RAIL SAFETY INVESTIGATION REPORT WHEEL DEFECT ON FREIGHT SERVICE T401G GRETA, NSW 1 APRIL 2019
RAIL SAFETY INVESTIGATION REPORT
WHEEL DEFECT ON FREIGHT SERVICE T401G GRETA, NSW 1 APRIL 2019
Released under the provisions of Section 45C (2) of the Transport Administration Act 1988 and
Section 137 of the Passenger Transport Act 2014
Investigation Reference 04814
Cover photo: Wheel defect - Source: Comsteel
Published by: The Office of Transport Safety Investigations
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Office location: Level 17, 201 Elizabeth Street, Sydney NSW 2000
Telephone: 02 9322 9200
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E-mail: [email protected]
Internet: www.otsi.nsw.gov.au
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THE OFFICE OF TRANSPORT SAFETY INVESTIGATIONS
The Office of Transport Safety Investigations (OTSI) is an independent NSW agency whose
purpose is to improve transport safety through the investigation of incidents and accidents in
the rail, bus and ferry industries. OTSI investigations are independent of regulatory,
operator or other external entities.
Established on 1 January 2004 by the Transport Administration Act 1988 (NSW), and
confirmed by amending legislation as an independent statutory office on 1 July 2005, OTSI
is responsible for determining the contributing factors of accidents and to make
recommendations for the implementation of remedial safety action to prevent
recurrence. Importantly, however, OTSI does not confine itself to the consideration of just
those matters that contributed to a particular accident; it also seeks to identify any transport
safety matters which, if left unaddressed, might contribute to other accidents.
OTSI’s investigations are conducted under powers conferred by the Transport Administration
Act 1988, Passenger Transport Act 1990 and Passenger Transport Act 2014. Additionally,
all OTSI publications that are considered investigation reports are also conferred by this Act.
OTSI investigators normally seek to obtain information cooperatively when conducting an
accident investigation. However, where it is necessary to do so, OTSI investigators may
exercise statutory powers to interview persons, enter premises, examine, and retain physical
and documentary evidence.
It is not within OTSI’s jurisdiction, nor an object of its investigations, to apportion blame or
determine liability. At all times, OTSI’s investigation reports strive to reflect our balanced
approach to the investigation, that properly explains what happened, and why, in a fair and
unbiased manner.
Once OTSI has completed an investigation, its report is provided to the NSW Minister for
Transport and Roads for tabling in Parliament. The Minister is required to table the report in
both Houses of the NSW Parliament within seven days of receiving it. Following tabling, the
report is published on OTSI’s website at www.otsi.nsw.gov.au.
.
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CONTENTS
TABLE OF FIGURES ii
EXECUTIVE SUMMARY iii
PART 1 FACTUAL INFORMATION 1
The occurrence 1 Wheel information 3
Related incidents 4
Remedial actions 5
PART 2 ANALYSIS 7
Wheel examination 7
Wheel maintenance 14
Wheel impact load detection 15
PART 3 FINDINGS 17
Contributing Factors 17
Other Findings 17
PART 4 RECOMMENDATIONS 18
PART 6 APPENDICES 19
Appendix 1: Sources, Submissions and Acknowledgements 19
Appendix 2: Wheel information 21
Appendix 3: ONRSR Safety Bulletin 22
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TABLE OF FIGURES
Figure 1: Location of incident 1
Figure 2: Wagon schematic with identification of wheel positions 2
Figure 3: Cracking in wheel tread 2
Figure 4: Manufacturing records for wheel 3
Figure 5: Thermal cracks identified on wheel at Pangela NSW (2015) 5
Figure 6: Field side ridge and tread cracks on Greta wheel 7
Figure 7: Outboard side ridge and tread cracks on Greta wheel 8
Figure 8: Magnetic particle inspection on Greta wheel 9
Figure 9: Ultrasonic test markings on Greta wheel showing discontinuity depth (mm) 10
Figure 10: Chemical composition of Greta wheel 11
Figure 11: Mircostructure at initiation point exhibiting a typical pearlitic microstructure with fine grain boundary ferrite 11
Figure 12: Cross section at the initiation point. No indication of non-metallic inclusions on the crack surface. Magnification X100 12
Figure 13: Brinell markings on Greta wheel 13
Figure 14: Micro hardness reading on Greta wheel 14
Figure 15: Wheel data at re-profiling intervals and incident date on Greta wheel 14
Figure 16: Wayside monitoring equipment in the Hunter Region, NSW 16
Figure 17: Standard terminology for wheels 21
Figure 18: Measuring the rim thickness 21
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EXECUTIVE SUMMARY
On 1 April 2019, as Pacific National freight service T401G entered the Greta Train
Service Facility, a cracked wheel was detected by an operations supervisor. The
cracked wheel was on the 34th wagon in the consist and the crack was evident on
both sides of the wheel. The bogie was removed from the wagon and the wheel later
sent for metallurgical examination. There was no injury or damage as a result of the
cracked wheel.
