Professional Documents
Culture Documents
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
UDC 621.642.02-98-034.715:629.4-592:620.1:62-777
BS EN 286-4:1995
Cooperating organizations
© BSI 07-1999
Amd. No. Date Comments
Contents
Page
Cooperating organizations Inside front cover
National foreword ii
Foreword 2
Text of EN 286-4 5
National annex NA (informative) Committees responsible Inside back cover
National annex NB (informative) Cross-references Inside back cover
© BSI 07-1999 i
BS EN 286-4:1995
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).
Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
the EN title page, pages 2 to 38, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.
ii © BSI 07-1999
EUROPEAN STANDARD EN 286-4
NORME EUROPÉENNE
September 1994
EUROPÄISCHE NORM
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
Récipientsá 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
CEN
European Committee for Standardization
Comité Européen de Normalisation
Europäisches Komitee für Normung
Central Secretariat: rue de Stassart 36, B-1050 Brussels
Foreword Contents
This European Standard was prepared by Page
CEN/TC 54, Unfired pressure vessels, of which the Foreword 2
secretariat is held by BSI.
1 Scope 5
This European Standard has been prepared under a
2 Normative references 5
Mandate given to CEN by the European
Commission and the European Free Trade 3 Symbols 6
Association, and supports essential requirements of 4 Materials 7
the EC Directive(s). 5 Design 7
CEN/TC 54 decided to submit the final draft for 6 Inspection and drainage bosses 15
formal vote by its resolution. The result was
7 Marking 15
positive.
This part is one of a series of four. The other Parts 8 Corrosion protection 16
are: 9 Qualification of welding procedures 19
— Part 1: Design, manufacture and testing; 10 Qualification of welders and
welding operators 19
— Part 2: Pressure vessels for air braking and
auxiliary systems for motor vehicles and their 11 Testing of the vessels 19
trailers; 12 Certification procedures 25
— Part 3: Steel pressure vessels designed for air 13 Information to be supplied at the time
braking equipment and auxiliary pneumatic of invitation to tender and time of order 25
equipment for railway rolling stock. 14 Delivery 25
This European Standard shall be given the status of 15 Documentation to accompany the vessel 25
a national standard, either by publication of an
identical text or by endorsement, at the latest by Annex A (normative) Verification 26
March 1995, and conflicting national standards Annex B (normative) Declaration of
shall be withdrawn at the latest by March 1995. conformity — Surveillance 26
According to the CEN/CENELEC Internal Annex C (normative) Design and manufacturing
Regulations, the following countries are bound to schedules 28
implement this European Standard: Annex D (normative) Type examination 29
Austria, Belgium, Denmark, France, Germany, Annex E (normative) Content of the
Greece, Iceland, Ireland, Italy, Luxembourg, manufactured record 29
Netherlands, Norway, Portugal, Spain and Annex F (informative) Assembly of the
United Kingdom vehicles 30
Annex G (informative) Service surveillance
of vessels 35
Figure 1 — Position of longitudinal welds
on the bottom of the shell 8
Figure 2 — Position of longitudinal welds
on the shell 8
Figure 3 — Torispherical end 9
Figure 4 — Theoretical curves for dished
ends 10
Figure 5 — Butt weld with centre lines
aligned 10
Figure 6 — Butt weld with centre lines offset 11
Figure 7 — Butt welds with centre lines
offset and connecting slope 11
Figure 8 — Weld of the shell ring to end
with necked edge 11
Figure 9 — Position of a hole in an end 14
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EN 286-4:1994
Page Page
Figure 10 — Distance between two welds Table 1 — Aluminium alloy materials 7
measured from the end of the edge preparation 12 Table 2 — Height of the cylindrical portion
Figure 11 — Reinforcement of opening 12 of ends 8
Figure 12 — Fixing of a boss by an external Table 3 — Diameters and locations of bosses 9
weld 13 Table 4 — Amount of testing required for
Figure 13 — Fixing of a boss by internal and welds made by a non-automatic process 10
external welds 13 Table 5 — Amount of testing required for
Figure 14 — Fixing of a boss by internal and welds made by an automatic procedure with
external fillet welds 13 P U 1,15Ps 10
Figure 15 — Fixing of a drainage boss by an Table 6 — Amount of testing required for
external weld 14 welds made by an automatic procedure with
Figure 16 — Fixing of a drainage boss by P U 1,15Ps 11
internal and external welds 14 Table 7 — Acceptance levels of defects in
