en15085-2 1st step

3 December 2008

Guideline of the Railway Vehicles Coordination Committee (Draft Guideline DVS 1619)

Procedure for the certification of welding manufacturers for welding railway vehicles and components according to EN 15085-2

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Contents 1 General

3

2

References to standards, regulations and guidelines

5

3

Classification of the certificates

8

4

Requirements

9

4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 5

Quality requirements Staff requirements Welding coordinators Welders/welding operators Inspection personnel Equipment Welding procedure specifications Certification procedure and verification

5.1 5.2 5.3 5.3.1 5.3.2 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14

Manufacturer certification bodies Application Audit Site inspection Interview with welding coordinators Documentation Final discussion Issuance of the certificate Period of validity Verification Renewal of the certificate Modification of the certificate Revocation of the certificate Validity of the certificate Exceptions Transitional regulations

9 9 9 10 11 11 11 15 15 15 16 17 17 20 20 20 22 22 23 23 23 23 23 Fehler! Textmarke nicht definiert.

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Annex 1

Application for certification for the welding of railway vehicles and components according to EN 15085-2

Annex 2

Sample report

Annex 3

Sample certificate for CL 1 to CL 3

Annex 4

Sample certificate for CL 4

Annex 5

Certified and also applicable materials groups according to CEN ISO/TR 15608 for certificates according to EN 15085-2

Annex 6

Special regulations for the repair of railway vehicles according to DIN 272016

Annex 7

Nomenclature for the certificate number EN 15085-2

Annex 8

Regulations for the transition from the DIN 6700 series of standards to EN 15085

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1 General This guideline describes the process of the certification of welding manufacturers for the welding of railway vehicles and components according to EN 15085-2 "Railway applications – Welding of railway vehicles and components – Part 2: Quality requirements and certification of welding manufacturer" and serves to define a uniform procedure. It is binding for all manufacturer certification bodies participating in this certification system and also includes supplementary information on the standard. The Federal Railway Authority (EBA) is the national safety authority responsible for railway traffic in Germany. The rules and regulations issued by the EBA must be taken into account for the certification of the welding manufacturers. Note: For railway traffic on non-federal railways, rules and regulations of the relevant authorities of the federal states may have to be observed. The Railway Vehicles Coordination Committee is the responsible steering body to ensure a uniform procedure of the manufacturer certification bodies. This guideline was prepared by the Coordination Committee in collaboration with DVS Working Group A7, "Welding in the Construction of Railway Vehicles". The certification of welding manufacturers is based on generally accepted rules of technology. For the welding of railway vehicles and components, these generally accepted rules of technology are embodied in: −

the EN 15085-1 to EN 15085-5 series of standards, and

−

additionally applicable reference standards.

Welding manufacturers wanting to undertake welding work in new build (including finishing welding) or in repair must provide evidence of their qualification according to EN 15085-2. Welded subassemblies of railway vehicles and components that have been manufactured or repaired by welding manufacturers not in possession of the required certificate are not considered to comply with the standards. Manufacturers who do not perform any welding work themselves but - design, or - purchase & assemble, or - purchase & resell welded components and subassemblies require a certificate for the certification level CL 4. Such qualification is considered to have been demonstrated if a certificate has been issued by a manufacturer certification body. A welding manufacturer having several welding facilities requires a separate certificate for each facility. The certificate becomes invalid when the prerequisites upon which it was granted, no longer exist. Annexes 6 and 8 contain supplementary regulations on the repair of railway vehicles and/or for the transition from the DIN 6700 series of standards to the EN 15085 that are only applicable to railway traffic in Germany. Coordination Committee Guideline / DVS 1619, Page 4 of 23

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2 References to standards, regulations and guidelines This Guideline incorporates provisions from other publications by dated or undated references. The relevant publications of such normative references in the text are listed below. In case of dated references, subsequent amendments or revisions of these publications are only included in this Guideline if they have been formally incorporated by an amendment or a revision. For undated references, always the latest edition of the referenced document applies. EN 15085-1

Railway applications – Welding of railway vehicles and components – Part 1: General

EN 15085-2

Railway applications – Welding of railway vehicles and components – Part 2: Quality requirements and certification of welding manufacturer

EN 15085-3

Railway applications – Welding of railway vehicles and components – Part 3: Design requirements

EN 15085-4

Railway applications – Welding of railway vehicles and components – Part 4: Production requirements

EN 15085-5

Railway applications – Welding of railway vehicles and components – Part 5: Inspection, testing and documentation

EN 287-1

Qualification test of welders – Fusion welding – Part 1: Steels

EN ISO 9606-2

Qualification test of welders – Fusion welding – Part 2: Aluminium and aluminium alloys

EN ISO 9606-3

Approval testing of welders – Fusion welding – Part 3: Copper and copper alloys

EN 1418

Welding personnel – Approval testing of welding operators for fusion welding and resistance weld setters for fully mechanized and automatic welding of metallic materials

EN ISO 14731

Welding coordination – Tasks and responsibilities

EN 473

Non destructive testing – Qualification and certification of NDT personnel – General principles

EN ISO 14555

Welding – Arc stud welding of metallic materials

EN ISO 15607

Specification and qualification of welding procedures for metallic materials – General rules

CEN ISO/TR 15608

Welding – Guidelines for a metallic materials grouping system

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EN ISO 15609-1

Specification and qualification of welding procedures for metallic materials – Welding procedure specification Part 1: Arc welding

EN ISO 15609-2

Specification and qualification of welding procedures for metallic materials – Welding procedure specification Part 2: Gas welding

EN ISO 15611

Specification and qualification of welding procedures for metallic materials – Qualification based on previous welding experience

EN ISO 15613

Specification and qualification of welding procedures for metallic materials – Qualification based on preproduction welding test

EN ISO 15614-1

Specification and qualification of welding procedures for metallic materials – Welding procedure test – Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys

EN ISO 15614-2

Specification and qualification of welding procedures for metallic materials - Welding procedure test – Part 2: Arc welding of aluminium and its alloys

EN ISO 15614-3

Specification and qualification of welding procedures for metallic materials - Welding procedure test – Part 3: Fusion welding of non-alloyed and low-alloyed cast irons

EN ISO 15614-6

Specification and qualification of welding procedures for metallic materials - Welding procedure test – Part 6: Arc and gas welding of copper and its alloys

EN ISO 15614-7

Specification and qualification of welding procedures for metallic materials – Welding procedure test – Part 7: Overlay welding of steel

EN ISO 15614-12

Specification and qualification of welding procedures for metallic materials – Welding procedure test – Part 12: Spot, seam and projection welding

EN ISO 15614-13

Specification and qualification of welding procedures for metallic materials - Welding procedure test – Part 13: Resistance butt and flash welding

EN ISO 15620

Welding – Friction welding of metallic materials

EN ISO 3834-2

Quality requirements for fusion welding of metallic materials – Part 2: Comprehensive quality requirements

EN ISO 3834-3

Quality requirements for fusion welding of metallic materials – Part 3: Standard quality requirements

EN ISO 3834-4

Quality requirements for fusion welding of metallic materials – Part 4: Elementary quality requirements Coordination Committee Guideline / DVS 1619, Page 6 of 23

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EN ISO 4063

Welding and allied processes – Nomenclature of processes and reference numbers

DIN 27201-6

State of railway vehicles – Basic principles and production technology – Part 6: Welding

DVS 1608 code of practice

Design and fatigue testing of welded joints of aluminium and aluminium alloys in the construction of railway vehicles (in preparation)

DVS 1610 code of practice

General guidelines for planning the welding production in the construction of railway vehicles

DVS 1617 code of practice

Quality requirements on subcontractors for welding railway vehicles and components

DVS 1620 code of practice

Inspection and testing of welding in the construction of railway vehicles

DVS 1621 code of practice

Production weld tests in the construction of railway vehicles Notes on implementing EN 15085 – Comparison with DIN 6700

DVS 1623 code of practice DVS 1109 guideline

Welding coordinators in the construction of railway vehicles

DVS 1612 guideline

Design and fatigue testing of welded steel joints in the construction of railway vehicles

DVS 1614 guideline

Straightening in the construction of railway vehicles

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3 Classification of the certificates The certificates are classified based on the certification levels (CL) defined in EN 15085-2. According to EN 15085-2, section 4, these certification levels depend on the weld performance class (CP) of the welded joints and the safety relevance of the components and subassemblies. The certification levels should be specified in the relevant drawing (see EN 15085-3). In the absence of such specification, the certification level according to EN 15085-2 must be determined prior to submitting the application. For this purpose, the national safety authority (which in Germany is the EBA) and the customer should be consulted as appropriate. The certification levels that are included in the level for which the certificate was issued are listed in the following Table 1: Table 1. Included certification levels Included certification level

Certified certification level

CL 1

CL 2

CL 3

CL 4

CL 1

X





1)

X



2)

CL 2 CL 3 CL 4

X X 3)

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.

1) 2) 3)

Note: If CL 4 for design is not included, this must be indicated in the certificate.

