Simple Unfired Pressure Vessels Designed to Contain Air Or Nitrogen

CEN ENx28b-4-94 ÏË 3404.589 0086835 394 BRITISH STANDARD BS EN 286-4: 1995

Simple unfired pressure vessels designed to contain air or nitrogen

Part 4. Aluminium alloy pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock --```,-`-`,,`,,`,`,,`---

The European Standard EN 286-4 : 1995 has the status of a British Standard

UDC 621 642.02-98-034 715 629.4-5yZ 620 1 62-777

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Cooperating organizations

--```,-`-`,,`,,`,`,,`--- The European Committee for Standardization, under whose supervision this European Standard was prepared, comprises the national standards organizations of the following Western European countries:

Austria Oesterreichisches Normungsinstitut Belgium Institut belge de normalisation Denmark Dansk Standard Finland Suomen Standardisoimisliito, r.y. France Association française de normalisation Germany Deutsches Institut für Normung e.V. Greece Hellenic Organization for Standardization Iceland Technological Institute of Iceland Ireland National Standards Authority of Ireland Italy Ente Nazionale Italiano di Unificazione Luxembourg Inspection du Travail et des Mines Netherlands Nederlands Nonnalisatie-instituut Norway Norges Standardiseringsforbund Portugal Instituto Portuguès da Qualidade Spain Asociación Española de Normalización y Certificación Sweden Standardiseringskommissionen i Sverige Switzerland Association suisse de normalisation United Kingdom British Standards Institution

Standards Board and comes into Amd. NO. Date Rxt affected effect on 15 February 1995 0 BSI 1995

The following BSI references relate to the work on this standard: Committee reference PVEí17 Draft for comment 90í81699 DC

ISBN O 580 2186û 3

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Contents

Page Cooperating organizations Inside front cover National foreword i Foreword 2 Text of EN 286-4 3 National annex NA (informative) Committees responsible Inside back cover National annex NB (informative) Cross-references Inside back cover

National foreword

This British Standard has been prepared under the direction of the Pressure Vessel Standards Policy Committee and is the English language version of EN 286-4 : 1994 Simple unfired pressure vessels designed to contain air or nitrogen - Part 4: Aluminium alloy pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock, published by the European Committee for Standardization (CEN). EN 286-4 was produced as a result of international discussions in which the UK took an active part. Compliance with a British Standard does not of itself confer immunity from legal obligations.

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Copyright European Committee for Standardization i Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale EUROPEAN STANDARD EN 286-4 NORME EUROPÉENNE EUROPÄISCHE NORM September 1994

UDC 621.642.02-98-034.715: 629.4-592 620.1 : 62-777

Descriptors: Railway rolling stock, brakes, pneumatic equipment, pressure vessels, tanks containers, aluminium alloys, design, computation, production control, weld defects, acceptability, assembling, certification, marking

English version Simple unfired pressure vessels designed to contain air or nitrogen - Part 4: Aluminium alloy pressure vessels designed for air braking equipment and auxiliary pneumatic equipment for railway rolling stock

Récipients á pression simples, non soumis à la Einfache unbefeuerte Druckbehälter für Luft flamme, destinés à contenir de l’air ou de oder Stickstoff - Teil 4: Druckbehälter aus l’azote - Partie 4: Récipients à pression en Aluminiumlegierungen für alliages d’aluminium destinés aux Druckluftbremsanlagen und pneumatische équipements pneumatiques de freinage et aux Hilfseinrichtungen in Schienenfahrzeugen équipements pneumatiques auxiliaires du matériel roulant ferroviaire

This European Standard was approved by CEN on 1994-09-09.CEN members are bound to comply with the CENKENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any GEN member. The European Standards exist in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a GEN member into its own language and notified to the Central Secretariat has the same status as the official versions. CEN members are the national standards bodies ofAustria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.

CEN European Committee for Standardization Comité Européen de Normalisation --```,-`-`,,`,,`,`,,`--- Europäisches Komitee für Normung

Central Secretariat: rue de Stassart 36, B-1050Brussels

@ 1994 Copyright reserved to CEN members Ref. No. EN 286-4 : 1994 E Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale

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Foreword Contents This European Standard was prepared by CEN/TC Page 54, Unfired pressure vessels, of which the Foreword 2 secretariat is held by BSI. 1 Scope 3 This European Standard has been prepared under 2 Normative references 3 a Mandate given to CEN by the European Commission and the European Free Trade 3 Symbols 4 Association, and supports essential requirements 4 Materials 4 of the EC Directive(s). 5 Design 5 CEN/TC 54 decided to submit the final draft for 6 Inspection and drainage bosses 13 formal vote by its resolution. The result was 7 Marking 13 --```,-`-`,,`,,`,`,,`--- positive. 8 Corrosion protection 13 This part is one of a series of four. The other Parts are : 9 Qualification of welding procedures 14 Part 1: Design, manufacture and testing 10 Qualification of welders and welding operators 14 Part 2: Pressure vessels for.air braking and auxiliary systems for motor vehicles and their 11 Testing of the vessels 17 trailers 12 Certification procedures 24 Part 3: Steel pressure vessels designed for air 13 Information to be supplied at the time of braking equipment and auxiliary pneumatic invitation to tender and time of order 24 equipment for railway rolling stock 14 Delivery 24 This European Standard shall be given the status 15 Documentation to accompany the vessel 24 of a national standard, either by publication of an Annex (normative) Verification 25 identical text or by endorsement, at the latest by A March 1995, and conflicting national standards www.bzfxw.comAnnex B (normative) Declaration of conformity shall be withdrawn at the latest by March 1995. - Surveillance 25 According to the CENKENELEC Internal Annex C (normative) Design and Regulations, the following countries are bound to manufacturing schedules 27 implement this European Standard: Annex D (normative) Type examination 27 Austria, Belgium, Denmark, France, Annex E (normative) Content of the Germany, Greece, Iceland, Ireland, Italy, manufactured record 28 Luxembourg, Netherlands, Norway, Portugal, Annex F (informative)Assembly of the vehicles 28 Spain and United Kingdom Annex G (informative) Service surveillance of vessels 31

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1 Scope 1.6 The requirements of this Part of this 1.1 This Part of this European Standard is European Standard apply to vessels designed to be applicable to simple unfired aluminium alloy fitted to rail vehicles used on the main national pressure vessels, referred to as 'vessel' in this networks, urban networks, underground railways, standard, designed for air braking equipment and trams, private networks (regional railways, auxiliary pneumatic equipment for railway rolling company railways, . . . 1. stock (see 1.6). 1.2 The vessels to this standard are: 2 Normative references a) made from a single shell; This European Standard incorporates by dated or b) made from aluminium alloy; undated reference, provisions from other publications. These normative references are cited c) fabricated by welding; at the appropriate places in the text and the d) used at a maximum working pressure of publications are listed hereafter. For dated 10 bar; references, subsequent amendments to or revisions of any of these publications apply to this European e) the product of the maximum working Standard only when incorporated in it by pressure (in bar) and the volume (in litre): amendment or revision. For undated references 500 bar litres < PV < 10 O00 bar litres ; the latest edition of the publication referred to f) made of a cylindrical part of circular cross- applies. section called the shell with two outwardly EN 287-2 Approval testing of welders - fusion dished torispherical ends, that is two dished welding - ends with the same axis of rotation. This Part 2: Aluminium and aluminium alloys standard therefore does not apply to vessels EN 288-1 Specifications and approval of welding with one or two flat ends or those made up of procedures for metallic materials - several compartments; Part 1: General rules for fusion welding g) calculated with a design pressure P (see www.bzfxw.comEN 288-2 Specification and approval of welding 5.1.4.2) ; procedures for metallic materials - h) designed for a working temperature of Part 2: Welding procedure specification for between - 50 "C and + 100 'C [ + 65 'C for certain arc welding grades of aluminium alloy (see 4.1.111; EN 288-4 Specification and approval of welding j) fastened to the vehicles by straps; procedures for metallic materials - Part 4: Welding procedure tests for the arc 1.3 In normal service, a momentary overpressure welding of aluminium and its alloy of 1 bar of the maximum working pressure is permitted (10 % of E',). EN 10025 Hot rolled products of non-alloy structural steels - Technical delivery conditions 1.4 This Part of this European Standard applies to EN 26520 Classification of imperfections in metallic the vessel proper, from the inlet connection to the fusion welds, with explanations outlet connection and to all other connections and fittings belonging to the vessel. Is0 209-1 Wmughi aluminium and aluminium alloys - Chemical composition and forms of 1.5 This Part of this European Standard gives the product - requirements to be met for the calculation, design, Part 1 Chemical composition fabrication, inspection during fabrication and certification of the vessel, and fittings for assembly Lso 209-2 Wmughi aluminium and aluminium &s to the vehicle. - Chemical composition and forms of product - These requirements cannot be written in sufficient Part 2 : Forms of products detail to ensure good workmanship or proper construction. Each manufacturer is therefore EO 2281 pipe threads where pressure-tightjoints are responsible for taking every necessary step to not made on the threads - make sure that the quality of workmanship and Part 1: Designation, dimensions and construction is such as to ensure compliance with tolerances good engineering practice. IS0 261 IS0 general purpose metric screw threads - General plan This Part of this standard gives: IS0 1101 Technical drawings - Geometrical a) in annex F, recommendations for assembly to tolerancing - Tolerancing of form, the vehicles; orientation, location and run-out - b) in annex G, recommendations for the service Generalities, definitions, symbols, surveillance of vessels. indications on drawings