Figure 17 — Fixing of a drainage boss with butt-welds, detected by visual examination 11
drainage groove 14 Table 8 — Acceptance levels of defects in
Figure 18 — Dip tube fixed to an end 14 butt-welds, detected by X-ray examination 11
Figure 19 — Dip tube fixed to the shell of a Table 9 — Maximum permissible
horizontal vessel 14 reinforcement for longitudinal and
circular welds 24
Figure 20 — Dip tube fixed to the shell of a
vertical vessel 14 Table 10 — Classification of vessels 12
Figure 21 — Dip tube fixed to a top end of a Table F.1 — Dimensions of straps 31
vertical vessel 14 Table F.2 — Tightening torques 31
Figure 22 — Dip tube fixed to the upper part Table G.1 — Service surveillance of vessels
of the shell of a horizontal vessel 15 used at Ps k 6 bar 36
Figure 23 — Fixing of a dip tube 15 Table G.2 — Service surveillance of vessels
Figure 24 — Fixing of a dip tube to a boss 15 used at 6 bar < Ps k 10 bar 36
Figure 25 — Recessed fixing of a dip tube Table G.3 — Annual sampling examination 36
to a boss 15
Figure 26 — Location of openings 16
Figure 27 — Location of identity and
service marks 17
Figure 28 — Marking plate 18
Figure 29 — Identity and service marks 19
Figure 30 — Reinforcement thickness 24
Figure F.1 — Fixing by straps of a vessel in
the horizontal position 31
Figure F.2 — Fixing by straps of a vessel in
the vertical position 31
Figure F.3 — End of straps with angle
brackets 32
Figure F.4 — Ends with straps folded
and reinforced 32
Figure F.5 — Ends of straps with welded
bolt 33
Figure F.6 — Ends of straps with grooved
welded bolt 33
Figure F.7 — Fixing to the vehicle with a bolt 34
Figure F.8 — Fixing to the vehicle with a nut 34
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EN 286-4:1994
© BSI 07-1999 5
EN 286-4:1994
ISO 2107, Aluminium, magnesium and their fb Permitted stress of the boss N/mm2
alloys — Temper designations.
ISO 2437, Recommendation practice for the X-ray g Throat thickness of a weld mm
inspection of fusion welded butt joints for h External height of the dished part of
aluminium and its alloys and magnesium and its an end mm
alloys 5 to 50 mm thick. (see Figure 3)
ISO 4520, Chromate conversion coatings on h1 External height of the cylindrical
electroplated zinc and cadmium coatings. part of the end mm
ISO 6361-2, Wrought aluminium and aluminium (see Figure 3)
alloy sheet, strip and plate — Part 2: Mechanical h2 Internal height of a dished part of
properties. the end mm
ISO 6362-2, Wrought aluminium and alloy extruded (see Figure 3)
rods/bars, tubes and profiles — Part 2: Mechanical Kc Design coefficient which is a
properties. function of the welding process —
3 Symbols L Total length of the vessel mm
For the purpose of this standard, the following L1 Distance between the axis of a
symbols apply: drainage opening and the end of the
vessel mm
A Elongation at rupture %
lrb Length of the boss contributing to
Afb Cross sectional area effective as reinforcement mm
compensation, of the boss mm2
lrbi Length of inward projecting boss
Afp Cross sectional area effective as contributing to reinforcement mm
compensation, of the reinforcing
plate mm2 lrp Length of the reinforcing plate
contributing to reinforcement,
Afs Cross sectional area effective as measured along the mid surface mm
compensation, of the shell mm2
lrs Length of the shell contributing to
Ap Area of the pressurized zone mm2 reinforcement, measured along the
c Absolute value of the minus rolling mid surface mm
tolerance for sheets as quoted in the P Design pressurea which is a function
standard mm of the maximum working pressure,
Do Outside diameter of the shell of the the welding process and inspection
vessel mm used bar
dib Internal diameter of the boss mm PS Maximum working pressurea bar
dob Outside diameter of the boss mm R Internal radius of the spherical
part of the end mm
e Nominal wall thickness mm
Ri Local internal radius at the location
ec Calculated thickness mm of the opening in question mm
ech Calculatd thickness of the end mm Rm Minimum tensile strength specified
ecs by the manufacturer or by the
Calculated thickness of the shell mm
standard defining the material N/mm2
eh Nominal thickness of the end mm Rp0,2 Minimum proof stress N/mm2
erb Wall thickness of the boss
r Internal radius of the torispherical
contributing to reinforcement mm
part of the end mm
erp Wall thickness of the reinforcing
Tmin Minimum working temperature °C
plate contributing to reinforcement mm
ers Wall thickness of the shell Tmax Maximum working temperature °C
contributing to reinforcement mm V Volume of the vessel l
f Nominal design stress at the design a All pressures are gauge pressures.