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4 Requirements The requirements on the welding manufacturer for the certification level applied for can be seen from EN 15085-2. For details please refer to section 5 and Annex C of EN 15085-2. Further explanations are included in Sections 4.1 to 4.4 of this Guideline. 4.1 Quality requirements With regard to the EN 15085 series of standards, the welding manufacturer must demonstrate its compliance with the requirements of EN ISO 3834-2 to EN ISO 3834-4 to the manufacturer certification body. For details, please refer to Annex C of EN 15085-2. Evidence of calibration and validation of the measuring, inspection and testing equipment (see section 16 of EN ISO 3834-2) is only necessary if this is contractually required. 4.2 Staff requirements 4.2.1 Welding coordinators The welding manufacturer must demonstrate its compliance with the requirements of section 5.1.2 and Annex C of EN 15085-2. EN 15085-2 contains minimum requirements on the availability of welding coordinators. The required number of welding coordinators depends on the size of the welding manufacturer as well as the extent of the welding production and the number of subcontractors. The tasks and areas of competence of the welding coordinators must comply with the requirements of EN 15085-2, Annex B. They must be laid down in writing for each welding coordinator and must be verified by the manufacturer certification body as part of the audit for the certification. The independence of the welding coordinators must be clearly shown in an organization chart. The manufacturer certification body must verify that the responsible welding coordinators are integrated in the organization of the welding manufacturer in a way that allows them to attend to their tasks in their areas of competence pursuant to EN ISO 14731 without any restrictions. For this purpose, they must have the required authority to instruct and their own decision-making power. If the areas of competence are separated (e.g. for production, subcontracting and design), this must be indicated in the certificate. The welding manufacturer must provide evidence of the professional experience of its welding coordinators (e.g. evidence of qualification). Welding coordinators without a qualification according to the relevant IIW/EWF guidelines (IWE/EWE, IWT/EWT, IWS/EWS) must demonstrate the necessary technical knowledge on welding during an extended interview as part of the certification audit. In addition, the welding manufacturer must furnish evidence of the professional experience of the welding coordinators. Note: For further details, please refer to section 5.3.2 "Interview with welding coordinators" of this Guideline. Section 5.1.2 of EN 15085-2 specifies who may deputise without restriction for the responsible welding coordinator.

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4.2.2 Subcontracted welding coordinators Welding coordinators who are not employed directly (on site) by the respective welding manufacturer are "subcontracted welding coordinators" (referred to below as "external welding coordinators) – please refer to section 5.1.3 "Subcontracted welding coordinator" of EN 15085-2. This also applies to part-time staff who work less than 50% of the collectively agreed working hours. According to EN 15085-2, the responsible welding coordinator may be subcontracted in special cases. For subcontracted welding coordinators, the following must be observed: 

The working hours of external welding coordinators must be contractually agreed so that they can perform their tasks as defined in Annex B of EN 15085-2 (evidenced in a work book). In addition, the following applies:  For new build production, the external welding coordinator should be present during at least 50% of the welding production within scope of the relevant standard (evidenced in a work book), 

For repair/finishing welding, the required presence depends on the extent of the welding production within the scope of the relevant standard (evidenced in a work book).



Auditors of a manufacturer certification body may not act as external welding coordinators.



A welding coordinator may only be approved for a maximum of two welding manufacturers. For certification level CL 4 (manufacturers without own welding production), a welding coordinator may serve a maximum of three manufacturers. The following table shall apply Maximum number of manufacturers for which a welding coordinator may be approved: Variant

CL 1, CL 2

CL 4

A

2

1

B

1

2

C

-

3

In that case, all work books must be submitted to the auditor of the manufacturer certification body to allow an assessment of the overall extent of his or her work. 4.2.3 Welders/welding operators For each welding process, material group, joint type and dimension, at least two welders/welding operators with a valid qualification pursuant to the applicable standards must be available. Since both butt and fillet welds are common in railway vehicle construction, the welding manufacturer must furnish BW and FW welder qualification test certificates. Coordination Committee Guideline / DVS 1619, Page 10 of 23

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The field of work of welders/welding operators in production must be in line with the scope of the available qualification test certificates. For welding work that is not covered by the welder qualification test, the welding manufacturer must additionally provide evidence of production weld tests prior to production as required by section 4.2.4 of EN 15085-4. Their performance and validity are governed by DVS 1621. Weld operators must be qualified pursuant to EN 1418. 4.2.4 Inspection personnel According to section 5.1.4 of EN 15085-2, the welding manufacturer must have inspection personnel. The existence of certified inspection personnel pursuant to EN 473 must be demonstrated if inspections in the inspection classes CT 1 and CT 2 according to EN 15085-3 are required. 4.3 Equipment The production workplaces, including workplaces for assembly, must be sufficient in size and nature to allow a proper and reproducible performance of welding work. The requirements of section 5.2 of EN 15085-2 must be complied with. 4.4 Welding procedure specifications According to EN 15085-2, welding procedure specifications (WPS) in line with EN ISO 15607 (EN ISO 15609ff, EN ISO 14555, EN ISO 15620) are required for welds of the weld performance classes CP A to CP C3. Evidence must be furnished as described in section 4.1.4 of EN 15085-4. Existing approved welding procedure specifications remain valid. The evidence based on available experience (EN ISO 15611) only applies to welds of the weld performance class CP C3 (see EN 15085-4) 4.5 Organization of welder qualification tests, acceptance of production weld tests, approval of welding procedure specifications The welding coordinators recognized for the welding manufacturer are authorized to organize, evaluate and conduct welder qualification tests, accept production weld tests, and conduct inspections for the approval of welding procedure specifications. Conditions: ○ The welding coordinators must have demonstrated appropriate technical knowledge and skills in the audit. ○ The welding coordinators concerned with these responsibilities must be named in the certificate pursuant to EN 15085-2.

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4.6 Supplementary regulations 4.6.1 Manufacturer's qualification for longitudinally welded pipes as semifinished products For the manufacturing of longitudinally welded pipes (with the welding procedures HF, LB) that are to be used as semi-finished products for the certification levels CL 1 and CL 2, a manufacturer's qualification is required. Instead of a certification pursuant to EN 15085-2, also one of the following comparable certifications may be accepted: ○ Certification pursuant to EN ISO 3834-2 including qualification of the welding procedure pursuant to EN ISO 15614 ○ Certification pursuant to the Building Products Guideline, system 2+ ○ Certification pursuant to AD 2000 code W 0. 4.6.2 Single-purpose production Single-purpose production in the certification level CL 1 is the fully mechanized welding production of identical subassemblies in a series (e.g. cardan shafts). The certificate pursuant to EN 15085-2 must be limited to the subassembly and the welding procedure specification. Notwithstanding the requirements of EN 15085-2, a responsible welding coordinator of the qualification level B may be approved for this purpose. Details on the inspection and verification measures must be agreed with the manufacturer certification body, a shorter verification interval (e.g. every six months) may be agreed. 4.6.3 Finishing welding Finishing welding on subassemblies of the certification level CL 1, the manufacturer (foundry) must furnish proof of the warranted properties and the necessary casting quality by tests and inspections. The evaluation criteria (such as weld performance class) and the inspection procedures (such as weld inspection class) must be determined by the welding coordinator and – if contractually agreed – be aligned with the customer. The responsible welding coordinator may also be a foundry engineer if he/she has demonstrated "comprehensive technical knowledge" pursuant to EN ISO 14731 for this field of application in the interview. The manual skill of the welder may be demonstrated by an appropriately documented production weld test. 4.6.4 Friction stir welding – application of the welding process For the application of friction stir welding, the following provisions apply: o Process number: 43 according to EN ISO 4063, draft 2008-03 o Materials: aluminium and Al alloys o Dimensions: all dimensions for which evidence of welding procedure specifications pursuant to EN 15085-4, section 4.1.4 is available at the welding manufacturer. Coordination Committee Guideline / DVS 1619, Page 12 of 23

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o Quality requirements: weld performance classes CP A to CP C2 according to EN 15085-3. o Scope of inspection: corresponding to EN 15085-5, table 1. o Operational prerequisites: - Certified according to EN 15085-2: certification level CL 1. - Welding coordinator: Level A according to EN 15085-2; for manufacturers only certified for friction stir welding, a responsible welding coordinator of the qualification level B may be approved. - Welding operator qualification test: according to EN 1418. - Welding procedure specification: according to EN ISO 15609-1, evidence according to EN ISO 15614-2. - Production weld tests: according to EN ISO 15613 with the following scope of verification:  visual inspection according to EN 970  radiography according to EN 1435  technological bend test according to EN 910  macrosection. 4.6.5 Weld performance class CP – Permissible shapes of welds – Allocation of the weld inspection class CT As a matter of principle, the selection criteria according to EN 15085-3, tables 2 and 3 apply. In addition, the following specifications must be observed: a) Permissible shapes of welds: CP

Permissible shapes of welds

CP A

Applies only to welds with full penetration and full accessibility for inspection (NDT) in production and maintenance.

CP B

1. For safety category "high": Applies only to welds with full penetration and full accessibility for inspection (NDT) in production and maintenance. 2. For safety category "medium": Also applies to welds without full penetration and without the possibility of a volumetric test. Testing for surface cracks in production and maintenance must be possible.

CP C1

Also applies to welds without full penetration and without the possibility of a volumetric test. Testing for surface cracks in production and maintenance must be possible.