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Page 4 EN 286-4 : 1994

IS0 2081 Metallic coatings -Electroplated coating External height of the dished part of zinc on iron or steel of an end mm Is0 2107 Aluminium, magmsium and their alloys - (see figure 3) Temper designations External height of the cylindrical part of the end mm IS0 2437 Recommendation practice for the X-ray (see figure 3) inspection of fusion welded butt joints Internal height of a dished part of for aluminium and its alloys and the end mm magnesium and its alloys 5 to 50 mm (see figure 3) thick Design coefficient which is a IS0 4520 Chromate conversion coatings on function of the welding process - electroplated zinc and cadmium Total length of the vessel mm coatings Distance between the axis of a Is0 6361-2 Wrought aluminium and aluminium alloy drainage opening and the end of sheet, strip and plate. the vessel mm Part 2: Mechanical properties Length of the boss contributing to IS0 6362-2 Wrought aluminium and alloy extruded reinforcement mm rods I bars, tubes and profiles Length of inward projecting boss Part 2: Mechanical properties contributing to reinforcement mm Length of the reinforcing plate contributing to reinforcement, measured along the mid surface mm 3 Symbols Length of the shell contributing For the purpose of this standard, the following to reinforcement, measured along symbols apply: the mid surface mm A Elongation at rupture % Design pressure'' which is a Afb Cross sectional area effective as function of the maximum working compensation, of the boss mm2 www.bzfxw.compressure, the welding process and AfP Cross sectional area effective as inspection used bar compensation, of the reinforcing Maximum working pressure1) bar plate mm2 Internal radius of the spherical Cross sectional area effective as part of the end mm Afs --```,-`-`,,`,,`,`,,`--- compensation, of the shell mm2 Local internal radius at the A, Area of the pressurized zone mm2 location of the opening in C Absolute value of the minus question mm rolling tolerance for sheets as Minimum tensile strength quoted in the standard mm specified by the manufacturer or

DO Outside diameter of the shell of by the standard defining the the vessel mm material N/mm2 dib Internal diameter of the boss mm Minimum proof stress Nímm' Outside diameter of the boss mm Internal radius of the e Nominal wall thickness mm torispherical part of the end mm e, Calculated thickness mm Minimum working temperature "C ech Calculatd thickness of the end mm Maximum working temperature "C ecs Calculated thickness of the shell mm Volume of the vessel 1 eh Nominal thickness of the end mm erb Wall thickness of the boss contributing to reinforcement mm 4 Materials erp Wall thickness of the reinforcing plate contributing to 4.1 Pressurized parts reinforcement mm The aluminium alloys used in the fabrication of ers Wall thickness of the shell the pressurized parts of the vessels shall hlfil the contributing to reinforcement mm following conditions: f Nominal design stress at the a) R, I350 N/mm2 design temperature N/mm2 b) elongation after rupture A shall be: fb Permitted stress of the boss N/mm2 g Throat thickness of a weld mm -if the test piece is taken parallel to the direction of rolling 2 16%; -if the test piece is taken perpendicular to "All pressures are gauge pressures. the direction of rolling 2 14%.

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4.1.1 Shell and ends 5 Design The shell and ends shall be made of aluminium alloy sheet or strip of one of the grades given in 5.1 Shell and ends table 1. 5.1.1 General 4.1.2 Inspection bosses, pipes connection The vessels are of simple geometrical form, branches and drainage bosses composed of a cylindrical body of circular cross- The bosses shall be made of 5083, 5086, 5454 or section and two outwardly dished torispherical 5754 aluminium alloy bars or tubes in condition M ends. in accordance with IS0 6362 : Part 2. The design of the vessels shall take into account the installation and maintenance conditions. The 4.2 Non-pressurized parts installation and maintenance conditions shall be The accessories to be welded to the vessel, but given by the manufacturer or the user (see clause which do not contribute to its strength, shall be 13) made of aluminium alloy compatible with the aluminium alloy from which the pressurized parts NOTE. Examples of installation and maintenance requirements of the vessel are made. The product analysis of the are given in informative annexes F and G. aluminium alloy shall meet the following requirements: 5.1.2 Design of the shell - R, I 350 N/mm2; Shells are generally made from a single sheet. If - Cu s 0,5 % and Zn I0,25 %. the shell is made of several welded parts, the number of circular welds shall be kept to a 4.3 Welding materials minimum. The filler material and gas fluxes shall be suitable Longitudinal weld seams of parts of the shell for the parent metals. shall : The recommended grades of filler material to be - not be located on the lower part of the vessel used are 5183 and 5356. These grades are suitable defined by an angle of 30” on either side of for welding the grades listed in 4.1 and 4.2. www.bzfxw.comthe vertical axis (see figure 1); Aluminium-silicon grades shall not be used. - be sufficiently far apart such as to form an The suitability of the welding products used is angle greater than 40” (see example in verified during the qualification of the procedures figure 2). described in clause 9. All welds, even of a temporary nature, located outside the designed seams are prohibited.

Table 1. Aluminium alloy materials IS0 designation’’ International Temper Maximum Temperature Design registration designation*’ temperature temperaturea’ record’) ‘C

Minimum proof Minimum design stress stress 1 N/m* I N/-* AlMg2Mn0,8 5049 O 100 80 80 70 48 48 G5’ 42 AlMg3 5754 O 100 80 80 70 48 48 G5’ 42 AlMg3Mn 5454 O 100 90 90 90 54 54 a5’54 1 AlMg4 5086 O 65 100 loo W’ 60 60 S5’ 54‘ AlMg4,5Mn0,7 5083 O 65 125 1s 1204) 75 75 745) 72‘

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specified in this standard as they vary according to the following criteria: - the grade of aluminium alloy; - the type of oven (other than direct radiation, convection, etc.) ; - the forming process (hot or cold drawing). The heat treatment shall not affect the values of R,o,z and R, used in calculating the thickness. Drainage opening In addition, after heat treatment the material shall satisfy the following conditions: - tensile strength R, I350 N/mm2; Figure Position of longitudinal welds on - elongation after rupture A 2 16 %. 1. --```,-`-`,,`,,`,`,,`--- the bottom of the shell The suitability of the heat treatment parameters shall be checked by the approved inspection body when the manufacturing record is submitted for the certification procedure (see clause 12). 5.1.4 Calculation of shell and end thicknesses 5.1.4.1 General The nominal thickness e of the shells and ends shall be such that: e>e,+c The value of e, shall in no case be less than 3 mm. The manufacturer shall apply a correction to allow Drainage point or reference www.bzfxw.comfor thinning resulting from the manufacturing mark on the Lower part process. 5.1.4.2 Calculation of the shell thickness ecs Figure 2. Position of longitudinal welds on

ecs = ~ K, the shell 20f + P The minimum design stress shall be taken from 5.1.3 Design of the ends table 1.