temperature N/mm2
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8 © BSI 07-1999
EN 286-4:1994
where:
b)
© BSI 07-1999 9
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10 © BSI 07-1999
EN 286-4:1994
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 ISO 228-1 or an
ISO metric thread in accordance with ISO 261.
The permitted shapes and welding are defined
in 5.2.4.1 and 5.4.2.2.
The minimum number, dimensions and location on
the vessel are defined in clause 6.
© BSI 07-1999 11
EN 286-4:1994
l rs = ( 2R i + e rs )e rs (1)
where:
a) Ri = Do/2 – ers for shells;
b) Ri = R for ends.
Reinforcement of the openings is obtained by the
use of:
a) recess welded bosses (see Figure 11a
and Figure 11b);
b) welded reinforcing plates and recess welded
bosses (see Figure 11c).
Adequate reinforcement shall be provided in all
planes passing through the axis of the opening.
5.2.3.2 Reinforcement of opening
Only bosses of the “full penetration” type as shown
in Figure 11a and Figure 11b may be used. Figure 11 — Reinforcement of opening
12 © BSI 07-1999
EN 286-4:1994
The length of the boss lrb contributing to the If the drainage opening cannot be made in the
reinforcement, used in equation (3) for determining bottom of the vessel, drainage shall nevertheless be
Afb shall not be greater than lrs [see equation (2)]: provided by one of the permitted methods shown
lrb k lrs in Figure 18 to Figure 25.
(2)
(3)
where:
a) the areas Ap, Afb, Afs and Afp are determined as
shown in Figure 11a, Figure 11b and Figure 11c;
b) the maximum height of the boss (lrb) to be used
in the calculation is:
Figure 13 — Fixing of a boss by internal and
external welds
c) the maximum height of the part of the boss
(lrbi) inside the vessel, to be used in the
calculation is:
lrbi = 0,5lrb
d) the dimensions of the reinforcing plate to be
used in the calculation are:
erp k ers and lrp k lrs
5.2.4 Welding of bosses
5.2.4.1 Inspection openings and pipe connection
branches
Welds can be either full penetration welds
(see Figure 12 and Figure 13) or partial penetration
welds (see Figure 14).
5.2.4.2 Drainage openings
Figure 14 — Fixing of a boss by internal and
The welds shall be full penetration welds of the wall external fillet welds
of the vessel. Weld preparation of the vessel may be
necessary.
Examples of permitted welds are given in Figure 15,
Figure 16 and Figure 17.
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14 © BSI 07-1999
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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.
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.
© BSI 07-1999 15
EN 286-4:1994
7.2 Marking stamped in the metal of the vessel 7.3 Marking stamped on a plate
Stamping of marks shall only be carried out on The dimensions of the marking plate are given
vessel walls of thickness e U 5 mm. in Figure 28.
The stamps shall not have any sharp edges and the 7.4 Identity and service marks
depth of the stamping shall not exceed one tenth of
This marking shall follow the general arrangement
the wall thickness. shown in Figure 29 or, if necessary, shall be in three
When the marking is on an end, the mark shall be zones (see Figure 27). These marks shall have a
stamped as far as possible away from the theoretical minimum height of 5 mm. The dimensions in
line of intersection of the knuckle radius and the Figure 29 are given for guidance.
spherical radius and shall be close to the end base,
without interfering with the weld of the pipe 8 Corrosion protection
connection branch.
8.1 General
Marking shall be carried out before the ends are
welded onto the shell. An aluminium alloy vessel is particularly sensitive
to electrochemical corrosion. It should therefore be
The only marks that shall be stamped onto the
insulated electrically from the chassis of the vehicle.
finished vessel are those given in items 6) and 10)
NOTE Examples of installation conditions are given in the
of 7.4. informative Annex F.
