Rollover Tank Car Test

In November 2009, FRA and Sharma & Associates tested a possible option to improve tank car safety

RIS removed the trucks from a donated tank car, attached it to supports bolted onto concrete slabs, and filled it with water. The yellow block in the lower-left of the frame is layers of concrete. Researchers expected the top layer or a few would be destroyed, but hoped that the bottom of the block might be reusable.

Kathi Kube

bolster breaks during tank car rollover test

As the tank car settled onto the ground, one of its bolsters succumbed, as well, creating its own dust as it broke free from its steel supports and landing on the support slab.

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Broken bolster on tank car during rollover

The bolster on the near end of the car didn’t fare as well, breaking cleanly from the rest of the car. This didn’t impact the test’s results, though, and is somewhat expected when conducting tests on older equipment.

Kathi Kube

Closer examination reveals a minor bend to the skid. The fittings themselves were completely protected from the 18-mph impact.

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Safety valve on tank car during rollover test

Upon impact, the safety valve performed exactly as designed and relieved the sudden increase in pressure by spraying a small amount of water onto the already muddy ground. Dust flies up from the concrete block as layers are crushed beneath the loaded tank car’s weight.

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Supports and cables for tank car rollover test

RIS also designed and built a support structure for the tank car. Hydraulic pumps (yellow and visible within the support structure) pushed the car to its tipping point, at which time gravity took over.

Kathi Kube

When the dust settled and researchers were confident it was safe for the observers to come out from behind our protective barrier, the sight was impressive. The concrete blocks were broken, as was the slab they sat upon. The manway cover, not tightened since the tank car was filled for fear the water might freeze overnight, leaked some water, but was not damaged even though it technically was outside the most protected zone. In fact, none of the fittings were damaged in the least, and even the skid itself bent a tiny bit.

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The hydraulics have done their work, and gravity is taking over. One of the cameras opposite the car records the action.

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This is a closeup view of the skid protection. Although the manway and one of the fittings is outside the rectangular protected area, modern designs put all the top fittings within the protected zone. Engineers from Sharma & Associates acquired the steel, designed the skid, and tested it in simulations. RIS personnel welded the actual pieces onto the car and provided the testing facility. Researchers also applied sensors and wires to various parts of the tank car and skid to monitor stresses as it impacted with the concrete slab.

Kathi Kube

Video cameras for tank car rollover test

Several cameras recorded the action in real-time, and in slow-motion, and in wide-angle and zoomed-in views.

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The camera closest to the action was behind a barrier in hopes that any flying debris would not damage the equipment. Observers also were kept well distant from the tank car and behind a steel barrier fitted with bullet-proof glass. Fortunately, no debris came anywhere near any of the observers.

Kathi Kube

Everyone involved in the transportation of hazardous materials knows that the quest to improve tank car safety in case of a wreck or derailment is very real, and ongoing. Usually we on the outside don’t get to go behind the scenes and see the research that goes into significant changes in railcar designs. But in recent months, TRAINS has been allowed to observe tests as the Federal Railroad Administration’s Office of Research and Development works with engineers throughout the country seeking possible solutions.

In November, FRA and Countryside, Ill.-based engineering firm Sharma & Associates Inc. hosted a full-scale test at Joliet-based Railway Industrial Services Inc. In general, researchers wanted to see if “skid protection,” that is, a steel bracing welded around a tank car’s top fittings, would protect the fittings in case of a rollover. The test confirmed researchers models and expectations.

The photos (right) show how it all happened.

Although researchers are far from saying, “Here’s this wonderful solution, please incorporate it into your new cars,” they are optimistic this is a viable option worthy of additional research. On the plus side, the skid was not difficult or overly expensive to manufacture and could be retrofitted to existing cars. However, this particular design would likely interfere with personnel or equipment working with the tank cars, as well as filling or emptying them. Additional modeling then testing will seek to address this issue.

In the meantime, researchers have many more options they’re examining in their efforts to make tank cars and hazmat transportation safer. – Kathi Kube

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