AAR Technical Committee Activities at TTCI

Transcription

1 AAR Technical Committee Activities at TTCI David Cackovic Chief, Technical Standards, TTCI Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 1 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

2 Today s Discussion AAR Technical Committee and Field Personnel Updates Equipment Engineering Wheels, Axles, Bearings, and Lubrication Coupling System and Truck Castings Brake Systems Risk Assessment for Technical Standards, MID, and BOE Example Standards Actions Testing/Analysis to Support Industry Issues and Specification Needs AAR / TTCI Publications Access Tools, Upgrades and Plans Mechanical Inspection Department TTCI/AAR, 2009, <Directory Number> p2

3 AAR Rules and Technical Committee Structure Safety & Operations Mgmt Committee Technical Services Working Committee Quality Assurance Equipment Engineering Committee Railroad Electronics Stds Comm. Open Top Loading Rules Committee Arbitration Committee Locomotive Committee Braking Systems Committee Wheels, Axles, Bearings & Lubrication Committee Coupling System & Truck Castings Committee Specially Equipped Freight Car Committee Car Repair Billing Committee Locomotive Repair Billing Committee TTCI/AAR, 2009, <Directory Number> p3

4 Interchange Rules and Standards Committee Structure re TTCI/AAR, 2009, <Directory Number> p4

5 EQUIPMENT ENGINEERING COMMITTEE Committee Manager Dave Cackovic Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 5 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

6 Equipment Engineering Responsiblities Oversight over Subordinate Committees Car Design Methods and Approvals Car Manufacturer Inspections/Approvals Rule 88 Car Modifications Draft Gear and Cushion Units Field Manual Rule Support MSRP Sections B, C, C-II, D, L and H-III TTCI/AAR, 2009, <Directory Number> p6

7 Hot Issues Loaded Hunting M-976 Equipment Engineering Safety Appliance Task Force S-2043 High Level Radioactive Waste Car Specification TTCI/AAR, 2009, <Directory Number> p7

8 Equipment Engineering Field and Office Manual Rules Support Rule 46 Truck Performance Detector Rules for Field Manual Rule 46 Hunting Detector Rules for Field Manual Rule 88 Rewrite TTCI/AAR, 2009, <Directory Number> p8

9 WHEELS, AXLES, BEARINGS, and LUBRICATION COMMITTEE Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 9 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

10 Wheels, Axles, Bearings, Lubrication Industry Roller Bearing Issues Warm trending rules for Field Manual implemented in 2008 Allows removal by coordinating existing hot box detector t data Derived from working backward in hot box data from failed bearings Acoustic detector rules for Field Manual WABL refining acoustic detector rules Inspection of roller bearing manufacturers First inspections per M-934 bearing specification in March 2009 TTCI/AAR, 2009, <Directory Number> p10

11 Coupling System & Truck Castings Committee Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 11 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

12 New Specification, M-220: Magnetic Particle Inspection of Railroad Knuckles Who Is Required To Perform Knuckle MPI? Mandatory: Manufacturers and Reclamation Shops Optional: Car repair shops, RIP tracks, and mobile operations Inspector Qualification ASNT Level I or higher or equivalent AAR member corporate program An ASNT Level III professional or equivalent AAR member professional must approve the training TTCI/AAR, 2009, <Directory Number> p12

13 New Specification M-216 Knuckle Fatigue Test Total Cyc cles to Failure Historical test results, plotted below, were used as a guideline for the new specification Knuckle Fatigue Test Results (NS Test Fixture) Average of 4 Tests Must Be Above 600,000 No Test May Be Below 400,000 Cycles The average life of four knuckles tested must exceed 600,000 cycles. No individual knuckle is to exhibit a life below 400,000 cycles. Goal of the CSTCC is to eliminate the poorest performing knuckles and to bring up the average performance Foundry TTCI/AAR, 2009, <Directory Number> p13

14 AAR Approved Foundries & Products Products Includes: Approval Includes: USA 5 Sideframes QA Audit China 5 Bolsters Technical Audit Canada 1 Couplers Component Mexico 2 Yokes Testing 1 Foundry Knuckles 1 Foundry Finishing Brazil 1 Czech Republic 1 India 1 TOTAL 16 TTCI/AAR, 2009, <Directory Number> p14

15 AAR Brake Systems Committee Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 15 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

16 AAR Brake Systems Committee MSRP Section E Brakes and Brake Equipment Includes Standards and Specifications for all parts of the freight car brake system including new car system design, inspection and tests, and repair and reconditioning. New Standards Recently In Process or Adopted Automatic Single Car Test Device Performance Specification Piston Travel / Slack Adjuster Inspection and Test Procedures High Capacity / Low Fade Tread Conditioning Brake Shoe Hook and Eye Foundation Brake Rigging Procedures for Lever Angularity Inspection and Adjustment Several End of Car Brake Equipment Arrangement Standards for EOCC and Draft Gear Cars TTCI/AAR, 2009, <Directory Number> p16