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
16 © BSI 07-1999
© BSI 07-1999
NOTE The location of marking on the shell or an end as shown in Figure 27 are recommended. Other locations may be used on condition that the marks are positioned horizontally
and can be read in the best possible conditions after installation on the vehicle.
Figure 27 — Location of identity and service marks
EN 286-4:1994
17
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EN 286-4:1994
(1) The dimensions shall be in the line with those of the marking described in 7.4.
Figure 28 — Marking plate
© BSI 07-1999
EN 286-4:1994
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
min (in °C).
8) Maximum service temperature T
max (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
If corrosion protection is necessary (see 8.3) it shall 11 Testing of the vessels
be the subject of an agreement between the railway
11.1 Testing of welds by the manufacturer
customer and the supplier and meet the service
surveillance requirements given in Annex G. Welds shall be tested in accordance with the
requirements of Table 4 to Table 6.
8.2 Protection of internal walls
The acceptance criteria are specified in 11.1.5.
No protection is required.
11.1.1 Welds made by non-automatic welding
8.3 Protection of external walls
In this case: P U 1,25PS and KC = 1,15 (see 5.1.4.2
The outer walls of vessels not protected against
case no. 3).
impact of ballast or particles from the braking of the
vehicle shall be given a protective surface coating. 11.1.2 Welds made by an automatic process
11.1.2.1 With P U 1,15PS and KC = 1 (see 5.1.4.2
9 Qualification of welding procedures case no. 1)
Welding procedures shall be specified in accordance 11.1.2.2 With P U 1,3PS and KC = 1 (see 5.1.4.2 case
with EN 288-1, EN 288-2 and EN 288-4. The no. 2).
qualification shall be witnessed by an approved 11.1.3 Destructive testing of welds on coupon
inspection body. plates
10 Qualification of welders and The following tests shall be carried out by the
welding operators manufacturer on coupon plates:
a) one face bend test around a mandrel of
Welders and welding operators shall be qualified in diameter 2e, through an angle of 180°;
accordance with EN 287-2. The qualification shall
be witnessed by an approved inspection body. b) one reverse bend test around a mandrel of
diameter 2e, through an angle of 180°;
© BSI 07-1999 19
EN 286-4:1994
c) one macro test. Following the bending tests, the sample shall not
11.1.4 Quality of the films have any defects greater than 3 mm in any
direction.
The quality class of the films shall be determined in
accordance with the requirements of ISO 2437. In the macrographic examination, the affected
surface of the sample shall show, through the
11.1.5 Acceptance criteria for welds microscope, a welded point image with an adequate
The results of all the tests shall be recorded. If a test penetration and with no defects other than those
gives an unsatisfactory result, the reason shall be permitted in Table 8.
sought and a further two samples shall be prepared 11.1.6 Finish of longitudinal and circular
and verified. If it can be shown that the failure is a joints
result of a local or accidental defect and that the
All welds shall have a smooth finish without valleys
re-tests are satisfactory, the re-test results shall be
and shall merge into the plates without
accepted.
undercutting or abrupt irregularity (see Table 7).
If a new sample gives unsatisfactory results all the
welds of all the vessels produced since the start of To ensure that the weld is fully penetrated and thus
production or since the last unsatisfactory that the surface of the weld metal does not fall below
the surface of the adjoining plate, weld metal may
non-destructive test shall undergo a non-destructive
be built up as reinforcement on each side of the
test.
plate. This reinforcement shall not exceed the
Table 7 and Table 8 show the acceptance levels. values given in Table 9.
If any part of a weld has been repaired the whole of The reinforcement need not be removed except to
the repaired weld seam shall be verified by means of the extent that it exceeds the permissible thickness.
a non-destructive test.
Table 4 — Amount of testing required for welds made by a non-automatic process
Testing by the manufacturer Verification by the
approved inspection body
where required
Test Non-destructive test (NDT) Destructive test (DT)
Each vessel 100 % visual inspection
During manufacture
Longitudinal weld
1 coupon plate for the
first 100 m of weld
Then every 100 m of weld
Each welding 1 100 % X-ray of the weld, or 1 coupon plate Visual inspection of
machine and each including junctions, on coupon plates and
welding procedure the same vessel films held by the
manufacturer.
