Broken wheelsets on freight wagons

Transcription

1 Broken wheelsets on freight wagons Outline of the state of play (EBA, DB AG, DB Schenker Rail, VPI, VAP, VDV, Netzwerk Pb.) Extraordinary NSA meeting, 29 July 2009 Chart 1

2 Contents 1. Findings dating from before General order of EBA dated Accidents during the past year 4. Summary Extraordinary NSA meeting, 29 July 2009 Chart 2

3 Contents 1. Findings dating from before General order of EBA dated Accidents during the past year 4. Summary Extraordinary NSA meeting, 29 July 2009 Chart 3

4 1 Findings dating from before 2007 Broken wheelsets due to wheelset damage Date Place Breakpoint RST Keeper Amsterdam (NL) Korbbogen Tals Railion A Merzig (D) Shaft Fal Railion B Thun (CH) Korbbogen Alumina SBB A Gelsenkirchen (D) Shaft Fal Railion B Salzburg-Gingl (A) Korbbogen Tank wagon VTG A Brig (CH) Shaft Tamns Railion A Mühlehorn Korbbogen Tank wagon VTG A Extraordinary NSA meeting, 29 July 2009 Chart 4

5 1 Findings dating from before 2007 Accident causes Starting with damages at the wheelset surface, cracks occur which develop until a full break of the wheelset due to varying bending loads. Starting points: Corrosion (partially widespread and far advanced) Damages of the surface - due to unappropriate storage - due to unappropriate transport - due to unappropriate transshipment - resulting from operation (rocks, grinding parts,...) As a consequence, suitable measures in logistics and maintenance have to be identified. Extraordinary NSA meeting, 29 July 2009 Chart 5

6 1 Findings dating from before 2007 Damages of the surface due to storage Extraordinary NSA meeting, 29 July 2009 Chart 6

7 1 Findings dating from before 2007 Defective protective coat and corrosion (3 months after maintenance activity) Damage due to transshipment Extraordinary NSA meeting, 29 July 2009 Chart 7

8 1 Findings dating from before 2007 Overcoated corrosion scars (1 month after maintenance activity) Extraordinary NSA meeting, 29 July 2009 Chart 8

9 1 Findings dating from before 2007 Overcoated Corrosion (1 month after maintenance activity) Damage due to storage Extraordinary NSA meeting, 29 July 2009 Chart 9

10 1 Findings dating from before 2007 Data strip in fresh coat... Extraordinary NSA meeting, 29 July 2009 Chart 10

11 1 Findings dating from before with corrosion underneath (2 months after maintenance) Extraordinary NSA meeting, 29 July 2009 Chart 11

12 1 Findings dating from before 2007 Corrosion underneath data strip (1 month after maintenance) Extraordinary NSA meeting, 29 July 2009 Chart 12

13 1 Findings dating from before 2007 ready for use wheelset (one month after maintenance) Extraordinary NSA meeting, 29 July 2009 Chart 13

14 1 Findings dating from before 2007 Statements from EN / UIC Durability approval requires the following: Approval is only valid if maintenance policy ensures an effective protection against corrosion during the whole lifecycle of the wheelset. The alternative of adjusted durability values has not been followed. [EN13103, chapter 7.2] Throughout the lifecycle of a wheelset, the consistency of its surface has to be in a state which to the greatest extend corresponds to the as-new condition. The required factor of safety S acc. to EN13103 has to be met (S=1,2 for A1N). By doing so, minor temporary damages of the surface and the corrosion protection are taken into consideration. Extraordinary NSA meeting, 29 July 2009 Chart 14

15 1 Findings dating from before 2007 Statements of E DIN The acceptable state of wheelsets is summarized in chapter 4.2.4: Rills not acceptable. Hollows not acceptable, if resulting from operation Grooves not acceptable or concept for fault tolerance Corrosion not acceptable or concept for fault tolerance Until now: No concept for fault tolerance Current UIC-project to set up a concept for fault tolerance First findings are applied by DB Schenker. Extraordinary NSA meeting, 29 July 2009 Chart 15

16 Contents 1. Findings dating from before General order of EBA dated Accidents during the past year 4. Summary Extraordinary NSA meeting, 29 July 2009 Chart 16

17 Content of general oder dated Maintenance programs have to be available, further developed and applied. - Measures and intervals have to take into account limits of wear in a way that ensures safe operation of the RST. - Base for criteria of limit of wear is E DIN Attention to conditions for surface and corrosion protection which underly the interpretation of durability/resistance. Amongst others, non-destructive testing has to be applied. Procedures and intervals of inspections have to be determined and regularly verified. Complete documentation of all activities. 2. General order of EBA dated Extraordinary NSA meeting, 29 July 2009 Chart 17

18 Contents 1. Findings dating from before General order of EBA dated Accidents during the past year 4. Summary Extraordinary NSA meeting, 29 July 2009 Chart 18

19 3. Accidents during the past year Accident Falkenhagen ( ) Wheelset type A acc. to UIC Broken in the wheelset s outer curve Result of accident investigation: Corrosion damages have led to the rupture. Extraordinary NSA meeting, 29 July 2009 Chart 19

20 3. Accidents during the past year Accident St. Peter Seitenstetten (1) ( ) Wheelset type A acc. to UIC Broken in the area of the shaft km since last mechanised US-testing The coated surface of the wheelset was apparently free from any damage. Result of accident investigation: Corrosion damages have led to the rupture. Many other cracks due to old corrosion. Extraordinary NSA meeting, 29 July 2009 Chart 20

21 3. Accidents during the past year Unfall St. Peter Seitenstetten (2) ( ) Fatigue break due to damages of the surface. Further findings regarding dimensioning: Axle load 1 t higher than allowed acc. to UIC and EN High (indeterminable) number of wheelsets type A have been operated non-compliant to relevant norms. Wheelset axles of type A were operated with diameters, which acc. to EN in the worst case only allow an axle load of 19,3 t. Extraordinary NSA meeting, 29 July 2009 Chart 21

22 3. Accidents during the past year Viareggio ( ) Wheelset type A acc. to UIC Broken in the wheelset s outer curve km since last manual US-testing. Accident investigation is under progress. Extraordinary NSA meeting, 29 July 2009 Chart 22

23 4. Summary Summary 1. The consistency of the surface of many wheelsets type A and B does not meet the requirements of EN (and E DIN ). 2. Wheelsets type A were operated outside the stipulations of EN Extraordinary NSA meeting, 29 July 2009 Chart 23

24 Contents 1. Findings dating from before General order of EBA dated Accidents during the past year 4. Summary Extraordinary NSA meeting, 29 July 2009 Chart 24

25 4. Summary Consequences Point The consistency of the surface of many wheelset axles type A and B does not meet the requirements of EN (and E DIN ). 2. Wheelset axles type A were operated outside the stipulations of EN Extraordinary NSA meeting, 29 July 2009 Chart 25