machine and to understandcorrect use

X

- To visually inspect the weld before leaving site. X X- Grind welds to the required standard X- To complete all necessary documentation before leaving site X X

2. Appraise good practice in the execution of arc welding processes applied to

railway track elements

X X


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RAILSAFE/GUIDE/CO/ISQ/JPH/050331/5

Rail welding Aluminothermic welding procedure specif ication



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RAILSAFE/GUIDE/CO/ISQ/J PH/050331/5 1/12

Contents Page

Foreword the RAILSAFE Project ...................................................................................................... 21. Scope and purpose ................................................................................................................... 32. Normative references ................................................................................................................ 33. Terms and def init ions ............................................................................................................... 34. Technical content of the aluminothermic welding p rocedure specification (WPS) .......... 54.1 Related to the rai l welding contractor ...................................................................................................54.2 Work descr iption......................................................................................................................................54.3 Related to the parent material, rail (s) ....................................................................................................54.4 Special limitations on local conditions ................................................................................................. 54.5 Related to the welding equipment / consumables ...............................................................................54.5.1 Kit reference............................................................................................................................................... 54.5.1.1 Portion...................................................................................................................................................54.5.1.2 Mould.....................................................................................................................................................54.5.1.3 Crucible / reaction chamber ..................................................................................................................64.5.1.4 Tapping system.....................................................................................................................................64.5.1.5 Pouring system...................................................................................................................................... 64.6 Related to the jo int...................................................................................................................................64.6.1 J oint preparation........................................................................................................................................64.6.2 J oint design................................................................................................................................................64.6.3 Requirements for datum marking ..............................................................................................................74.6.4 Requirements on mould adjustments ........................................................................................................74.7 Weld details: .............................................................................................................................................74.7.1 Pre-heating................................................................................................................................................74.7.2 Ignition ....................................................................................................................................................... 74.7.3 Critical process timings / temperatures / mould removing instructions .....................................................74.7.4 Stripping.....................................................................................................................................................74.7.5 Final grinding.............................................................................................................................................74.8 Weld collar geometry ..............................................................................................................................74.9 Inspection .................................................................................................................................................84.10 Safety information ................................................................................................................................... 8Annex A - Weld ing p rocedure speci ficat ion (WPS)........................................................................... 9Bibliography ......................................................................................................................................... 12


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Foreword the RAILSAFE ProjectThis document has been prepared by RAILSAFE project partner ISQ with the assistance of TWI, IIS and VSRT

ISQ developed this guideline with the support of the Portuguese Railway Authority REFER.

The RAILSAFE project aims for well-trained and qualified welders. In the project the cause for weld failures andrejects will be analysed. An education, training, qualification and certification system for railway track welderswill be developed, using the best of existing national material, but with a fresh look at rejects and failureprevention and thus on quality and safety. As far as welding processes are concerned, RAILSAFEs mainattention will go to aluminothermic welding.

The objectives of this project are to harmonise education, qualification and certification to make exchange ofwelders for national railway authorities and companies in the European Union possible and to assure the qualityof and access to continuing vocational education and certification for life-long competences and betteremployability of railway welders across national borders. The harmonisation will comprise the performance

objectives and curriculum for education and training (not the training material), examination, qualification(European diploma) and certification (European certificate, database of certified welders).

RAILSAFE is a collaboration between the following organizations:

TWI LtdIr. J .B. van den Brug Raadgevend Ingenieur (RI)Schweitechnische Lehr- und Versuchsanstalt Hannover (SLV)Istituto Italiano della Saldatura (IIS)Volker Stevin Rail & Traffic (VSRT)European Federation for Welding, J oining and Cutting (EWF)Instituto de Soldadura e Qualidade (ISQ)Svetskommissionen (Swedish Welding Commission) (SWC)

Prva Zvaracska a.s. (PZ) (First Welding Company)

The project is managed by TWI Ltd and is partly funded by the EC under the Leonardo da Vinci programme ref:UK/04/B/F/PP/162-152.


