Heavy Haul Rail 2013 Paper on Freight Train Spring Brakes

1/8/13

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AGENDA

• CONTEXT AND OBJECTIVES

• BFCB-F Combined Bogie Mounted Brake Cylinders & Spring Park Brakes

• ECP Electronic Controlled Pneumatic Brakes

• AAR 320-W302 Long Life Sintered Metallic Brake Blocks

• Combining the above.

How things have changed for handbrakes

• Wagons are twice as heavy & only half the wheels can be used.

• Additional complicated chain pulley systems are needed, all exposed to the elements.

• Not fail safe as energy stored wants to release.

• Can lock wheels on empty wagons causing wheel flats & when loaded high impacts on wheels & rail with every turn of the wheels.

Runaway Ashburys UK., 4/5/10 (Ref 3)

• TICKING TIME BOMB

• MISLEADING FEEDBACK TO STAFF

• OPPORTUNITY TO ADJUST OUT (REMOVE) ANY HANDBRAKE PERFORMANCE

Runaway Enfield Yard, Sydney 3/5/11 (Ref 2)

• STAFF FOOLED INTO THINKING HANDBRAKES WERE HOLDING THE RAKE

• AIR BRAKE HAD TO BE RELEASED TO CHANGE BRAKE BLOCK PRECIPITATING RUNAWAY

• HALF THE HANDBRAKES RETROSPECTIVELY TESTED DID NOT HAVE 1/3 EXPECTED PERFORMANCE

• ANOTHER ASHBURYS IF RAKE HAD NOT BEEN TOUCHED

Consequences

• Subsequent testing by major operators have found the same poor handbrake performance across fleets.

• Handbrakes can be brought up to spec. but only after extensive cleaning and lubrication.

• Lubricant holds contaminants so handbrake performance drops 1/3 p.a. so after 3 years back to same problem.

• No maintainer has allowed for this on-going.

Body Mounted Brake Cylinder Foundation Rigging with Handbrake

Clifton Derailment 23/11/2011 (Ref 7)

Unanderra S.P.A.D. 7/2/11 (Ref 8)

• Driver release and re-applied air brakes without leaving enough time to re-charge back along the train.

• Brake pipe pressure dropped below 250 kPa so locomotive Dynamic Brake (DB) shut off on a 1:30 decent.

• Over 500 metres S.P.A.D. onto the main line. • 4 Locomotives should have been used for the

trailing tonnage with 2 just for air brake but only 2 were used. DB would have cut out on all 4 anyway.

Shift from ISO 31000 to model WHS act (Ref 9)

• Engineers Australia Draft Safety Case Guideline, Third Edition, How to engineer safety due diligence under the provisions of the model WHS Act

• Table on page 14 “Precaution based Due Diligence” versus “Hazard based ISO 31000”

Bogie Mounted Brake Cylinder without Handbrake

Close UP

STARTING POINT FOR SPRING PARK BRAKES (BFC Loco Tread Brake)

SPRING BRAKE HELD OFF WITH COMPRESSED AIR

16

NO AIR IN THE WAGON/TRAIN SO SPRING BRAKE APPLIES

17

PULL RING TO RELEASE SPRING BRAKE

18

HEAVY HAUL

19

UP TO 23 T.A.L. (DIRN & Narrow)

20

21

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WAGON EQUIPMENT

Brake Control Valves, Multi-Chambered Reservoirs, Bogie

Mounted Brake Cylinders with Spring Park Brake, Load Sensors,

Cocks, Brake Blocks (and handbrakes)

Advantages of SPB

• FAILSAFE

• NO ADJUSTMENT

• NO WHEEL FLATS

• ENCLOSED

• CONSISTENT

Anti-compounding of brake cylinder and park brake

• Avoids handbrakes being fully applied on top of a full air brake application compounding the force on brake blocks well in excess of specifications.

• Avoids when the air leaks off there is significant tension in the handbrake system that if released in an uncontrolled manner can cause handbrake gear box and/or chain damage.

Wagon Loading and Unloading

• Wagon(s) may be stationary, stop start indexed or slowly moving during loading or unloading. Handbrakes are applied with stationary wagon(s).

• Controlled SPB application and release on a few end wagons of a rake could assist indexing the whole rake.

• Have attached an air supply rail vehicle that can remotely vary the air supply while all the wagons are drawn through the unloading facility. Such a process does not use locomotives so frees them up for other operations.

25

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ECP BENEFITS

What installing the ECP equipment can offer you:

•AAR-4200 compliant system

•Interoperable with competitors’ head end units and CCDs

•Ability to quickly and simply retrofit relayed brake systems – the majority of the Australian fleet

•Opportunity to actively manage wagon critical faults – before they cause major incidents

26

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AAR 320-W302 SINTERED BLOCKS

SINTERED BLOCKS • Sintered metal brake blocks - Individual materials such as Iron/ Copper/ Carbon and other ceramics are combined with a binder are fired at high temperatures.

