Derailments and Derailment Prevention

Transcription

1 Derailments and Derailment Prevention Dr. Allan M Zarembski Professor and Director Railroad Engineering and Safety Program University of Delaware dramz@udel.edu 2015 Allan M Zarembski

2 Railroad Safety and Derailments Railroads are a primary shipper of crude oil and hazardous materials Railroads are fundamentally a safe mode of transport However accidents and derailments do occur Most accidents/derailments do not result in a release of hazardous materials

3 Hazardous Materials For a major release event to occur Accident/derailment must occur Rupture/release must occur Failure of the tank car shell Failure of the release valves Much attention has been devoted to the issue of tank car release Cumulative Probability of Release (CPR) defines risk of release New generation tank cars such as DOT-117 designed to reduce risk of release ( low CPR)

4 Accidents/Derailments Accident/derailment must occur for a incident to take place Accidents include: Derailments Collisions Other Derailments are most common class of accidents 70% of all accidents ( 2014)

5 Total Accidents/Incidents TOTAL ACCIDENTS/INCIDENTS 11,896 11,598 TOTAL TRAIN ACCIDENTS (including derailments): 1,762 1,824 HIGHWAY-RAIL INCIDENTS 2,287 2,098 OTHER INCIDENTS (including trespassers) : 7,847 7,676

6 Total Train Accidents/Incidents CBR Focus is on Train Accidents/Derailments

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9 Main track accidents about 30% of all accidents

10 TRAIN ACCIDENTS Summary Statistics ,022 1,760 1,824 1,762 Collisions Derailments 1,468 1,294 1,299 1,246 Other

11 Distribution of Accidents/Derailments Total Train Accidents/Derailments (2014) 1762 Collisions Other 0.1% fatal Derailments

12 Safety Statistics Summary-Train Accidents TOTAL TRAIN ACCIDENTS: 1,762 1,824 Collisions: % % Derailments: 1, % 1, % Other accidents: % % Number of accidents on yard track: % of all train accidents % of all train accidents Number of train accidents involving passenger trains % % Number of fatal train accidents 1 0.1% 6 0.3% Number accidents per million train miles:

13 Hazmat Data TOTAL ACCIDENTS/INCIDENTS: 11,896 11,598 Total train accidents 1,762 1,824 Accidents w HAZMAT release % % Number of rails cars releasing HAZMAT Persons evacuated 1,537 3,187

14 HAZMAT Data HAZMAT releases HAZMAT Cars derailed Cars releasing

15 Safety Statistics Summary-Train Accidents by Cause TOTAL TRAIN ACCIDENTS: 1,762 1,824 Human factors: % % Track defects: % % Equipment defects: % % Signal defects: % % Miscellaneous causes: % %

16 Distribution of All Accidents by Major Category

17 Main Line Accidents/Derailments by Category Main track accident/derailments approximately 30% of all accidents

18 FRA Reported Derailment Causes

19 2012 Safety Statistics Summary-Track Track Geometry: 206 $36.4 M Rail Defects: 206 $50.0 M Frogs, Switch, etc. 124 $ 8.1M Other: 48 $ 4.0 M Roadbed: 14 $ 4.3 M

20 FRA Reported Equipment Subcategories

21 2012 Safety Statistics Summary-Equipment Wheels: 43 $ 13.4 M Truck Components: 35 $ 3.1 M Brakes: 30 $ 2.0 M Coupler & Draft Gear 29 $ 2.6 M Locomotives 20 $ 0.9 M Axles and Bearings: 19 $ 7.2 M Body 19 $ 1.0 M Other 10 $ 0.9 M

22 FRA Reported Human factors Subcategories

23 2012 Safety Statistics Summary-Human Factors General Switching Rules: 235 $ 11.7 M Switches: 137 $ 6.7 M Train Handling/Makeup: 88 $ 5.0 M Speed: 68 $ 6.8 M Use of Brakes 32 $ 2.0 M Main Track Authority 14 $ 1.0 M Employee Condition 2 $ 0.2 M Other 32 $ 2.0 M

24 2012 Collisions Head on collision Rear end collision Damage ($) Casualty Causes Cnt Amount Kld Inj Eqp Hmn Othr Sig Trk 6 12,458, ,218, Side collision 80 5,190, Raking collision Broken train collision 46 3,852, ,