Inspection of the
Circumferential weld results of the various
If the welding process or the designation of the filler tests carried out in
metal is identical to that used for the longitudinal weld, application of this
standard.
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 weld with a minimum on any one
vessel of the batch of:
1 100 % X-ray of the weld or 1 coupon plate
20 © BSI 07-1999
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Table 9 — Maximum permissible In addition, the wall of the vessels shall be free of
reinforcement for longitudinal and circular localized defects such as sudden local irregularities,
welds bumps, flats, cavities, folds, tool marks or visible
Dimensions in millimetres
symmetry defects. Cavities or bumps are permitted
provided that they connect with the surrounding
Thickness of the thicker Maximum reinforcement surface with gentle slopes not exceeding 25 % (14°)
plate thickness r1
or r2 (see Figure 30)
and with rounding of radius greater than 50 mm.
Their dimensions shall not exceed:
ek5 2,5
f) radially ± 3 mm;
5 < e k 12 3,5
g) longitudinally 0,25 L;
h) transversely ;Do/20.
24 © BSI 07-1999
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Annex A (normative)
Verification
A.1 General
Verification shall be performed by an approved inspection body on batches of vessels submitted by their
manufacturer or by his authorized representative. Batches shall be accompanied by the type-examination
certificate (see Annex D) or by the certificate of approval of the design and manufacturing schedule
(certificate of adequacy) (see Annex C).
When a batch is examined, the inspection body shall ensure that the vessels have been manufactured and
checked in accordance with the design and manufacturing schedule and shall perform a hydrostatic test or,
subject to the agreement of the Member State, a pneumatic test on each vessel in the batch at at a pressure
equal to 1,5 times the design pressure. Moreover, the inspection body shall carry out tests on test pieces
taken from a representative production coupon plate or from a vessel, as the manufacturer chooses, in order
to examine weld quality. The tests shall be carried out on longitudinal welds. However, where differing
welding techniques are used for longitudinal and circumferential welds, the tests shall be repeated on
representative test pieces of circumferential welds.
A.2 Construction verification
The approved inspection body shall perform the following checks and examinations.
A.2.1 Check of the manufacturing record
The manufacturing record shall be checked (see Annex E).
A.2.2 External and internal inspection, dimensional check
The inspection body shall check the identification of the vessel, e.g. the data-plate, and shall inspect the
vessels visually, externally and internally, for defects, especially the seams.
The inspection shall be performed before any permanent covering coatings are applied. The inspection body
shall check dimensions of shells, ends, openings and other parts, that are of importance to the safety of the
vessel, for conformity with the drawings. Distances important for safety
(e.g. distance between openings) shall be checked if considered necessary.
NOTE Normally it is adequate if 10 % of vessels are checked and inspected, these to be selected by the approved inspection body.
A.2.3 Destructive testing
Destructive testing as required by 11.1.3 shall be witnessed by the approved inspection body who will
certify the results.
A.2.4 Non-destructive testing
Non-destructive testing of butt weld seams as required by clause 11 shall be checked by the approved
inspection body. This includes spot checks of films. If the films are not available, spot NDT shall be
performed according to Table 4 to Table 6.
Annex B (normative)
Declaration of conformity — Surveillance
B.1 General
B.1.1 Declaration of conformity
Vessels in accordance with the European Standard whose product Ps and V exceeds 50 bar litres but which
does not exceed 3 000 bar litres are, at the choice of the manufacturer, either subject to verification
(see Annex A) or subject to the declaration of conformity.
B.1.2 Surveillance
By the declaration of conformity the manufacturer becomes subject to surveillance for vessels for which the
product of Ps and V exceeds 200 bar litres and does not exceed 3 000 bar litres. The purpose of surveillance
is to ensure that the manufacturer duly fulfils the obligations required by this European Standard.
In the case of vessels manufactured in accordance with an approved specimen, for which a type
examination certificate exists, surveillance shall be the responsibility of the approved inspection body
which issued this type of examination certificate.
26 © BSI 07-1999
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In the case of vessels not manufactured in accordance with an approved specimen, surveillance shall be the
responsibility of the approved inspection body which issued the certificate of approval of the design and
manufacturing schedule (certificate of adequacy) (see C.2).