A metallurgical analysis found that the cracking in the wheel had likely propagated
from subsurface rolling contact fatigue. The rim cracking had multiple fatigue
initiation sites located at different depths from the wheel tread. Seven fatigue crack
initiation sites were detected. The wheel was manufactured in 2006 and had
travelled approximately 1,170,000 km up until the time of the incident.
The investigation found that maintenance processes were ineffective in allowing this
wheel to return to service with an identified defect after undergoing wheel shop
maintenance in 2016.
A number of recommendations to Pacific National were made, including:
Evaluate the existing processes for communication between Pacific National
and maintenance contractors to ensure that the reasons for wheelset
removal are accurately conveyed.
Review the non-destructive testing requirements for wheels in the Pacific
National Wagon Maintenance Manual and ensure the requirements are clear
to maintenance contractors.
Conduct regular audits on wheelset maintenance practices, including non-
destructive testing processes, to ensure compliance with Pacific National
specifications.
Full details of the Findings and Recommendations of this investigation are contained
in Parts 3 and 4 respectively.
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PART 1 FACTUAL INFORMATION
The occurrence
1.1 At 13301 on 1 April 2019, Pacific National freight service T401G entered the
Greta Train Service Facility (see Figure 1) as part of its regular 28-day
examination. The train was crewed by a driver and a second person. An
operations supervisor, who was walking next to the moving train, noticed a
noise coming from one of the wheels.
Source: Geoscience Australia, annotated by OTSI
Figure 1: Location of incident
1.2 An inspection of the train T401G identified a cracked wheel on the 34th
wagon (NHRH50260T).2 The cracked wheel was from wheelset 1G6S9862 in
the L4 position (see Figure 2). The incident was reported to Office of National
Rail Safety Regulator (ONRSR) on 3 April 2019.
1 Times in this report are in 24-hour clock form in Australian Eastern Standard Time. 2 The wheel type was RLN4.5-212, Heat number: C37043, Grade: AAR M107 Class BM, Batch: WDZ, Serial No. 06021468, Dispatch Date: 24 October 2006.
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Source: OTSI
Figure 2: Wagon schematic with identification of wheel positions
1.3 The rear bogie was removed from the wagon and the bogie was examined by
Pacific National’s engineering maintenance personnel before the L4 wheelset
was removed and prepared for a metallurgical examination. The initial
examination by Pacific National found a crack in the rim extending from a
crack on the tread (see Figure 3). The brake shoe was not overhanging the
wheel tread face. Brake shoe overhang had previously been identified by
Pacific National as a contributory factor to wheel rim defects.
Source: Pacific National, annotated by OTSI
Figure 3: Cracking in wheel tread
1.4 Comsteel were the manufacturer of the wheel and considered the most
appropriate organisation to conduct the metallurgical examination. The scope
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for metallurgical examination of the cracked wheel was prepared by Pacific
National for Comsteel and included the following requirements:
Visual examination,
Tread profile measurements at four locations around the tread,
Magnetic Particle inspection, and
Ultrasonic inspection.
1.5 The wheel was sent to Comsteel in Waratah, NSW for metallurgical
examination.
Wheel information
1.6 The wheel was originally supplied in April 2007 to United Group Rail Maintrain
to the specification AAR M - 107 B MOD (Microalloy B Material). Since the
time the wheel entered service until the incident on 1 April 2019, this wheel
had travelled approximately 1,170,000 km. See Figure 4 for wheel
manufacturing details.
