Transcript Document

Using Technology to Protect the Railway Asset
Global Rail Freight Conference
New Delhi, March 22, 2007
Dr. A. J. Reinschmidt
<Global Rail Freight> - 1
© Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2007
TTCI and TTC: Two Different Things
TTCI: The
Company
TTC: The
Facility
®
© TTCI/AAR, 2007, Global Rail Freight p2
The Transportation
Technology Center, Inc.
 Our Landlord
• Our Owner
ASSOCIATION
OF AM ERICAN
RAILROADS
®
© TTCI/AAR, 2007, Global Rail Freight p3
AAR - Association of American Railroads
A not-for-profit association, established in 1934
Represent 8 class 1 freight railroads (200,000 mile of trackage, 2.1
trillion ton-kilometers Freight Haulage)
 Annual Revenues - $36 Billion dollars
 Public policy advocacy
 Network efficiency and interchange by electronic information
exchange
®
© TTCI/AAR, 2007, Global Rail Freight p4
TTCI: The Company
 Wholly owned subsidiary of the Association of
American Railroads
 Headquartered at TTC
 Operated by our own management team
 Guided by our own Board of Directors
 Charged with developing TTC to become the worlds
leading railway research testing and training facility
®
© TTCI/AAR, 2007, Global Rail Freight p5
U.S. Freight Intercity
Modal Market Share
Pipeline
Water 2%
1%
Other
RRs
7%
10%
Pipeline
17%
RRs
42%
Water
13%
Trucks
28%
TonMiles
®
© TTCI/AAR, 2007, Global Rail Freight p6
“Other” for ton-miles is less than 0.5%.
Trucks
80%
Revenue
Source: Eno Transportation Foundation
Class I Railroad Traffic in 2005
(Gross Freight Revenue)
Intermodal* - $10.1 bil
Coal - $9.4 bil
Chemicals - $5.4 bil
Transportation equipment - $4.0 bil
Farm products (mainly grain) - $3.6 bil
Food - $3.3 bil
Lumber & wood - $2.3 bil
Pulp & paper - $2.0 bil
Primary metal products (e.g., steel) - $1.7 bil
Stone, clay & glass products (e.g., cement) - 1.5 bil
Nonmetallic minerals (e.g., sand, gravel) - $1.3 bil
0%
5%
10%
15%
20%
25%
30%
Source:® AAR *Estimated. Some intermodal revenue is also included in individual
© TTCI/AAR, 2007, Global Rail Freight p7
commodities.
Intermodal is Now the Top Class
of U.S. Freight Rail Traffic
Intermodal and Coal as a % of Revenue*
26%
25%
24%
23%
22%
21%
20%
19%
Coal
Intermodal
18%
17%
1998
1999
2000
2001
*Data for BNSF, CSX, KCS, NS, and UP
®
© TTCI/AAR, 2007, Global Rail Freight p8
2002
2003
2004
2005
Source: railroad financial reports
Railroads Are Moving More Traffic
Today Than Ever Before
14%
12%
10%
8%
6%
4%
2%
U.S. Rail Traffic: %
Change From Previous
Year –
Q1-01 to Q2-06
0%
-2%
-4%
-6%
Carloads
Source: AAR Weekly Railroad Traffic
®
© TTCI/AAR, 2007, Global Rail Freight p9
Intermodal
U.S. Rail Ton-Mile Growth: 1964-2005
(Index 1981 = 100)
200
175
150
Staggers Act Passed Oct. 1980
125
100
75
50
25
0
1964
1969 1973 1977 1981 1985 1989 1993 1997 2001 2005
Source: AAR
®
© TTCI/AAR, 2007, Global Rail Freight p10
U.S. Class I Tons Originated
(billions)
2.0
1.9
1.8
1.7
1.6
1.5
1.4
1.3
1.2
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
Source: AAR
®
© TTCI/AAR, 2007, Global Rail Freight p11
Railroad Traffic Density is Rising
Millions of Class I Ton-Miles
Per Mile of Road Owned
18
16
14
12
10
8
6
4
2
0
1980
1985
Source: AAR
®
© TTCI/AAR, 2007, Global Rail Freight p12
1990
1995
2000
2005
Railroads are Safe and Getting Safer
RR Safety Trends: 1980-2005 (1980 = 100)
110
100
90
80
70
60
50
40
30
20
10
0
1980
Accidents Per Million Train-Miles
Injuries & Illness Per 100 Employees
Loss & Damage as % of Revenue
1985
Source: FRA, AAR
®
© TTCI/AAR, 2007, Global Rail Freight p13
1990
1995
2000
2005
RRs Are Safer Than Other Industries
Cases With Days Away From Work, Job Transfer, or Restriction Per 100 Full-Time
Workers - 2004
10.0