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1. Scope and purposeThe current practice in the rail welding industry is for the supplier of aluminothermic welding equipment andconsumables (the process supplier) to produce a manual describing in detail the correct application of itsvariant of the process to the range of rail welding situations normally encountered. This Process Manual thenforms the basis for rail welder training in that process variant, and for ensuring the correct execution of welds onsite.

Process Manuals can be large documents and do not particularly lend themselves to day-to-day use by sitewelding teams. The current document provides a mechanism for distilling from a Process Manual all theessential data needed by a welder to execute a weld correctly in a specific set of circumstances. In most othertypes of welding, the term that is widely used and accepted for such a document is a welding procedurespecification and it seems appropriate to adopt the term for the kind of specification described by the currentdocument.

This document specifies minimum requirements for the content of a welding procedure specification for the

aluminothermic welding process of rails, by defining all variables important for the correct reproduction andunderstanding of the welding procedure by those involved in the welding activity.

The variables listed in this document are those influencing the quality of the welded joint.

This document could also act as a guidance on the requirements for a harmonised aluminothermic weldingprocess manual which can be used to satisfy the requirements of the prEN 14730-1:2003 process manual thatas to be submitted with the request for approval.

The laboratory tests and requirements for the approval of the aluminothermic welding process using weldsproduced in workshop conditions are specified in prEN 14730-1:2003.

The requirements for the approval of the aluminothermic rail welder are specified in prEN 14730-2:2003.

2. Normative referencesThis document incorporates by dated or undated reference, provisions from other publications. These normativereferences are cited at the appropriate places in the text, and the publications are listed hereafter. For datedreferences, subsequent amendments to or revisions of any of these publications apply to this document onlywhen incorporated in it by amendment or revision. For undated references the latest edition of the publicationreferred to applies (including amendments).

EN 13674-1, Railway applications Track Rail Part 1: Vignole railway rails 46 kg/m and above

EN ISO 4063, Welding and allied processes Nomenclature of processes and reference numbers.(ISO 4063:1998)

prEN 14969, Railway applications Track Qualification of railway trackworks contractors

prEN 14730-1:2003, Railway applications Track Aluminothermic welding of rails Part 1: Approval ofwelding processes

prEN 14730-2:2003, Railway applications Track Aluminothermic welding of rails Part 2: Qualification ofaluminothermic welders, approval of contractors and acceptance of welds.

3. Terms and definitionsFor the purpose of this document, the following terms and definitions apply:


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welding procedure specification (WPS): a document that provides all the required variables of the weldingprocedure and which has been approved for use.

preliminary welding procedure specification (pWPS): a document that provides all the required variables ofthe welding procedure and which has to be approved.

welding procedure qualification record (WPQR): record comprising all necessary data needed for theapproval of a preliminary welding procedure specification

portion: Individually packed iron oxide (Fe2O3) and aluminium metal powder sufficient for one weld.

mould: two or three pieces of refractory material (sand) that sustain the molten metal while it solidifies.

nominal welding gap: Free space between the two rail section top. The welding gap shall be measured afterweld alignment (peaking) at the running surface, web mid point and both foot tips. The maximum gap is themaximum at any of the above points and minimum the minimum of any of the above points. See figure below.

vertical alignment: Is defined by the following figure for a peaked alignment (Note: dipped alignment is theopposite of a peaked one and it is measured in the centre).

horizontal alignment: Alignment of the two rail sections measured from the inside of the track.

ballastless track: track not supported by ballast, generally a track which is constructed either on sleepersembedded in concrete or asphalt or on a concrete slab.

high speed lines: lines that come within the scope of the Technical Specification of Interoperability (S.T.I) ofthe infrastructure sub-system of the trans European high speed rail network. Conventional lines are all otherthan high speed ones.

conductor rail: Additional rails (or rail) provided on electric railways where power is transmitted to trains fromthe track. Often referred to as the 'third rail' or 'current rail'.

