A P T A S T A N D A R D S D E V E L O P M E N T P R O G R A M RAIL STANDARD American Public Transportation Association 1666 K Street, NW, Washington, DC, 20006-1215 APTA PR-I&M-S-015-00 Rev 1 First Published January 8, 2001 First Revision MMM DD, 2014 Working Group Approved January 31, 2014 Public Comment March 14, 2014 Rail CEO Approved MMM DD, 2014 Rail Policy & Planning Committee Approved MMM DD, 2014 APTA Passenger Rail Equipment Safety Standards (PRESS) Inspection & Maintenance Working Group Roller Bearing Inspection and Testing on Passenger Rail Equipment after a Derailment Abstract: This Rail Standard provides a procedure for the inspection and testing of roller bearings on rail passenger equipment after a derailment. Keywords: inspection and testing, major derailment, minor derailment, roller bearing inspection and testing, roller bearings, wheel set Summary: This safety standard describes the inspection and testing tasks to be performed and the circumstances requiring the performance of these tasks. It also lists references that must be on hand or are useful for the implementation of this standard; definitions of terms used in this standard; and acronyms used in this standard. Scope and purpose: This document is a safety standard for performing the inspection and testing of roller bearings on passenger rail equipment following a derailment and prior to the derailed equipment being returned to service. It provides a set of inspection and testing tasks that shall be performed after a derailment. This safety standard is meant to provide organizations with basic requirements to be satisfied by the inspection and testing process. This Rail Standard represents a common viewpoint of those parties concerned with its provisions, namely, transit operating/planning agencies, manufacturers, consultants, engineers and general interest groups. The application of any standards, practices or guidelines contained herein is voluntary. In some cases, federal and/or state regulations govern portions of a transit system s operations. In those cases, the government regulations take precedence over this standard. NATSA (North American Transit Standards Association) and its parent organization APTA recognizes that for certain applications, the standards or practices, as implemented by individual transit agencies, may be either more or less restrictive than those given in this document. 2014 NATSA and its parent organization.. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of NATSA..
Contents Introduction... iii 1.Inspection and testing procedures... 1 Participants The American Public Transportation Association greatly appreciates the contributions of Jon Condrasky, Dave Elliott, Paul Kovacs, Jayendra Shah, Sherman Shreves, Mike Yeager, and Robert Young who provided the primary effort in revising this Rail Standard. At the time this standard was completed, the Passenger Rail Equipment Safety Standards (PRESS) Vehicle Inspection & Maintenance Working Group included the following members: Paul Kovacs, Chair Robert Young, Vice Chair 1.1 Major derailment... 1 1.2 Minor derailment... 1 1.3 Guidelines for defective internal parts... 2 References... 3 Definitions... 3 Abbreviations and acronyms... 3 Summary of changes... 3 Document history... 4 Antonio, Jr., Ben Baron, Ron Bastawros, Sherif Blackman, Jerry Bonina, Stephen Burke, Alan Campbell, Gordon Campbell, Richard Canjea, Stelian Carter, Jr., Homer Chakraborty, Dhiren Condrasky, John Consavage, Terry Curtis, Richard Davis, Jr., Henry Eberl, Phil Eichin, Chris Elliott, Dave Grogan, Scott Holland, Ben Huggins, Antonio Hughson, David Jamieson, Paul Johnson, Ronald Kolesar, Henry Kowalski, David Krempasky, Joseph Ley, Brian Mack, Lloyd Olekszyk, Phil Plomin, James Porter, Mike Porter, Vicki Pylkas, Laird Rehfuss, Dennis Rettig, Thomas Romeo, Dave Sadorra, John Seaton, Richard Shah, Jayendra Shea, Jr., John Shreves, Sherman Skaggs, James Stangas, Paul. Turner, Brian Yeager, Mike Wallace, Wilson Wilson, Dan Woodbury, Cliff Project team Martin Schroeder American Public Transportation Association Charles Joseph American Public Transportation Association 2014 American Public Transportation Association ii
Introduction This introduction is not part of APTA PR-IM-S-015-00 First Revision MMM DD, 2014 Standard for Roller Bearing Inspection and Testing on Passenger Rail Equipment after a Derailment. This introduction provides some background on the rationale used to develop this standard. It is meant to aid in the understanding and application of this standard. This standard describes the requirements for inspection and testing of roller bearings on passenger coaches after a derailment. It is intended for the following: individuals or organizations who maintain roller bearings on passenger rail equipment individuals or organizations who contract with others for the maintenance of roller bearings on passenger rail equipment individuals or organizations who influence how roller bearings are maintained on passenger rail equipment 2014 American Public Transportation Association iii