B.2 Procedure required before commencement of manufacture of vessels of classes 2 and 3
(see clause 12) subject to a declaration of conformity
B.2.1 Responsibilities of the manufacturer
Before commencing manufacture, the manufacturer shall submit to the approved inspection body which
issued the type examination certificate or the certificate of adequacy (see Annex C), a document describing
the manufacturing processes and all of the predetermined, systematic measures taken to ensure
conformity of the vessels with this European Standard.
This document shall include the design and manufacturing schedule and the documents referred to
in B.2.1.1 to B.2.1.5.
The manufacturer shall appoint a management representative who, irrespective of other responsibilities,
shall have independent authority and responsibility for ensuring that the requirements of this European
Standard are implemented and maintained.
B.2.1.1 A description of the means of manufacture and inspection appropriate to the construction of the
vessels.
B.2.1.2 An inspection document describing the appropriate examinations and test to be carried out during
manufacture together with the procedures thereof and the frequency with which they are to be performed.
B.2.1.3 An undertaking to carry out the examinations and tests in accordance with the inspection
document referred to above and to have a hydrostatic test carried out on each vessel in accordance with this
European Standard.
B.2.1.4 The addresses of the places of manufacture and storage and the date on which manufacture is to
commence.
B.2.1.5 In addition, when the product of Ps and V exceeds 200 bar litres, the manufacturer shall authorize
access to the said places of manufacture or storage by the body responsible for the surveillance, for
inspection purposes, and allow that body to select sample vessels and provide it with all necessary
information and in particular:
a) the design and manufacturing schedule;
b) the inspection report;
c) the type examination certificate or certificate of adequacy, where appropriate;
d) a report on the examinations and test carried out.
B.2.2 Responsibilities of the approved inspection bodies
The inspection body responsible for the surveillance shall examine the documents referred to in B.2.1.1
and B.2.1.3 in order to check their conformity with the requirements of this European Standard and with:
a) the conditions stated in the certificate of adequacy; or
b) the design and manufacturing record and the conditions stated in the type examination certificate.
Manufacturing cannot commence before the approved inspection body has issued written approval of this
document.
B.3 Procedures required during manufacture of vessels of classes 2 and 3 (see clause 12)
subject to a declaration of conformity
B.3.1 Responsibilities of the manufacturer
The manufacturer shall ensure that the inspections and testing are carried out in accordance with the
documented procedures to complete the evidence of full conformance of the vessel to this European
Standard. The inspection and test status of vessels shall be identified by using markings, authorized
stamps, tags, labels, inspection records, physical location or other suitable means which indicate
conformance or non-conformance of vessels with regard to inspection and tests performed.
Records shall identify the inspection authority responsible for the release of conforming vessels.
The manufacturer shall maintain control of vessels that do not conform to the requirements of this
European Standard. All nonconforming vessels shall be clearly identified and segregated to prevent
unauthorized use, delivery or mixing with conforming vessels.
© BSI 07-1999 27
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Annex C (normative)
Design and manufacturing schedules
C.1 Content
The design and manufacturing schedules shall contain the name of the manufacturer and the place of
manufacture and shall give the following information:
— a detailed manufacturing drawing of the vessel type;
— a set of instructions comprising:
a) the maximum working pressure, Ps ......... bar;
b) the maximum working temperature, Tmax ...... °C;
c) the minimum working temperature, Tmin ...... °C;
d) the volume of the vessel, V .......... litre;
e) the name or mark of the manufacturer;
f) a drawing showing assembly of the vessel to the rolling stock approved by the client network
indicating in particular the method of attachment (see Annex F);
g) the service surveillance requirements approved by the client network (see Annex G);
— a document describing:
a) the materials selected;
b) the welding processes used;
c) the checks to be carried out;
d) any pertinent details as to the vessel design including the design pressure;
e) the certificates relating to the suitable qualification of the welding procedures and of the welders
or operators;
28 © BSI 07-1999
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f) if the certificates for the welding procedures, welders or operators are not available, this shall not
prevent the approved body from evaluating the other documents. However, they shall be submitted
before approval is given or manufacturing commences;
g) the inspection slips for the materials used for the manufacture of parts and assemblies contributing
to the strength of the pressure vessel or a specimen of these inspection slips;
h) a specimen of the proposed report on examination and tests.
