Presentation on theme: "Wayside Detection The Detroit Edison Experience"— Presentation transcript:
1 Wayside Detection The Detroit Edison Experience Dennis J. BudaDetroit EdisonRailroad Engineering ProgramUniversity of IllinoisUrbana-Champaign, ILLDecember 2006
2 Discussion Topics The Detroit Edison Strategy WILD Issues Financial IssuesConclusions and Recommendations
3 Introduction 36” Wheels Heavy Haul High Mileage Service Comparison of DTE and AAR CRB Data2002 and 2003 Data - CRB LimitationsDTE - Michigan Publicly Traded Utility2.1 Million Customers - $17.0 Billion Assets7,000 Aluminum Rotary RailcarsAverage Car Mileage 100,000/YearFuel Source from PRB and Appalachian Mines
4 Wheel Failures and WM Codes WM 66, Flange Cracked or BrokenWM 68, Cracked RimWM 71, Shattered RimWM 72, Spread RimWM 83, Cracked PlateWM 75, Shelling, Spalling, Thermal-MechanicalWM 65 and 67, Out of Round (WILD or Gage)WM 76, Built-Up TreadWM 78, Slid Flat
5 Recent AAR Rule Changes WM 65 Wheel Impact Load Detector Removal at Impact Greater Than 90 Kips97% of the Benefit Falls to Class I RR’sRim Thickness Credit – RemovedWindow of Opportunity - Stress State
6 DTE vs. CRB Comparison Why Made Codes 66, 72, 74, 83 DTE = 0, AAR CRB = 4,197 totalDTE = 0, AAR CRB = 4,841 totalDTE = 1 shattered rim in 2002, 0 in 2003AAR CRB = 174 in 2002, 143 in 2003Chi-square was then used to determine if there is a statistically significant difference for various Why Made Codes…..
7 Chi-square Comparisons There is a statistically significant difference in wheel removal performance for DTE vs. AAR CRB - DTE has fewer than expected removals for the following Why Made Codes:65, 67, 75, 76, 78,This is true despite heavy haul, high mileage coal train operations….
8 The Detroit Edison Strategy The TheoryThe WILD Program50+ Kip Maintenance Strategy
9 The TheoryThe private car owner can effectively manage the life and performance of heavy haul-high mileage wheel sets, by developing a proactive maintenance strategy based upon way-side detection methodologies in combination with Class I Railroads, private railcar maintenance providers, and railway suppliers.
10 The WILD Program Data Purchased from TTCI By Train By Railcar By Wheel LocationBy GraphProactive Maintenance Strategy
24 Targeted Considerations Rail Maintenance Management ForumContinue Investigative Wheel Failure AnalysisEquipment Health Monitoring TAGComponent Performance Within AAR RulingsRailcar Capacity and Loading CriteriaBreak Even Point: Railroad vs. Private ShopWILD Site and Software PerformanceThe PUR Owner Requires a Rule Making Vote
25 DTE Wheel Removals With Brake System Repairs DTE wheel changes that also had a brake system repair within previous yearData for 1/03 to 7/04, Job Codes Analyzed21,035 wheel changes - 1,738 also w/brake repairAir hose (1,182)Emergency portion (380)Service portion (125)Hand brake related (51)
26 Wheel Removals With Brake System Repairs By Why Made Code (Data 1/03-7/04)
27 Wheel Removals With Brake System Repairs By Why Made Code - 75, 65, 78, 67 (1/03-7/04)
28 2003 Removals with Brake Repairs Chi-Square Analysis DTE 21,035 removals - 1,185 also with air brake system repair within previous yearWM ,156 removals w/brake repairWM removals w/brake repairWM removals - 30 w/brake repairCompared WM 65, 75, 78 with brake repairs to all 2003 DTE removals with brake repairs - statistically significant difference - “Worse”
29 WILD Issues WILD Calibration: Frequency & Uniformity Effects of Train SpeedEffects of Track Structure & Sub-gradeEffects of Concrete TiesWILD Reading VariationEtc.
30 Conclusions DTE Wheel Removals Wayside Detectors are Useful Tools Better vs. AAR CRB for WM 65, 67, 75, 76, 78Also Better Failure Performance Than AAR CRBWayside Detectors are Useful ToolsVariation is a ConcernDTE 50+ Kip Strategy Lengthens Wheel LifeBrake System Repairs Linked to Wheel LifeWM 65, 67, 75 Appear to be Affected
50 Financial Impact WM 65, 67 and WM 75 Wheel Changes 2002, 2003 and 2004 ,279 Total - 1,769,179 Total - 2,179,013 Total - 2,005AAR Labor Rates per wheel switch $1,000.00Total Cost $1,769,000Total Cost $2,179,000Total Cost $2,005,000
51 Financial Impact Train days lost equals number of wheels pulled. One train cycle equals seven days (52 cycles per train per yearTotal number of cycles lost(5 sets)2003 – 311 (6 sets)2004 – 286 (5.5 sets)At current lease rates ($500 pcpm), cost to Detroit Edison is approximately $3,600,000.00
52 Summary The 50+ Kip Strategy Extends Wheel Life. WM65 Exhibits Shortest Life Span.What’s the contribution of variation by the measuring system? - What are the variation contributions from the Repeatability & Reproducibility tests of the measuring devices?
53 Recommendations Root Cause of Wheel Defects WM 65 & WM 75 Computerized SCAT at All Repair TracksRail Maintenance Management ForumWILD Calibration Should be Standardized and Meet AAR M-1003 Quality SystemImproved Efforts to Share Costs and Benefits Within the Railroad IndustryPrivate Railcar Owner - Voting AAR Member
54 The Final ThoughtOur greatest challenge as an industry is to get the departments responsible for the vehicle performance and the track maintenance to work together and define a wheel rail interaction strategy to obtain synergy between the vehicles, track and the long term profitability of the heavy haul operation.Source: International Heavy Haul Association (2001)