5.1.3.1 Shape and dimensions of the ends NOTE. It has been established from the standards quoted in The torispherical ends shall be made from a single this part that 0,3Rm is always greater than 0,6R,,,,. sheet. The values of P and K, to be taken into account Dishing and flanging shall be carried out by a are : mechanical forming procedure, for example by a) case no. 1: P 2 1,15P8and K, = 1 for pressing or spinning. Hand forming is not automatic welding and when tests are carried permitted. out in acordance with 11.1.2.1; The torispherical end shall meet the requirements b) case no. 2: P 2 1,3Psand K, = 1 for automatic of figure 3 and table 2. welding and when tests are carried out in accordance with 11.1.2.2; c) case no. 3: P 2 1,25Psand K, = 1,15 for Table 2. Height of the cylindrical portion of welding using a non-automatic process and ends when tests are carried out according to 11.1.1. Dimensions in millimetres 5.1.4.3 Calculation of the thickness of the ends ech eh 131 4 151 61 8 10 The end thickness shall be calculated in the himin I 12 I 16 I 20 I 24 I 32 40 following manner: I himax I 25 I 40 I 50 1 a) Select the values off from table 1, and with P = P,, calculate Pllof. 5.1.3.2 Heat treatment after forming The parameters of the heat treatment to which ends are subjected after forming cannot be

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R (nominal) = 0, 0,10, < r (nominal) < 0,150, Figure 3. Torispherical end

b) Calculate hJD, with he the smaller of the Calculate he/D,, with he = smallest of 3 values: three values: a) h = eh + Do - ,+/(Do - rI2 - (D,/2 - eh - r)' www.bzfxw.com= (3,38) + 400 - 2 J(400 - 40)' - [400/2 - 3,38 - 4012 where : = 79,24 0; ech = ecs ; = 99,23 h = eh + hz b, 4íR + ech) =eh+Do- (Do - r)' - (D,/2 - eh - r)' (take eh = ecs + (3). C) 2' ech) = 92,82 NOTE. 0,3 is the minus rolling tolerance for the sheet. when echis taken as c) Determine ech/D0from figure 4. --```,-`-`,,`,,`,`,,`--- equal to ecs = ~ Kc d) Multiply the value found by Do to obtain the 20f + P thickness ech. e) Verify the calculation with this value in place = 3,08 of that of ecs. thus eh = 3,08 + 0,3 = 3,38 = = Example of calculation of thickness eeh of an end of giving he 79,24 and he/D, 0,198 aluminium alloy 5083 in accordance with IS0 From figure 4: ech/Do= 0,0101 6361-2 for a vessel of diameter Do = 400 mm and a maximum service temperature of 65 OC. ech = 0,0101 x 400 = 4,04. The verification of the calculation with ech = 4,04 P = 1,15P, = 1,15 x 10 = 11,5 bar (case no. 1 in in place of ecs = 3,08 gives: 5.1.4.2) for'the shell P = P, = 10 bar for the ends ech = 4. K, = 1 5.1.5 Weldedjoints of shells and ends R =Do= 400 mm r = O,lDo = 40 mm 5.1.5.1 Longitudinal welds T,,, = 65 "C The welds shall be full penetration butt welds. f= 74 N/mm' from table 1 Backing strips, even of a temporary nature, are Therefore P/(lOf) = 10/(10 x 74) = 0,0135 not permitted.

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0.0140" 9 8 7 6 I I

ii I 0,150 0,250 0,300 0,350 0,400

e 1% -

0,001 - 1 I 2 3 4 5 6 7 8 9 I O,Oì35 1 3 0,001 0,Ol P/(lOf) Figure 4. Theoretical curves for dished ends

5.1.5.2 Circular welds alignment either of the neutral axes (figure 5) or The shell/end joints permitted are those shown in of the walls of the internal face or external face, figures 5 to 8. The welds in figures 5 to 7 Shall be the Connecting Slope not exceeding 25 % (14")(see of the full penetration type of the shell/end wall; figures and 7, and the misaliWment Of the and for figure 8 full penetration of the shell wall. axes not exceeding mm- If the misalignment of the neutral axes is greater than 1 For welding of sheets of different nominal mm, levelling shall be carried out as shown in thicknesses (shell/end weld), there shall be figures 7a and 7b.

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5.2 Openings

5.2.1 General Inspection bosses, pipe connection branches and drainage bosses are cylindrical parts comprising an internal pipe thread complying with IS0 228-1 or an IS0 metric thread in accordance with IS0 Figure 5. Butt weld with centre lines aligned 261. The permitted shapes and welding are defined in 5.2.4.1 and 5.4.2.2. 11 25% rnax(t~ol-, The minimum number, dimensions and location on the vessel are defined in clause 6. The wall thickness of bosses shall not be less than 2 times the thickness of the sheet to which they are welded. 5.2.2 Holes for bosses Figure 6. Butt weld with centre lines offset Where the diameter of the hole in the wall is greater than 75 mm, a reinforcement calculation is necessary in accordance with the method described in 5.2.3. Where holes require reinforcement, the distance that they are to be apart is defined in 5.2.3.1. The maximum distance between the centre of the dished end and the outer edge of any holes shall Figure 7a not be greater than 0,40, (see figure 9). Holes in shells and ends should be located as far yb 25% max [14O) as possible from welded seams and shall in no case cross any welded seam. The distance between any two welds measured from the extremity of the edge preparation shall not be less than 4 times the nominal thickness of the shell or end, with a minimum of 25 mm (see figures 10a and lob).

Figure 7. Butt welds with centre lines offsel and connecting slope

Figure 9. Position of a hole in an end

Figure 8. Weld of the shell ring to end with necked edge

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~~ Ge min I

Figure 10a

be min

I I/A P Figure lla. Reinforcement of cylindrical shell with boss

Figure 10. Distance between two welds measured from the end of the edge preparation Afb +I

5.2.3 Calculation of the opening reinforcement 5.2.3.1 General The calculation method described in 5.2.3.2 and 5.2.3.3 is applicable to shells and dished ends in which circular holes are made in compliance with the following conditions and hypotheses. Reinforcing plates, where used, shall be made from the same material as that of the vessel to which they are welded. I 1 The distance between openings, measured from the outer face of the reinforcing plates or openings Figure llb. Reinforcement of spherical shell with boss shall not be less than 2 x I,, where two openings require reinforcement, or I,, where only one of the two openings requires reinforcement. 1,s = JGGaG (1) where : a) Ri = D,/2 - e,, for shells; b) Ri = R for ends. Reinforcement of the openings is obtained by the use of: a>recess welded bosses (see figures lla and 1lb); b) welded reinforcing plates and recess welded bosses (see figure llc). Adequate reinforcement shall be provided in all planes passing through the axis of the opening. Figure llc. Reinforcement of spherical shell by reinforcing plate and boss 5.2.3.2 Reinforcement of opening Only bosses of the ‘full penetration’ type as shown Figure 11. Reinforcement of opening in figures lla and llb may be used.

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The length of the boss contributing to the reinforcement, used in equation (3) for determining Ab shall not be greater than I,, [see equation (211: Irh 5 ITS (2) The value of erb used for determining Aa in equation (3) shall not be more than twice ers. The following condition shall also be complied with: Figure 12. Fixing of a boss by an external (3) I weld 5.2.3.3 Reinforcement by reinforcing plate and I

--```,-`-`,,`,,`,`,,`--- boss One of the following two conditions shall be complied with: - the permissible stress fb is less than stress f: Pl10 (A, + 0,5(Afs+Ab + 0,7Af,)] _< f(& + 0,7Afp)+ fh&, - the permissible stress fb is greater than stress f: A, & (Af,+ Am + 0,7Afp Figure 13. Fixing of a boss by internal and where : external welds a) the areas A,, Ab, Af, and Af, are determined as shown in figures lla, llb and llc; b) the maximum height of the boss to be used in the calculation is:

Irh = 0,8v?(doh - erb)e,h c) the maximum height of the part of the boss (&.hi) inside the vessel, to be used in the calculation is : hi = 0,5Irb d) the dimensions of the reinforcing plate to be used in the calculation are: erp Iers and I,, 5 I,, 5.2.4 Welding of bosses Figure 14. Fixing of a boss by internal and 5.2.4.1 Inspection openings and pipe connection external fillet welds branches Welds can be either full penetration welds (see figures 12 and 13) or partial penetration welds (see figure 14). 5.2.4.2 Drainage openings The welds shall be full penetration welds of the wall of the vessel. Weld preparation of the vessel may be necessary. Examples of permitted welds are given in figures 15, 16 and 17. If the drainage opening cannot be made in the bottom of the vessel, drainage shall nevertheless Figure 15. Fixing of a drainage boss by an be provided by one of the permitted methods external weld shown in figures 18 to 25.

Figure 20. Dip tube fixed to the shell of a Figure 16. Fixing of a drainage boss by vertical vessel internal and external welds

Figure 17. Fixing of a drainage boss with drainage groove Figure 21. Dip tube fixed to a top end of a vertical vessel

I I /// 'f.L/ A I

Figure 18. Dip tube ked to an end

Figure 22. Dip tube fixed to the upper part of the shell of a horizontal vessel

Figure 19. Dip tube fixed to the shell of a horizontal vessel SW figures x 12, 13 and 14

Figure 23. Fixing of a dip tube

The locations of the bosses shown in figure 26 are recommended. Other locations may be specified as 'igures long as they permit access for internal inspection and 14 and drainage of the vessel.