Category Details
Manufacturer Comsteel
Type: RLN4.5-212
Heat No.: C37043
Grade: AAR M107 Class BM
Batch: WDZ
Serial No.: 06021468
Despatch date: 24 October 2006
Source: Pacific National
Figure 4: Manufacturing records for wheel
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Related incidents
1.7 ONRSR Safety Bulletin. There were two identified Pacific National wheel
incidents in 31 May 2013 and 25 August 2013 and, as a result, ONRSR
published a Safety Bulletin in June 2014. It was titled: An emerging issue:
‘shattered rim’ wheel defects, and is included at Appendix 3.
1.8 The bulletin stated that ‘the failure mechanism is usually the result of rolling
contact fatigue initiating from a subsurface tread defect or inclusion’. The
safety bulletin reminded operators to question current maintenance and
wagon inspections and enhance wagon maintenance for those wheelsets
which are approaching the condemning diameter.
1.9 Failed wheel and derailment, Pangela, NSW, 2015. In 2015, a loaded
Pacific National coal train MB520 derailed at Pangela. The ATSB investigation
determined that the derailment was the result of a fractured wheel on the
leading right hand wheel on the 19th wagon. 3 This led to the wheel moving off
the wheel seat towards the centre of the axle. The train continued travelling
until a damaged inter car brake cable activated an automatic application of the
train’s brakes. There were no injuries, but the derailment caused damage to
over 590 m of track including 963 sleepers.
1.10 The Pangela investigation found that the wheel inspection processes were not
effective in detecting surface damage or cracks. The failed wheel was
approaching the end of its service life with a rim thickness of 25 mm (see
Appendix 2 for an explanation of how rim thickness is measured). This low rim
thickness increases propensity for thermal distortion and is likely a significant
factor into the thermal crack formation and propagation that occurred.
1.11 A metallurgical analysis conducted after the Pangela derailment found that the
wheel had multiple cracks in the wheel rim. Thermal cracks of this type are
generally associated with high thermal input under service brake conditions.
In Figure 5: Image 1 shows the location of the thermal cracks in relation to the
fracture. Image 2 identifies thermal cracks located on the front face of the
wheel tread.
3 ATSB Rail occurrence investigation report RO-2015-015 Derailment of freight train MB520 – published 20
June 2016.
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Source: Comsteel, annotated by OTSI
Figure 5: Thermal cracks identified on wheel at Pangela NSW (2015)
1.12 Low rim thickness was a contributory factor in six earlier Pacific National
wheel cracks incidents between 2013 and 2016. The rim section thicknesses
ranged between 22 – 26 mm. Following the derailment at Pangela, Pacific
National implemented a program to remove wheels with a rim thickness under
25 mm. The rim thickness of the cracked wheel at Greta was 32 mm, within
Pacific National’s stated acceptable range.
Remedial actions
1.13 Pacific National have notified OTSI that they have undertaken the following
remedial actions:
a. A revised process for communication between Pacific National and
maintenance contractors has been put in place. Identified personnel
have been trained in the revised processes to ensure the reasons for
wheelset removal is understood.
b. A review of the Wagon Maintenance Manual (WMM 09-05) was
undertaken. It was amended to include shelling and spalling defects.
This required that the rim edge be marked and tested with magnetic
particle inspection after turning, to ensure complete removal of defects.
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c. Assurance / surveillance activities are now conducted bi-annually. The
previously specified time period was 12 months. Sites are audited
against Pacific National wheelset overhaul standards.
d. Non-conformance items identified in audits are managed internally in
the Pacific National Safety Management System. Actions are
monitored for effective closure.
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PART 2 ANALYSIS
Wheel examination
2.1 Comsteel prepared the failed wheel for assessment and completed a
metallurgical report for Pacific National in December 2019.4 The metallurgical
information in this section is based on the Comsteel report.
2.2 The wheel was intact when it was received by Comsteel where it was
subjected initially to a visual examination. The visual inspection found that
significant wear had occurred on the wheel tread. There was a field side ridge
on the tread approximately 40 mm from the front rim face (see Figure 6).
There was no sign of flange wear.
Source: Comsteel, annotated by OTS
Figure 6: Field side ridge and tread cracks on Greta wheel
Two wheel profiles of the cracked wheel were taken using a rim profiling
device. A profile of the wheel was taken in the area of the tread defect and
then again 180° on the opposite side of the wheel. The recorded profile of the
wheel was compared against the original wheel profile template. This showed
4 Comsteel Customer Quality Report No. 2388957, Examination of cracked rim RLN4.5-212 Wheel Pacific
National Wagon NHRH50260, prepared December 2019.