CP C2, CP C3, CP D

Applies to all shapes of welds without special requirements on the testing of the welds; visual inspection in production is sufficient. For maintenance, generally weld performance class CP C 2 applies, if appropriate with higher weld inspection class CT.

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b) Allocation of the weld inspection class CT: Considering the material conditions (e.g. materials tending to crack), a different allocation may be decided; e.g. for steels of group 11 according to CEN ISO/TR 15608: CP C2 - CT 2 (100% VT + 10% surface tests).

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5 Certification procedure and verification Section 6 of EN 15085-2 describes the procedure for certifying welding manufacturers. The manufacturer certification body must audit and verify the welding manufacturers in a way that it can be demonstrated that the requirements of the EN 15085 series of standards and this Guideline are complied with. For subcontracting, the DVS 1617 code of practice includes further information. 5.1 Manufacturer certification bodies Audits may only be performed by the manufacturer certification bodies recognized by the national safety authority. In Germany, the EBA keeps a list of the recognized manufacturer certification bodies. The manufacturer certification bodies must be included in the Online Register Railway Vehicles (register of the certified welding manufacturers in railway vehicle construction) (see section 5.6). 5.2 Application Annex 1 contains the "Application for certification for the welding of railway vehicles and components according to EN 15085-2". The application for the initial or renewed certification must be addressed by the welding manufacturer to one of the manufacturer certification bodies recognized by the national safety authority. With the application, the welding manufacturer confirms that it complies with the generally accepted rules of technology and that it submits to the annual verification. The manufacturer certification body issuing the certificate must be notified of any modifications occurring during the period of its validity. If it can be seen from the application that the manufacturer used to be handled by another manufacturer certification body, the "new" manufacturer certification body must inform the "old" manufacturer certification body. The documents on the previous certification(s) must be made available to the "new" manufacturer certification body. After the completion of the certification procedure, it must be verified that the welding manufacturer is only listed once in the Online Register Railway Vehicles. If an external welding coordinator has been recognized by several manufacturer certification bodies, these must consult with each other. For a renewal of the certificate, the application form must again be completed and the "renewal application" box must be checked. If no changes have occurred in the meantime, the submission of the Annex(es) to the application is waived. With its application for certification according to EN 15085-2, the welding manufacturer defines the range of certification (welding process, material group according to CEN ISO/TR 15608, dimensions) in a way that it meets the requirements for its welding production. In the certification procedure, the welding manufacturer must furnish evidence that it has the welder qualifications tests and evidence of welding procedure specifications required for the range of certification applied for; if applicable these must be supplemented by production weld tests (this applies in particular to repair welding manufacturers).

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5.3 Audit The certification is preceded by an audit. During that audit, the welding manufacturer must demonstrate that the welding coordinators have the technical knowledge on welding and the qualification as required by section 5.1.2 of EN 15085-2 (see also further information on the interview in sections 4.2.1 and 5.3.2 of this guideline). The extent of the audit depends on the certification level, the field of application, the number of welders and the welding procedures, the scope of the welding shops and the materials used. As part of the audit, the following is verified: −

available personnel including evidence of valid qualification test certificates

−

equipment including production and production quality

−

welding procedure specifications, qualification of welding procedures

−

documentation of the welding planning (drawings, welding plan, inspection and test plan).

−

compliance with the quality requirements of EN ISO 3834-2, -3 and/or -4.

As part of the first audit, welding tests in the form of production weld tests, welder qualification tests or procedure qualification tests are mandatory to demonstrate the practical knowledge of the welding coordinators. Otherwise, welding tests are required for planned new entries of welding coordinators, procedures and material groups as required by the applicable standards. Note: Welder qualification tests and/or production weld tests may only be accepted by welding coordinators who have demonstrated the related qualification as part of the audit. The test certificate may only be issued by welding coordinators who are identified in the certificate of the welding manufacturer. If the manufacturer has welders with valid qualification tests certificates, the verification is performed on the basis of production weld tests for the responsible welding coordinators' evaluation. If the required welder/welding operator qualification test certificates are not available, these tests can be made as part of the audit and the related certificates can be issued by the manufacturer certification body. For a renewal of the certificate, some of the welder qualification tests or production weld tests accepted by the welding coordinators must be submitted to the manufacturer certification body for examination. If the manufacturer certification body does not confirm the test results, new tests have to be taken. If there are doubts concerning the knowledge and skills of the welders, production weld tests will be necessary, so test specimens with tack welds should be available. The test covers: welding procedure specification, evaluation sheet, issued test certificate, memorandum on the verification of the technical knowledge and the weld test specimens.

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The welding coordinators must keep a list of the employed welders showing which welders have which valid qualifications. The welding coordinators are also responsible for making the relevant entries on the semi-annual internal qualification renewals at the manufacturer's (may be software-assisted). For certification level CL 4, the compliance with the requirements of sections 5.1 (welding coordination) and 5.3 (welding coordination organization) of EN 15085-2, and the compliance with the quality requirements of EN ISO 3834-3 (if applicable) must be verified. 5.3.1 Site inspection Site inspections are made together with the welding coordinators. During these inspections, the implementation of the above requirements in the welding production is verified. In addition, the proper execution of the welded subassemblies and structures resulting from the current production will be verified. If during the initial certification, no corresponding subassemblies are in use, the first verification audit is made when production is started. 5.3.2 Interview with welding coordinators During this informal interview, documents (such as technical books, training documents, standards, guidelines) or provisions if any issued by the national safety authority may be used freely. In the interview, the welding coordinators must demonstrate technical knowledge on the special requirements of the EN 15085 series of standards and the related DVS codes of practice / guidelines. This also includes any other standards and regulations applicable to the field of activity. This does not mean that the welding coordinators must know all these standards and regulations by heart. Rather, they must know where to find provisions on specific problems. To demonstrate this, the welding coordinators must find the applicable standard and the relevant provision included in it within a reasonable time. The standards must be available in a language that the welding coordinators understand. The questions are limited to issues that may arise within the scope of the standards, materials and welding procedures for which the certificate is applied for. Persons without a IIW/EWF qualification who are to be recognized as welding coordinators must demonstrate the required technical knowledge pursuant to EN ISO 14731 and section 5.1.2 of EN 15085-2 in an extended interview. As a matter of principle, the technical knowledge according to section 6 of EN ISO 14731 must be demonstrated depending on the level of the welding coordinator. In addition, adequate knowledge must be demonstrated in the fields listed below, depending on the certification level. In this respect, the national rules and regulations on occupational safety and the prevention of accidents must be taken into account. 5.3.2.1 For certification levels CL 1 and CL 2: General requirements based on EN 15085-1: Scope, terms and definitions, quality requirements. Coordination Committee Guideline / DVS 1619, Page 17 of 23

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Quality requirements and certification based on EN 15085-2: Quality requirements on the welding manufacturer, technical requirements, testing laboratories, staff requirements, organization, welding procedure specifications. Design requirements based on EN 15085-3: Design requirements, drawing data, tolerances, weld performance classes and weld inspection classes, quality levels, material selection, requirements on weld joints, joint preparation. Production requirements based on EN 15085-4: Planning documents, evidence of welding procedure specifications, production weld tests, requirements on the welding, welding consumables, parent materials, welding procedures, repair. Inspection, testing and documentation based on EN 15085-5: Inspection and testing before, during and after welding, inspection and test planning, documentation, conformity. Special issues (see Annex 2, item 4) The requirements also include knowledge on other standards and regulations that may be applicable, such as:  DVS 1608  DVS 1610  DVS 1612  DVS 1614  DVS 1617  DVS 1620  DVS 1621

Design and fatigue testing of welded joints of aluminium and aluminium alloys in the construction of railway vehicles General guidelines for planning the welding production in the construction of railway vehicles Design and fatigue testing of welded steel joints in the construction of railway vehicles Straightening in the construction of railway vehicles Quality requirements on subcontractors for welding railway vehicles and components Inspection and testing of welding in the construction of railway vehicles Production weld tests in the construction of railway vehicles

5.3.2.2 For certification level CL 4, field of application: Design: General requirements based on EN 15085-1: Scope, terms and definitions, quality requirements, to the extent applicable. Quality requirements and certification based on EN 15085-2: Quality requirements, technical requirements, testing laboratories, staff requirements, organization, to the extent applicable. Design requirements based on EN 15085-3: Design requirements, drawing data, tolerances, weld performance classes and weld inspection classes, quality levels, material selection, requirements on weld joints, joint preparation. Production requirements based on EN 15085-4: Planning documents, including welding plan, welding sequence plan Coordination Committee Guideline / DVS 1619, Page 18 of 23

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Inspection, testing and documentation based on EN 15085-5: Inspection and test planning, documentation, conformity. Special issues (see Annex 2, item 4) The requirements also include knowledge on other standards and regulations that may be applicable, such as:  DVS 1608  DVS 1610  DVS 1612  DVS 1620

Design and fatigue testing of welded joints of aluminium and aluminium alloys in the construction of railway vehicles General guidelines for planning the welding production in the construction of railway vehicles Design and fatigue testing of welded steel joints in the construction of railway vehicles Inspection and testing of welding in the construction of railway vehicles

