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In the July issue of Welding Lines, there was a summary of activities in this area - now we look at the present state of affairs.
Rail welding, like any other kind of welding, is a special process that needs special controls. The new approach to competence and QA in rail welding is aimed at introducing new practices which have proved valuable in other industrial sectors that rely on high integrity welding.
Progress to date is indicated under a number of headings as discussed below:
- Welding procedure documentation and approval
Railtrack are involved in introducing revisions to the line specifications that deal with track welding. These are RT/CE/S/032 for aluminothermic welding and RT/CE/S/132 for arc welding. It is expected that the new specifications will be issued in March 2003. These revisions take account of good practice in other industries, for example the way in which welding procedures and welders are approved. Work is also underway in the development of European standards for rail welding procedures and rail welder qualifications. Progress on this was reported in the April issue of Welding Lines. Similar activities are under way with flash butt welding of rails and it is expected that work will begin on developing specifications for gas pressure welding of rails.
- Welder training, examination and qualification
For aluminothermic welding the IoRW Training Sub-Committee is developing a standard syllabus and training materials. It is expected that these will be available by March 2003. Following this, work will begin on producing a standard syllabus and training materials for arc welding.
In parallel with the above, it was decided to ensure that rail welding qualifications form part of the National Framework of Qualifications. To this end, draft Occupational Standards have been developed for aluminothermic welding, arc welding and flash butt welding of rails. This will mean that where appropriate, rail welding personnel can seek National or Scottish Vocational Qualifications.
The IoRW Training Sub-Group will also develop standard procedures for assessing components in rail welding which will be adopted by training organisations for National Qualification and by contractors for ongoing competence assurance. Competence assurance regimes will be based on the above mentioned Occupational Standards.
- Welder training organisations
Any organisation wishing to train in aluminothermic or arc welding will need to be approved under the Certification Scheme for Welder Training Organisations (CSWTO) and the detailed criteria for this are available on the IoRW web-site.
The criteria include the qualification of welding instructors and for convenience, a secondary document which embraces all the requirements for rail welding training organisations and instructors in one place has been approved. This will be available on the web-site in the near future. Two welder training organisations have already applied for certification.
- Welding contractors
As reported in the earlier article, it is expected that welding contractors will be required to gain certification under the Welding Fabricator Certification Scheme operated by TWI Certification Ltd. The criteria are also available on the web-site and they include a special supplement on rail welding. TWI CL has expanded its team of assessors to include individuals with rail welding expertise and one organisation has applied for certification.
- Welding Inspector training, examination and certification
An outline scheme has been produced and discussed by the IoRW Management Committee and this is undergoing further development.
- Procedures for introducing new welding processes or techniques
Although prior to the formation of the IoRW this was identified as a problem area in the industry, the current indications are that the system for adopting new technology has been streamlined and therefore no further action is envisaged at present.
- Records and associated databases
It has been decided that all records of welder qualifications will be maintained on the Railtrack Sentinel system and that standard cards will be issued to all welders. Railtrack are also considering requirements for maintaining records of welds in track and a number of options are being considered.
Feedback on all the above is welcomed and further progress will be reviewed in future issues of Welding Lines.
Tim Jessop
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