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any deviations from the original profile. The rim profile in Figure 7 shows two
wear zones either side of a field side ridge at about 40 mm from the rim face.
This profile was taken from the area at the tread defect. Both wheel profiles
taken at 0° and 180° exhibited defined wear zones on either side of the field
side ridge, indicating the worn wear profile was likely present before the wheel
failed.
Source: Comsteel, annotated by OTSI
Figure 7: Outboard side ridge and tread cracks on Greta wheel
2.3 Previous profiles supplied by Pacific National, taken four months before the
incident, showed no evidence of wear.
2.4 The worn wheel profiles indicate that this wheel had been tracking centrally
about the tread line. This is an area where the highest concentration of
wheel/rail contact stress cycles and is a likely location for subsurface rolling
contact fatigue cracking to occur. The other wear zone towards the front face
may have been the result of plastic deformation of the metal caused by forces
in other areas acting on the tread face.
2.5 The wheel was cleaned with a 5% nital solution (nitric acid and alcohol) and
inspected. This solution is used to reveal the microstructure of carbon steel
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during microscopic assessment. There was no white etch layer detected.5
White etch layers have been observed on rail running bands for more than
half a century. They are brittle and are known to act as crack initiators. They
are about three times harder than the traditional rail steel used.
2.6 A mechanical saw cut was made in the wheel and the residual stress in the
rim of the wheel was determined in accordance with BS5892 Part 3. There
was a measured contraction of 2.9 mm. This level of compression indicated
that there was no excessive heating of the wheel rim during service
operations. Excessive heating of the wheel rim is a potential contributing
factor to this type of failure, but based on the result of the test described, it
was discounted as a contributory factor.
2.7 A magnetic particle inspection was conducted on the surface of the wheel.
This indicated the presence of subsurface damage from rolling contact fatigue
in the flange float area and thermo-mechanical cracks across the tread in the
area between the two visible cracks. There were cracks detected in the rim
face and rim back extending approximately 110 mm from the rim into the plate
(see Figure 8).
Source: Comsteel, annotated by OTSI
Figure 8: Magnetic particle inspection on Greta wheel
5 Wear (2016) Influence of the initial surface state of bodies in contact on the formation of white etching layers under dry sliding conditions.
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2.8 Ultrasonic testing was conducted on the wheel tread and the rim back face.
There were no other defects detected other than the visible cracks and there
were no other non-complying indications detected in the wheel. The ultrasonic
tests showed the maximum depth of the discontinuity in the area below the
visible crack on the front rim face was approximately 16 mm (see Figure 9).
Other than the crack area, the wheel complied with the requirements of
AAR M107 for carbon steel wheels.6
Source: Comsteel
Figure 9: Ultrasonic test markings on Greta wheel showing discontinuity depth (mm)
2.9 Atomic emission spectroscopy was used to determine the chemical
composition of the wheel. Analysis showed the wheel complied with AAR
requirements.7 The composition of the wheel is shown in Figure 10.
6 Association of American Railroads M-107. 7 Association of American Railroads, AAR Manual of Standards and Recommended Practices Wheels
and Axles Wheels, Carbon Steel Specification M-107/M-208, Pueblo, CO: Transportation. Technology Center, 2011.
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C Si Mn P S Ni Cr Mo Cu V
0.62 0.87 0.74 0.009 0.014 0.12 0.11 0.032 0.25 0.083
Source: Comsteel
Figure 10: Chemical composition of Greta wheel
2.10 Assessment of the microstructure showed typical pearlitic structure with fine
grain ferrite at the boundaries (see Figure 11). There was no indication of
microstructural abnormalities and there were no large or abnormal non-
metallic inclusions found in the vicinity of the crack initiation site (see Figure
12).
Source: Comsteel
Figure 11: Mircostructure at initiation point exhibiting a typical pearlitic microstructure with fine grain boundary ferrite
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Source: Comsteel
Figure 12: Cross section at the initiation point. No indication of non-metallic inclusions on the crack surface. Magnification X100
2.11 A rim cross section was removed next to the rim crack. A Brinell hardness test
was conducted in locations 9 mm away from the surface (see Figure 13). The
determined hardness values complied with the specified hardness range of
302 - 363 HBW (Brinell Hardness Scale) for class BM wheels.