500 mm

h2h1

Peak =(h1 +h2)/2

500 mm

top

Max gap =max{top +mid + foot tip 1 +foot tip 2}Min gap =min{top + mid +foot tip 1 +foot tip 2}

mid

Foot tips


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4. Technical content of the aluminothermic welding procedurespecification (WPS)

A aluminothermic welding procedure specification (pWPS/WPS) shall provide all the necessary informationrequired to make a specific weld. The information required for the pWPS/WPS is given in clauses 4.1 to 4.10.

An example of the pWPS/WPS format is shown in annex A.

4.1 Related to the rail welding contractor- Identification of the contractor;- Identification of the aluminothermic WPS (Reference number);- Reference to the welding procedure qualification record (WPQR) or other documents as required (e.g. see

prEN 14730-1 and prEN 14969)

4.2 Work description

- Identification of the type track and line where the weld are to be made. (e.g. Ballast track / ballastless track,high speed lines/conventional lines; conductor rail)

- Number of persons (rail welder / rail welder assistant) needed to perform the welding operation- Dealing with any differences in rail profile or rail head wear.

4.3 Related to the parent material, rail(s)- Identification of the material(s) and reference standard(s);- Number(s) of the group as given in EN 13674-1.- Identification of the rail(s) profile as given in EN 13674-1 and/or rail(s) profile drawing (optional).

4.4 Special limitations on local conditions

- Description of any limitations on the local conditions (e.g. minimum ambient temperature)

4.5 Related to the welding equipment / consumables

4.5.1 Kit reference- if applicable, manufacturer, trade name and designation of welding kit.

4.5.1.1 Portion- Trade name and/or designation- Composition. Elements weight- Shelf life period- Storage precautions

NOTE: Some applications may require the identification of the weld metal composition instead of the portioncomposition (see ANSI/AWS D15.2-94)

4.5.1.2 Mould- Trade name and/or designation- Number of pieces- Shelf life period- Storage precautions


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4.5.1.3 Crucible / reaction chamber- Trade name and/or designation- Refractory chemical nature

- Storage precautions- Maximum number of welds

NOTE: The designation shall be related and identify the internal crucible geometry - prEN 14730-1:2003 mayrequire the internal crucible geometry drawing.

4.5.1.4 Tapping system

- Trade name and/or designation- Refractory chemical nature- Releasing mechanism

NOTE: The designation shall be related and identify the tapping system geometry - prEN 14730-1:2003 mayrequire the tapping system geometry drawing.

4.5.1.5 Pouring system- Trade name and/or designation

NOTE: The designation, shall be related and identify the pouring system geometry. A pouring system geometrydrawing may be required.

4.6 Related to the joint

4.6.1 Joint preparation- Identification of the rail end preparation/cutting method, e.g. sawed / abrasive disc- Rail stressing equipment (if used)- Identification the pre-welding cleaning method for oxide, dirt, grease, burns, fins and/or moisture removal- Identification of special precautions to be observed, e.g.:

o looseness of the rails to be welded;o remove defects from the joint than can disturb the mould placement;o holes axes shall be at 100mm (minimum) from weld area;o over tightening the base plate or mould clamp screws may cause cracking of the mould and

subsequent leaking of the molten metal;

4.6.2 Joint design- A sketch of the joint design/configuration;- Identification of the following dimensions:

o (Nominal) welding gapo Vertical alignment (Flatness / Dip);o Horizontal alignment

NOTE: The method for measuring the vertical and horizontal alignment may influence the dimension.


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4.6.3 Requirements for datum marking- Datum marking information (e.g. number of marks; position; checking intervals and amount of movement

accepted; corrections to be made if necessary)

4.6.4 Requirements on mould adjustments- Mould adjustment information (e.g. maximum mould depth removal; mould areas required to fit; other

indications)

4.7 Weld details:

4.7.1 Pre-heating- Heating equipment reference

- Identification of the method and fuel type to be used (composition of the mixture and partial pressures)- The minimum temperature applied at the start of welding- Rail length from weld face to be pre heated

NOTE: The minimum temperature applied at the start of welding and the rail length from face to be pre heatedcan be substituted by expressing the time (duration) and joint location to apply the heating.