7 Marking 7.1 General Vessels complying with this Part of this European Standard shall bear the identification and service marks given in 7.4. Figure 24. Fixing of a dip tube to a boss These marks are stamped either in the metal of the vessel itself or on a plate welded to the vessel wall. These marks shall be located on the vessel at one of the positions shown in figure 27. figures 13 and 14 7.2 Marking stamped in the metal of the vessel Stamping of marks shall only be carried out on vessel walls of thickness e 2 5 mm. The stamps shall not have any sharp edges and the depth of the stamping shall not exceed one tenth of the wall thickness. When the marking is on an end, the mark shall be stamped as far as possible away from the Figure 25. Recessed fixing of a dip tube to a theoretical line of intersection of the knuckle boss radius and the spherical radius and shall be close to the end base, without interfering with the weld of the pipe connection branch. Marking shall be carried out before the ends are 6 Inspection and drainage bosses welded onto the shell. The vessels shall have at least the inspection and The only marks that shall be stamped onto the drainage bosses of the dimensions given in table 3 finished vessel are those given in items 6) and 10) of 7.4. However, vessels with a PV less than or equal to 1000 bar litres (with L < 1500) may have only onc 7.3 Marking stamped on a plate boss for pipe connection, inspection and drainage. The dimensions of the marking plate are given in In this case, the minimum diameter is 30 mm. figure 28. Other bosses intended particularly for pipe 7.4 Identity and service marks connections may be provided, as long as they are This marking shall follow the general arrangement located well away from welded joints or seams shown in figure 29 or, if necessary, shall be in subject to deformation, and in particular away three zones (see figure 27). These marks shall from the knuckle ends. have a minimum height of 5 mm. The dimensions in figure 29 are given for guidance.

dibl Minimum diameter: 30 mm A diameter of 30 mm corresponds 8 Corrosion protection approximately to internal threads G1 and M33 8.1 General An aluminium alloy vessel is particularly sensitive dibi Minimum diameter: 18 mm to electrochemical corrosion. It should therefore be A diameter of 18 mm corresponds insulated electrically from the chassis of the approximately to internal threads vehicle. and M20 NOTE. Examples of installation conditions are given in the informative annex F.

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fi ¡b2

Le 1500 mm

c -ID II I nl

L ‘1 L Z 1500 rnm

NOTE. The drainage opening may be located other than in the bottom of the vessel provided that the vessel has a system for ensuring its complete drainage (see 5.2.4.2) Figure 26. Location of openings

If corrosion protection is necessary (see 8.3) it 9 Qualification of welding procedures shall be the subject of an agreement between the Welding procedures shall be specified in railway customer and the supplier and meet the accordance with : 1, 4. service surveillance requirements given in annex EN 288 Parts 2 and The G. qualification shall be witnessed by an approved inspection body. 8.2 Protection of internal walls No protection is required. 10 ualification of welders and 8.3 Protection of external walls we13 ing operators The outer walls of vessels not protected against Welders and welding operators shall be qualified impact of ballast or particles from the braking of in accordance with EN 287 : Part 2. The the vehicle shall be given a protective surface qualification shall be witnessed by an approved coating. inspection body.

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O I

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1) Name or trademark of the manufacturer and place of fabrication. (The arrangement and height of the characters are left to the discretion of the manufacturer). 2) Year of fabrication. --```,-`-`,,`,,`,`,,`--- 3) Vessel pattern number and batch identification. 4) Internal volume (in litres). 5) Maximum working pressure (in bars). 6) Mark of compliance with this European Standard : EN 286-4, and the last 2 digits of the year in which the mark is affixed. The CE mark and the distinguishing number of the approved inspection body. 7) Minimum service temperature T,,, (in C). 8) Maximum service temperature T,,, (in C) 9) Name or trademark of the user. Order number allocated by the user. 10) Provision for date (last 2 digits of the year) and inspectors stamp corresponding to the detailed inspections and tests given in G.6. NOTE. If the vessel is re-tested, the corresponding marks (data and stamp) should be located next to the existing obligatory marks. In the case of a plate, it should have a free space for this purpose. Figure 29. Identity and service marks

11 Testing of the vessels diameter 2e, through an angle of 180"; b) one reverse bend test around a mandrel of 11.1 Testing of welds by the manufacturer diameter 2e, through an angle of 180"; Welds shall be tested in accordance with the c) one macro test. requirements of tables 4 to 6. The acceptance criteria are specified in 11.1.5. 11.1.4 Quality of the films The quality class of the films shall be determined 11.1.1 Welds made by non-automatic welding in accordance with the requirements of IS0 2437. In this case: P 2 1,25Ps and Kc = 1,15 (see 5.1.4.2 case no. 3). 11.1.5 Acceptance criteria for welds 11.1.2 Welds made by an automatic process The results of all the tests shall be recorded. If a test gives an unsatisfactory result, the reason 11.1.2.1 With P 2 1,15Ps and Kc = 1 (see 5.1.4.2 shall be sought and a further two samples shall be case no. 1) prepared and verified. If it can be shown that the failure is a result of a local or accidental defect 11.1.2.2 With P 2 1,3Ps and Kc = 1 (see 5.1.4.2 and that the re-tests are satisfactory, the re-test case no. 2). results shall be accepted. 11.1.3 Destructive testing of welds on coupon If a new sample gives unsatisfactory results all the plates welds of all the vessels produced since the start of The following tests shall be carried out by the production or since the last unsatisfactory non- manufacturer on coupon plates: destructive test shall undergo a non-destructive a) one face bend test around a mandrel of test.

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Tables 7 and 8 show the acceptance levels. 11.1.6 Finish of longitudinal and circular If any part of a weld has been repaired the whole joints of the repaired weld seam shall be verified by All welds shall have a smooth finish without means of a non-destructive test. valleys and shall merge into the plates without Following the bending tests, the sample shall not undercutting or abrupt irregularity (see table 7). have any defects greater than 3 mm in any To ensure that the weld is fully penetrated and direction. thus that the surface of the weld metal does not In the macrographic examination, the affected fall below the surface of the adjoining plate, weld surface of the sample shall show, through the metal may be built up as reinforcement on each

microscope, a welded point image with an side of the plate. This reinforcement shall not --```,-`-`,,`,,`,`,,`--- adequate penetration and with no defects other exceed the values given in table 9. than those permitted in table 8. The reinforcement need not be removed except to the extent that it exceeds the permissible thickness.

Table 4. Amount of testing reauired for welds made by a non-automatic process ~ Testing by the manufacturer Verification by the approved inspection body where required Test Nondestructive test (NDT) Destructive test @T) Each vessel i00 yo visual inspection

Each welding 1 i00 yo X-ray of or 1 coupon plate Visual inspection of machine and each the weld, including coupon plates and films welding procedure junctions, on the held by the manufacturer. same vessel Inspection of the results Circumferential weld of the various tests carried out in application If the welding process or the designation of the of this standard. filler metal is identical to that used for the longitudinal weld, then the circumferential weld needs no further testing.

If the welding process or standard designation of the filler metal differs from those used for making the longitudinal weld:

1 coupon plate at the start of fabrication

Then every 300 m of we-3 with a minimum on any one vessel of the batch of

1 100 % X-ray of or 1 coupon plate the weld I

Table 5. Amount of testing required for welds made by an automatic rocedure with P 2 1,15P Testing by the manufacturer Verification by the approved inspection body where required Non-destructive test (NDT) Destructive test (DT) FEach vessel 100% visual inspection

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

During manufacture

Every 100 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change of standard designation of the filler metal:

1 X-ray per film of or 1 coupon plate Visual inspection of

--```,-`-`,,`,,`,`,,`--- length greater than coupon plates and films 200 mm including at least held by the manufacturei one junction

Circumferentia1 weld Inspection of the results of the various tests If the welding process or the designation of the filler carried out in applicatioi metal is identical to that used for the longitudinal of this standard. weld, then the circumferential weld needs no further testing.

If the welding process or standard designation of the filler metal is different from those used for making the longitudinal weld :

After adjustment

1X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

During manufacture

Every 300 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change in the standard designation of the filler metal:

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

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Table 5. Amount of testing required for welds made by an automatic procedure with P 2 1,15Ps (concluded) Testing by the manufacturer Verification by the approved inspection body where reauired Test I Non-destructive test ("ï)I Destructive test (DT) I With a minimum per batch of vessels or per month:

2 X-rays per film or 2 coupon plates of length greater than 200 mm including at least one junction NOTE. The coupon plates or X-rays shall be from different vessels in the batch

Table 6. Amount of testing required for welds made by an automatic procedure with P 2 1,15P, Testing by the manufáctwer Verification by the approved inspedion body where rw- Test Non-destrucüve test 0 Destructive test (DT) Each vessel 100%visual inspection Longitudinal weld ARer adjustment .