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Source: Comsteel
Figure 13: Brinell markings on Greta wheel
2.12 Micro hardness readings were taken on the wheel tread on the tread line and
27 mm from the front rim face (see Figure 14). There were higher hardness
readings on the tread line, which suggested work hardening had occurred
during service.
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Source: Comsteel
Figure 14: Micro hardness reading on Greta wheel
Wheel maintenance
2.13 The wheel was re-profiled approximately every 3 years and 280,000 km. The
previous three wheel re-profiles were in July 2010, August 2013 and March
2016. Measurements were also taken following the incident in April 2019.
Information about the wheel at each of these stages is shown in Figure 15.
Date Distance
travelled
Incoming
rim
thickness
Outgoing
rim
thickness
Outgoing
wheel
diameter
Incoming
defects
Jul 2010 Not available 55 mm 49 mm 908 mm Nil
Aug 2013 Not available 45 mm 42 mm 890 mm Thermals
Mar 2016 266,300 km 38 mm 34 mm 876 mm Spalls
Apr 2019 308,061 km 32 mm na 870 mm Cracked
Figure 15: Wheel data at re-profiling intervals and incident date on Greta wheel
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2.14 The specified range for the original machined wheel diameter is 920 mm to
926 mm. The condemning diameter for this wheel is 850 mm. At the time of
the incident, the wheel diameter was 870 mm and within the acceptable
dimensional range.
2.15 Pacific National examined, and provided to OTSI, the maintenance records for
this wheelset (1G6S9862). A key record provided was Pacific National Work
Order Number 1271225. The work order, dated 23 February 2016, identified
the reason the wheel was removed from service with a code ’69 – thermal
cracks extending into the plate’ allocated for axle 4. However, the
maintenance contractor, on their maintenance service records, applied the
label ‘spalling’ to Incoming Wheel Defects Category.
2.16 As a result of the different label, the wheel was not subject to non-destructive
testing before it returned to service. A non-destructive test was only required if
a thermal code was applied to the wheel defect. It should be noted, the
metallurgical report into the wheel defect found that a subsurface defect, not a
thermal crack, initiated the wheel crack found at Greta on 1 April 2019.
Wheel impact load detection
2.17 Wheel Impact Load Detectors (WILD) measure the force of impact on the
track caused by each wheel in the train consist passing over the sensors. This
can provide early detection of wheel defects such as skids and wheel out-of-
round. The WILD was originally installed to detect wheel defects that
introduced damaging impact loads to the track.
2.18 The network access provider, the Australian Rail Track Corporation (ARTC),
operate and maintain the wayside monitoring systems in the Hunter Valley
where this incident occurred. There are different types of wayside devices
including detectors for hot bearings, wheel impact loads, acoustic wheel
monitoring, dragging equipment, door closed positioning and weighbridges.
These trackside systems are primarily used by ARTC to prevent damage to
the track infrastructure. They detect a variety of rollingstock and track faults
and are positioned at strategic locations in the network (Figure 16).
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Source: ARTC – annotated by OTSI
Figure 16: Wayside monitoring equipment in the Hunter Region, NSW
2.19 The WILD data was examined for this wheelset from the Hunter Valley area
where this wheel mostly travelled. This indicated increasing impact loads from
early March 2019. This likely indicated the early stage of the crack in the
wheel. The data indicated peak impact loads on the wheel of less than 200 kN
prior to the crack being detected. The Pacific National specification only
requires WILD results to be monitored when impact loads exceed 200 kN.8
2.20 The other wheelset, position 3 on the bogie, was also inspected following the
detection of the crack. The wheel profiles of both wheels showed no issues
and the WILD data found no wheel impacts exceeding the specified limits.
8 Pacific National, Wagon Maintenance Manual - Management of Wayside Condition Monitoring Systems, WMM 01-12 _ 02, 2009.
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PART 3 FINDINGS
From the evidence available, the following findings are made with respect to the rail
wheel defects on Pacific National freight service T401G found at Greta, NSW on 1
April 2019.
Contributing Factors
3.1 Examination of the failed wheel revealed the cracking to be likely the result
of subsurface rolling contact fatigue failure.
3.2 The rim cracking had multiple fatigue initiation sites located at different
depths across the tread face and different distances from the wheel tread.