17 AAR Brake Systems Committee MSRP-Section EII- Electronically Controlled Brake Systems Covers the basic performance requirements of electronically controlled pneumatic (ECP) brake systems. ECP Brake System Benefits: Improved fuel efficiency and emissions Improved rail system capacity Shorter Stopping distances (40-60%) Reduced Air Consumption Improved Train Handling Graduated Brake Application and Release Automatic Train Consist ID and Sequencing Real-time train brake status and feedback Exact braking force based on ECP commands and not piston travel TTCI/AAR, 2009, <Directory Number> p17

18 INTERMODAL CAR PERFORMANCE SUBCOMMITTEE Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 18 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

19 Intermodal Car Performance Committee Consists of railroad and car owner mechanical personnel. Responsible for issues with design and maintenance of railcars and their components used in intermodal service, including trailer hitches and container securement pedestals. Maintains Section I of the AAR s Manual of Standards and Recommended Practices, including: M Closed Van Container for Domestic Intermodal Service M-952 Intermodal Container Support and Securement System for Freight Cars Issued a new specification, M998 Intermodal Container Support and Interbox Connector (IBC) TTCI/AAR, 2009, <Directory Number> p19

20 Intermodal Car Performance Committee Ongoing Efforts Maintaining the Loading Capabilities Guide on the AAR Website Updating RP-899-Car Owner s Manual for the Inspection and Maintenance of Double-Stack Container Cars, which provides guidelines for the inspection and maintenance of all double-stack container cars. TTCI/AAR, 2009, <Directory Number> p20

21 AAR Quality Assurance Committee Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 21 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

22 AAR QA Committee Focus Quality Systems Certify facility systems that meet the requirements of AAR Specification M-1003 Updates to MSRP Section J (M-1003) Quality Products Verify that technical requirements and M-1003 requirements are met Technical Checklists Quality Auditors Certify AAR Auditors TTCI/AAR, 2009, <Directory Number> p22

23 AAR QA Committee Focus Certify facility systems that meet the requirements of AAR Specification M companies provide 112 mandatory products and services 82 companies provide voluntary products and services 72 companies provide both mandatory and voluntary products and services (note: mandatory = required by other AAR rules and/or specifications) TTCI/AAR, 2009, <Directory Number> p23

24 2008 Auditor Evaluation Results 100% 95% 90% 85% 80% 75% 70% 65% 60% 55% 50% Auditor TTCI/AAR, 2009, <Directory Number> p24

25 Risk Assessment for Technical Standards, MID, BOE Accelerating the use of clean, safe and efficient technologies by railways worldwide. <Directory Number> - 25 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

26 Risk Assessment A structured methodology for identifying and analyzing risks Useful: For developing standards When making changes When introducing new technology When seeking to improve safety TTCI/AAR, 2009, <Directory Number> p26

27 Risk Assessment Steps Define scope Identify existing conditions Hazards Controls Relate hazards and controls (risk control matrix) Evaluate Hazard frequencies Hazard consequences Determine risk (risk ranking, detailed d risk computation) ti Assess options TTCI/AAR, 2009, <Directory Number> p27

28 Conclusions Hazard and control identification has documented the current situation Risk control matrix provides a 1-page summary Risk ranking has identified critical hazards Detailed risk computation may be required Only continue risk assessment until sufficient level of detail has been reached to answer the scope question(s) TTCI/AAR, 2009, <Directory Number> p28

29 Today s Discussion AAR Technical Committee and Field Personnel Updates Equipment Engineering Wheels, Axles, Bearings, and Lubrication Coupling System and Truck Castings Brake Systems Risk Assessment for Technical Standards, MID, and BOE Example Standards Actions Testing/Analysis to Support Industry Issues and Specification Needs AAR / TTCI Publications Access Tools, Upgrades and Plans Mechanical Inspection Department TTCI/AAR, 2009, <Directory Number> p29

30 <Directory Number> - 30 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

31 Technical Project Freight Car Fatigue Example <Directory Number> - 31 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

32 New Analysis Tools Current Guidelines Based on: 1970s and older car designs Cars used for tests all out of production 263K GRL and lighter vs. today s 286K GRL Today s tare weights are often lower Materials today are higher strength Today use of aluminum is common TTCI/AAR, 2009, <Directory Number> p32

33 Test Program Coal Car Phase I Tests, with instrumentation coach Phase II Tests, unattended Mine GPS Position Loaded Train Cities Chicago Dunkirk Cleveland Omaha North Platte TTCI/AAR, 2009, <Directory Number> p33