5.3.2.3 For certification level CL 4, field of application: purchase & resale or purchase & assembly (as applicable): General requirements based on EN 15085-1: Scope, terms and definitions, quality requirements. Quality requirements and certification based on EN 15085-2: Quality requirements, technical requirements, testing laboratories, staff requirements, organization, welding procedure specifications. Design requirements based on EN 15085-3: Drawing data, tolerances, weld performance classes and weld inspection classes, quality levels, material selection, requirements on weld joints, joint preparation. Production requirements based on EN 15085-4: Planning documents, evidence of welding procedure specifications, production weld tests, requirements on the welding, welding consumables, parent materials, welding procedures. Inspection, testing and documentation based on EN 15085-5: Inspection and testing before, during and after welding, inspection and test planning, documentation, conformity. Special issues (see Annex 2, item 4) The requirements also include knowledge on other standards and regulations that may be applicable, such as:  DVS 1614  DVS 1617  DVS 1620  DVS 1621

Straightening in the construction of railway vehicles Quality requirements on subcontractors for welding railway vehicles and components Inspection and testing of welding in the construction of railway vehicles Production weld tests in the construction of railway vehicles

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5.4 Documentation The manufacturer certification body documents its professional/technical assessment in a report based on the sample enclosed as Annex 2 to this Guideline. An official copy of this report is given to the welding manufacturer and a copy is sent to the national safety authority. 5.5 Final discussion The result of the audit is evaluated in a discussion with the welding coordinators and, if appropriate, with the management of the firm. 5.6 Issuance of the certificate Upon a successful audit, the manufacturer certification body issues a certificate pursuant to Annex 3 (for CL 1 to CL 3) or Annex 4 (CL 4) of this Guideline which states that the welding manufacturer is qualified to perform welding work in line with the requirements of the standard and the manufacturer certification body posts the certificate in the Online Register Railway Vehicles (link: "www.en15085.net" or "www.en15085.de") The manufacturer certification body is obliged to post the certificate in the Online Register Railway Vehicles within two weeks of completion of the certification procedure. Only certificate posted in the Online Register Railway Vehicles are valid. The certificate is posted in the Online Register Railway Vehicles in one of the three language versions of the EN 15085 series of standards agreed within Europe (German, English, French). The welding manufacturer can specify the language in its application. The qualification of the welding coordinators must be stated in line with EN 15085-2. For comparable foreign qualifications, the manufacturer certification body must evaluate their equivalence. The certification level according to EN 15085-2 must be stated in the certificate. As a minimum, the certificate must contain the following information: −

Name and address of the welding manufacturer For each welding manufacturer, a separate certificate is required.

−

Certification level Here, the highest certification level pursuant to EN 15085-2 must be stated.

−

Field of application The field of application must be stated in line with Annex A of EN 15085-2. If there are any restrictions, these must already be indicated in the field of application. It must also be indicated if the "design" field of application of certification level CL 4 is not to be included in the range of certification of certificates of levels CL 1 or CL 2 (recommended wording "except design"). Finishing welding recognition for a single-purpose production must be stated separately. For CL 4 certificates, also the allocation of parts and subassembly allocation with the corresponding certification level must be stated for the range of certification.

−

Range of certification The range of certification must be presented in a clear format (see Annex 3). It is Coordination Committee Guideline / DVS 1619, Page 20 of 23

3 December 2008

the welding manufacturer's responsibility to ensure that the welder qualification tests and the evidence of welding procedure specifications required for the respective job are available. ○ Welding processes Welding processes must be indicated using the nomenclature and reference number of DIN EN ISO 4063. ○ Material groups The following specifications apply to the definition of the materials: - Indication of the materials according to the CEN ISO/TR 15608 technical report; for steels of groups 1 to 3, the sub-group must be indicated, for all other materials, the group is sufficient. - Materials that cannot be allocated to a group according to CEN ISO/TR 15608 (e.g. materials pursuant to CIS standards) are identified in the comments section. Austenitic manganese steel is indicated as "Austenitic manganese steel" in the materials section. This material is included in the Online Register Railway Vehicles. Based on the EN ISO 15614 ff. series of standards, Annex 5 contains the also applicable material groups and related material designations of the materials customary in railway vehicle construction.

−

−

○ Dimensions The following specifications apply to the definition of the dimensions: - The dimensions must be clear and be stated separately for sheets and pipes. The dimensions to be stated include the wall thickness tmin - tmax and for pipes additionally Dmin - Dmax. - In special cases, there may be deviations for fillet welds (e.g. hard facing with austenitic manganese steel plates, grounding bushes) - Fillet weld thicknesses are only in exceptional cases included in the dimensions (e.g. in case of single-purpose production) - Ranges of dimensions are not to be stated with decimal points but rounded. ○ Comments Special characteristics, e.g. type of weld, overlay welding, finishing welding, must be stated in the range of certification or on the reverse. If they are stated on the reverse, this must be indicated on the front. Responsible welding coordinator First name, family name, date of birth, IIW/EWF qualification (e.g. IWE/EWE, IWS/EWS, IWT/EWT, IWP/EWP) or level according to EN 15085-2 must be stated. In case of separate areas of competence, these must be indicated as well (e.g. design, production, different organizational units). External welding coordinators must be marked "external". Deputy with equal rights First name, family name, date of birth, IIW/EWF qualification (e.g. IWE/EWE, IWS/EWS, IWT/EWT, IWP/EWP) or level according to EN 15085-2 must be stated.

Coordination Committee Guideline / DVS 1619, Page 21 of 23

3 December 2008 −

Additional deputies First name, family name, date of birth, IIW/EWF qualification (e.g. IWE/EWE, IWS/EWS, IWT/EWT, IWP/EWP) or level according to EN 15085-2 must be stated. Note: If additional deputies are stated on the reverse, this must be indicated on the front.

−

Certificate number The nomenclature described in Annex 5 of this Guideline must be observed. The year of the initial certification is kept. Each welding manufacturer may only have one number (no duplication of numbers).

−

Period of validity

−

Date of issue

−

Name of auditor

−

Signature (head of the manufacturer certification body or its authorized representative)

5.7 Period of validity of the certificate The certificate is issued for a limited period and subject to revocation. It is valid for a maximum period of three (3) years. If there are good reasons, the manufacturer certification body may make the validity of the certificate contingent on the satisfaction of additional conditions (e.g. additional welding coordinators, testing and assignment of additional welders, additional inspection and testing as part of the quality assurance, continuous production weld tests, production verified by the manufacturer certification body); any such conditions must be stated in the report according to Annex 2. 5.8 Verification As stipulated in section 7 of EN 15085-2, the manufacturer certification body verifies the compliance with the requirements of EN 15085-1 to -5 in the field of application for which the certificate was granted during the period of the certificate's validity. The verification relates to the current production (parts, subassemblies) and the quality records on running and completed projects as well as to knowledge about new standards and regulations. The verification is based on the following principles: − compliance with EN 15085-1 to -5; and −

annual verification on site by the manufacturer certification body.

The annual verification will also be carried out if no parts or subassemblies according to EN 15085 ff are available in the workshop at the time of the audit. This means that the welding manufacturer must in any case demonstrate that it continues to satisfy the staffrelated and operational requirements of the standard for as long as its certificate is listed in the register. This serves to ensure that follow-up jobs can be processed without delay. If certification was granted with conditions, the verification interval may be shortened, depending on the extent of production. During the annual on-site verification, the results of internal audits may be considered

Coordination Committee Guideline / DVS 1619, Page 22 of 23

3 December 2008

(e.g. in case of separate welding shops). 5.9 Renewal of the certificate After the period of validity of the certificate has expired, the certificate may be renewed following an audit of the welding manufacturer (site inspection) by the manufacturer certification body without comprehensive interview and production weld tests if:  the welding coordinators continue to perform their functions without any changes over the previous certification and  the technical, staff-related and organizational conditions comply with the requirements of the standard and  valid qualification test certificates for the welders and the welding personnel are available and  there have been no material complaints in the range of certification. During the site inspection, the welding coordinators must also demonstrate their knowledge of new standards and regulations. 5.10 Modification of the certificate If there are any changes in the scope of the certificate, a modification application (no special form required) must be submitted to the manufacturer certification body without delay. 5.11 Revocation of the certificate The manufacturer certification body or the national safety authority may revoke a certificate if the conditions pursuant to EN 15085-2 are no longer satisfied. The welding manufacturer must acknowledge the revocation to the manufacturer certification body in writing. The national safety authority must be notified of the revocation by the manufacturer certification body. The main customer for the current production must be informed of the revocation by the welding manufacturer. 5.12 Validity of the certificate The certificate is only valid for the respective welding manufacturer (site of the facility) and its welding coordinators. 5.13 Exceptions Any exceptions and disputes between the welding manufacturer and the manufacturer certification body are decided by the national safety authority. In case of violations against generally accepted rules of technology or this Guideline, the national safety authority must be informed (e.g. also by the customer).

