A CASE-STUDY OF THE EFFECT OF LUBRICATION AND PROFILE GRINDING ON LOWRAIL ROLLOVER DERAILMENTS AT CSX TRANSPORTATION

Kingsport and Blue Ridge are two subdivisions of CSX Transportation's Corbin Division. Annually they carry 42 million gross tons (MGT) of pr edominantly 100 ton coal car traffic through Kentucky, Tennessee, and North Carolina. Because of the mountainous terrain, the track has seve ral sharp curves (up to 14 degrees) and steep grades (up to 1.2%). Bet ween the period of January 1990 through October 1991, eight derailment s occurred. Some of the derailments were called low rail roll-over der ailments and the others, although not listed as low rail rollover dera ilments, had several common features. Under normal operating condition s the track structure would have been considered good. However, becaus e of the rugged conditions on these two subdivisions, the track struct ure needed strengthening and upgrading. Factors contributing to low ra il roll-over include heavy axle loads, under-balanced train speeds, in adequate lubrication, wide track gauge and poor rail head profiles. Du ring the period of the derailments, maintaining track gauge, line and level was a continuous operation. In the sharp curves, damage occurred rapidly to newly replaced timber ties and premium head hardened rail. The average life of the low rail in a 14 degrees curve was 18 months (60 MGT). These conditions were costly and required a solution. Resear ch and tests carried out by National Research Council of Canada, CSX T ransportation and Loram Maintenance of Way, led to the development of a comprehensive lubrication and grinding program. The lubrication emph asized friction control between the low rail-wheel interface. The grin ding method was changed from corrective to preventive. NRC/LORAM asymm etric profile geometry of low and high rails was scrupulously maintain ed. Since the implementation of these two programs, there has not been a low rail roll-over derailment or a derailment with any feature asso ciated with low rail roll-over derailment.