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2005 AAR CAR REPAIR BILLING WHEEL REMOVAL ANALYSIS Richard - - PowerPoint PPT Presentation
2005 AAR CAR REPAIR BILLING WHEEL REMOVAL ANALYSIS Richard - - PowerPoint PPT Presentation
2005 AAR CAR REPAIR BILLING WHEEL REMOVAL ANALYSIS Richard Sullivan Cameron Lonsdale Shannon Berge RWMEC Who we are Approved AAR Wheel Manufacturers Mission - Support the WABL Committee and the Railroad Industry 7 Year Trend for Wheel
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7 Year Trend for Wheel Removals
500000 600000 700000 800000 100000 200000 300000 400000 500000 1999 2000 2001 2002 2003 2004 2005
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Reasons for Increase
- A. Increase in Traffic
- B. Change in Rules for Condemning Axles
- C. Increase in Usage of Why Made Code 65
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2004 Effect of High Impact Usage
70000 80000 90000 100000
Out of Round
10000 20000 30000 40000 50000 60000 1999 2000 2001 2002 2003 2004
Thermal Cracks Tread Shell Slit Flat High Impact
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2005 Effect of High Impact Usage
80000 100000 120000 Out of Round Thermal Cracks 20000 40000 60000 1999 2000 2001 2002 2003 2004 2005 Thermal Cracks Tread Shell Slit Flat High Impact
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7 Year Trend for Thin Flange and High Flange
40000 50000 60000 70000 10000 20000 30000 40000
1999 2000 2001 2002 2003 2004 2005
60 Thin Flange 64 High Flange
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WHEEL REMOVAL CATEGORIES
Categories
Administrative
50000 100000 150000 20000 25000 30000 35000 40000 45000
Wheel Failure Environment Wear Related Administrative
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Administrative
Administrative Wheels
07 Obsolete
100000 200000 300000 400000
90 Mate Wheel 25 Owner's Req. 23 Govt. Reg. 11 Good Condition
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Unusual Trends
Why Made Code 11 Removals have increased 175,000 during the past three years.
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7 Year Trend – Administrative Wheels
Administrative Wheels
450,000 200,000 250,000 300,000 350,000 400,000 450,000
1999 2000 2001 2002 2003 2004 2005
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Wear Related
Wear Related Wheels
60=Thin Flange
20000 40000 60000 80000
98=Reapplication 73=Thin Rim 64=High Flange
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7 Year Trend – Wear Related Wheels
Wear Related Wheels
60,000 80,000 100,000 120,000
1999 2000 2001 2002 2003 2004 2005
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Environmental
Environmental Wheels
67=Out-of-Round 65 High Impact 20000 40000 60000 80000 100000 120000 78=Tread Slid Flat 76=Tread Build-Up 75=Tread Shelled 74=Thermal Cracks
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7 Year Trend- Environmental Wheels
Environmental Wheels
200,000 50,000 100,000 150,000 1999 2000 2001 2002 2003 2004 2005
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Spalling Spalling
Spalling starts when a thin localized layer of tread metal is transformed to martensite. The martensite, being very hard and brittle, forms cracks that propagate into the non- cracks that propagate into the non- transformed material. These cracks turn and grow in fatigue roughly parallel to the tread. When these cracks link together material vacates the tread leaving a pitted surface.
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Failed Wheels
Failed Wheels
66=Flange Cracked 100 200 300 400 72=Rim Spread 71=Rim Shattered 68=Rim Cracked
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7 Year Trend – Failed Wheels
Failed Wheels
1,200 600 700 800 900 1,000 1,100
1999 2000 2001 2002 2003 2004 2005
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26-Year Trend Shell/Spall Wheels
Tread Shelled (Spalled) Wheels
80000 100000 20000 40000 60000 80000 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004
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Distribution of Failed Wheels by Year
Failed Wheel Distribution
80 100 20 40 60 80 1 9 6 1 1 9 7 1 9 7 4 1 9 7 8 1 9 8 2 1 9 8 6 1 9 9 1 9 9 4 1 9 9 8 2 2
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Wheel Removals by Year Manufactured
Year Built Distribution
80000 20000 40000 60000 1959 1965 1971 1977 1983 1989 1995 2001
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Average Wheel Life/Category
Administrative 9.8 Years Wear Related 11.0 Years Environmental 8.8 Years Wheel Failure 12.2 Years
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Average Wheel Life/Car Type
Type of Car Wheel Life, Years Box 12.5 Gondola 8.5 Hopper 9.5 Hopper 9.5 Covered Hopper 12.6 Tank 12.5 Flat 7.8 Articulated 4.5
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Wheel Removals by Year Manufactured
Year Built Distribution
80000 20000 40000 60000 1959 1965 1971 1977 1983 1989 1995 2001
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Distribution of Wheel Types
Wheel Type HT-CP NHT-CP HT-SP NHT-SP AAR Raw 91.7% 5.7% .7% 1.8% AAR Accel. 92.1% 6.2%
- 0. 6%
1.1%
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Distribution of SP Wheels
SP Wheel By Car Type
Co vered Ho pper Cars Tank Cars
1000 2000 3000 4000 5000 6000
Bo x Cars Flat Cars Go ndo las Ho pper Cars Co vered Ho pper Cars
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RWMEC Recommendations
Already Implemented
Accelerate removal of straight plate wheels Proposal to accelerate earlier removal of Non- Heat Treated Curve Plate Wheels Heat Treated Curve Plate Wheels Improving their wheel marking procedures
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RWMEC Recommendations
Improve air brake testing methods. Train employees about the proper use of hand brakes.
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Comparisons
Removals for high impact are more common for 36-inch and 38-inch wheels. 36-inch wheels have a higher percentage of wheels removed for slid flat, thin flange, built- wheels removed for slid flat, thin flange, built- up-tread and out-of-round.
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Comparisons
Articulated cars have many unique characteristics. The wheels wear out faster. They have the most wheels removed for High Flange.
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Comparisons
Covered Hopper Cars have the most wheels for all causes. Tank cars and covered hopper cars have the most wheel removals for Why Made Code 78, most wheel removals for Why Made Code 78, Slid Flat.
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Comparisons
The primary reasons for wheel removals from flat cars: Why Made 64, High Flange Why Made 65, High Impact Why Made 65, High Impact Why Made 75, Tread shelled
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Comparisons
Tank cars have the second highest wheel removals for Why Made 74, Thermal Cracks.
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Comparisons
Gondolas, Hoppers and Box Cars have a similar
- pattern. The most frequent causes for removal for
these car types are: Why Made 65, High Impact Why Made 65, High Impact Why Made 64, High Flange Why Made 60, Thin Flange
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Thanks
RWMEC thanks the AAR for providing 2005 wheel repair data for this analysis and report. RWMEC thanks the Railway Supply Institute and MARTS for the opportunity to present this and MARTS for the opportunity to present this information at the 2006 RSI conference.
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