C.2 Approval of design and manufacturing schedule (certificate of adequacy)
If vessels are not manufactured on the basis of a type-examination certificate, the manufacturer or his
authorized representative shall submit to an approved inspection body an application for design approval
and enclose three copies of this design and manufacturing schedule (see C.1).
Various vessels or vessel families can be included in one design and manufacturing schedule, but all vessel
details (including branches, bosses and attachments) of the production envisaged shall be included.
The approved inspection body shall examine these documents in order to check the conformity of the
design, of the required tests, and of the qualifications with the requirements of this standard. If they are
in agreement with the requirements of this standard the approved inspection body shall issue a certificate
of adequacy which shall be forwarded to the applicant.
Annex D (normative)
Type examination
Type examination is the procedure by which an approved inspection body ascertains and certifies that a
prototype vessel satisfies the provisions of this part of this European Standard. The manufacturer or his
authorized representative shall submit to an approved inspection body an application for type examination.
The application shall include three copies of the design and manufacturing schedule (see Annex C) and a
prototype vessel which is representative of the production envisaged.
If the application is lodged for various vessels, a prototype vessel is required for each vessel type.
Various vessels or vessel types can be included in one design and manufacturing schedule, but all vessel
details (including branches, bosses and attachments) of the production envisaged shall be included.
The approved inspection body shall examine the documents in order to check the conformity of design,
qualifications and the proposed tests with the requirements of this European Standard.
The approved inspection body shall also verify that the vessel has been manufactured in conformity with
the design and manufacturing schedule and is representative of the type and shall perform appropriate
examinations and tests (including 100 % NDT of main seams and a hydrostatic test).
If the design and manufacture schedule and the prototype(s) comply with the provisions of this part of this
European Standard, the approved inspection body shall draw up a type-examination certificate (per vessel
type) which shall be forwarded to the applicant. The certificate shall state the conclusions of the
examination, indicate any conditions to which its issue may be subject and be accompanied by the
descriptions and drawings necessary for identification of the approved prototype.
Annex E (normative)
Content of the manufacturing record
The manufacturing record of the vessels shall contain (at least) the following information.
E.1 General information
a) the name or mark of the manufacturer;
b) the place of manufacture;
c) the qualification certificates for the welding procedures and the welders or welding operators;.
d) the reports of the tests and inspections performed, or description of the proposed verifications.
E.2 Specific information
a) the identification codes of the vessels specific to the manufacturer (example No. ... to ...);
b) the type approval number or the certificate of adequacy;
c) the diameter of the vessels;
d) the volume of the vessels;
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Annex F (informative)
Assembly to the vehicles
F.1 General
Particular attention should be paid to the materials from which surrounding components are made (straps,
cradle, pipes etc.). The difference between materials in the vessel and the surrounding unit affects the
corrosion resistance of the aluminium alloy of the vessel.
This corrosion is generally the result of the difference in the electrical potentials of the materials present,
the presence of stray electric current and the electrolyte resulting from a moist environment.
Particular attention should be paid to the assembly of the vessel on the vehicle in order to avoid the effects
of electrochemical corrosion.
F.2 Fixing
The vessels should be fixed by means of straps with properties as indicated in F.3 and inserts of corrosion
protection tape as defined in F.4.
The vessel is generally fixed by means of two straps (see Figure F.1 and Figure F.2 for typical examples).
However, for small vessels, a single strap may be used as long as it does not obstruct reading of the identity
and service marks.
The straps are fastened to the vehicles by one of the approved methods shown in Figure F.3 to Figure F.6.
Other methods may be used provided that all safety requirements are complied with.
The means of fixing to the vehicle should be electrically insulated (see the assembly examples shown
in Figure F.7 and Figure F.8). The cradle should, as far as possible, be part of the vehicle chassis.
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F.5 Mounting
F.5.1 General
The drawing showing assembly of the vessel on the vehicle should ensure that the identity and service
marks can be read under all possible conditions.
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.
The fixing straps and their insulating tape should always be placed around the shell (see Figure F.1
and Figure F.2). All necessary steps should be taken to avoid movement of the insulating tape relative to
the straps and the vessel.
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Annex G (informative)
Service Surveillance of vessels
G.1 General
The maintenance recommendations in this annex meet the minimum safety requirements during normal
service of aluminium alloy vessels which comply with the requirements of this European Standard.
