Technical Specifications for Manufacture and Supply of 60E2 Rail R260 Grade

Transcription

1 ISRAEL RAILWAYS LTD INFRASTRUCTURE DIVISION TRACK AND RIGHT OF WAY DEPARTMENT Technical Specifications for Manufacture and Supply of 60E2 Rail R260 Grade No. E June 2011

2 CONTENTS 1. SCOPE 2 2. GENERAL REQUIREMENTS 2 3. QUALITY CONTROL AND QUALITY TESTS 3 4. QUALIFYING TESTS 3 5. ACCEPTANCE TESTS 4 6. LABORATORY CERTIFICATES 5 7. INSPECTION BY A REPRESENTATIVE OF THE ISRAEL RAILWAYS 5 8. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 6 9. PACKING 7 1

3 1. SCOPE 1.1 This technical specification pertains to the manufacture and supply of 60E2 rails having R260 steel grade for use by Israel Railways Ltd. 2. GENERAL REQUIREMENTS 2.1 Unless otherwise and to the extent specified hereafter, the rails shall comply in every aspect with the latest edition of EN Vignole railway rails 46 kg/m and above". 2.2 The rails shall be made of steel grade R260 in accordance with EN :2011. The manufacturing process shall be continuous casting and no other process shall be approved. 2.3 The rails steel shall be in accordance with EN :2011, Table 5a Chemical composition/mechanical properties, Minimum tensile strength: 880 MPa Elongation:10% Maximum hydrogen content: 2.5 ppm Hardness - point on the center line rail running surface (RS): HBW Table 5b Maximum residual elements 2.4 The rail tolerances shall be in compliance with EN :2011 paragraph 9.2 Table 7 - Profile tolerances, profile class X. Table 8 - Straightness, surface flatness and twist tolerances, class A. Body vertical flatness d 0.3 mm along a length of 3 meter and d 0.2 mm along a length of 1 meter. Body Horizontal flatness d 0.45 mm along a length of 1.5 meter. End length - 2 meter. End vertical straightness d 0.4 mm along a length of 2 meter and d 0.3 mm along a length of 1 meter and e 0.2mm. End Horizontal straightness d 0.6 mm along a length of 2 meter and d 0.4 mm along length of 1 meter. Overlap length - 2 meter. Overlap length vertical flatness d 0.3 mm along a length of 2 meter. Overlap length horizontal flatness d 0.6 mm along a length of 2 meter. Whole rail upsweep and down-sweep 10 mm. Twist whole rail max. gap of 2.5 mm. Twist End Max. Rotational twist of 0.2º and max. relative twist of x c (see also EN :2011 figure 11). 2

4 2.5 The rails shall be supplied in lengths of 18, as will be ordered by the ISR. Rail length tolerances shall be in according with EN :2011, Table Each rail shall be supplied with a 28 mm diameter hole drilled at each of its two ends. The center of the hole shall be positioned at a distance of 230 mm from the rail end. The size and location tolerances of drilled holes and the squareness of rail ends tolerance shall be in accordance with EN :2011 Table The rail manufacturing process shall be complied with the requirements according with EN :2011, Paragraph The rails identification branding and stamping shall be according with EN :2011, Paragraph The rails of straightness class A shall be identified with a green mark, 3 meters from the rail end on each end of the rail 3. QUALITY CONTROL AND QUALITY TESTS The Manufacturer shall demonstrate compliance including documented evidence with the factory control system required. Manufacturers having a factory production submit, together with his Proposal, a comprehensive quality control manufacturer instruction manual follow by ISO9001:2008 according EN :2011 and this technical specification. 4. QUALIFYING TESTS 4.1 The rails qualifying tests shall be in according to EN 13674, Paragraph The manufacturer shall carry out qualifying testing on the 60E1 profile. 4.3 The manufacturer shall describe any bloom slow cooling or isothermal treatment process used to demonstrate compliance with the requirements. 4.4 The manufacturer shall give access to all test records, calibrations and calculations that contribute to the final results. 4.5 The results for the grades to be supplied shall be provided at the time of tendering. 3