• Fine control over specific braking qualities not available by any other manufacturing method.

• Sintered blocks excel in high energy braking. W30 and W302 materials have been developed specifically for highly loaded freight wagons.

• Removal of heat from the wheel tread through the blocks results in consistent, low wheel wear.

• W302 offers minimal change in braking performance over temperature, speed and brake application force, reducing inter wagon forces and less wear on couplers and draft gear.

27

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

AAR 320-W302 BENEFITS

What using W302 Sintered Blocks can offer you:

• Increased periods between block changes – Increase of 3 - 5 times between block change over commonly used organic material blocks. 20 times for cast iron

• Increased periods between wheel maintenance and replacement.

• Designed for operation up to 120 km/h in excess of 40T axle loads.

• Reduced noise, dust particles and smoke.

• Application specific solutions possible – Tailoring of composition and block thickness of our standard products can provide significant reductions in brake block usage and wheel wear.

•Exceeds AAR requirements – The W302 can be considered a direct replacement for existing AAR blocks.

SPRING BRAKE POTENTIAL?

1. LIMP HOME’ ECP BACKUP 2. NOW ECP ONLY CONTROLS THE AIR BRAKE SO NO AIR,

NO BRAKE 3. SPRING BRAKE IS FAILSAFE SO ECP COULD PUSH

SPRINGS OFF 4. COMBINE AIR & SPRINGS FOR EMERGENCY BRAKE (1

kW/wheel) 5. SINTERED METAL BLOCKS HOLD BACK 25% OF THE HEAT

SO COULD EMETGENCY STOPPING DISTANCES BE REDUCED?

6. SHORTEN SIGNALLING HEADWAY & INCREASE HEAVY HAUL CORRIDOR CAPACITY

Discussion on Potential Applications of Illustrated SPB

• The Newlands Coal Line in north Queensland has a long steep grade that causes trains to not use a passing loop half way down thereby halving the capacity of the line.

Summing Up

A STOPPED TRAIN IS A SAFE TRAIN

&

THE POWER TO STOP GIVES THE POWER TO SPEED

References 1. Transport Safety Victoria Alert No. 2011-03 dated 21/7/11 2. OTSI Reference 04514, 2011:- Office of Transport Safety Investigations (OTSI) N.S.W.

Rail Safety Investigation Report, Runaway of Rolling Stock, Enfield Yard, 3 May 2011, Investigation Reference 04514

3. RAIB Report No. 07/2011:- Rail Accident Investigation Branch (RAIB), U.K. Department for Transport Runaway Ashburys 4 May 2010,Report 07/2011,March 2011

4. OTSI 28/7/09:- Office of Transport Safety Investigations (OTSI) N.S.W. Rail Safety Investigation Report, Runaway Grain Wagon, Temora 28 July 2009

5. Formenton 2009:- Improving Operational Performance of Freight Trains using Electronically Controlled Pneumatic (ECP) Braking, presented to The Institution of Railway Signal Engineers (IRSE) Inc., Australasian Section Incorporated, Sydney, 13 November 2009.

6. WSC, 2008:- Wingecarribee Shire Council (WSC) submission to the Inquiry into Australian Future Infrastructure Requirements, Australian Government – Infrastructure Australia, September 2008.

7. OTSI 23/11/11:- Office of Transport Safety Investigations (OTSI) N.S.W. Derailment of Pacific National Service MC92, Clifton.

8. OTSI 7/2/11:- Office of Transport Safety Investigations (OTSI) N.S.W. Uncontrolled Movement of El Zorro Grain Service 3996, Unanderra.

9. Engineers Australia (EA) Draft SAFETY CASE GUIDELINE, 2013

Bogie Mounted Brake Cylinder without Handbrake

Close UP

STARTING POINT FOR SPRING PARK BRAKES (BFC Loco Tread Brake)

SPRING BRAKE HELD OFF WITH COMPRESSED AIR

35

NO AIR IN THE WAGON/TRAIN SO SPRING BRAKE APPLIES

36

PULL RING TO RELEASE SPRING BRAKE

37

HEAVY HAUL

38

UP TO 23 T.A.L. (DIRN & Narrow)

39

40

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

WAGON EQUIPMENT

Brake Control Valves, Multi-Chambered Reservoirs, Bogie

Mounted Brake Cylinders with Spring Park Brake, Load Sensors,

Cocks, Brake Blocks (and handbrakes)

Advantages of SPB

• FAILSAFE

• NO ADJUSTMENT

• NO WHEEL FLATS

• ENCLOSED

• CONSISTENT

Anti-compounding of brake cylinder and park brake

• Avoids handbrakes being fully applied on top of a full air brake application compounding the force on brake blocks well in excess of specifications.

