What is a code:

A systematic collection of regulations and rules of procedure

IPC Indian Penal Code - It is a comprehensive code,
intended to cover all substantive aspects of criminal law.

IBR Indian Boiler regulation - Regulations in respect of

materials, design and construction, inspection and testing of
boilers and boiler components for compliance by the
manufacturer's and users of boilers in the country.

ASME BPVC Section IX - Welding and Brazing Qualifications

What is a standard:
A Standard can be defined as a set of technical definitions and guidelines
that function as instructions for designers, manufacturers, operators, or
users of equipment.

Different standards adopted

American Welding Society Standards (AWS)

American petroleum institute standards (API)

Australian / New zealand standards (AS/NZS)

British Standards (BS)

International Organisation for standardisation (ISO)

European Union Standards (EN)

German Standards (DIN)

Bureau of Indian Standards (BIS)

Difference between a code and a standard

A code is a model, a set of rules that knowledgeable people

recommend for others to follow. It is not a law, but can be
adopted into law.

A standard tends be a more detailed elaboration, the nuts

and bolts of meeting a code.

A standard becomes a Code when it has been adopted by

one or more governmental bodies and is enforceable by law,

or when it has been incorporated into a business contract.

Current Scenario
No code or standard is available / followed for welding of
railway vehicles and components.

EN 15085: 2007 (part 1 5)

Railway applications Welding of Railway vehicles and
components

EN 15085: 2007 consists of

Part 1 General
Part 2 Quality Requirements and
certification of welding manufacturer
Part 3 Design requirements
Part 4 Production Requirements
Part 5 Inspection, testing and
documentation.

Railway Applications - Welding of Railway

vehicles and components part 1 -General
EN 15085 -1 : 2007
1. Scope
. Provides general recommendations
. Definitions for welding railway vehicles and associated
components
. Applies to all assemblies, sub-assemblies or parts welded by
any welding processes, (manual / partly mechanised / fully
mechanised /automatic ) as per EN ISO 4063 except for
specific contractual provisions.
. Does not deal with product qualification

2Normative

reference

EN 45020:06 Standardization & related

general vocabulary

activities

CEN/TR 14599:05 Terms & definitions for welding purposes

in relation with EN 1792
EN ISO 17659:04 Welding Multilingual terms for welded
joints with illustrations
3. Terms & Definitions
3.1 Manufacturer certification body - a competent body that
certifies the manufacturer according to EN 15082-2

3.2 Certification level (CL)- Level to classify the welded railway

vehicle or the welded component depending on the weld
performance class (CP)
Certified certification level

Included certification level

CL 1

CL 1
CL 2
CL 3
CL 4

CL 2

CL 3

CL 4

x
x

x - Certified Certification Level

- Included certification level
A CL 1 certificate also permits design or purchase & resale or purchase & assembly
for all certification levels if so indicated in the certificate
A CL 2 certificates also permits design or purchase & resale or purchase &
assembly for the certification levels CL 2 and CL 3 if so indicated in the certificate
A CL 4 certificate permits design or purchase & resale or purchase & assembly
for the certification level specified in the field of application of the certificate
Note: If CL 4 for design is not included, this must be indicated in the certificate

3.3 Weld performance class - Performance requirements of the

welded joint as defined by the stress category and the safety
category of welded joint
3.4 Weld inspection class defines the inspections to be carried
out for a given weld with respect to weld performance class

3.5 Customer Organisation responsible for defining the

technical, quality requirement and the acceptance
procedures for welded product.
3.6 Manufacturer organisation that
uses a welding facility to manufacture or maintain railway
vehicle or parts of vehicle certification level CL 1, CL 2,
CL 3 ( or )
Designs welded rail vehicles or parts of vehicle/buys welded
parts for assembly into railway vehicles or sells them for
assembly into railway vehicles certification level CL 4

3.7 National safety authority - National government body

responsible to set up the safety requirements
3.8 Qualification - Evidence of training, professional
knowledge, skill and experience to enable the personnal to
perform the task

3.9 Qualified Person with evidence of training,

professional knowledge, skill and experience, proven
by an internal test.
3.10 Subcontracted welding coordinator Welding
coordinator not employed by the welding manufacturer
3.11 Joint static dimensioning - defines the
dimensions of the weld joint to achieve the required
mechanical characteristics.