8.0
6.0
4.0
Avg. All
Private
Industry
Constr.
Avg.
Mfg.
Trucks
2.0
0.0
RRs
®
© TTCI/AAR, 2007, Global Rail Freight p14
Water Transport.Grocery Stores
Source: U.S. Bureau of Labor Statistics
Agric.
Air Trans.
Railroads Have Been Increasing Spending for a
Long Time...
Class I Spending* on Infrastructure & Equipment
Per Mile of Road Owned
$200,000
$180,000
$160,000
Trend line
$140,000
$120,000
$100,000
$80,000
$60,000
$40,000
$20,000
$0
1990
1993
1996
1999
*Capital spending + maintenance expenses - depreciation
®
© TTCI/AAR, 2007, Global Rail Freight p15
2002
2005
Source: AAR
...And Are Poised to Spend Even More
Class I RR Capital Expenditures
($ Billions)
$5.7
2002
e – AAR estimate
®
© TTCI/AAR, 2007, Global Rail Freight p16
$5.9
2003
$6.2
2004
Source: AAR
$8.3
$6.4
2005
2006e
RRs Have Far Higher Capital
Expenditures Than Other Industries
20%
18%
16%
Capital Expenditures as a % of Revenue: Avg.
1995-2004
Class I RRs
14%
12%
10%
8%
6%
4%
Avg. All
Mfg.
Computers
Plastics
Petrol. &
Coal
Prod.
Transp.
Equip.
2%
0%
®
© TTCI/AAR, 2007, Global Rail Freight p17
Nonmet.
Minerals
Sources: U.S. Census Bureau,
Paper
Chemicals
Wood
Prod.
Food
EFFICIENCY
Railroad Spending Trends
Total Spending = 37.7 Billion
Equipment
$8,087
Way & Structures
$8,795
Transportation
$16,203
Millions $
Source: Class I railroad (R-1 data) 2004.
Spending is independent of depreciation expense.
®
© TTCI/AAR, 2007, Global Rail Freight p18
General &
Administrative
$4,586
Railroad Spending Trends
Roadway (MOW) Track Related Spending
Signals &
Interlockers, $722
Ballast
$613
Bridges
$391
Administration
$273
Roadway
$244
Grade Crossings
$38
Tunnels & Subways
$8
Millions $
Source: Class I railroad (R-1 data) 2004.
®
© TTCI/AAR, 2007, Global Rail Freight p19
Rail & Track
Material $2,034
Ties
$1,164
Rail and Crossties Laid
Year
New Rail (tons)
Crossties
(thousands)
1995
443,084
12,784
1996
491,488
14,269
1997
549,726
13,363
1998
653,612
12,185
1999
698,713
12,147
2000
689,992
11,454
2001
623,866
11,383
2002
584,942
13,416
2003
572,828
13,777
2004
471,426
13,813
®
© TTCI/AAR, 2007, Global Rail Freight p20
Anatomy of Track Strength
Curve Spirals
Track
Transitions
Poor
Foundations
Bonded
IJs
3091-Davis-1
®
© TTCI/AAR, 2007, Global Rail Freight p21
Typical
Mainline Track
Special
Trackwork
New
Construction
Track on
Bridges
Anatomy of Train Loads
Steering
Trucks
Tangent
Track
Heavy Curves
Bad Actor Trucks
Track Transitions
Special
Trackwork
3091-Davis-2
®
© TTCI/AAR, 2007, Global Rail Freight p22
Methods of Reducing the Stress State
Strengthen all track (e.g. Rail Steels)
Fix weak points
Better (Dynamically Designed) track
Match track strength to train loads
Forces
From Train
Strength
ofT
rack
Potential Problems
®
© TTCI/AAR, 2007, Global Rail Freight p23
Methods of Reducing the Stress State
Strengthen all track
Fix weak points (e.g. Rail Welding)
Better (Dynamically Designed) track
Match track strength to train loads
Forces
From Train
Strength
ofT
rack
Potential Problems
®
© TTCI/AAR, 2007, Global Rail Freight p24
Methods of Reducing the Stress State
Strengthen all track (Capital Intensive)
Fix weak points
Better (Dynamically Designed) track (e.g. STW)
Match track strength to train loads
Forces
From Train
Strength
ofT
rack
Potential Problems
®
© TTCI/AAR, 2007, Global Rail Freight p25
Methods of Reducing the Stress State
Strengthen all track (Capital Intensive)
Fix weak points
Better (Dynamically Designed) track
Match track strength to train loads (e.g. TOR)
Forces
From Train
Strength
of Track
Where train is applying high forces, track is strong.
®
© TTCI/AAR, 2007, Global Rail Freight p26
Inspections with Existing
Technologies
 Truck Curving (TPD)