25 Top 10 FRA Reported Derailments Rail defects/failure Track geometry defects Total Cost Number of Accidents/Derailments Cost/derailment Derailments/yr. $ 288,094,362 1,060 $ 271, $ 173,480,951 1,081 $ 160, Wheel failure $ 78,269, $ 350, Axle and Bearing Failure $ 59,885, $ 415, Frogs, Switches, Track Appliances $ 50,179, $ 83, Train Handling and Makeup $ 38,537, $ 91, General Switching Rules and Switching $ 62,804,707 1,306 $ 48, Operations Improper Use of Switch $ 40,793, $ 60, Road Bed Effects $ 45,320, $ 368, Speed $ 47,238, $ 144,

26 CBR Derailment Causes Year Date Location Train type Cause /5/2015 Galena, IL CBR Broken Rim /16/2015 Mt Carbon, WV CBR Vertical Split Head /4/2015 Dubuque, IA ethanol Trasverse/compoud fissure /9/2014 La Salle, CO CBR Track aligment irregular /30/2014 Lynchburg, VA CBR Detail fracture from shell /13/2014 Vandergrift, PA CBR Wide Gauge-fasteners T /31/2014 New Augusta, MS Methanol and Gas Broken base rail /28/2014 Mcdavid, FL Phosphoric Acid Detail fracture from shell /30/2013 Casselton, ND CBR Broken axle /7/2013 Aliceville, AL CBR Could not be determined-track suspected /21/2013 Smithboro CBR Bolt crack or break /21/2013 Tampa, FL Alcohol Trasverse/compoud fissure /17/2013 Buffalo, NY Alcohol Truck bolster stiff /20/2013 Bassett, IA Ethanol Extreme enviromental condition /27/2013 Parkers Prairie, MN CBR Trasverse/compoud fissure /7/2012 Columbus, OH Alcohol Cause under investigation /5/2015 Plevna, MT Alcohol Track aligment irregular Broken Rail represents the largest single category

27 Rail Failure (Broken rail)

28 Rail Defect Detection Rail is tested to identify internal defects by using an Ultrasonic Rail Flaw Testing Vehicle Visual inspection not effective 28

29 Risk Reduction Using Improved Testing Improved rail test management has shown ability to reduce rate of service defects and associated rail caused derailments Documented reduction in both service defects and rail related derailments Analysis of risk based testing requirements show that selectively increased rail testing can reduce derailments Recently incorporated into FRA track safety standards

30 Track Geometry Defects Surface, warp and twist defects

31 Excessive Dynamic Response

32 Track Geometry Parameters Surface ( left, right) Cross-level ( super-elevation) Twist (warp) Alignment ( left, right) Curvature Gage

33 Visual Track Inspection Walking the track 2x week Hi-Rail Inspection Inspection from Train Visual inspections, continue to be an essential means for assessing track. 33

34 Track Geometry Inspection Cars Rail-bound geometry car loads the track dynamically and measures deviations from railroad standards. Self propelled or locomotive pulled Measurements of gage, profile, cross-level and alignment are compared to regulatory limits. 34

35 Wheel Failure Wheel failure zones: Thermal cracks: Tread, Plate Surface contact/rolling contact fatigue/spalling: Tread Loose wheel: Hub, Bore Excessive wear: Flange, tread

36 Broken Wheel

37 Wheel Inspection Wheel Impact Load Detector (WILD) Measurement of vertical forces exerted by each wheel of a passing train. Generated by wheel surface conditions Hot Wheel Detector Overheated wheels Wheel profile measurement System Identify Worn wheels

38 Broken Axle and Bearing at B Broken Axle

39 Axle Fracture Surface Fatigue fracture surface covered 65% of axle

40 Bearing Failure Detected by Hot Bearing detector when it overheads By Acoustic Bearing detector prior to overheating

41 Overheated Bearing Burned Off Journal

42 Bearing Detectors Hot Box detectors (HBD) are designed to monitor axle and bearing temperatures indicating any overheating which could lead to bearing and axle failure Uses thermal measurement techniques Acoustic Bearing Detector designed to monitor roller bearings and identify bearings with internal defects prior to overheating. Uses acoustic signature analysis techniques

43 Special Trackwork

44 Chipped Switchpoint at Point of Derailment

45 Automated Switch Inspection Vehicle

46 Broken Switch Point

47 Frog and wing rails in poor condition

48 Train Handling In-Train Forces:Buff and Draft Train Handling category of derailment causes 3-8

49 Speed

50 Positive Train Control

51 Improper/Eccentric Loading CONCENTRATED LOAD CONCENTRATED LOAD

52 Improper Switching

53 Roadbed Defects

54 Track Buckle

55 Spring and Suspension Failures