1X-ray per film of or 1coupon plate length greater than 200 mm including at least one junction

During manufacture

Every 200 m of weld or at each change of adjustment outside the tolerances fixsed in the description of the welding procedure or at each change of standard designation of the mer metal:

Each welding 1X-ray per film of or 1 coupon plate Viiual inspechon of machine and length greater than coupon plates and films each welding 200 mm including at held by the manufacturer. ProCedure least one junction Inspection of the various circumferential weld tests carried out in --```,-`-`,,`,,`,`,,`--- application of this If the welding process or the designation of the mer standard. metal is identical to that used for the longitudid weld, then the circumferential weld needs no further testing:

Table 6. Amount of testing required for welds made by an automatic procedure with P 2 1,3P, (concluded) Testing by the manufacturer Verification by the approved inspection body where required Non-destructive test (NDT) I Destructive test (DT) If the welding process or standard designation of the filler metal is different from those used for making the longitudinal weld :

After adjustment

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

During manufacture

Every 500 m of weld or at each change of adjustment outside the tolerances fixed in the description of the welding procedure or at each change of standard designation of the filler metal:

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

Within a minimum per batch of vessels or per month:

1 X-ray per film of or 1 coupon plate length greater than 200 mm including at least one junction

NOTE. The coupon plates or X-rays shall be from any vessels in the

batch --```,-`-`,,`,,`,`,,`---

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Table 7. Acceptance levels of defects in butt-welds, detected by visual examination

Defect --```,-`-`,,`,,`,`,,`--- TEN 26520 reference I Acceptance level Lack of penetration I 402 I Not permitted Undercut 5011 Slight and intermittent, permitted provided not 5012 sharp and does not exceed 0,5 mm depth 5013 As undercut ShrinkageII groove I I Root concavity I515 I Asundercut I Excessive penetration I 504 I See 11.1.6 I Excess weld metal 502 See 11.1.6 Irregular surface 514 Reinforcement to be of continuous and regular 509 shape with complete filling of groove 511 513 517 b Overlap 506 Not permitted Linear misalignment 507 See 5.1.5.2 Arc strike 60 1 Grind smooth Spatter 602 Acceptance subject to thickness verification and Torn surface 603 crack detection test Grinding mark 604 Chipping mark 605

Table 8. Acceptance levels of lefects in butt-welds, detected by X-ray examination Defect EN 26520 reference I Acceptance level Cracks 100 Not permitted Porosity (isolated and grouped) 2011 Individual diameter e/4 but not more than 2 mm 2013 for a 2 % projected area max.” 2017 Porosity (uniformly distributed) 2012 Individual diameter e/4 but not more than 2 mm for a 2 % projected area max.” Porosity (linear) 2014 Check for lack of fusion before accepting. Otherwise as 2011,2012,2013 Crater pipes 2024 Not permitted Slag and flux inclusions 3011 Individual length max. e/3 and elongated cavities 302 1 (individual and parallel 2015 Summation of length = e max. in 12e length if to weld axis) separation < 6 x longest defect Slag and flux inclusions 3012 Individual length max. e/3 and wormholes (random not 3013 parallel to weld axis) 3022 3023 2016 Copper inclusions 3042 I Not permitted Lack of fusion (side, 40 1 root or inter-run) I Not pe-itted ’’ Area = maximum length of weld affected x local width of weld.

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Table 9. Maximum permissible reinforcemenl not exceeding 25% (14”)and with rounding of for longitudinal and circular welds radius greater than 50 mm. Their dimensions shall not exceed : Dimensions in millimetres f) radially - 3 mm; Thickness of the thicker Maximum reinforcement + plate thickness rl g) longitudinally 0,25 L; or r2 (see figure 30) h) transversely 71DJ20. In addition, surface scratches are permitted as 5

13 bar (case no. 2 - 5.1.4.2); --```,-`-`,,`,,`,`,,`--- c) 18,75 bar when the design pressure is taken as 12,5 bar (case no. 3 - 5.1.4.2). 11.2 Dimensional inspection in the presence of a person of recognized Vessels fabricated manually shall be inspected competence (see clause 12). individually in order to ensure that they comply This pressure shall be maintained for a sufficient with the tolerances specified below. length of time to permit a visual examination of all For vessels fabricated on an automatic line, the the surfaces and all the welded joints. The vessel inspector shall ensure, at the start of fabrication, shall show no sign of plastic deformation or that the vessels meet the following dimensional leakage. requirements. He shall then carry out a thorough Subject to agreement, a pneumatic test may be examination on at least one vessel in every 50 carried out on each vessel, at the pressure defined fabricated. above. Unless otherwise stated, the following tolerances apply: WARNING. The pneumatic test is potentially a a) length L f 7 mm; much more dangerous operation than the b) diameter Do ( 5 500 mm) f 3 mm; hydraulic test in that, irrespective of the size of ( > 500 mm) 0,6 %; the vessel, any failure during testing may result in c) circularity of the cylindrical body 0,01D,;2’ an explosion. It should therefore only be carried out after consultation with the inspection body and d) straightness of any generating line having ensured that the safety measures taken of the cylindrical body * 0,O1Do;2’ comply with current legislation of the country in d) straightness of any generating line which the test is carried out. o,01L;2’ of the cylindrical body f All vessels which fail the pressure test shall be e) volume of the vessel in the rejected. Repairs may be permitted, with the as-delivered state f 3,5 %. agreement of the client network, but in this case In addition, the wall of the vessels shall be free of the pressure test shall be repeated. localized defects such as sudden local irregularities, bumps, flats, cavities, folds, tool marks or visible symmetry defects. Cavities or bumps are permitted provided that they connect with the surrounding surface with gentle slopes

2’Thetolerances of shape and position are set out in IS0 1101.

12 Certification procedures 14 Delivery This standard specifies three classes of vessel to After complete drying of the inside walls, the which the certification procedure set out in table vessel in the delivery condition shall have all its 10 applies. openings plugged with plastic stoppers or some other means to ensure that the inside of the vessel is free from dust, water or any other foreign 13 Information to be sup lied at the bodies. time of invitation to ten 8er and the Prior to despatch, the vessel shall be suitably time of order protected to avoid any damage (impact, The invitation to tender and order, to which is deformation . . . ) during transport. attached the final drawing of the vessel, shall indicate the number of this standard and specify The packing shall be determined by the railway the following, if they have not already been customer and the manufacturer. specified in the drawing or the documents attached to it: a) the dimensions and volume of the vessel; 15 Documentation to accompany the b) the aluminium alloy or alloys, together with vessel the number of the reference standard, from The documentation to accompany the vessel shall which the shell and ends are to be made (see include : clause 4); a) particulars given on the vessel nameplate, c) the type of shell/end joints (see 5.1.5.2); including the serial identification; d) the shape of the openings and their welding b) the use for which the vessel has been to the vessel (see 5.2.4); designed; c) the installation and maintenance e) the location of the openings (see clause 6); requirements where they differ from those given f) whether the marking is stamped in the metal in annexes F and G respectively; or on a plate (see clause 7); d) a declaration that the vessel is in accordance g) the marks which the vessel shall have and with the requirements of this European their location on it (see 7.4); Standard (see annex BI; e) for information to the customer, a statement h) corrosion protection measures (see clause 8); on the test certificate that there shall be no j) a drawing showing how the vessel is welding operations carried out on pressurized assembled on the vehicle (see annex F); parts of the vessel. k) the requirements for service surveillance (see The documentation shall be in the language, or informative annex G). languages, of the country of destination. Table 10. Classification of vessels

Certification Drocedure2’ I Comment Class 1 Greater than Type examination” Verification See annex A 3000 bar litres (see annex D) and not more than or approval 10000 bar litres of design and _____~ construction Class 2 Greater than dossier” Verification’’ See annex A 200 bar litres (see annex C, or declaration of and not more clause 2) conformity” than 3000 bar litres and surveillance (and special documents) See annex B

Class 3 Greater than Verification” See annex A 50 bar litres or declaration of and not more conformity’’ (and than 200 bar litres special documents) See annex B ”At manufacturer’s choice. ‘)The mark of the inspection body shall be affixed to the vessels subjected to verification.