Coordination Committee Guideline / DVS 1619, Page 23 of 23

Annex 1, 3 December 2008

Application for certification for the welding of railway vehicles and components according to EN 15085-2 Name of welding manufacturer: Street, no.: Postcode, town/city, state: Telephone:

Fax:

Email:

Internet:

Owner:

Technical plant manager:

Contact for questions: The application is submitted for the welding facility (if other than above): Street, no.: Postcode, town/city: Certification level applied for: CL 1 CL 2 CL 3 CL 4, for: Design of subassemblies of certification level:____ Purchase & assembly of parts of certification level: ____ (please complete only the applicable items from the description of the facility)

Purchase & resale of parts of certification level: ____ Application: initial application renewal application because of expiry of the current certificate because of a modification in the following conditions: Do/did you have a certificate pursuant to EN 15085-2 (DIN 6700-2) issued by another manufacturer certification body? Yes (please state body): No The welding manufacturer - declares its compliance with generally accepted rules of technology (EN 15085 series of standards and other applicable standards), - agrees that the information is included in the Online Register Railway Vehicles, - submits to the annual verification. Annex: Organization chart ---------------------------------------------------(Place, date)

-------------------------------------------------(Stamp and signature)

Coordination Committee Guideline / DVS 1619 / Application, Page 1 of 9

Annex 1, 3 December 2008

Description of the facility – Certification for welding according to EN 15085-2 The above facility demonstrates its qualification for welding by furnishing the following information/documents: 1

Staff

1.1

Number of staff in the technical office:

________________________

1.2

Number of staff in the workshop:

________________________

1.3

Permanent welding staff:

1.3.1

Welding coordinators:

1.3.1.1 Responsible welding coordinator: First name, family name: _______________________________________________________ Date of birth:

_______________________________________________________

Area of competence:

_______________________________________________________

Professional training 1):

Welding training 1):

Is the responsible welding coordinator to be classified as "external"? Yes No Does the welding coordinator also act as welding coordinator for other facilities? Yes – please indicate number_______ and enclose certificates. No

1)

Please indicate the designation of the profession and enclose evidence of qualifications (copies of certificates) as well as a table showing the previous occupations.

Coordination Committee Guideline / DVS 1619 / Application, Page 2 of 9

Annex 1, 3 December 2008

1.3.1.2 Deputy welding coordinator: First name, family name:: _______________________________________________________ Date of birth:

_______________________________________________________

Area of competence:

_______________________________________________________

Professional training 1): Welding training 1): Is the welding coordinator to be classified as "external"? Yes No Does the welding coordinator also act as welding coordinator for other facilities? Yes – please indicate number_______ and enclose certificates. No

1.3.1.3 Additional deputy welding coordinator: First name, family name:: _______________________________________________________ Date of birth:

_______________________________________________________

Area of competence:

_______________________________________________________ 1)

Professional training : Welding training 1):

1.3.1.4 Additional deputy welding coordinator: First name, family name:: _______________________________________________________ Date of birth:

_______________________________________________________

Area of competence:

_______________________________________________________ 1)

Professional training : Welding training 1):

1.3.2

Description of the tasks and areas of competence of the welding coordinators pursuant to EN ISO 14731: Yes / No

1)

Please indicate the designation of the profession and enclose evidence of qualifications (copies of certificates) as well as a table showing the previous occupations.

Coordination Committee Guideline / DVS 1619 / Application, Page 3 of 9

Annex 1, 3 December 2008

1.4

Welder(s) / welding operator(s) for the range of certification applied for

Welder's sign

Name

2)

Designation according to welder / welding operator qualification test standards

Range of certification ( tmin-tmax, Dmin-Dmax)

Date of test

2)

As an alternative to listing by name, it is also possible to state the number of welder / welding operator qualification tests for the individual welding procedures and material groups.

1.5 Name

Visual inspectors and NDT inspection staff 3)

Qualification according to EN 473

Inspection authority

3)

As an alternative to listing by name, also the number of inspection staff for the individual inspection and testing procedures may be stated. Evidence of training must be submitted during the site inspection.

Coordination Committee Guideline / DVS 1619 / Application, Page 4 of 9

Annex 1, 3 December 2008

2

Evidence of WPS according to the EN ISO 15609 series of standards, EN ISO 14555 or EN ISO 15620 for the range of certification applied for

WPS no.

Welding Material process group

4)

Type of weld

Range of dimensions (mm )

Position

Evidence 4)

Comments

Evidence by welding procedure qualification record e.g. according to EN ISO 15614-1 or EN ISO 15614-2; production weld test according to EN ISO 15613.

Coordination Committee Guideline / DVS 1619 / Application, Page 5 of 9

Annex 1, 3 December 2008

3

Quality requirements according to EN ISO 3834-2 to -4

3.1

Description of the quality requirements according to EN ISO 3834

Quality requirements according to EN ISO 3834

Description 5)

Review of requirements, technical review: Does the manufacturer have fixed rules for performance and responsibility? Subcontracting: Can it be demonstrated that subcontracting is performed as required by EN ISO 3834? Equipment: Is the proper functioning, accuracy and compliance of equipment with industrial safety requirements verified regularly? Quality assurance: Is the welding staff instructed regularly on the technical bases of welding quality criteria? Does the manufacturer have fixed rules for monitoring, inspection and testing before, during and after welding? Are inspectors and/or staff with defined inspection and testing tasks deployed for the welding quality assurance? Which steps are taken in case of nonconformances? Are quality records maintained? How are the quality records evaluated and filed? Identification and traceability: What is done to assure the identification of components and subassemblies in all phases of cutting, preliminary assembly and assembly? 5)

If available, describe the manufacturer's rules, if not, enter "not applicable".

Coordination Committee Guideline / DVS 1619 / Application, Page 6 of 9

Annex 1, 3 December 2008

4

Technical equipment

4.1

Welding machines, devices and equipment for the performance of welding work

Quantity

Type of machine

Model / performance data

Coordination Committee Guideline / DVS 1619 / Application, Page 7 of 9

Annex 1, 3 December 2008

4.2 Quantity

4.3 Quantity

Equipment for the inspection and testing of welds Kind of equipment

Manufacturer

Model / parameter

Other facilities, machines and systems required for the welding equipment (e.g. for heat treatment) Kind of equipment

Model / parameter

Coordination Committee Guideline / DVS 1619 / Application, Page 8 of 9

Annex 1, 3 December 2008

5

Range of certification applied for

5.1

Scope

The evidence is furnished for certification level ___ and the sub-assemblies Weld performance class(es) ___ with / without design

5.2

Welding processes, materials, dimensions, comments:

Welding process according to EN ISO 4063

6

Material group according to CEN ISO/TR 15608

Range of dimensions

Comments

Evidence of manufacturer's qualifications

(e.g. EN ISO 9001; EN ISO 3834-2,-3,-4; EN 15085-2/ DIN 6700-2)6) 7

Comments

(e.g. customers, subsuppliers) 6)

Please enclose copies

Coordination Committee Guideline / DVS 1619 / Application, Page 9 of 9

Sample Report

Annex 2, 3 December 2008

Report on the certification / verification according to EN 15085-2 – Welding of railway vehicles and components Welding manufacturer: Street, no.: Postcode, town/city, state: Date of the verification: Manufacturer certification body: Auditor(s): Verification on the basis of the application dated: Participants from the welding manufacturer: - Welding coordinators: - Other participants: Reason of the audit: Initial inspection Modification; reason: Verification during the period of validity Recurrent inspection after the end of the period of validity

___________________________________________ The verification covered: Information contained in the application and the description of the facility Availability and knowledge of generally accepted rules of technology (EN 15085 series), the EN and ISO standards and other contractually agreed codes of practice and/or guidelines Project planning / design / technology Manufacture / production / repair welding of railway vehicles, components or subassemblies Quality assurance for the production and repair of railway vehicles, components or subassemblies Documentation Welder / welding operator qualification tests, production weld tests Evaluation of test specimens by the welding coordinators WPQRs, WPSs and other welding planning documents Purchase & resale or purchase & assembly of welded components and parts Compliance with the requirements of the EN 15085 series of standards Compliance with the requirements of DIN 27201-6

Coordination Committee Guideline / DVS 1619 / Report, Page 1 of 5

Sample Report

Annex 2, 3 December 2008

1. Results: 1.1 Welding coordinator(s): The following welding coordinators were examined: Responsible welding coordinator: First name, family name, date of birth, qualification For an external welding coordinator, state the registered office of the primary employer.

Deputy with equal rights: First name, family name, date of birth, qualification For an external welding coordinator, state the registered office of the primary employer.

Additional deputies: First name, family name, date of birth, qualification For an external welding coordinator, state the registered office of the primary employer.

1.2 Organizational integration of the welding coordinators: Tasks and areas of competence of the welding coordinators: Implementation of EN ISO 14731: yes / no Organization chart showing the independence of the welding coordinators: yes / no Implementation of EN ISO 3834 Part(s) 2, 3, 4 (delete as applicable). 1.3 Evaluation of test specimens by the welding coordinator(s): For the evaluation, no separate test specimens were welded but existing test specimens were examined. 1) The following tests were made under the guidance and supervision of the welding coordinator(s): 1) WPS no.