4.7.2 Ignition- The method to be used

4.7.3 Critical process timings / temperatures / mould removing instructions- Time from ignition to tap:- Rate of cooling or time/temperature until mould removal- Time/temperature before course grinding- Time/temperature before trains can pass

4.7.4 Stripping- Stripping equipment- Method description / Mould removing instructions- Removal of rail stressing equipment (if used)

4.7.5 Final grinding- Method to be used;- Machine to be used, manufacturer and trade name- Maximum grinding length- Finished profile requirements

4.8 Weld col lar geometry- A sketch of the weld collar geometry as indicated in prEN 14730-1, clause 5.5.2- Identification of the following dimensions:

o Weld collar width (W1)o Maximum collar depths at section B-B (D1, D2)


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o Minimum collar depths at section B-B (d1, d2)o Riser cross section at footo Riser cross section at neutral axis;o

Number of risers.o Position of risers

4.9 Inspection- Description of the inspection to be done by the welder and the acceptance requirements. (e.g. identification ofthe weld; profile requirements)

4.10 Safety information- Critical safety information about the welding process and subsequent operations (e.g. preheating; cutting;grinding) shall be presented in the pWPS/WPS, e.g.

o DANGER: INTRODUCTION OF MOISTURE TO THE ALUMINOTHERMIC WELDINGPROCEDURE PROCESS MAY CAUSE SERIOUS OR FATAL INJURY. Molten steel and hotslag can cause serious explosion upon coming into contact into snow, ice, standing water,frozen blast or soil

o Improper or careless luting (sealing) of the mould may cause leakage of the molten metal;o Personnel must wear railroad approved safety glasses at all times.o Slag basin should be emptied only after the slag has completely solidified.o Solid slag should be disposed of in such a manner as not to pose any hazard to operating

personnel


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Annex A - Welding procedure specification (WPS)

ALUMINOTHERMIC WELDING PROCEDURE SPECIFICATION

1. GENERAL

ManufacturerWPS Reference numberWPQR Reference number

2. WORK DESCRIPTIONType of track / lineNumber of persons needed ___ Rail welders ___ Rail welder assistants

Rail profile/ rail head wear differences

3. RAIL(S) - PARENT MATERIAL

Material / Standard designation welded to(EN 13674-1) Group welded to(EN 13674-1) Profile welded to

4. LIMITATIONS ON LOCAL CONDITIONS

Description

5. CONSUMABLESKit reference (manufacturer and designation)

Designation

/ Ref. No.

Storage

precautions

Shelf lif e

period Other

Portion

Elements weight composition:

Mould

Number of pieces:

Crucible ---

Refractory chemical nature:

Maximum number of welds:

Tappingsystem

--- ---

Refractory chemical nature:

Releasing mechanism:

Pouringsystem

--- --- ---

WPS ref. Date Approved by Page N.o

1 of 3


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6. JOINT DETAILS

Rail end preparation/cutting methodRail stressing equipmentPre-welding cleaning methodSpecial precautions

Joint relevant dimensions

Vertical alignment (mm)

Horizontal alignment (mm)

Nominal welding gap (mm)

Sketch area

Requirements for datum marking

Requirements on mould adjustments

7. WELD DETAILSHeating equipmentMethod / Fuel type

Temperature / timeLength from weld face to be pre heated

Ignition method

Critical process timings / temperatures

Time / temperature from ignition to tapRate of cooling or time/temperature until mould removal

Time/temperature before course grindingTime/temperature before trains can pass

Stripping

Mould removing instructionsEquipmentMethod descriptionRemoval of rail stressing equipment


2 of 3


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Final Grinding

EquipmentMethod descriptionMaximum grinding length (mm)Finished profile requirements

8. WELD COLLAR / INTERNAL MOULD GEOMETRYWeld collar width (W1)Maximum collar depths at section B-B (D1 and D2)

Minimum collar depths at section B-B (d1 and d2)Riser cross-section at footRiser cross-section at neutral axisNumber of risersPosition of risers

9. INSPECTION REQUIREMENTS

10. SAFETY INFORMATION


3 of 3


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Bibliography

[1] ANSI/AWS D15.2-94, Recommend practices for the welding of rails and related components for use byrail vehicles

[2] prEN 14730-1:2003, Railway applications Track Aluminothermic welding of rails Part 1: Approvalof welding processes

[3] prEN 14730-2:2003, Railway applications Track Aluminothermic welding of rails Part 2:Qualification of aluminothermic welders, approval of contractors and acceptance of welds.