Annex A (normative) A.2.4 Non-destructive testing Verification Non-destructive testing of butt weld seams as required by clause 11 shall be checked by the A.1 General approved inspection body. This includes spot Verification shall be performed by an approved checks of films. If the films are not available, spot inspection body on batches of vessels submitted by NDT shall be performed according to tables 4 to 6. their manufacturer or by his authorized representative. Batches shall be accompanied by Annex B (normative) the type-examination certificate (see annex D) or by the certificate of approval of the design and Declaration of conformity - manufacturing schedule (certificate of adequacy) Surveillance (see annex C). B.l General When a batch is examined, the inspection body B.l.l Declaration of conformity shall ensure that the vessels have been manufactured and checked in accordance with the Vessels in accordance with the European Standard design and manufacturing schedule and shall whose product Ps and V exceeds 50 bar litres but perform a hydrostatic test or, subject to the which does not exceed 3000 bar litres are, at the agreement of the Member State, a pneumatic test choice of the manufacturer, either subject to

--```,-`-`,,`,,`,`,,`--- on each vessel in the batch at at a pressure equal verification (see annex A) or subject to the to 1,5 times the design pressure. Moreover, the declaration of conformity. inspection body shall carry out tests on test pieces taken from a representative production coupon B.1.2 Surveillance plate or from a vessel, as the manufacturer By the declaration of conformity the manufacturer chooses, in order to examine weld quality. The becomes subject to surveillance for vessels for tests shall be carried out on lonstudinal welds. which the product of Pc and V exceeds 200 bar However, where differing welding techniques are litres and does not exceed 3000 bar litres. The used for longitudinal and circumferential welds, purpose of surveillance is to ensure that the the tests shall be repeated on representative test manufacturer duly fulfils the obligations required pieces of circumferential welds. by this European Standard. A.2 Construction verification In the case of vessels manufactured in accordance with an approved specimen, for which a type The approved inspection body shall perform the examination certificate exists, surveillance shall be following checks and examinations. the responsibility of the approved inspection body A.2.1 Check of the manufacturing record which issued this type of examination certificate. In the case of vessels not manufactured in The manufacturing record shall be checked (see accordance with an approved specimen, annex E). surveillance shall be the responsibility of the A.2.2 External and internal inspection, approved inspection body which issued the dimensional check certificate of approval of the design and manufacturing schedule (certificate of adequacy) The inspection body shall check the identification (see C.2). of the vessel, e.g. the data-plate, and shall inspect the vessels visually, externally and internally, for B.2 Procedure required before defects, especially the seams. commencement of manufacture of vessels of The inspection shall be performed before any classes 2 and 3 (see clause 12) subject to a permanent covering coatings are applied. declaration of conformity The inspection body shall check dimensions of shells, ends, openings and other parts, that are of B.2.1 Responsibilities of the manufacturer importance to the safety of the vessel, for Before commencing manufacture, the conformity with the drawings. Distances important manufacturer shall submit to the approved for safety (e.g. distance between openings) shall be inspection body which issued the type examination checked if considered necessary. certificate or the certificate of adequacy (see annex NOTE. Normally it is adequate if 10% of vessels are checked C), a document describing the manufacturing and inspected, these to be selected by the approved inspection processes and all of the predetermined, systematic body. measures taken to ensure conformity of the vessels A.2.3 Destructive testing with this European Standard. Destructive testing as required by 11.1.3 shall be This document shall include the design and witnessed by the approved inspection body who manufacturing schedule and the documents will certify the results. referred to in B.2.1.1 to B.2.1.5.

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The manufacturer shall appoint a management B.3 Procedures required during manufacture representative who, irrespective of other of vessels of classes 2 and 3 (see clause 12) responsibilities, shall have independent authority subject to a declaration of conformity and responsibility for ensuring that the B.3.1 Responsibilities of the manufacturer requirements of this European Standard are implemented and maintained. The manufacturer shall ensure that the inspections and testing are carried out in B.2.1.1 A description of the means of manufacture accordance with the documented procedures to and inspection appropriate to the construction of complete the evidence of full conformance of the the vessels. vessel to this European Standard. The inspection B.2.1.2 An inspection document describing the and test status of vessels shall be identified by appropriate examinations and test to be carried using markings, authorized stamps, tags, labels, out during manufacture together with the inspection records, physical location or other procedures thereof and the frequency with which suitable means which indicate conformance or they are to be performed. non-conformance of vessels with regard to B.2.1.3 An undertaking to carry out the inspection and tests performed. examinations and tests in accordance with the Records shall identify the inspection authority inspection document referred to above and to have responsible for the release of conforming vessels. a hydrostatic test carried out on each vessel in The manufacturer shall maintain control of vessels accordance with this European Standard. that do not conform to the requirements of this B.2.1.4 The addresses of the places of manufacture European Standard. All nonconforming vessels and storage and the date on which manufacture is shall be clearly identified and segregated to to commence. prevent unauthorized use, delivery or mixing with B.2.1.5 In addition, when the product of Ps and V conforming vessels. exceeds 200 bar litres, the manufacturer shall Repaired or re-worked vessels shall be re-inspected authorize access to the said places of manufacture in accordance with documented procedures. or storage by the body responsible for the B.3.2 Responsibilities of approved inspection surveillance,--```,-`-`,,`,,`,`,,`--- for inspection purposes, and allow that body to select sample vessels and provide it bodies with all necessary information and in particular: For vessels whose product of Ps and V exceeds 200 a) the design and manufacturing schedule; bar litres, the inspection body responsible for surveillance shall, during fabrication: b) the inspection report; a) ensure that the manufacturer manufactures c) the type examination certificate or certificate and checks the vessels in accordance with the of adequacy, where appropriate; documents described in B.2.1; d) a report on the examinations and test carried b) take random samples - two at each visit (see out. B.3.4.2) - at the place of manufacture or B.2.2 Responsibilities of the approved storage of vessels for inspection purposes as inspection bodies given in B.3.3 and B.3.4. The inspection body responsible for the B.3.3 Frequency of inspection body operation surveillance shall examine the documents referred to in B.2.1.1 and B.2.1.3 in order to check their Initial operation a) and b) of B.3.2 shall be carried conformity with the requirements of this European out within two months of the commencement of Standard and with: manufacture and, afterwards, random checks will be made at the normal rate of one visit per year if a) the conditions stated in the certificate of the rate of production of vessels of the same type adequacy; or is up to 3000/year and twice if production is more b) the design and manufacturing record and the than 6000/year. For production quantities between conditions stated in the type examination these, the rate of visit will be adjusted accordingly. certificate. B.3.4 Surveillance checks and tests Manufacturing cannot commence before the approved inspection body has issued written To ensure that the manufacturer produces and approval of this document. checks vessels subject to the declaration of conformity in accordance with this European Standard, the inspection body responsible for the surveillance shall perform the following checks, inspections, examinations and tests.

--```,-`-`,,`,,`,`,,`--- Page 27 EN 286-4 : 1994

B.3.4.1 Check of the design and manufacturing f) if the certificates for the welding record, the inspection report and the report on the procedures, welders or operators are not examinations and tests carried out, in particular available, this shall not prevent the approved with respect to completeness, consistency, validity body from evaluating the other documents. of certificates, qualification of personnel, etc. However, they shall be submitted before B.3.4.2 The inspection body shall select at random approval is given or manufacturing at least two vessels in such a manner that at least commences ; one vessel per family is selected per year. On these g) the inspection slips for the materials used vessels, it shall perform an external and internal for the manufacture of parts and assemblies inspection, a dimensional check, a non-destructive contributing to the strength of the pressure test of all butt welds (radiographic examination) vessel or a specimen of these inspection slips; and a hydrostatic test (see A.l). h) a specimen of the proposed report on B.3.4.3 The inspection body shall make available examination and tests. to the manufacturer a copy of the surveillance C.2 Approval of design and manufacturing report that has been prepared. schedule (certificate of adequacy) If vessels are not manufactured on the basis of a type-examination certificate, the manufacturer or Annex C (normative) his authorized representative shall submit to an approved inspection body an application for design Design and manufacturing schedules approval and enclose three copies of this design C.l Content and manufacturing schedule (see C.1). The design and manufacturing schedules shall Various vessels or vessel families can be included contain the name of the manufacturer and the in one design and manufacturing schedule, but all place of manufacture and shall give the following vessel details (including branches, bosses and information: attachments) of the production envisaged shall be - a detailed manufacturing drawing of the included. vessel type; The approved inspection body shall examine these - a set of instructions comprising: documents in order to check the conformity of the design, of the required tests, and of the a) the maximum working pressure, Ps ...... qualifications with the requirements of this bar; standard. If they are in agreement with the b) the maximum working temperature, requirements of this standard the approved T,,, ...... "C; inspection body shall issue a certificate of c) the minimum working temperature, adequacy which shall be forwarded to the T,,, ...... 'C; applicant. d) the volume of the vessel, V ...... litre; e) the name or mark of the manufacturer; Annex D (normative) f) a drawing showing assembly of the vessel Type examination to the rolling stock approved by the client Type examination is the procedure by which an network indicating in particular the method approved inspection body ascertains and certifies of attachment (see annex F); that a prototype vessel satisfies the provisions of g) the service surveillance requirements this part of this European Standard. The approved by the client network (see annex GI; manufacturer or his authorized representative - a document describing: shall submit to an approved inspection body an a) the materials selected; application for type examination. b) the welding processes used; The application shall include three copies of the design and manufacturing schedule (see annex C) c) the checks to be carried out; and a prototype vessel which is representative of dj any pertinent details as to the vessel the production envisaged. design including the design pressure; If the application is lodged for various vessels, a e) the certificates relating to the suitable prototype vessel is required for each vessel type. qualification of the welding procedures and of Various vessels or vessel types can be included in the welders or operators; one design and manufacturing schedule, but all vessel details (including branches, bosses and attachments) of the production envisaged shall be included.