Test specimens

Kind of test

Evaluation by responsible additional welding welding coordinator coordinators

inspector

The welding coordinators are able to evaluate test specimens according to EN 287-1, ISO9609-2, ISO 15613: yes / no / not applicable. 1) The welding coordinators are able to test the professional knowledge of the welders according to EN 287-1, EN ISO 9606-2: yes / no / not applicable1) 1)

Evaluation: y = yes, n = no, n.a. = not applicable

Coordination Committee Guideline / DVS 1619 / Report, Page 2 of 5

Sample Report

Annex 2, 3 December 2008

Comments: 1.4 Other personnel-related evidence List of welder / welding operator qualification test certificates is available: yes / no Internal EN 473 staff: yes / no 2. Equipment: – Basic equipment: conditions satisfied / partly satisfied / not satisfied – Additional equipment (e.g. turning devices, clamps and fixtures etc.): conditions satisfied / partly satisfied / not satisfied. Comments: 3. Additional requirements: List of WPQRs / WPSs is available: yes / no Production weld tests performed and documented: yes / no Conformity of welding consumables with EN 15085-4: yes / no Conformity of parent materials with EN 15085-4: yes / no Self-inspection by welder or welding operator according to EN 15085-5: yes / no Contractual agreements on non-conformances: yes / no Traceability contractually required: yes / no 4. Technical knowledge of the welding coordinators (as applicable): Field

Contents (terms and definitions, examples of other applicable standard)

General: EN 15085-1

Changes, application, terms and definitions, requirements

Quality requirements and certification: EN 15085-2

Quality requirements, technical requirements, testing laboratories: EN ISO 3834 ff, EN ISO/IEC 17025 Staff requirements, organization: EN 287-1 / EN ISO 9606-2 / EN 1418, EN ISO 14731, EN 473 Welding procedure specs.: EN ISO 14555, EN ISO 15607, EN ISO 15609, EN ISO 15620

Design requirements: EN 15085-3

Design requirements, drawing data, tolerances: EN 22553, EN ISO 13920 Weld performance classes and weld inspection classes, quality levels: EN ISO 5817, EN ISO 10042 Material selection: CEN ISO/TR 15608, requirements on weld joints, joint preparation: EN ISO 9692-1,-2

Deputy Resp. welding coord.

Add. deputy

Coordination Committee Guideline / DVS 1619 / Report, Page 3 of 5

Sample Report

Annex 2, 3 December 2008

Field

Contents (terms and definitions, examples of other applicable standard)

Production requirements: EN 15085-4

Planning documents: see section 4.1 Evidence of welding procedure specifications: EN ISO 15610, EN ISO 15611, EN ISO 15612, EN ISO 15613, EN ISO 15614 ff, EN ISO 15620, EN ISO 14555 Production weld tests: EN ISO 14555, EN ISO 15613, EN ISO 15614-13 Requirements on the welding: EN 1011ff , EN ISO 13916, EN ISO 9013 Consumables: EN 13479, EN 14532-1 to -2 Parent materials: EN 10204, EN 10025-1 to -6, EN 10088-1-3, EN 573-1 to -5 Welding procedures: EN ISO 4063 Repair: DIN 27201-6

Inspection, testing and documentation: EN 15085-5

Inspection and testing before, during and after welding, test planning, documentation: EN ISO 3834-2 to -4, EN 473, EN 12062 Conformity: EN ISO /IEC 17050-1, -2

Special issues

Subcontracted welding coordinators: EN 15085-2, section 5.1.3 Certification: EN 15085-2, section 6 Verification: EN 15085-2, section 7 Part allocations: EN 15085-2, Annex A Finishing welding: EN 15085-4, section 5.4. Self-inspection by the welder or welding operator: EN 15085-5, section 4.4.2 Subcontracting: EN 15085-5, section 8 Traceability: EN 15085-5, section 10 Inspection and testing of welded joints: EN 15085-5, Annex A

Deputy Resp. welding coord.

Add. deputy

Total result: Evaluation: s = satisfied, ns = not satisfied, ./. = not applicable *: tested at the manufacturer

Comments: The regulations are available in a language that the welding coordinators understand: yes / no The interview was an extended interview (welding coordinator without qualification according to IIW / EWF guidelines): yes / no The need to comply with applicable national rules and regulations on occupational health and safety (e.g. BG rules) was pointed out: yes / no

Coordination Committee Guideline / DVS 1619 / Report, Page 4 of 5

Sample Report

Annex 2, 3 December 2008

5. Overall evaluation: The conditions for issuing the certificate are satisfied / partly satisfied / not satisfied. Certification level:

CL

Required weld performance class: weld inspection class:

CP CT

Field(s) of application:

with / without design

Declaration of conformity: according to EN 10204 Customer: Subcontractors: Range of certification: Welding process according to EN ISO 4063

Comments:

Material group according to CEN ISO/TR 15608 and other materials

Range of certification

Comments

t min – t max

Annual verification

Conditions:

Place, date: Recognized auditor(s), name(s) and signature(s):

Noted: Place, date: Responsible welding coordinator of the welding manufacturer, name and signature:

Coordination Committee Guideline / DVS 1619 / Report, Page 5 of 5

Sample certificate for CL 1 - CL 3

Annex 3, 3 December 2008

Manufacturer certification body

CERTIFICATE Welding of railway vehicles and components according to EN 15085-2 This is to certify that:

Welding International facility I, Welding Avenue 1 1000 Welding city

is qualified to perform welding work within the range of certification of:

Certification level CL 1 according to EN 15085-2 Field of application:

New build of railway vehicles and their components Finishing welding of grey cast iron parts for railway vehicles (except design)

Range of certification: Welding process according to EN ISO 4063

Material group according to CEN ISO/TR 15608

Dimensions

Comments

111

1.2, 11.1 t = 3 - 24 mm Austenitic manganese steel / 1.2 t = 3 - 8 mm

135

1.2 6 7, 8

t = 3 - 24 mm ./. t = 1.5 - 3 mm

Overlay welding

131

23

t = 3 - 12 mm

./.

141

7, 8 23

t = 3 - 6 mm t = 10 - 15 mm

./.

311

1.2

t = 2 - 6 mm D = 17 - 168 mm ./.

73

Fillet weld

Finishing welding

Responsible welding coordinator: John Smith, born 01/01/1950, IWE Deputy with equal rights: James Smith, born 01/02/1950, level A Additional deputies: see reverse Comments: see reverse Certificate no.: HZS/15085/CL1/001/0/2008 Valid: from DD/MM/YYYY to DD/MM/YYYY Issued on: DD/MM/YYYY Auditor: Miller

______________________________________ (Head/representative of certification body, name and signature) General regulations (see reverse)

Coordination Committee Guideline / DVS 1619 / Sample Certificate CL 1, Page 1 of 2

Sample certificate for CL 1 - CL 3

Annex 3, 3 December 2008

Comments: Additional deputies: -

Bogie manufacture: Body-in-white production, final assembly: Training workshop

George Smith, born 01/03/1950, IWS Thomas Smith, born 01/04/1950, IWS Arthur Smith, born 01/05/1950, LS

Authority to test the qualification of welders / welding operators: The following welding coordinators are authorized to test the qualification of welders / welding operators according to the applicable standards within the range of certification of this Certificate: - Alfred Smith (IWE) - Brad Smith (level A).

General regulations according to EN 15085-2

Revocation of the Certificate The national safety authority or the manufacturer certification body issuing this Certificate may revoke the Certificate if: -

there are justified doubts as to the proper execution of the welding work according to the stated standards;

-

there are justified doubts as to the proper welding coordination according to the stated standards;

-

no recognized welding coordinator is available any longer;

-

no valid qualification test certificates for the welders and welding operators according to the specified standards are available;

-

welders or welding operators without tested qualifications have been entrusted with the execution of welding work under the stated standards ;

-

other conditions according to the stated standards are no longer satisfied;

-

the manufacturer certification body was refused an opportunity to perform the annual verification;

-

the welding manufacturer waives the Certificate.

The welding manufacturer shall acknowledge the revocation in writing to the manufacturer certification body. The manufacturer certification body shall notify the national safety authority. If a valid certificate is to be renewed, the renewal must be applied for with the manufacturer certification body at least two months before the end of the period of validity of the current certificate.

Distribution list: 1. Applicant (original) 2. Files

Coordination Committee Guideline / DVS 1619 / Sample Certificate CL 1, Page 2 of 2

Sample certificate for CL 4

Annex 4, 3 December 2008

Manufacturer certification body

CERTIFICATE Welding of railway vehicles and components according to EN 15085-2 Welding International - Railway vehicle engineering Welding Avenue 1 1000 Welding city

This is to certify that:

is qualified to perform welding work within the range of certification of:

Certification level CL 4 according to EN 15085-2 Field of application:

Design* / Purchase & resale* / Purchase & assembly*

Range of certification:

Railway vehicles and components of certification level CL 1* Railway vehicle components of certification level CL 2*

* Complete as applicable

Responsible welding coordinator: Deputy:

Certificate no.: Valid: Issued on: Auditor:

William Smith, born 13/10/1947, IWE (external, Welding International works) ./.