34 Today s Discussion AAR Technical Committee and Field Personnel Updates Equipment Engineering Wheels, Axles, Bearings, and Lubrication Coupling System and Truck Castings Brake Systems Risk Assessment for Technical Standards, MID, and BOE Example Standards Actions Testing/Analysis to Support Industry Issues and Specification Needs AAR / TTCI Publications Access Tools, Upgrades and Plans Mechanical Inspection Department TTCI/AAR, 2009, <Directory Number> p34

35 Publications and Document Management TTCI/AAR, 2009, <Directory Number> p35

36 Publications and Document Management TTCI/AAR, 2009, <Directory Number> p36

37 Publications and Document Management TTCI/AAR, 2009, <Directory Number> p37

38 Publications and Document Management TTCI/AAR, 2009, <Directory Number> p38

39 Publications and Document Management www. Future to be determined TTCI/AAR, 2009, <Directory Number> p39

40 Today s Discussion AAR Technical Committee and Field Personnel Updates Equipment Engineering Wheels, Axles, Bearings, and Lubrication Coupling System and Truck Castings Brake Systems Risk Assessment for Technical Standards, MID, and BOE Example Standards Actions Testing/Analysis to Support Industry Issues and Specification Needs AAR / TTCI Publications Access Tools, Upgrades and Plans Mechanical Inspection Department TTCI/AAR, 2009, <Directory Number> p40

41 Railway Supply Institute September 16-18, 2009 MECHANICAL INSPECTION DEPARTMENT Presented by: A. E. Ciccarelli, Director Mechanical Inspections <Directory Number> - 41 Transportation Technology Center, Inc., a subsidiary of the Association of American Railroads, 2009

42 Assist the Rail Industry in providing safe transportation through Quality Assurance, Technical Inspections and Training, to ensure customers meet industry specifications, Codes of Federal Regulations (CFR) and AAR Interchange Requirements TTCI/AAR, 2009, <Directory Number> p42

43 Prior to 1934 the American Railway Association added a new Rule 124 to provide a system of checking by the Mechanical Inspection Department, and authority for refund of proper charges detected by such checks. On October 12, 1934 the AAR was established by combining the ARA and several groups that had been formed to represent other railroads. TTCI/AAR, 2009, <Directory Number> p43

44 This unification established an organization that could speak for the entire industry. Rule 124 (now Rule120), and the Mechanical Inspection Department,was continued in the Interchange Rules when the AAR was formed. TTCI/AAR, 2009, <Directory Number> p44

45 Routine Technical Inspections Certification/Recertification Inspections AAR Office Manual Rule 88 Inspections AAR M-1003 Quality Assurance Audits Mechanical Training Component Test Observation TTCI/AAR, 2009, <Directory Number> p45

46 Compliance to AAR Interchange Rules and applicable Governmental Regulations Safe and efficient interchange of equipment Industry self-regulation The support of a seasoned technical inspection/auditing team, with a 75 + year tradition of serving the Rail Industry s needs TTCI/AAR, 2009, <Directory Number> p46

47 Chief, Technical Standards and Inspections Director Mechanical Inspection Chief Inspector MID Field Inspectors - Mechanical Chief Inspector - BOE Field Inspectors - BOE TTCI/AAR, 2009, <Directory Number> p47

48 RAC Inspectors Canada Bureau of Explosives G. Smith A. Maty Vacant L. Kerting A. Ciccarelli D. Casey C. Hall PDraper P. Scott Moore RG Ashton TTCI/AAR, 2009, <Directory Number> p48

49 R. Shaw Canada Mechanical Inspection Department D Sullivan Cumulative Industry Experience = 352 years M. Lodge D. Healy Inspector average service years = 32 R. Turner A. Ciccarelli D. Walters J. Marsh G. Mills S. Berkshire B. Benton K. Stout F. Althoff Jorge Molina Mexico TTCI/AAR, 2009, <Directory Number> p49

50 Major Moderate Minor Train Yard Repair Track / Repair Facilities ,556 TOTALS ,621 TTCI/AAR, 2009, <Directory Number> p50

51 Publications Required Gages Outbound Inspection S.C.T.D. / B.C.P.D. / 28 mm Test coupling over-date Material Storage - 82 TTCI/AAR, 2009, <Directory Number> p51