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The approved inspection body shall examine the m) the inspection document for the materials documents in order to check the conformity of used in the manufacture of main pressurized design, qualifications and the proposed tests with parts; the requirements of this European Standard. For parts, other than shells and ends with The approved inspection body shall also verify that diameters not exceeding 250 mm, a the vessel has been manufactured in conformity declaration by the manufacturer stating that with the design and manufacturing schedule and only materials complying with the required is representative of the type and shall perform documents have been used, is acceptable. appropriate examinations and tests (including n) the date of the hydrostatic test, signed by the 100 % NDT of main seams and a hydrostatic test). manufacturer’s inspector and, in the case of If the design and manufacture schedule and the verification, by the inspector from the approved prototype(s) comply with the provisions of this part inspection body. of this European Standard, the approved E.3 Records inspection body shall draw up a type-examination Records shall contain information required by certificate (per vessel type) which shall be E.1 and in such a way as to allow traceability. For forwarded to the applicant. The certificate shall E.2 state the conclusions of the examination, indicate the purpose of traceability, records shall be any conditions to which its issue may be subject maintained of the vessel numberícustomer. Records shall be kept for least 40 years. and be accompanied by the descriptions and at drawings necessary for identification of the approved prototype. Annex F (informative) Assembly to the vehicles Annex E (normative) F.l General Particular attention should be paid to the Content of the manufacturing record materials from which surrounding components are made (straps, cradle, pipes etc.). The difference The manufacturing record of the vessels shall between materials in the vessel and the contain (at least) the following information. surrounding unit affects the corrosion resistance of E.l General information the aluminium alloy of the vessel. --```,-`-`,,`,,`,`,,`--- This corrosion is generally the result of the a) the name or mark of the manufacturer; difference in the electrical potentials of the b) the place of manufacture; materials present, the presence of stray electric c) the qualification certificates for the welding current and the electrolyte resulting from a moist procedures and the welders or welding environment. operators; Particular attention should be paid to the d) the reports of the tests and inspections assembly of the vessel on the vehicle in order to performed, or description of the proposed avoid the effects of electrochemical corrosion. verifications. F.2 Fixing E.2 Specific information The vessels should be fked by means of straps with properties as indicated in F.3 and inserts of a) the identification codes of the vessels specific corrosion protection tape as defined in F.4. to the manufacturer (example No. . . . to . . . 1; The vessel is generally fixed by means of two b) the type approval number or the certificate of straps (see figures F.l and F.2 for typical adequacy; examples). However, for small vessels, a single c) the diameter of the vessels; strap may be used as long as it does not obstruct reading of the identity and service marks. d) the volume of the vessels; The straps are fastened to the vehicles by one of e) the maximum working pressure; the approved methods shown in figures F.3 to F.6. f) the maximum working temperature; Other methods may be used provided that all g) the minimum working temperature, if below safety requirements are complied with. - 10 OC; The means of fixing to the vehicle should be h) the test pressure; electrically insulated (see the assembly examples shown in figures F.7 and F.8). The cradle should, the drawing number(s); j) as far as possible, be part of the vehicle chassis. k) the date of manufacture; 1) the size of the batch;

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rWersd vessel ,Cradle

Insulating tapes I

Figure F.l Fixing by straps of a vessel in the horizontal position

-Welded vessel joints

Insulating tapes

Figure F.3 End of straps with angle brackets

--```,-`-`,,`,,`,`,,`--- I ‘L- Welded vessel joints Cradle- Straps made of circular rod are not permitted. Insulating tapes F.3.1 Fixing by two straps The dimensions of the straps are given in table F.1. F.3.2 Fixing by a single strap - The strap section should be approved by the customer for each particular case. Strap F.4 Insulating tapes The insulating tapes should meet the following requirements : Figure F.2 Fixing by straps of a vessel in thc vertical position a) remain elastic within the limits of the service temperatures specified by this standard; F.3 Fixing straps b) not be susceptible to creep; The fixing straps should be made of flat galvanized C) retain their insulating Properties on ageing steel of minimum tensile strength R, 5 580 N/mm2 and in the presence of moisture. The value of the as specified in EN 10025 or steel with equivalent insulating resistance should, under no mechanical properties and dimensions specified in circumstances, be less than 700 ka. F.3.1.

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Figure F.4 Ends with straps folded and reinforced

YIW Figure F.7 Fixing to the vehicle with a bolt --```,-`-`,,`,,`,`,,`---

$,;suia r $,;suia t ing washer n:&:

Straps as shown in figures F5 Figure F.5 Ends of straps with welded bolt LI- and F6 Figure F.8 Fixing to the vehicle with a nut

Table F.l Dimensions of straps Dimensions in miliimetres

60 x 6

F.5* Mounting F.5.1 General The drawing showing assembly of the vessel on the vehicle should ensure that the identity and service Figure F.6 Ends of straps with grooved marks can be read under all possible conditions. welded bolt Contact between the vessel and the vehicle should always be via cradles, with insulating tape (see F.4) inserted between the vessel and the cradle.

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The fixing straps and their insulating tape should F.5.3 Fixing by single strap always be placed around the shell (see figures F.l a and F.2). All necessary steps should be taken to It should be located so as not to obscure the avoid movement of the insulating tape relative to circular welds. the straps and the vessel. F.6 Pipe connections The cradle should: Connections between the non-alloy steel pipes and a) be placed transversely in relation to the vessel; the vessels should be of passivated and galvanized b) be adapted to the shape of the vessel; steel FeíZn 12 c 2C or Fe/Zn 12 c 2D in accordance with IS0 2081 and ISO. 4520. c) have a width at least equal to that of the fixing straps; F.7 Protection of the drainage mechanism d) have a span equal to or greater than 0,6D,. Where an automatic drainage mechanism is The tension on the straps required to prevent mounted directly on to the vessel opening, it should movement of the vessel is applied via fasteners (see be protected against accidental damage by a cap. figures F.7 and F.8). NOTE. In the case of vehicles fitted with an air dryer, the drainage opening may be closed by a passivated and galvanized NOTE. The nuts should have locking devices. (see F.6) steel threaded plug with a pressure relief hole and Excessive tightening causes plastic deformation of gasket. the vessel wall at the position of the straps, resulting in rapid fatigue fracture of the vessel. The assembly drawing should therefore state the Annex G (informative) maximum torque to be applied to the fasteners. Table F.2 gives the permitted tightening torque Service surveillance of vessels values which have been calculated for a Shore hardness of the insulating tape of 50, and with a G.l General coefficient of friction in the fasteners of 0,2. The maintenance recommendations in this annex meet the minimum safety requirements during F.5.2 Fixing by two straps normal service of aluminium alloy vessels which They should be located as close as possible to the comply with the requirements of this European circular welds without, however, obscuring them as Standard. they should remain visible once the vessel has been The vessels are used throughout the whole service fixed. life of the vehicle or device to which they are fitted, to a maximum of 40 years. At the end of this period, they are dispensed with under the I Table F.2 Tightening torques I conditions specified in G.10 However, under special Diameter of vessel Maximum tightening torque circumstances (a series of vehicles being replaced or 1 daN.m vehicles destined for a museum), the service life of I the vessels may be prolonged subject to suitable Fastener diameter surveillance specified in G.9. mm M10 M12 M16 M20 The service surveillance of the vessels complying < 450 0,3 0,35 with this European Standard is carried out during 450 < Do < 600 0,5 0,65 periodic inspections or revisions to the vehicle or > 600 035 1.2 the device fitted with it, under the following conditions. --```,-`-`,,`,,`,`,,`---

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6.2 Vessels used at: Ps 5 6 bar

I Table G.l Service surveillance of vessels used at P, I6 bar I ~ Maximum interval between 2 operations Operation Removal Method and sanction In a scheduled examination before External visual inspection and No G.4 600000 km" or 6 years drainage -24 years on the occasion of a revision I Internal and external inspection I No I G.4 and G.5 "This period may be extended to a maximum of 6 years if the vessel is protected against external attacks, for example if it is installed in an enclosure or is an integral part of the apparatus.