HZS/15085/CL4/002/0/2008 from DD/MM/YYYY to DD/MM/YYYY DD/MM/YYYY Miller

______________________________________ (Head/representative of certification body, name and signature) General regulations (see reverse)

Coordination Committee Guideline / DVS 1619 / Sample Certificate CL 4, Page 1 of 3

Sample certificate for CL 4

Annex 4, 3 December 2008

Comments:

General regulations according to EN 15085

Revocation of the Certificate The national safety authority or the manufacturer certification body issuing this Certificate may revoke the Certificate if: -

there are justified doubts as to the proper welding coordination according to the stated standards;

-

no recognized welding coordinator is available any longer;

-

other conditions according to the stated standards are no longer satisfied;

-

the manufacturer certification body was refused an opportunity to perform the annual verification;

-

the welding manufacturer waives the Certificate.

The welding manufacturer shall acknowledge the revocation in writing to the manufacturer certification body. The manufacturer certification body shall notify the national safety authority. If a valid certificate is to be renewed, the renewal must be applied for with the manufacturer certification body at least two months before the end of the period of validity of the current certificate.

Distribution list: 1. Applicant (original) 2. Files

Coordination Committee Guideline / DVS 1619 / Sample Certificate CL 4, Page 2 of 3

Sample certificate for CL 4

Annex 4, 3 December 2008

Coordination Committee Guideline / DVS 1619 / Sample Certificate CL 4, Page 3 of 3

Annex 5, 3 December 2008

Certified and also applicable materials groups according to CEN ISO/TR 15608 for certificates according to EN 15085-2 Table 1: Grouping for steels Certified material group

Applicable material groups according to CEN ISO/TR 15608

Material designation according to selected EN material standards 1)

Material group 1 according to CEN ISO/TR 15608 (unalloyed steels with ReH ≤ 460 MPa) 1.1

1.1

S235JR - S275J2+N EN 10025-2 S275N EN 10025-3 S275M EN 10025-4

1.2

1.1, 1.2

S235JR - S355J2+N EN 10025-2 S275N - S355NL EN 10025-3 S275M - S355ML EN 10025-4

1.3

1.1, 1.2, 1.3

S235JR - S355J2+N EN 10025-2 S275N - S460NL EN 10025-3 S275M - S460ML EN 10025-4

1.4

1.4

S275J0W - S355J2W+N EN 10025-5

Material group 2 according to CEN ISO/TR 15608 (thermomechanically rolled fine-grain structural steels with ReH ≥ 360 MPa) 2.1

1.1, 1.2, 1.3, 2.1

S235JR - S355J2+N EN 10025-2 S275N - S460NL EN 10025-3 S275M - S460ML EN 10025-4

2.2

1.1, 1.2, 1.3, 2.1, 2.22)

S235JR - S355J2+N EN 10025-2 S275N - S460NL EN 10025-3 S275M - S460ML EN 10025-4 S355MC - S700MC EN 10149-2 2)

Material group 3 according to CEN ISO/TR 15608 (quenched and tempered fine-grain structural steels with ReH ≥ 360 MPa) 3.1

1.1, 1.2, 1.3, 2.1, 3.12)

S235JR - S355J2+N EN 10025-2 S275N - S460NL EN 10025-3 S275M - S460ML EN 10025-4 S355MC - S700MC EN 10149-2 2) S460Q - S690Q EN 10025-6 2)

3.2

1.1, 1.2, 1.3, 2.1, 2.22), 3.12), 3.22)

S235JR - S355J2+N EN 10025-2 S275N - S460NL EN 10025-3, S275M - S460ML EN 10025-4 S355MC - S700MC EN 10149-2 2) S460Q - S960Q EN 10025-6 3)

Material group 4 according to CEN ISO/TR 15608 (low vanadium alloyed Cr-Mo-(Ni) steels); not used in railway vehicle construction. Material group 5 according to EN ISO 15608 (vanadium-free Cr-Mo steels) 5

Corresponding to EN ISO 15614-1

13CrMo4-5 EN 10028-2

Material group 6 according to EN ISO 15608 (high vanadium alloyed Cr-Mo-(Ni) steels) 6

Corresponding to EN ISO 15614-1

G17CrMoV5-10 EN 10213-2

1)

This table contains an example allocation of materials customary in railway vehicle construction.

2)

Applies to steels with same or lower minimum specified yield point of the same material group. In case of ReH ≥ 460 MPa, the maximum permissible ReH is to be indicated in the comments section.

3)

Only in case of the use of a welding consumable for material group 8.

Coordination Committee Guideline / DVS 1619 / Material Groups, Page 1 of 3

Annex 5, 3 December 2008

Certified material group

Applicable material groups according to CEN ISO/TR 15608

Material designation according to selected EN material standards 1)

Material group 7 according to EN ISO 15608 (ferritic, martensitic stainless steels) 7

7, 8 3)

X2CrNi12 (1.4003) EN 10088 X2CrTi12 (1.4512) EN 10088 X5CrNiMoTi 15-2 (1.4589) DIN 5512-3

Material group 8 according to CEN ISO/TR 15608 (austenitic stainless steels) 8

7, 8

X2CrNi12 (1.4003) EN 10088 X2CrTi12 (1.4512) EN 10088 X5CrNiMoTi 15-2 (1.4589) DIN 5512-3 X5CrNi18-10 (1.4301) EN 10088 X6CrNiTi18-10 (1.4541) EN 10088 X5CrNiMo17-12-2 (1.4401) EN 10088 X6CrNiMoTi17-12-2 (1.4571) EN 10088

Material group 9 according to CEN ISO/TR 15608 (nickel alloyed steels); not used in railway vehicle construction. Material group 8 according to CEN ISO/TR 15608 (duplex steels/compound steels) 10

Corresponding to ISO 15614-1

X2CrNiMoN 22-5-3 (1.4462) EN 10088-3

Material group 11 according to CEN ISO/TR 15608 (unalloyed steels with C content of > 0.25%) 11

11

E295 - E360 EN 10025-2 C35 - C60 EN 10083-2

Table 2: Grouping for aluminium and aluminium alloys Certified material group

Applicable material groups according to CEN ISO 15608

Material designation according to EN 573-3 1)

Material group 21 according to CEN ISO/TR 15608 (pure aluminium) 21

21

EN AW-1098 (Al 99,98) EN AW-1080A (Al 99,8(A)) EN AW-1050A (Al 99,5) EN AW-1200 (Al 99,0)

Material group 22 according to CEN ISO/TR 15608 (Non heat-treatable AlMg alloys) 22

22

EN AW-5049 (AlMg2Mn0,8) EN AW-5052 (AlMg2,5) EN AW-5754 (AlMg3) EN AW-5083 (Mg4,5Mn0,7) EN AW-5019 (AlMg5)

Material group 23 according to CEN ISO/TR 15608 608 (heat-treatable AlMgSi and AlZnMg alloys) 23

22, 23

EN AW-6060 (AlMgSi) EN AW-6005A (AlSiMg(A)) EN AW-6082 (AlSi1MgMn) EN AW-7020 (AlZn4,5Mg1)

Material group 24 according to CEN ISO/TR 15608 (non heat-treatable AlSi and heat-treatable AlSiMg casting alloys) 24

24

EN AC-44200 (AlSi12) EN AC-42000 (AlSi7Mg) EN AC-43300 (AlSi9Mg) EN AC-43400 (AlSi10Mg)

Material group 26 according to CEN ISO/TR 15608 (heat-treatable AlCu casting alloys) 26

26

EN AC-21100 (AlCu4Ti) Coordination Committee Guideline / DVS 1619 / Material Groups, Page 2 of 3

Annex 5, 3 December 2008

Table 3: Grouping for copper and copper alloys Certified material group

Applicable material groups according to CEN ISO/TR 15608

Material designation EN 1652, EN 1653, EN 1654 1)

Material group 31 according to CEN ISO/TR 15608 (pure copper) 31

31

Cu-ETP (CW004A) Cu-FRTP (CW006A) Cu-OF (CW008A) Cu-DLP (CW023A) Cu-DHP (CW024A)

Table 4: Grouping for cast iron Certified material group

Applicable material groups according to CEN ISO/TR 15608

Material designation according to selected EN material standards 1)

Material group 71 according to CEN ISO/TR 15608 (lamellar graphite cast iron / grey cast iron) 71

Corresponding to EN ISO 15614-3

EN-GJL-100 to EN-GJL-350 EN 1561

Material group 72 according to CEN ISO/TR 15608 (spheroidal graphite cast iron / ductile cast iron) 72

Corresponding to EN ISO 15614-3

EN-GJS-350 to EN-GJS-900 EN 1563

Material group 73 according to CEN ISO/TR 15608 (malleable cast iron) 73

Corresponding to EN ISO 15614-3

EN-GJMW-350 to EN-GJMW-800 EN 1562

Coordination Committee Guideline / DVS 1619 / Material Groups, Page 3 of 3

Annex 6, 3 December 2008

Special regulations for the repair of railway vehicles according to DIN 27201-6 1. Subcontracted welding coordinator Supplementary to section 4.2.2 of the Coordination Committee Guideline, the special regulations of DIN 27201-6 are applicable to the repair of railway vehicles (a responsible welding coordinator may serve two further welding manufacturers of the same railway vehicle operator).