3.9 Qualified Person with evidence of training,

professional knowledge, skill and experience, proven by an
internal test.
3.10 Subcontracted welding coordinator Welding
coordinator not employed by the welding manufacturer
3.11 Joint static dimensioning - defines the dimensions
of the weld joint to achieve the required mechanical
characteristics.

3.12 Acceptance authority - organisation responsible for

acceptance of the product.
3.13 Effect cross section cross section of a welded joint
considered for dimensional calculations.
3.14 Joint fatigue dimensioning - the dimension of a weld to
achieve the required fatigue characteristics.
3.15 Stress category
calculated fatigue stress / admissible fatigue stress

3.19 Production weld test Mock up sample welded joint to prove the skill of
operator or to demonstrate acceptable production of
welded joint

3.16 Stress factor calculated fatigue stress / admissible fatigue stress

3.17 Admissible fatigue stress
maximum stress applicable to materials to which a
specific coefficient to the assembly to be welded is
applied
3.18 Safety category
consequences of failure of the welded joint with
respect to persons, facilities and environment

EN 15085 2 Quality requirements

and certification of welding
manufacturer
Scope: Defines the certification levels as well as the requirements for
welding manufacturers and describes the procedure for the
recognition of welding manufacturers.
Four certification levels (CL) are laid down for the certification of
welding manufacturers (Level 1 to level 4)
Level 1 to Level 3 depends on the weld performance classes CP A to
CP D of the welded joints specified in EN 15085-3:2007, Table 2

Certification Level
Description

Certification Level
(CL)

Applies to manufacturer of welded railway

vehicles/parts with welded joints classified in weld
performance classes CP A to CL 4 is included

CL 1

Manufacturers of welded parts of railway vehicles

with welded joints classified in weld performance
classes CP C2 to CP D.

CL 2

Welded joints classified in weld performance class

CP C1 are included if these welds are checked
according to weld inspection class CT 1 according to
EN 15085-5:2007, table 1. Certification level CL 4 is
only included according to welded joints of
certification level CL 2 to CL 3

Description

Certification level

For manufacturers of welded parts of railway vehicles

with welded joints classified in weld performance class
CP D

CL 3

For manufacturers who do not weld but design railway

vehicles and parts of rail vehicles or buy and assemble
or sell them. Certification not required for welding works
of certification level CL 3

CL 4

Items to 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 ( 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.
As per EN 15085-3:2007, certification level CL1 to CL3 shall be
clearly indicated in the drawings.

5 Quality requirements for the welding manufacturer

5.1 Staff requirements
5.1.1. Welders and welding operators
o Welders with qualification in accordance with EN 287-1 / EN ISO
9606-2 or EN 1418
o Such qualification shall be carried out by either
--

accredited examining body

--

responsible welding co ordinator of the manufacturer,

recognised by the manufacturer certification body

--

if fillet welds are done, then a fillet weld test piece is

necessary

5.1.2 Welding coordination

-- The manufacturer shall have suitable experienced welding
coordinators with relevant technical knowledge according to EN
ISO 14731
-- The manufacturer shall clearly prove to the manufacturer
certification that the technical knowledge of the welding
coordinator is at the required level.
Welding coordinators with comprehensive technical knowledge (level A)
-- Personnel with qualification according to Doc. IAB-002-2000/EWF409 International Welding Engineer (IWE) or European Welding
Engineer (EWE)
-- Personnel with qualification according to Doc IAB-003-2000 /EWF
410 International Welding Technologist (IWT) or European Welding
Technologist (EWT) with suitable experience in welding supervision

. Welding

coordinators with specific technical

knowledge (Level B)
Personnel with atleast three years and proof of specific technical
knowledge with
-- Personnel with qualification according to Doc. IAB-003-2000/EWF410 International Welding Technologist (IWT) or European
Welding Technologist (EWT)
-- Personnel with qualification according too Doc. IAB-0042000/EWF-411 International Welding Specialist (IWS) or
European Welding Specialist (EWS) with suitable experience and
proof of technical knowledge

Welding coordinators with basic technical

knowledge (Level C)
Personnel with atleast three years of experience and proof of basic
technical knowledge.
--- Personnel with qualification according to Doc. IAB-0042000/EWF-411 International Welding Specialist (IWS) or
European Welding Specialist (EWS)
--- Personnel with qualification according too Doc. IAB-0052001-451 International Welding Practitioner (IWP) or European
Welding Practitioner (EWP) with suitable experience in welding
supervision and proof specific technical knowledge.