6.3 Vessels used at: 6 bar < P, < 10 bar

mG.2Service surveillance of vessels used at 6 bar < P, I10 bar I Maximum interval between 2 operations Operation Removal Method and sanction In a scheduled examination before 2 External visual inspection and No 6.4 years and 8 weeks'' drainage 24 years on the occasion of a revision I Internal and external inspection I No I 6.4 and 6.5 "This period may be extended to a maximum of 6 years if the vessel is protected against external attacks, for example if it is installed in an enclosure or is an integral part of the apparatus.

In addition, the satisfactory performance of these vessels is ensured by an annual sampling examination under the following conditions.

Population--```,-`-`,,`,,`,`,,`--- of vessels concerned Sample Removal Method and sanction Vessels of the same type, from whole 1 % rounded to the nearest whole Yes G.6 and 6.7 vehicle fleet or from items they are number fitted to, more than 20 years old

G.4 External inspection If a data plate is deformed as a result of impact or oxidation, but the marks are still visible, it may be 6.4.1 Cleaning replaced. Conformity to the original marking should Vessels that are particularly dirty should be be certified by the affixing of the expert's stamp. cleaned so as to permit examination of the walls under acceptable conditions. Cleaning by air blast If a new plate is welded on to the vessel, the vessel should be carried out until all dirt is completely should undergo a pressure test in accordance with removed. If a cleaning agent is used, it should not 11.3. be aggressive to aluminium alloys. G.4.3 Inspection of the walk 6.4.2 Examination of marking G.4.3.1 Deformation and irregularities If the marks specified in clause 7 are illegible, the If the walls of the vessel show localized vessel should be rejected. deformations or irregularities resulting mainly from impacts, the vessel should be rejected if these deformations or irregularities exceed the tolerances given in G.4.3.1.1 and G.4.3.1.2.

G.5 Internal examination G.4.3.1.1 Dished ends Internal inspection of the vessel walls is carried out Deformations and irregularities should not: with suitable apparatus, such as an endoscope for a) have any sharp angles (radius less than half example. the knuckle radius); If traces of corrosion are detected, their extent b) be located on the welds or at a tangent to should be assessed. Any pitting of depth equal to or them; greater than 1/10 of the wall thickness should lead c) be located more than 0,4D, from the centre of to rejection of the vessel. the end; If there is doubt about the assessment of the depth dj have a depth greater than U100 of the vessel of the corrosion, suitable apparatus for measuring diameter. the wall thickness should be used, for example G.4.3.1.2 Shell wall ultrasonic apparatus. Deformation and irregularities should not: If the extent of the corrosion does not lead to a) connect with the surrounding surface with rejection of the vessel but is located in an area slopes greater than 25% (14 ) or with roundings corresponding to an external area where traces of or radius less than half the knuckle radius ; corrosion have already been detected, but without leading to rejection of the vessel, this vessel should b) be deeper than: be rejected. - 1/50 of the vessel diameter and width less than 4 times the depth; G.6 Detailed inspection and hydrostatic test - 1/25 of the vessel diameter for other cases. G.6.1 General G.4.3.2 Corrosion These operations should be carried out by The process of electrochemical corrosion of the walls competent approved personnel. of the vessels can only start as a result of a defect in the electrical insulation of the hing. G.6.2 Detailed inspection This type of corrosion always starts from the Detailed inspection of a vessel entails its removal. outside of the vessel. Before carrying out the various phases of the inspection, the vessel should be examined to see if The vessel should therefore be visually examined to there are any defects which might lead to its check: rejection. a) that the external surface of the vessel will be protected until the next scheduled inspection at G.6.2.1 Preparation the intervals stated in G.2 and G.3 and if not, Internal and external walls of the vessel should be the protection should be re-applied; exposed by careful cleaning, if necessary using b) for presence of corrosion. If any corrosion is of chemical cleaning agents which are not aggressive a depth equal to or greater than 1/10 of the wall to aluminium alloys. thickness, the vessel should be rejected. G.6.2.2 Internal and external inspection If the vessel is not rejected, the surface protection and, if necessary, the electrical insulation of the The internal and external inspection of the walls fastening described in G.4.4 should be re-applied. should be carried out in accordance with the provisions in G.4 and G.5 with the specified G.4.3.3 Other cases leading to rejection of the vessel consequences. If there is doubt about the seriousness of the defects listed above, or if the vessel has other In addition, if any crack, discontinuity in the weld discontinuities which may adversely affect its seams or deterioration of the internal threads of the strength, it should be rejected. inspection openings or pipe connection branches are detected, the vessel should be replaced. G.4.4 Inspection of the fixings If it is observed that a strap is broken or cracked it G.6.3 Hydrostatic test should be replaced. Welded repairs are not The vessel which has satisfactorily undergone the permitted. detailed inspection should then be subjected to a Check the value of the electrical insulation hydrostatic test under the conditions described in resistance between the straps and the vessels 11.3 of this standard. greater than 700 kR. If not, replace the defective Once the vessel has successfully undergone the insulation. hydrostatic test, it should be stamped by the Inspect for traces of corrosion on the vessel walls, representative of the approved inspection body, or particularly at the strap points, in accordance with by the accredited representative, who witnessed the G.4.3.2. test.

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He atñxes: G.10 Rejection a) the date of the test (last 2 digits of the year); Any vessel rejected during the surveillance b) his stamp. operation or as a result of 6.8 should be rendered unusable by puncturing its walls to the right of the 6.6.4 Return to service marking by means of a blow torch. Vessels having successfully undergone the detailed Marking stamped in the metal or on a plate welded inspection and hydrostatic test may be refitted to to the wall of the vessel should be rendered the vehicle or device. illegible. 6.7 Analysis of the results of the annual sampling on 1%of the population of a specific of vessel G.11 Filing of results of examination, type inspection and tests Every 2 years, the results of the detailed inspections and hydrostatic tests which the vessels Results of examination, inspections and hydrostatic undergo and which are covered by 1%sampling tests should be recorded in a maintenance register, and visual inspections should be analysed by a or by any means of storing and analysing them. competent administrative authority. Measures The results of analyses of sanctions following the should be taken if the results of the 1%sampling detailed inspections and hydrostatic tests should be and internal inspections show a significant trend. recorded. 6.8 Withdrawal of vehicles or devices to It should be possible to submit all the results on which the vessel is fitted request at any time to the representative of the approved body on intervention by the national When a vehicle or device to which the vessel is administration. fitted is withdrawn, the vessel should be discarded. G.9 Special cases of vessels fitted to a series of 6.12 Responsibilities vehicles being phased out, vehicles intended for a museum, or vehicles kept in service for The service surveillance operations on the vessels historical reasons should be carried out on the responsibility of the railway companies and under the control of and Vessels fitted to these vehicles may be maintained under the conditions fixed by the competent in service beyond 40 years subject to the following administrative authority. provisions : a) vessels removed after 40 years; b) vessels then removed every 10 years thereafter ; in order to subject them to the operations described in 6.6. --```,-`-`,,`,,`,`,,`---

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BS EN 2864 : 1995

National annex NA (informative) Committees responsible The United Kingdom participation in the preparation of this European Standard was entrusted to Technical Committee PVE/ 17 upon which the following bodies were represented: Associated--```,-`-`,,`,,`,`,,`--- Offices Technical Committee BEAMA Ltd. British Compressed Air Society British Railways Board British Steel Industry Department of Trade and Industry (Mechanical Engineering and Manufacturing Technology Division (Mmt)) Electricity Industry in United Kingdom Health and Safety Executive Independent Engineering Insurers’ Committee Process Plant Association Railway Industry Association of Great Britain Society of Motor Manufacturers and Traders Limited Transmission and distribution Association (BEAMA Limited)

National annex NB (informative) Cross-references

Publication referred to Corresponding British Standard BS EN 287 Approval testing of welders for.fusion welding EN 287-2 Part 2 Aluminium and aluminium alloys BS EN 288 Specification and approval of welding procedures for metallic materials EN 288-1 Part 1. General rules-forfusion welding EN 288-2 Part 2. Welding procedure specification for arc welding EN 288-4 Part 4. Welding procedure tests for arc welding of aluminium and its alloys EN 10025 BS EN 10025 Hot rolled products of non-alloy structural steels. Technical deliverry conditions EN 26520 BS EN 26520 Classtyication of imperfections in metallic fusion welds, with explanations IS0 228-1 BS 2779 Specification for pipe threads for tubes and fittings where pressure-tight joints are not mude on the threads (metric dimensions) IS0 261 BS 3643 IS0 metric screw threads Part 1 Principles and basic data IS0 4520 BS 6338 Specification for chromate conversion coatings on electroplated zinc and cadmium coatings

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