• Avoids when the air leaks off there is significant tension in the handbrake system that if released in an uncontrolled manner can cause handbrake gear box and/or chain damage.

Wagon Loading and Unloading

• Wagon(s) may be stationary, stop start indexed or slowly moving during loading or unloading. Handbrakes are applied with stationary wagon(s).

• Controlled SPB application and release on a few end wagons of a rake could assist indexing the whole rake.

• Have attached an air supply rail vehicle that can remotely vary the air supply while all the wagons are drawn through the unloading facility. Such a process does not use locomotives so frees them up for other operations.

44

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

ECP BENEFITS

What installing the ECP equipment can offer you:

•AAR-4200 compliant system

•Interoperable with competitors’ head end units and CCDs

•Ability to quickly and simply retrofit relayed brake systems – the majority of the Australian fleet

•Opportunity to actively manage wagon critical faults – before they cause major incidents

45

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

AAR 320-W302 SINTERED BLOCKS

SINTERED BLOCKS • Sintered metal brake blocks - Individual materials such as Iron/ Copper/ Carbon and other ceramics are combined with a binder are fired at high temperatures.

• Fine control over specific braking qualities not available by any other manufacturing method.

• Sintered blocks excel in high energy braking. W30 and W302 materials have been developed specifically for highly loaded freight wagons.

• Removal of heat from the wheel tread through the blocks results in consistent, low wheel wear.

• W302 offers minimal change in braking performance over temperature, speed and brake application force, reducing inter wagon forces and less wear on couplers and draft gear.

46

+ + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + +

AAR 320-W302 BENEFITS

What using W302 Sintered Blocks can offer you:

• Increased periods between block changes – Increase of 3 - 5 times between block change over commonly used organic material blocks. 20 times for cast iron

• Increased periods between wheel maintenance and replacement.

• Designed for operation up to 120 km/h in excess of 40T axle loads.

• Reduced noise, dust particles and smoke.

• Application specific solutions possible – Tailoring of composition and block thickness of our standard products can provide significant reductions in brake block usage and wheel wear.

•Exceeds AAR requirements – The W302 can be considered a direct replacement for existing AAR blocks.

SPRING BRAKE POTENTIAL?

1. LIMP HOME’ ECP BACKUP 2. NOW ECP ONLY CONTROLS THE AIR BRAKE SO NO AIR,

NO BRAKE 3. SPRING BRAKE IS FAILSAFE SO ECP COULD PUSH

SPRINGS OFF 4. COMBINE AIR & SPRINGS FOR EMERGENCY BRAKE (1

kW/wheel) 5. SINTERED METAL BLOCKS HOLD BACK 25% OF THE HEAT

SO COULD EMETGENCY STOPPING DISTANCES BE REDUCED?

6. SHORTEN SIGNALLING HEADWAY & INCREASE HEAVY HAUL CORRIDOR CAPACITY

Discussion on Potential Applications of Illustrated SPB

• The Newlands Coal Line in north Queensland has a long steep grade that causes trains to not use a passing loop half way down thereby halving the capacity of the line.

Summing Up

A STOPPED TRAIN IS A SAFE TRAIN

&

THE POWER TO STOP GIVES THE POWER TO SPEED

References 1. Transport Safety Victoria Alert No. 2011-03 dated 21/7/11 2. OTSI Reference 04514, 2011:- Office of Transport Safety Investigations (OTSI) N.S.W.

Rail Safety Investigation Report, Runaway of Rolling Stock, Enfield Yard, 3 May 2011, Investigation Reference 04514

3. RAIB Report No. 07/2011:- Rail Accident Investigation Branch (RAIB), U.K. Department for Transport Runaway Ashburys 4 May 2010,Report 07/2011,March 2011

4. OTSI 28/7/09:- Office of Transport Safety Investigations (OTSI) N.S.W. Rail Safety Investigation Report, Runaway Grain Wagon, Temora 28 July 2009

5. Formenton 2009:- Improving Operational Performance of Freight Trains using Electronically Controlled Pneumatic (ECP) Braking, presented to The Institution of Railway Signal Engineers (IRSE) Inc., Australasian Section Incorporated, Sydney, 13 November 2009.

6. WSC, 2008:- Wingecarribee Shire Council (WSC) submission to the Inquiry into Australian Future Infrastructure Requirements, Australian Government – Infrastructure Australia, September 2008.

7. OTSI 23/11/11:- Office of Transport Safety Investigations (OTSI) N.S.W. Derailment of Pacific National Service MC92, Clifton.

8. OTSI 7/2/11:- Office of Transport Safety Investigations (OTSI) N.S.W. Uncontrolled Movement of El Zorro Grain Service 3996, Unanderra.

9. Engineers Australia (EA) Draft SAFETY CASE GUIDELINE, 2013