The vessels are used throughout the whole service 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 conditions specified
in G.10 However, under special circumstances (a series of vehicles being replaced or vehicles destined for
a museum), the service life of the vessels may be prolonged subject to suitable surveillance specified in G.9.
The service surveillance of the vessels complying with this European Standard is carried out during
periodic inspections or revisions to the vehicle or the device fitted with it, under the following conditions.
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In addition, the satisfactory performance of these vessels is ensured by an annual sampling examination
under the following conditions.
Table G.3 — Annual sampling examination
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 G.7
vehicle fleet or from items they are number
fitted to, more than 20 years old
NOTE 1 Inspections are fairly regular periodic maintenance operations. They are essentially checks intended to ensure that the
main or critical components are always in a good operating condition.
NOTE 2 The purpose of it is to overhaul the various components, so that they operate satisfactorily until the next inspection.
Revisions are periodic maintenance operations at intervals greater than the inspection.
NOTE 3 The inspection and revision cycles are specific to each type of equipment.
G.4 External inspection
G.4.1 Cleaning
Vessels that are particularly dirty should be cleaned so as to permit examination of the walls under
acceptable conditions. Cleaning by air blast should be carried out until all dirt is completely removed. If a
cleaning agent is used, it should not be aggressive to aluminium alloys.
G.4.2 Examination of marking
If the marks specified in clause 7 are illegible, the vessel should be rejected.
If a data plate is deformed as a result of impact or oxidation, but the marks are still visible, it may be
replaced. Conformity to the original marking should be certified by the affixing of the expert’s stamp.
If a new plate is welded on to the vessel, the vessel should undergo a pressure test in accordance with 11.3.
G.4.3 Inspection of the walls
G.4.3.1 Deformation and irregularities
If the walls of the vessel show localized 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.
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G.6.2.1 Preparation
Internal and external walls of the vessel should be exposed by careful cleaning, if necessary using chemical
cleaning agents which are not aggressive to aluminium alloys.
G.6.2.2 Internal and external inspection
The internal and external inspection of the walls should be carried out in accordance with the provisions
in G.4 and G.5 with the specified consequences.
In addition, if any crack, discontinuity in the weld seams or deterioration of the internal threads of the
inspection openings or pipe connection branches are detected, the vessel should be replaced.
G.6.3 Hydrostatic test
The vessel which has satisfactorily undergone the detailed inspection should then be subjected to a
hydrostatic test under the conditions described in 11.3 of this standard.
Once the vessel has successfully undergone the hydrostatic test, it should be stamped by the representative
of the approved inspection body, or by the accredited representative, who witnessed the test.
He affixes:
a) the date of the test (last 2 digits of the year);
b) his stamp.
G.6.4 Return to service
Vessels having successfully undergone the detailed inspection and hydrostatic test may be refitted to the
vehicle or device.
G.7 Analysis of the results of the annual sampling on 1 % of the population of a specific type of
vessel
Every 2 years, the results of the detailed inspections and hydrostatic tests which the vessels undergo and
which are covered by 1 % sampling and visual inspections should be analysed by a competent
administrative authority. Measures should be taken if the results of the 1 % sampling and internal
inspections show a significant trend.
G.8 Withdrawal of vehicles or devices to which the vessel is fitted
When a vehicle or device to which the vessel is fitted is withdrawn, the vessel should be discarded.
G.9 Special cases of vessels fitted to a series of vehicles being phased out, vehicles intended for
a museum, or vehicles kept in service for historical reasons
Vessels fitted to these vehicles may be maintained in service beyond 40 years subject to the following
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 G.6.
G.10 Rejection
Any vessel rejected during the surveillance operation or as a result of G.8 should be rendered unusable by
puncturing its walls to the right of the marking by means of a blow torch.
Marking stamped in the metal or on a plate welded to the wall of the vessel should be rendered illegible.
G.11 Filing of results of examination, inspection and tests
Results of examination, inspections and hydrostatic tests should be recorded in a maintenance register, or
by any means of storing and analysing them.
The results of analyses of sanctions following the detailed inspections and hydrostatic tests should be
recorded.
It should be possible to submit all the results on request at any time to the representative of the approved
body on intervention by the national administration.
G.12 Responsibilities
The service surveillance operations on the vessels should be carried out on the responsibility of the railway
companies and under the control of and under the conditions fixed by the competent administrative
authority.
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© BSI 07-1999
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