[4] AWS Welding Handbook Volume 2 8th Edition Chapter 29 Other welding processes ThermicWelding, American Welding Society

[5] KLK- Soldal, Procedimiento de Soldadura Carril/Carril FE-4-1992, Electro Materiales KLK, s.a.

(KLK- Soldal, Rail/Rail welding procedure FE-4-1992, Electro Materiales KLK, s.a.)

[6] prEN ISO 15609-1:2003, Specification and qualification of welding procedures for metallic materials Welding procedure specification Part 1: Arc welding (ISO/FDIS 15609-1:2003)


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RAILSAFE/GUIDE/PR/EWF/IF/050512/4 1/3

Development of a Harmonised System for

Education, Qualification and Certification of


Proposal for the Microsoft Access Data Base for Welders

A) Structure

Administrator:

Permissions to update the Microsoft Access application in terms of layout, new cells, and so on (this can beat the level of company and/or at the level of National Body)

National Body:Permissions to update and insert Companies information, sort information

Company/Employer:

Permissions to update and own insert Welders information, sort information, warning welders approvals endof validity

B) Type of information to be inserted on the data base

i) Welder name (text cell 50 characters)

ii) Date of Birth (day/month/year)

iii) Company (company identification, text cell 50 characters)

iv) Welder Approvals

Cert #1 to #8 (cell with 25 characters) icon to open more information

Related welding process

Note: In the access data base can be stored for each welder 1 to 8 Welders approvals certificates

v) For each Welder Approval certificate the related information

- Cert #1 (cell with 25 characters) icon to see the pdf of the welder approval

- Welder Certification code/standard/specification (cell with 50 characters)

- Date of issuing (day/month/year)

- Date of end of Validity (day/month/year)


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RAILSAFE/GUIDE/PR/EWF/IF/050512/4 2/3

- Range of approval (text cell with 600 characters)

- Documents that supported the welder approval

- 2 or 3 cells with identification of the document, on each cell an icon to see the pdf file- Prolongation of the welder approval

- 1st prolongation

- Date of prolongation issuing (day/month/year)

- Date of end of the validity (day/month/year)

- Icon to see the pdf of the certificate prolongation validation

- 2 or 3 cells with identification of the document that supported the prolongation, on eachcell an icon to see the pdf file

- 2nd, 3rd, 4th and 5th prolongation

- Date of prolongation issuing (day/month/year)

- Date of end of the validity (day/month/year)

- Icon to see the pdf of the certificate prolongation validation

- 2 or 3 cells with identification of the document that supported the prolongation, on eachcell an icon to see the pdf file

C) The utilities of the access data base

C.1) At the level of Companies, it will be possible to:

i) Insert

- New welders- New welder approval for an existing welder- New welder approval prolongation for an existing welder- Pdf documents regarding each welder approval and/or prolongation

ii) Sort

- By welder- By Type of welding process- By Code/standard/specification- By date of end of welding approval validity

iii) Warnings:

- Expiration date for welder approvalC.2) At the level of National Body, it will be possible to:

i) Insert/update

- New Companies- Update information regarding a certain company


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ii) Sort

- By Company- By Type of welding process

- By Code/standard/specification

- By National level- By Type of welding process

- By Code/standard/specification

Note:

At Company Level the Data Base will work on a computer using Access software, and the folders (accesstable and pdf files) will be allocated in a computer.

At National Level the Data Base will work using a site in a web server (the servers must be able to run ASPpages). This will allow an easier way to update and insert information from Companies to the National Data

Base.

Rail Welders with entry in the database will be awarded a passport with information on the certificatesthey have and respective expiry dates.