5 5. ACCEPTANCE TESTS 5.1 The manufacturer shall perform all the acceptance tests described in EN :2011 Paragraph 9 and provide a complete set of results for these tests. 5.2 Chemical composition shall be in compliance with EN :2011, Paragraph The microstructure shall be perlitic but grain boundary ferrite may occur. There shall be no martensite, bainite or grain boundary cementite. 5.4 The Manufacturer's acceptance tests process, shall also include the following tests and be subject to the following quality requirements: FREEDOM FROM DEFECTS - INTERNAL DEFECTS Ultrasonic tests shall be performed on 100% of the rails, by a continuous process ensuring that the entire length and specified cross-sectional area is inspected with particular emphasis on the rail ends. The technique used shall ensure that the minimum cross-sectional area covered by the inspection is no less than: (a) 70% of the head. (b) (c) 60% of the web. All the central part of the foot included below the maximum width of the web. These areas are based on projecting the nominal crystal size of the probe. The rail head shall be tested from both sides and from the running surface. The method of inspection shall be subject to approval by the Israel Railways. Together with the proposal, a detailed description of the ultrasonic test method he intends to employ, including the locations and dimensions of the artificial defects in the rail head, web and foot shall be submitted. Where an ultrasonic testing system is employed, which cannot cover the rail ends, separate ultrasonic manual tests shall be performed on each of the said rail ends FREEDOM FROM SURFACE DEFECTS PROTRUSIONS All protrusions on the running surface or the underside of the foot shall be dressed. Any protrusions affecting the fit of the fishplate at less than 1 m from the extremity of the manufactured rail shall be dressed to shape FREEDOM FROM SURFACE DEFECTS SURFACE MICROSTRUCTURAL DAMAGE Any sign of surface microstructure damage resulting in martaensite or white 4

6 phase shall be dressed or the rail shall be rejected. The dressed area shall be proved by appropriate hardness testing. The hardness of the dressed area shall not exceed that of the surrounding area by more than 50 HB FREEDOM FROM SURFACE DEFECTS AUTOMATIC HEAD AND FOOT INSPECTION Each rail shall be NDT automatically inspected on the rail head from both sides and on the running surface, and also on the underside of the foot, along its entire length, and shall comply with the following requirements: (a) Detection of transversal defects (b) Detection of longitudinal defects (c) The length of any individual defect of 1 mm depth, 20 mm length and (d) 0.5 mm, tolerance of ±0.1 shall be applied. The length of any individual defect of 1.5 mm depth, 10 mm length and 0.5 mm, tolerance of ±0.1 shall be applied. Together with his proposal, a detailed description of the automatic test method he intends to employ, including the locations and dimensions of the artificial defects in the rail head and foot shall be submitted. Draws showing the locations and dimensions of the artificial defects shall be submitted DECARBONISATION Decarburization test shall be assessed by hardness test of 0.5 mm depth according EN :2011 paragraph TENSILE STRENGTH AND ELONGATION TEST Management procedures execution and calculations procedures reports of tensile strength and elongation shall be submit according with EN :2011 paragraph LABORATORY CERTIFICATES 6.1 The laboratory performing the qualifying and acceptance tests shall be certified with at least the following certifications: A laboratory certified in accordance with ISO/IEC17025:2005 in the field of steel quality testing. or A laboratory accredited by national laboratory accreditation authority in the field of steel quality testing. 7. INSPECTION BY A REPRESENTATIVE OF THE ISRAEL RAILWAYS 7.1 The Israel Railways will appoint a representative who shall inspect the manufacturing processes and the quality control tests, as specified in EN 5

7 :2011 and in this technical specification. The manufacturer shall extend to the said Representative all necessary assistance and cooperation. 7.2 The manufacturer shall be responsible to coordinate inspection process time table with the ISR representative. 7.3 The manufacturer shall report all qualifying and/or acceptance tests results to ISR representative for approval for every order. 8. LIST OF DOCUMENTS TO BE SUBMITTED WITH BIDDER'S PROPOSAL 8.1 The manufacturer shall submit documentation demonstrates continuing compliance, including documented evidences, with the factory production and control system complies with EN :2011 and ISO9001: The manufacturer shall submit the following certificates of the laboratory where all the tests should be carried out: A laboratory certified in accordance with ISO/IEC17025:2005 in the field of steel quality testing. or A laboratory accredited by national laboratory accreditation authority in the field of steel quality testing. 8.3 The manufacturer shall submit all the qualifying tests reports from the last five years including all the test records, reports, calibrations and calculations that contribute to the final qualifying results EN :2011, Paragraph The manufacturer shall describe any bloom slow cooling or isothermal treatment process used to demonstrate compliance with the requirements in EN :2011, Paragraph The manufacturer shall submit the results for the grade to be supplied at the time of tendering (EN :2011, Paragraph 8.1.2). 8.6 The manufacturer shall submit a detailed description of the ultrasonic test method he intends to employ, including the locations and dimensions of the artificial defects in the rail head, web and foot. 8.7 The manufacturer shall submit a detailed description of the automatic test method he intends to employ, including the locations and dimensions of the artificial defects in the rail head and foot. Draws showing the locations and dimensions of the artificial defects shall 6

8 be submitted. 9. PACKING 9.1 Packing shall be loose, provided that loading is carried out by means of a special device which enables the loading of 5 rails at one time. Appropriate spaces shall be kept between the rails on the ship in order to enable unloading with a similar device. 7