52 Major Moderate Minor TTCI/AAR, 2009, <Directory Number> p52

53 MID Codes and Inspection Activity Totals MD CODE EXPLANATION & TOTALS Jan. 1 - Dec. 31, 2009 TYPE Description Railroad Private Non Member Totals MD01 Repair Track Inspection MD02 Air Brake Shop Inspection MD03 Wheel Shop Inspection MD04 Roller Bearing Maintenance MD05 Axle Plating Inspection MD06 M-970 Inspection MD07 Roller Bearing Mounting Cert MD08 M-970 Certification MD09 Roller Bearing End Cap R/A MD10 Roller Bearing Mounting Insp MD11-13 Quality Assurance Audits MD14 Rule 88 / Structural Insp MD15-21 Misc. Certification / Inspections MD22 Open Top Loading Insp MD25 Follow-Up Inspection MD26 Special Inspection MD28 MID Training Provided MD41 TOFC / COFC Inspections MD46 Freight Car Builder Insp MD00-06 Component Certification Testing Days MD32 Annual Tank Car Certifications SUBTOTAL MD45 Technical Committee Support - Days MD28.B.2 Training Received - Days MD42 MID Management Support - Days TOTALS TTCI/AAR, 2009, <Directory Number> p53

54 Inspectors document activity from working papers and forward report's to the office of the Director Mechanical Inspections within 7 days of the particular inspection activity Reports are reviewed within fifteen days of receipt from field The Director Mechanical Inspection and/or the Executive Director, Rules and Standards review and process field inspection reports TTCI/AAR, 2009, <Directory Number> p54

55 Requests for copies of reports should be addressed to: Director Mechanical Inspection Transportation Technology Center, Inc DOT Road Pueblo, Colorado or via using the address - mid@aar.com Policy prohibits field inspectors from distributing report copies TTCI/AAR, 2009, <Directory Number> p55

56 TTCI/AAR, 2009, <Directory Number> p56

57 How can I comply and prepare for MID Routine Freight Car Maintenance Inspection and/or other required AAR Inspections? TTCI/AAR, 2009, <Directory Number> p57

58 TTCI/AAR, 2009, <Directory Number> p58

59 How to Obtain a Checklist & Information Ask your MID Inspector Go to TTCI/AAR, 2009, <Directory Number> p59

60 MID Web page Cont. Get Technical Standards Drop Down Box Select Mechanical Inspection Dept. TTCI/AAR, 2009, <Directory Number> p60

61 MID Web page Cont. Select Technical Checklist TTCI/AAR, 2009, <Directory Number> p61

62 A. Outbound Inspection B. Inbound Inspection C. Train Yard D. Scrap Inspection E. Repair Practices - (1) Air Brake (2) Coupler/Draft Gear (3) Running Gear (4) Car Body (5) Truck Side Frames/Bolsters (6) Gages & Publications F. AAR Billing and Forms G. Material ID/Packaging & Storage TTCI/AAR, 2009, <Directory Number> p62

63 Review of 2008 Top Five Exceptions TTCI/AAR, 2009, <Directory Number> p63

64 Outbound Outbound Inspection Inspection Car meets or exceeds Federal Railroad Administration Safety Regulations Original Record of Repair is reviewed/verified AAR maintenance requirements regarding repair to cars while on the repair track have been satisfied TTCI/AAR, 2009, <Directory Number> p64

65 Repair Practices Air Brake Proficiency observed during performance of: Daily Test of the Single Car Air Brake Test Device Single Car Air Brake Test TTCI/AAR, 2009, <Directory Number> p65

66 Repair Practices Air Brake Last ABT date verified for cars on Repair Track Single Car Test Device, Brake Cylinder Pressure Gauge &.28 mm Test Coupling on hand and indate TTCI/AAR, 2009, <Directory Number> p66

67 Repair Practices Coupler/Draft Gear Use of coupler gages observed TTCI/AAR, 2009, <Directory Number> p67

68 Repair Practices Running Gear Wheel sets removed from repaired car inspected for condemning defect TTCI/AAR, 2009, <Directory Number> p68

69 Required Gages on hand (20) Required Publications on hand and current issue / revision (16) Visit for a listing of Rule 1 required publications, including current issue/revision e s date TTCI/AAR, 2009, <Directory Number> p69

70 Select Field Manual Tab TTCI/AAR, 2009, <Directory Number> p70

71 TTCI/AAR, 2009, <Directory Number> p71

72 Control & auxiliary brake valves properly stored Truck and body mounted piston assemblies properly stored TTCI/AAR, 2009, <Directory Number> p72

73 Rubber Gaskets in-date and properly stored TTCI/AAR, 2009, <Directory Number> p73

74 Minimum 1 letter H on CP-HT wheels applied/maintained i i d Wheel sets properly stored TTCI/AAR, 2009, <Directory Number> p74

75 All items of repair covered in proper detail on Oi Original i lrecord of Repair Original Record of Repairs retained as required (Electronic) TTCI/AAR, 2009, <Directory Number> p75

76 TTCI/AAR, 2009, <Directory Number> p76

77 TTCI/AAR, 2009, <Directory Number> p77