High Lateral Loads
High L/V Ratio
High Angle of Attack
 Acoustic Bearing
Detector (TADS)
 Smart HBD’s
 Machine Vision Based
Inspection Systems
(FactIS)
®
© TTCI/AAR, 2007, Global Rail Freight p27
Truck Performance Detector Site
N.A. Freight – 18 TPD Installations
®
© TTCI/AAR, 2007, Global Rail Freight p28
Trackside Acoustic Detector Site
N.A. Freight – 8 TADS Installations
®
© TTCI/AAR, 2007, Global Rail Freight p29
Example: Inner Ring or Cone Defect
Time history and frequency spectrogram
®
© TTCI/AAR, 2007, Global Rail Freight p30
Sound file for cone defect
Example: Outer Ring or Cup Defect
Time history and frequency spectrogram
®
© TTCI/AAR, 2007, Global Rail Freight p31
Sound file for cup defect
Example: Roller Defect
Time history and frequency spectrogram
®
© TTCI/AAR, 2007, Global Rail Freight p32
Sound file for roller defect
Wheel Profile Condition Monitoring
3 FactISTM Sites in North America
®
© TTCI/AAR, 2007, Global Rail Freight p33
Cracked Wheel Detection
Problems:
 Annual costs related to cracked
railroad wheels is approximately $24
million
 Thermal cracks and shattered rim
cracks account for many derailments
 Problem continues to grow under HAL
Goals:
 Develop a wayside inspection system
 Reduce derailments resulting from
broken wheels
 Develop new wheel alloys
Accomplishments to date
 Developed and demonstrated
effectiveness of a wayside cracked
wheel detection system