5.1.3 Subcontracted welding coordinator

1. Only one welding coordinator per location site shall be subcontracted.
2. At least one deputy who is employed by the manufacturer is available
in the location site and recognized.
3. The welding coordinator shall be contractually tied to the welding
manufacturer.
4. The minimal hours of work depends on the extent of the welding
production and shall contractually be regulated & shall be recorded
in a production log.
5. The sub contracted welding coordinator may work for more than one
manufacturer. If he works for more than two welding manufacturers,
agreement with all customers is required. Further subcontracted
welding coordination shall be accepted by the customer.

5.1.4 Inspection personnel

The welding manufacturer shall have sufficient qualified inspection
personnel for
-- quality testing within the welding production facility.
-- Inspection required either by design or by the performance
class of the weld.
--This inspection shall be carried out as per EN 473. The
inspection personnel for PT, MT, ET, UT, RT shall have a
procedure based qualification of at least level 1.
The testing evaluator shall be certified atleast to level 2 of EN
473. Non destructive tests may be done by external inspection
personnel certified according to EN 473.

5.2 Technical requirements

The technical requirements shall be as per EN ISO 3834 and
roofed, dry, ventilated and sufficiently lit workshops and working places.
Dry store rooms for welding fillers and ancillary supplies
If different materials are welded, separate tools, machines and
equipments shall be used for each materials, and cleaned before use.
Suitable power supply
If no suitable testing equipment is available, an external inspection body
can be contracted.
Lifting gear for transporting and turning parts
Work platforms
Turning devices or manipulators to facilitate welding in the flat position.

Clamping devices for welding assemblies

Devices for straightening
Protection when working with aluminium or stainless steel to keep away
dust, spatter, gases and fumes which might reduce the corrosion
resistance of the parent metal or the quality of weld.

5.3 Welding coordination organisation

a welding coordinator can be recognised only if he is involved in the
welding manufacturer organisation in such a way that they can accept
their tasks and responsibility without rreservation as per EN ISO 14731
and according welding coordination (5.1.2 of EN 15085-2)
The responsibilities , competencies and should be documented. The
following items, in particular should be specified and described.
-- tasks of the welding coordinators
-- rules for who deputises for the welding coordinator
-- activities which require the attendance of the responsible welding
coordinators
-- measures which are required if the welding coordinator is absent
-- involvement of the responsible welding coordinator in the internal
process.

5.4 Welding procedure specification

For welds which are classified in the weld performance
classes CP A to CP C3, a welding procedure specification is
necessary according to EN ISO 15607 and depending on the
welding process, according to series of standards EN ISO 15609,
EN ISO 14555 or EN 15620.
For welds which are classified in the weld performance class
CP D, a welding procedure specification is necessary only if it is
demanded by the customer.

6 Certification procedure
6.1 Audit for certification
the manufacturer certification body undertakes verification of
compliance with the requirements of this standard, particularly
-- welding personnel (welding coordinators, welders, welding
operators ) requirements
-- welding coordinators shall be interviews to demonstrate that
they have the necessary knowledge on welding as per EN ISO
14731 and this series of standards
-- welding procedure specifications based on WPQR
-- Qualification test of welders according to EN 287-1 or EN ISO
9606-2
-- Qualification test for operators according to EN 1418
-- Additional test specimens (mock-up)
-- technical requirements and welding production
-- welding quality requirements according to the relevant parts of
EN ISO 3834

6.2 Certificate
The certificate shall indicate
--

name and address of certified welding manufacturer

--

certification level at which welding manufacturer is entitled

to weld

--

field of application

--

range of certification(welding procedures, materials, sheet

thickness, remarks)

--

welding coordinators (first name, name, date of birth &

qualification)

-- remarks and extension of application

-- validity
-- date of issue

7 Validity
The validity is limited to a maximum of 3 years