2. Welders / welding operators Supplementary to section 4.2.3 of the Coordination Committee Guideline, the special regulations of DIN 27201-6 must be observed for the repair of railway vehicles.

3. Inspection personnel Supplementary to section 4.2.4 of the Coordination Committee Guideline, the special regulations of DIN 27201-6 must be observed for the repair of railway vehicles (NDT inspection staff according to EN 473, visual inspector). The inspection personnel must be qualified for the industry sector "basic metals and fabricated metal products" or "railway maintenance" (applicable to VT, MT, ET, UT only) and the product sector "welded products" (w). In addition, the following provisions are applicable: o Welding manufacturers that are also certified for the repair of railway vehicles must observe the regulations of DIN 27201-6. According to these regulations, the industrial sector "railway maintenance" may become necessary for the procedures VT, MT, ET and UT if also NDT work according to DIN 27201-7 must be carried out. o The requirement for the industrial sector "railway maintenance" is not a component of the certification according to EN 15085-2 (it is verified as part of the NDT qualification of vehicle workshops according to DIN 27201-7). o The range of certification for NDT activities according to DIN 27201-7 comprises the mere maintenance inspection of the components wheels, wheelset axles, bogie frames, pushing and buffing gear and vehicle frames. These activities also cover welds that exist in the components and must be subjected to non-destructive testing as part of the regular inspections. These activities fall into the industrial sector "railway maintenance" and are governed by special NDT test instructions. o Welds produced or repaired as part of a repair according to DIN 27201-6 are covered by the product sector "welded products" (w).

4. Allocation of the weld inspection class CT Supplementary to section 4.2.5 of the Coordinating Committee Guideline, deviating allocations may be applicable for the repair of railway vehicles and considering the specifications in Table 3 of DIN 27201-6, for instance in case of the refurbishment of cracked welds: CP C2 - CT 1 (100% visual inspection + 100% surface test).

5. Certification procedure and interview: Supplementary to section 5 of Coordinating Committee Guideline, welding manufacturers performing repairs on railway vehicles according to DIN 27201-6 must also demonstrate that they comply with the requirements of that standard. During the interview, the welding coordinators must also furnish proof of their knowledge of DIN 27201-6.

Coordinating Committee Guideline / DVS 1619 / Repair, Page 1 of 1

Annex 7, 3 December 2008

Nomenclature for the certificate number EN 15085-2 Manufacturer certification body

Standard

Certification level

No.

Type

Year

XXX *

15085

CL1

001

0 – initial certification

2008

CL2

1 – 1st renewal

CL3

2 – 2nd renewal

CL4

3 – 3rd renewal 0A1 – 1st modification after initial certification 0A2 – 2nd modification after initial certification 0A3 – 3rd modification after initial certification 1A3 – 3rd modification after 1st renewal 3A8 – 8th modification after 3rd renewal 4A6 – 6th modification after 4th renewal

* Abbreviation to be agreed with SLV Halle Example:

SLVHal/15085/CL1/001/0/2008

Note: -

The year of the initial certification remains unchanged in the certificate number, also in case of renewals and modifications. The same also applies for the transition from DIN 6700-2 to EN 15085-2.

-

Modifications have no influence on the end of the respective period of validity.

Coordination Committee Guideline / DVS 1619 / Nomenclature, Page 1 of 1

Annex 8, 3 December 2008

Regulations for the transition from the DIN 6700 series of standards to EN 15085 1. Transition period: The period for the transition from the DIN 6700 series of standards to EN 15085 ends on: 31 December 2010.

2. Transition from the "Certificate for Welding according to DIN 6700-2" to the "Certification for Welding according to EN 15085-2": After 1 April 2008, the following provisions apply: 1. Certificates according to DIN 6700-2 may have a maximum period of validity until the end of the transition period. 2. For new certification and in case of expired certificates, the renewal must be made according to EN 15085-2. 3. Any changes, supplements or extensions of a valid certificate according to DIN 6700-2 made before the expiry of the period of validity can still be made according to DIN 6700-2. 4. Until the end of the transition period, a welding manufacturer having a "Certificate according to DIN 6700-2" or a "Certificate according to EN 15085-2" may manufacture according to either DIN 6700 or EN 15085.

3. Allocation of parts and subassemblies to the certification levels according to EN 15085-2: The certification level pursuant to EN 15085-3 must be determined depending on the highest weld performance class existing on the part and the listing according section 4 of EN 15085-2. In addition, Annex A of EN 15085-2 must be observed. Supplementary the customer may specify an allocation of the parts and subassemblies to the certification levels. For the transition from parts class C 1 and C 2 according to DIN 6700-2 to the certification level CL 1 according to EN 15085-2, the following provisions apply: 3.1 New build Description of the welding work

Parts class acc. to DIN 6700-2

CL acc. to EN 15085-2

According to DIN 6700-2: New build, conversion of railway vehicles and their components (bogies, underframes, vehicle body). According to EN 15085-2: Welding manufacturers authorized to produce welds of all weld performance classes and having a comprehensive welding production in several welding shops

C1

CL 1 *)

According to DIN 6700-2: New build of railway vehicles with high safety relevance according to DIN 6700-2, Table 1. According to EN 15085-2: Welding manufacturers authorized to produce welds of all weld performance classes and with minor welding production (single welding shop).

C2

CL 1 **)

*) Responsible welding coordinator: Level A and deputy with equal rights (level A) according to EN 15085-2 required. **) Responsible welding coordinator: Level A according to EN 15085-2, deputy with equal rights (level A) not required.

Coordination Committee Guideline / DVS 1619 / Transition regulations, Page 1 of 3

Annex 8, 3 December 2008

3.2 Repair Parts class acc. to DIN 6700-2

CL acc. to EN 15085-2

Application

C1

CL 1; Responsible welding coordinator: Level A; Deputy: Level A

Workshops with comprehensive welding repairs and welding production in several welding workshops.

C2

CL 1; Responsible welding coordinator: Level A; Deputy: Level B or C

Workshops with minor welding repairs and a single welding workshop.

4. Treatment of "current projects completed according to DIN 6700": Case A: Current new build project for which an EBA or EC examination (TSI conformity assessment) based on DIN 6700 is available: Irrespective of the certification of the executing welding manufacturer, current projects can be continued according to DIN 6700 until the end of the transition period. Case B: Replica (reproduction) project for which an EBA or EC examination based on DIN 6700 is available: The design must be adapted to EN 15085; irrespective of the certification of the executing welding manufacturer, the production can be made according to DIN 6700 or EN 15085 until the end of the transition period. Case C: New build or replica (reproduction) project with EC examination: The project must be completed according to EN 15085 from design through to production. Case D: Repair: Corresponding to DIN 27201-6, the repair can be performed on the basis of drawings according to DIN 6700 or other, older regulations (e.g. DS 951 01) without an adjustment of the drawings; however in that case, all welding planning documents for the production must comply with EN 15085.

5. Requirements on the inspection personnel: Section 5.1.4 of EN 15085-2 requires that welding manufacturers performing weld inspections of the weld inspection classes CT 1 or CT 2 must have inspection personnel certified according to EN 473. Until the end of the transition period, inspection personal qualified according to EN 473 will be sufficient.

6. Conversion of weld performance classes from DIN 6700 to EN 15085 The provisions in this section apply to the conversion of drawings to the new EN 15085 series of standards. Before converting the weld performance classes from DIN 6700-3 to EN 15085-3, it must be reviewed which factors were decisive for the determination of the respective weld performance class according to DIN 6700-3. This particularly applies to the weld performance classes 2.1 and 2.2, since apart from the stress factors and the safety category, additional factors have been taken into account for the determination of the weld performance class (e.g. difficult access, material with limited suitability for welding, high internal stress of the weldment). The weld performance classes 2.1, 2.2 and 2.3 defined in DIN 6700-3 relate to quality level C for outer imperfections and quality level B for inner imperfections of the EN 25817 as applicable in 2002. According to the now applicable EN ISO 5817, this corresponds to the quality level C for all imperfections. To maintain the level of quality, the conversion of the weld performance classes according to DIN 6700-3 to EN 15085-3 e.g. in drawings must be based on the following relationships: Coordination Committee Guideline / DVS 1619 / Transition regulations, Page 2 of 3

Annex 8, 3 December 2008

 







Weld performance class 1 according to DIN 6700-3 as a rule corresponds to CP A according to EN 15085-3 (special case). For weld performance class 2.1 according to DIN 6700-3, CP C1 - CT 1 according to EN 15085-3 is recommended; for welds of safety category "high" and stress category "high" or "medium" (e.g. for machined butt welds with full penetration or machined T-joints with full penetration): CP B - CT 1. For weld performance class 2.2 according to DIN 6700-3, CP C1 according to EN 15085-3 is recommended; for welds of safety category "medium" and stress category "high" (e.g. butt weld with full penetration or T-joint with full penetration): CP B. Weld performance class 2.3 according to DIN 6700-3 as a rule corresponds to CP C2 according to EN 15085-3; for welds of safety category "high" and stress category "low", CP C1 may become necessary. Weld performance class 3 according to DIN 6700-3 as a rule corresponds to CP D according to EN 15085-3.

Coordination Committee Guideline / DVS 1619 / Transition regulations, Page 3 of 3