Hospital and FAST train tests
®
© TTCI/AAR, 2007, Global Rail Freight p34
SRI 6A Cracked Wheel Detection
Conceptual Operation
Cracked Wheel Detection Wayside Tracking System
®
© TTCI/AAR, 2007, Global Rail Freight p35
SRI 6A Cracked Wheel Detection
Actual Operation
Cracked Wheel Detection Wayside Tracking System
®
© TTCI/AAR, 2007, Global Rail Freight p36
Cracked Wheel Detection - Results
Pattern Recognition
A-Scan
Artificial Flaw
Indications
®
© TTCI/AAR, 2007, Global Rail Freight p37
Electronic Strip Chart
Service Flaw
Indications
Artificial and Service
Flaw Indications
HAL Axle Program
Problem:
Derailments due to broken axles have
increased over the past 4 to 5 years
 Approximately 20 broken axles per
year in the 2000’s as compared to 4
in the late 1990’s
 Problem Size is $15M+
Goals:
Determine the ability of currently
designed 286,000-lb Class F axles to
survive in the railroad environment
Reduce/eliminate derailments caused
by broken axles
Research Approach
Multi-faceted program focused on
both prevention and detection
 Prevention – New axle designs?
 Detection – Laser ultrasonics
®
© TTCI/AAR, 2007, Global Rail Freight p38
Cracked Axle Detection
Wheel Sensors
Beam Turning
and Shaping
Air-Coupled
Transducers
Indexing Mirrors
Turning Mirrors
Laser Heads
®
© TTCI/AAR, 2007, Global Rail Freight p39
Amplitude
Prototype System
No Crack Present
Direct
Wave
Amplitude
Time (microseconds)
®
© TTCI/AAR, 2007, Global Rail Freight p40
Crack Present
Direct
Wave
Time (microseconds)
Reflected
Wave
Cracked Axle Inspection System

No Crack Condition
Primary wave detected at
~1130 microseconds
Calculated primary wave for a
36-inch wheel is ~1145
microseconds
No crack reflection present



150
180
Direct Wave
160
Optic Base Station
Direct Wave
140
100
120
Axle Inspection Station
100
80
50
60
40
20
0
0
1000
1050
1100
1150
1200
1250
1300
200
400
600
800
1000
1200
1400
400
400
Direct Wave
350
Direct Wave
350
300
300
250
Reflected
Wave
200
150
250
Reflected
Wave
200
150
100
100
50
50
0
1200

1250
1300
1350
1400
1450
0
0
Beam Expander
200
400
600
800
1000
1200
1400
1600
Crack Condition

Crack located 89 mm from axle centerline

Calculated primary wave for a 38-inch wheel
is ~1265 microseconds

Crack reflection expected at 1339
microseconds
®
Crack reflection observed at 1340
© TTCI/AAR, 2007, Global Rail Freight p41
microseconds
ATSI & EHMS Steering Committee –
Mission
 Provide overall leadership and governance
for the industry’s Advanced Technology
Safety Initiative and Equipment Health
Management Systems (EHMS)
®
© TTCI/AAR, 2007, Global Rail Freight p42
ATSI & EHMS – “Changing Finders into Fixers”
 Develop shared responsibility for car condition



Railroads
Private Car Owners
Maintenance Responsible Parties
 Use detector data to identify distressed cars and
assess level of distress
 Issue notifications to maintenance reponsibile party
to affect repair
®
© TTCI/AAR, 2007, Global Rail Freight p43
2006 Accomplishments
 Worked in conjunction with the AAR’s Equipment
Engineering Committee & the SRI Program to
develop criteria for truck hunting performance
 Developed consensus on 2007 – 2008 detector focus



Bearings – Acoustic detection and temperature
trending
Vision systems for wheel profile and brake shoes
Imbalanced / overloaded car detection
®
© TTCI/AAR, 2007, Global Rail Freight p44
Progress: High Impact Load Wheels – 3-year Trend
®
© TTCI/AAR, 2007, Global Rail Freight p45
Progress: Estimated Truck Hunting Alerts
900
800
700
600
500
400
300
200
100
0
767
484
528
351
283
Estimated # of trucks alarmed between
01-Mar-04 and 28-Feb-05 (Approx # of
cars)
Once over 0.65 ≤ |Hunting Index|
®
© TTCI/AAR, 2007, Global Rail Freight p46
177
Estimated # of trucks alarmed between
01-Jan-05 and 31-Dec-05 (Approx # of
cars)
Twice over 0.50 ≤ |Hunting Index|
2007 Activities and Focus Areas
 Rule 88 Examination
When in the car owners control, are all appropriate
conditions identified and repaired?
 Home Shopping
 How can the industry work together to efficiently
identify and remediate cars that need extensive
repair?
 Interface with Other AAR Activities
 How can ATSI & EHMS support other related AAR
initiatives?