Seven fatigue crack initiation sites were detected.
3.3 It is likely that maintenance processes were ineffective in allowing this
wheel to return to service with an identified defect after undergoing wheel
maintenance in 2016.
Other Findings
3.4 The chemical composition and mechanical properties of the wheel met all
required standards.
3.5 There were no substantial non-metallic inclusions found in the wheel.
3.6 The rim thickness was within the acceptable range of Pacific National’s
specification for wheels to remain in service.
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PART 4 RECOMMENDATIONS
To improve the safety of its operations and prevent a recurrence of this type of
incident, it is recommended that the following remedial safety actions be undertaken
by Pacific National.
4.1 Evaluate the existing processes for communication between Pacific National
and maintenance contractors to ensure that the reasons for wheelset removal
are accurately conveyed.
4.2 Evaluate the effectiveness of the current standards relating to the detection
and treatment of wheel defects.
4.3 Review the non-destructive testing requirements for wheels in the Pacific
National Wagon Maintenance Manual and ensure the requirements are clear
to maintenance contractors.
4.4 Conduct regular surveillance audits on wheelset maintenance practices,
including non-destructive testing processes, to ensure compliance with Pacific
National’s specifications.
4.5 Conduct regular surveillance audits on wheelset maintenance record-keeping
to ensure the correct coding is applied to wheel defects.
4.6 Ensure that any non-compliance or recommendations from these audits are
closed out.
4.7 Assess the frequency and effectiveness of audits conducted on contractors to
provide for satisfactory assurance that wheelsets are being inspected
according to industry standards and internal specifications.
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PART 6 APPENDICES
Appendix 1: Sources, Submissions and Acknowledgements
Sources of Information
ARTC
Pacific National
ONRSR
TfNSW
References
Asset Standards Authority NSW (2013). Wheel defect manual. May 2013.
Australian Rail Track Corporation (2014) Wheel Impact Load Detection (WILD)
Alarm Specifications, Version 2.0, 12 March 2014.
Comsteel (2019) Customer Quality Report CQR 2388957, Examination of
Cracked Rim, RLN4.5-212 Wheel Pacific National Wagon NHRH50260,
December 2019.
Mutton and Laczko. (2006) Metallurgical and NDT aspects in the management
overheated railway wheels. MATe05 paper.
Office of National Rail Safety Regulator (2014). An emerging issue ‘shattered rim’
wheel defects. Safety Bulletin No. 3 June 2014.
Pacific National (2009). Management of Wayside Condition Monitoring Systems,
Wagon Maintenance Manual. 01-12_02.
Pacific National (2019) Operational Risk Register ORR NSW-Vic.
Rail Industry Safety and Standards Board (2010) Glossary of Rail Terminology –
Guideline.
Rail Industry Safety and Standards Board (2018) AS 7514:2018 Rolling stock
standard – Wheels.
Rail Industry Safety and Standards Board (2018) AS 7517:2014 Rolling stock
standard – Wheelsets.
U.S. Department of Transportation Federal Railroad Administration (2014)
Broken Rims in Railroad Wheels.
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Wear (2016) Influence of the initial surface state of bodies in contact on the
formation of white etching layers under dry sliding conditions.
Submissions
The Chief Investigator forwarded a copy of the Draft Report to the Directly Involved
Parties (DIPs) to provide them with the opportunity to contribute to the compilation of
the Final Report by verifying the factual information, scrutinising the analysis,
findings and recommendations, and to submit recommendations for amendments to
the Draft Report that they believed would enhance the accuracy, logic, integrity and
resilience of the Investigation Report. The following DIPs were invited to make
submissions on the Draft Report:
ARTC
Pacific National
ONRSR
TfNSW
Submissions were received from the following DIPs:
Pacific National
ONRSR
The Chief Investigator considered all representations made by DIPs and responded
to the author of each of the submissions advising which of their recommended
amendments would be incorporated in the Final Report, and those that would not.
Where any recommended amendment was excluded, the reasons for doing so were
explained.
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Appendix 2: Wheel information
Source: Asset Standards Authority
Figure 17: Standard terminology for wheels
Source: Asset Standards Authority
Figure 18: Measuring the rim thickness
In this example, the rim thickness is 48 mm.
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Appendix 3: ONRSR Safety Bulletin