Roller Bearing Inspection and Testing on Passenger Rail Equipment after a Derailment 1. Inspection and testing procedures CAUTION: If speed or distance cannot be ascertained, it must be assumed that the wheel sets in question were involved in a major derailment and must be removed from service. NOTE: In accordance with the railroad s operation and maintenance instructions and safety procedures, visually inspect for any external sign of damage and perform a roll by inspection to detect any unusual noise indicating internal damage, roughness, or catches in the rotation of the wheel set if the equipment is going to be moved from the derailment site to a shop facility for wheel set removal. The integrity of the equipment should be verified prior to movement, even if moved at a reduced speed. 1.1 Major derailment Wheel sets must be removed and handled in accordance with the AAR Wheel and Axle Manual and the Railroad s safety and maintenance procedures. The roller bearings must be removed and disassembled for inspection and necessary repairs. 1.2 Minor derailment Wheel sets on empty or passenger loaded cars involved in a derailment at a speed of not over 10 miles per hour or which have not moved on the ground more than 200 feet; inspect the roller bearings as follows: 1.2.1 Remove wheel sets 1.2.2 Bearings must be sufficiently clean to permit adequate inspection of all exterior parts. 1.2.3 Carefully inspect the outer cup for cracks or breaks. 1.2.4 Inspect for loose or damaged front and rear seals. 1.2.5 Inspect for missing or loose end cap screws. 1.2.6 Inspect for loose backing rings. 1.2.7 Inspect the roller bearing in accordance with the guidelines in section 1.3 below. 1.2.8 Check for a bent axle in accordance with AAR Rule 43.E. and the Railroad s safety and maintenance procedures. 1.2.9 Inspect end cap for cracks, broken ears or nicks, and dents and gouges in excess of 1/8 inches deep. 1.2.10 If all of the above checks are satisfactory, continue wheel sets in service in accordance with the Railroad s operating procedures for returning equipment to service. Otherwise, the roller bearings must be removed, disassembled, and inspected for damage. NOTE: Field repair of axle bearing assemblies is not permitted by the AAR. 2014 American Public Transportation Association 1
1.3 Guidelines for defective internal parts Feel for internal roughness or catches while holding rollers and raceways against each other during complete rotation of both the bearing and the wheel as follows: 1.3.1 Push the cup toward the inner raceway and rotate the cup in one direction for at least two complete revolutions. 1.3.2 Pull the cup toward the outer raceway and rotate the cup in the same direction as step 1.3.1 for at least two complete revolutions. 1.3.3 Roll the wheel 1/3 of the way around (120 degrees) and then repeat steps 1.3.1 and 1.3.2. 1.3.4 Roll the wheel 1/3 of the way around (120 degrees) in the same direction and then repeat steps 1.3.1 and 1.3.2. NOTE: Noise can be misleading. A clicking sound can result from the normal shifting of the rollers in their cages. Shifting of the rollers can also be felt particularly when the direction of cup rotation is changed. In general practice, neither of these conditions necessarily indicates the presence of a defect. The Railroad s safety and maintenance procedures will govern any decisions. 2014 American Public Transportation Association 2
References AAR Rule 36 Roller Bearings 49 CFR, Part 238, Passenger Equipment Safety Standards This safety standard shall also be used with the following publications. If the following publications are superseded by an approved revision, then the revision shall apply. Applicable state and local regulations Original equipment manufacturer instructions Railroad maintenance instructions Definitions major derailment: Any derailment either occurring at a speed in excess of 10 mph or resulting in the derailed truck(s) being dragged on the ground for a distance of 200 ft. or more. minor derailment: Any derailment either occurring at a speed of less than 10 mph or resulting in the derailed truck(s) being dragged on the ground for a distance less than 200 ft. periodic maintenance: The performance of selected inspection and maintenance actions on systems or subsystems. Regulatory agencies or the operating authority may set the frequency of these actions. The frequency may be expressed as a function of time (i.e., days, weeks or months) or of utilization (i.e., mileage, cycles, etc.). The scope of these inspection and maintenance actions must be in full compliance with all applicable federal, state and local regulations. roller bearing: The general term applied to a group of journal bearings that depend on the rolling action of a set of rollers, in order to reduce rotational friction. The different types are distinguished by the shapes of the rollers and by their arrangement in the bearing. Three types of rollers are in common use at present for car journals: cylindrical, tapered and spherical. wheel set: The term used to describe a pair of wheels mounted on an axle. Abbreviations and acronyms AAR Association of American Railroads APTA American Public Transportation Association CFR Code of Federal Regulations NATSA North American Transit Standards Association PRESS Passenger Rail Equipment Safety Standards Summary of changes 1. Document formatted to the new APTA standard format. 2. Sections have been moved and renumbered. 3. Scope and summary moved to the front page. 4. Sections of definitions, abbreviations and acronyms moved to the rear of the document. 5. Two new sections added: Summary of document changes and Document history. 2014 American Public Transportation Association 3
6. Some global changes to section headings and numberings resulted when sections dealing with references and acronyms were moved to the end of the document, along with other cosmetic changes, such as capitalization, punctuation, spelling, grammar and general flow of text. Document history Document Version Working Group Vote Public Comment/ Technical Oversight Rail CEO Approval Rail Policy & Planning Approval Published Date First published Nov 1, 2000 - - Jan 8, 2001 January 2001 First revision January 31, 2014 2014 American Public Transportation Association 4