®
© TTCI/AAR, 2007, Global Rail Freight p47
ATSI & EHMS Technology Roadmap
 Wheel Profile



 Truck Performance
Data in InteRRIS® – late ’06
Remediation
recommendation – ’07
Rules not specific to wayside
detection systems


Data in InteRRIS® – ’02
Remediation
recommendation – late ‘07
 Overload / Imbalance
 Base data in InteRRIS® – ‘01
 Additional work needed for
alarming (SRI Program in ’07)
 Remediation recommendations – ‘09
®
© TTCI/AAR, 2007, Global Rail Freight p48
ATSI & EHMS Technology Roadmap
 Hot / Cold Wheel


Data in InteRRIS® – Ready to accept data
Remediation recommendation – ‘09
 Brake Shoe – Visual



Data in InteRRIS® – ’08
Remediation recommendations – prior to ’10
Rules not specific to wayside detection
systems
 Vision Systems


Data in InteRRIS® (beyond WPMS) – ’08
Remediation recommendation – ’10
®
© TTCI/AAR, 2007, Global Rail Freight p49
ATSI & EHMS Roadmap
 Technology Driven Train Inspection


Data in InteRRIS® – Early ’08
Remediation recommendation – ‘11
 Cracked Axle


Data in InteRRIS® – ‘10 (est)
Remediation recommendation – prior to
’11
 Cracked Wheel


®
© TTCI/AAR, 2007, Global Rail Freight p50
Data in InteRRIS® – ’09
Remediation recommendations – ‘13
ATSI vs TDTI
“Changing Finders to Fixers”
 ATSI
Focus on interchange process
 Develops shared responsibility for car
condition
 Railroads
 Private Car Owners
 Maintenance Responsible Parties
 Uses detector data to identify distressed
cars and assess level of distress
 Issues notifications to maintenance
responsible party to affect repairs

®
© TTCI/AAR, 2007, Global Rail Freight p51
ATSI vs TDTI
“Changing Finders to Fixers”
 TDTI
Focus on regulatory revision
 Uses detector data to certify car health
 Vehicle health report in lieu of visual
inspection
 Car health sufficient to make it to
destination

®
© TTCI/AAR, 2007, Global Rail Freight p52
InteRRIS® - EHMS Review
 Functions
 Contrasts
 Customers
 Progress
 Issues
®
© TTCI/AAR, 2007, Global Rail Freight p53
Functions: Understanding InteRRIS®
 Industry Objectives for InteRRIS®
Centralize railroad detector data for mutual
sharing
 Support preventive and predictive
maintenance planning through data
availability [provide a commercial service] to
private car owners
 InteRRIS® was designed for and is built to
support industry vehicle health monitoring
initiatives
 ATSI adopted InteRRIS® because it readily
provided the initially required functionality
without modification
 ATSI was initiated in 6 months by using
existing systems

®
© TTCI/AAR, 2007, Global Rail Freight p54
Functions: How InteRRIS® meets industry
requirements (current/future)
TADS
PCO\MRP:
EHMS ATSI
Notification
InteRRIS® :
Decision Support
+
Complete
Measurement
History
WILD
WPMS
Alerts
Alerts
TPD
InteRRIS®
Subscriber
Custom Alert
Notification
Data
Railroad Internal
Databases, NOCs & Alarm
Systems
InteRRIS®
Subscriber: data
feeds
InteRRIS® TTCI
Engineering user:
data mining\
analysis
InteRRIS®
Subscriber 3rd
party: data feeds
InteRRIS® EHMS:
data feed
®
© TTCI/AAR, 2007, Global Rail Freight p55
InteRRIS®
Subscriber, RR
user: data mining\
analysis
InteRRIS® TTCI
Engineering AAR\
SRI user: data
mining\analysis